ETM/V 214-325 10.

04 -

G
Operating Instructions

50441301
02.10
 Declaration of Conformity Declaration of Conformity

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

Type Option Serial No. Year of Construction Type Option Serial No. Year of Construction
ETM 214 ETM 214
ETV 214 ETV 214
ETM 216 ETM 216
ETV 216 ETV 216
ETM 320 ETM 320
ETV 320 ETV 320
ETM 325 ETM 325
ETV 325 ETV 325

Additional information Additional information

Authorised signatory Authorised signatory

Date Date

G EU Declaration of Conformity G EU Declaration of Conformity

The signatories hereby certify that the specified powered industrial truck conforms to The signatories hereby certify that the specified powered industrial truck conforms to
the EU Directive 2006/42/EC (Machine Directive) and 2004/108/EEC (Electro-Magne- the EU Directive 2006/42/EC (Machine Directive) and 2004/108/EEC (Electro-Magne-
tic Compatibility, EMC) including their amendments as translated into national legisla- tic Compatibility, EMC) including their amendments as translated into national legisla-
tion of the member countries. The signatories are individually empowered in each case tion of the member countries. The signatories are individually empowered in each case
to compile the technical documentation. to compile the technical documentation.
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 Important notes on transporting and mounting load lifting devices Important notes on transporting and mounting load lifting devices
to reach trucks to reach trucks
Transport Transport
Depending on the overall height of the lifting mast and the local conditions transport Depending on the overall height of the lifting mast and the local conditions transport
can be performed in three different ways can be performed in three different ways
– Standing, with the lifting mast mounted (for trucks with low overall height) – Standing, with the lifting mast mounted (for trucks with low overall height)
– Standing, with martially mounted lifting mast tilted towards the overhead guard (for – 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- trucks with medium overall height). Hydraulic line for the lifting function is interrup-
ted. ted.
– Standing, with the lifting mast dismounted (for trucks with large overall height) – Standing, with the lifting mast dismounted (for trucks with large overall height)

Safety Instructions for Assembly and Commissioning Safety Instructions for Assembly and Commissioning

f The assembly of the truck on site, commissioning the truck and instructing the driver
must be carried out by personnel trained and authorised by the manufacturer
f The assembly of the truck on site, commissioning the truck and instructing the driver
must be carried out by personnel trained and authorised by the manufacturer
Connect the hydraulic lines to the basic machine / mast interface and commission the Connect the hydraulic lines to the basic machine / mast interface and commission the
truck only after having installed the mast as per the instructions. truck only after having installed the mast as per the instructions.
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 Foreword Foreword
The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide
sufficient instruction for the safe operation of the industrial truck. The information is sufficient instruction for the safe operation of the industrial truck. The information is
provided clearly and concisely. The chapters are arranged by letter. Each chapter provided clearly and concisely. The chapters are arranged by letter. Each chapter
starts with page 1. The page identification consists of a chapter letter and a page starts with page 1. The page identification consists of a chapter letter and a page
number. number.
For example: Page B 2 is the second page in chapter B. For example: Page B 2 is the second page in chapter B.

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

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

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

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

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

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

Z Used before notices and explanations.

Z Used before notices and explanations.

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

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

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

Copyright Copyright

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

Jungheinrich Aktiengesellschaft Jungheinrich Aktiengesellschaft

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

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

www.jungheinrich.com www.jungheinrich.com
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 Table of Contents Table of Contents
Declaration of Conformity Declaration of Conformity

A Correct Use and Application A Correct Use and Application

1 General ............................................................................................... A 1 1 General ............................................................................................... A 1

2 Correct application .............................................................................. A 1 2 Correct application .............................................................................. A 1
3 Approved application conditions ......................................................... A 1 3 Approved application conditions ......................................................... A 1
4 Proprietor responsibilities .................................................................... A 2 4 Proprietor responsibilities .................................................................... A 2
5 Adding attachments and/or accessories ............................................. A 2 5 Adding attachments and/or accessories ............................................. A 2

B Truck Description B Truck Description

1 Application ........................................................................................... B 1 1 Application ........................................................................................... B 1

2 Assemblies and Functional Description .............................................. B 2 2 Assemblies and Functional Description .............................................. B 2
2.1 Truck ................................................................................................... B 3 2.1 Truck ................................................................................................... B 3
2.2 Load handling ...................................................................................... B 6 2.2 Load handling ...................................................................................... B 6
3 Standard Version Specifications ......................................................... B 7 3 Standard Version Specifications ......................................................... B 7
3.1 Performance Data ............................................................................... B 7 3.1 Performance Data ............................................................................... B 7
3.2 Dimensions ......................................................................................... B 9 3.2 Dimensions ......................................................................................... B 9
3.3 Standard mast version dimensions ..................................................... B 11 3.3 Standard mast version dimensions ..................................................... B 11
3.4 Weights ............................................................................................... B 11 3.4 Weights ............................................................................................... B 11
3.5 Wheels/tyres ....................................................................................... B 12 3.5 Wheels/tyres ....................................................................................... B 12
3.6 Battery ................................................................................................. B 12 3.6 Battery ................................................................................................. B 12
3.7 Hydraulics ........................................................................................... B 12 3.7 Hydraulics ........................................................................................... B 12
3.8 Mast weights ....................................................................................... B 13 3.8 Mast weights ....................................................................................... B 13
3.9 EN norms ............................................................................................ B 15 3.9 EN norms ............................................................................................ B 15
3.10 Conditions of use ................................................................................ B 15 3.10 Conditions of use ................................................................................ B 15
3.11 Electrical requirements ........................................................................ B 16 3.11 Electrical requirements ........................................................................ B 16
4 Identification points and data plates .................................................... B 17 4 Identification points and data plates .................................................... B 17
4.1 Truck data plate .................................................................................. B 18 4.1 Truck data plate .................................................................................. B 18
4.2 Truck load chart (capacity) .................................................................. B 19 4.2 Truck load chart (capacity) .................................................................. B 19
4.3 Attachment load chart ......................................................................... B 19 4.3 Attachment load chart ......................................................................... B 19
4.4 Stability ................................................................................................ B 20 4.4 Stability ................................................................................................ B 20

C Transport and Commissioning C Transport and Commissioning

1 Transport ............................................................................................. C 1 1 Transport ............................................................................................. C 1

2 Lifting by crane .................................................................................... C 2 2 Lifting by crane .................................................................................... C 2
2.1 Lifting the basic truck by crane ............................................................ C 3 2.1 Lifting the basic truck by crane ............................................................ C 3
2.2 Lifting the basic truck and cabin by crane ........................................... C 4 2.2 Lifting the basic truck and cabin by crane ........................................... C 4
3 Securing the truck during transport ..................................................... C 5 3 Securing the truck during transport ..................................................... C 5
4 Using the truck for the first time .......................................................... C 6 4 Using the truck for the first time .......................................................... C 6
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 D Battery Maintenance, Charging & Replacement D Battery Maintenance, Charging & Replacement

1 Safety regulations for handling acid batteries ..................................... D 1 1 Safety regulations for handling acid batteries ..................................... D 1
2 Battery types ....................................................................................... D 2 2 Battery types ....................................................................................... D 2
3 Exposing the battery ........................................................................... D 3 3 Exposing the battery ........................................................................... D 3
4 Charging the battery ............................................................................ D 5 4 Charging the battery ............................................................................ D 5
5 Battery removal and installation .......................................................... D 6 5 Battery removal and installation .......................................................... D 6

E Operation E Operation

1 Safety Regulations for the Operation of Forklift Trucks ...................... E 1 1 Safety Regulations for the Operation of Forklift Trucks ...................... E 1
2 Controls and Displays ........................................................................ E 2 2 Controls and Displays ........................................................................ E 2
3 Starting up the truck ............................................................................ E 6 3 Starting up the truck ............................................................................ E 6
3.1 Entry and exit ...................................................................................... E 6 3.1 Entry and exit ...................................................................................... E 6
3.2 Setting up the operator position .......................................................... E 7 3.2 Setting up the operator position .......................................................... E 7
3.3 To prepare the truck for operation ....................................................... E 12 3.3 To prepare the truck for operation ....................................................... E 12
3.4 Emergency stop device ....................................................................... E 13 3.4 Emergency stop device ....................................................................... E 13
3.5 Testing after daily operation ................................................................ E 14 3.5 Testing after daily operation ................................................................ E 14
4 Industrial Truck Operation ................................................................... E 15 4 Industrial Truck Operation ................................................................... E 15
4.1 Safety regulations for truck operation ................................................. E 15 4.1 Safety regulations for truck operation ................................................. E 15
4.2 Procedure in extraordinary situations .................................................. E 16 4.2 Procedure in extraordinary situations .................................................. E 16
4.3 Emergency Disconnect ....................................................................... E 17 4.3 Emergency Disconnect ....................................................................... E 17
4.4 Travel, steering, braking ...................................................................... E 18 4.4 Travel, steering, braking ...................................................................... E 18
4.5 Adjusting the forks ............................................................................... E 21 4.5 Adjusting the forks ............................................................................... E 21
4.6 Lifting and depositing loads ................................................................. E 21 4.6 Lifting and depositing loads ................................................................. E 21
4.7 Emergency lowering (-10/07) .............................................................. E 26 4.7 Emergency lowering (-10/07) .............................................................. E 26
4.8 Emergency lowering (10/07-) .............................................................. E 26 4.8 Emergency lowering (10/07-) .............................................................. E 26
4.9 Operating Attachments ....................................................................... E 27 4.9 Operating Attachments ....................................................................... E 27
4.10 Parking the truck safely ....................................................................... E 32 4.10 Parking the truck safely ....................................................................... E 32
5 Driver’s display (t) ............................................................................. E 33 5 Driver’s display (t) ............................................................................. E 33
5.1 Driver’s Display LED Buttons .............................................................. E 37 5.1 Driver’s Display LED Buttons .............................................................. E 37
5.2 Driver Display Switches ...................................................................... E 38 5.2 Driver Display Switches ...................................................................... E 38
5.3 Driver’s Display Warning Messages ................................................... E 38 5.3 Driver’s Display Warning Messages ................................................... E 38
6 On board computer (o) ....................................................................... E 44 6 On board computer (o) ....................................................................... E 44
6.1 On board computer display symbols ................................................... E 45 6.1 On board computer display symbols ................................................... E 45
7 Keypad (CANCODE) (o) .................................................................... E 49 7 Keypad (CANCODE) (o) .................................................................... E 49
7.1 Code Lock ........................................................................................... E 49 7.1 Code Lock ........................................................................................... E 49
7.2 Parameters .......................................................................................... E 50 7.2 Parameters .......................................................................................... E 50
7.3 Parameter Settings ............................................................................. E 51 7.3 Parameter Settings ............................................................................. E 51
8 ISM (o) ............................................................................................... E 54 8 ISM (o) ............................................................................................... E 54
9 Changing truck parameters ................................................................. E 54 9 Changing truck parameters ................................................................. E 54
10 Troubleshooting .................................................................................. E 55 10 Troubleshooting .................................................................................. E 55
11 Moving the truck without a battery, recovery ....................................... E 55 11 Moving the truck without a battery, recovery ....................................... E 55
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 12 Optional equipment ............................................................................. E 58 12 Optional equipment ............................................................................. E 58
12.1 Headlights .......................................................................................... E 58 12.1 Headlights .......................................................................................... E 58
12.2 Beacon / strobe .................................................................................. E 58 12.2 Beacon / strobe .................................................................................. E 58
12.3 Limit switch system / electrical lift limit switch ..................................... E 59 12.3 Limit switch system / electrical lift limit switch ..................................... E 59
12.4 Seat heating ....................................................................................... E 60 12.4 Seat heating ....................................................................................... E 60
12.5 12 V DC / 24 V DC transformer .......................................................... E 60 12.5 12 V DC / 24 V DC transformer .......................................................... E 60
12.6 180°/360° steering angle display ........................................................ E 61 12.6 180°/360° steering angle display ........................................................ E 61
12.7 Sideshift centre position ..................................................................... E 61 12.7 Sideshift centre position ..................................................................... E 61
12.8 Forks horizontal button ....................................................................... E 62 12.8 Forks horizontal button ....................................................................... E 62
12.9 Weigher .............................................................................................. E 62 12.9 Weigher .............................................................................................. E 62
12.10 Clamp button ...................................................................................... E 63 12.10 Clamp button ...................................................................................... E 63
12.11 Weatherproof cab ............................................................................... E 64 12.11 Weatherproof cab ............................................................................... E 64
12.12 Parabolic mirror ................................................................................... E 65 12.12 Parabolic mirror ................................................................................... E 65
12.13 Removable load backrest .................................................................... E 66 12.13 Removable load backrest .................................................................... E 66
12.14 Rack Height Select .............................................................................. E 67 12.14 Rack Height Select .............................................................................. E 67
12.15 ISM access module ............................................................................. E 68 12.15 ISM access module ............................................................................. E 68
12.16 Assembly and hydraulic ports of additional attachments .................... E 69 12.16 Assembly and hydraulic ports of additional attachments .................... E 69

F Industrial Truck Maintenance F Industrial Truck Maintenance

1 Operational Safety and Environmental Protection .............................. F 1 1 Operational Safety and Environmental Protection .............................. F 1
2 Maintenance safety regulations .......................................................... F 2 2 Maintenance safety regulations .......................................................... F 2
3 Servicing and Inspection ..................................................................... F 6 3 Servicing and Inspection ..................................................................... F 6
4 ETM/V 214-325 Maintenance Checklist .............................................. F 7 4 ETM/V 214-325 Maintenance Checklist .............................................. F 7
5 ETM/V 214-325 Maintenance Schedule ............................................. F 9 5 ETM/V 214-325 Maintenance Schedule ............................................. F 9
5.1 Lubricants and Lubrication Schedule .................................................. F 10 5.1 Lubricants and Lubrication Schedule .................................................. F 10
5.2 Consumables ..................................................................................... F 11 5.2 Consumables ..................................................................................... F 11
5.3 Reservoir capacity ............................................................................... F 12 5.3 Reservoir capacity ............................................................................... F 12
6 Maintenance Instructions .................................................................... F 13 6 Maintenance Instructions .................................................................... F 13
6.1 Preparing the truck for maintenance and repairs ................................ F 13 6.1 Preparing the truck for maintenance and repairs ................................ F 13
6.2 Remove seat panel ............................................................................. F 14 6.2 Remove seat panel ............................................................................. F 14
6.3 Check the hydraulic oil level ................................................................ F 14 6.3 Check the hydraulic oil level ................................................................ F 14
6.4 Opening the fuse cover ....................................................................... F 15 6.4 Opening the fuse cover ....................................................................... F 15
6.5 Opening the instrument panel cover ................................................... F 15 6.5 Opening the instrument panel cover ................................................... F 15
6.6 Checking electrical fuses .................................................................... F 16 6.6 Checking electrical fuses .................................................................... F 16
6.7 Checking the wheel attachments. ....................................................... F 17 6.7 Checking the wheel attachments. ....................................................... F 17
6.8 Recommissioning ................................................................................ F 17 6.8 Recommissioning ................................................................................ F 17
7 Decommissioning the industrial truck .................................................. F 17 7 Decommissioning the industrial truck .................................................. F 17
7.1 Prior to decommissioning: ................................................................... F 17 7.1 Prior to decommissioning: ................................................................... F 17
7.2 During decommissioning: .................................................................... F 18 7.2 During decommissioning: .................................................................... F 18
7.3 Returning the truck to operation after decommissioning ..................... F 18 7.3 Returning the truck to operation after decommissioning ..................... F 18
8 Safety checks to be performed at regular intervals and 8 Safety checks to be performed at regular intervals and
following any unusual incidents ........................................................... F 19 following any unusual incidents ........................................................... F 19
9 Final de-commissioning, disposal ....................................................... F 19 9 Final de-commissioning, disposal ....................................................... F 19
10 Human vibration measurement ........................................................... F 19 10 Human vibration measurement ........................................................... F 19
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 Appendix Appendix

JH Traction Battery Operating Instructions JH Traction Battery Operating Instructions

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

M Batteries with closed EPzV and EPzV-BS ironclad plates must not be used in trucks
with the regenerative lowering option.
M Batteries with closed EPzV and EPzV-BS ironclad plates must not be used in trucks
with the regenerative lowering option.
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 A Correct Use and Application A Correct Use and Application
1 General 1 General

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

2 Correct application 2 Correct application

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

– Lifting and lowering of loads. – Lifting and lowering of loads.

– Transporting lowered loads over long distances. – Transporting lowered loads over long distances.
– Do not travel with a raised load (>30 cm). – Do not travel with a raised load (>30 cm).
– Do not carry or lift passengers. – Do not carry or lift passengers.
– Do push or pull load units. – Do push or pull load units.

3 Approved application conditions 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. 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 loose The driver must ensure that the loading ramp / bridge cannot move or come loose
during loading / unloading. during loading / unloading.

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

Z Special equipment and authorisation are required if the truck is to be constantly used
in extreme conditions.
Z Special equipment and authorisation are required if the truck is to be constantly used
in extreme conditions.
The truck is not authorised for use in areas at risk of explosion. The truck is not authorised for use in areas at risk of explosion.
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A1 A1
4 Proprietor responsibilities 4 Proprietor responsibilities

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

M Failure to comply with the operating instructions shall invalidate the warranty. The same
applies if improper work is carried out on the truck by the customer or third parties
M Failure to comply with the operating instructions shall invalidate the warranty. The same
applies if improper work is carried out on the truck by the customer or third parties
without the permission of the manufacturer’s customer service department. without the permission of the manufacturer’s customer service department.

5 Adding attachments and/or accessories 5 Adding attachments and/or accessories

The mounting or installation of additional equipment which affects or enhances the The mounting or installation of additional equipment which affects or enhances the
performance of the forklift truck requires the written permission of the manufacturer. performance of the forklift truck requires the written permission of the manufacturer.
Local authority approval may also need to be obtained. Local authority approval does Local authority approval may also need to be obtained. Local authority approval does
not however constitute the manufacturer’s approval. not however constitute the manufacturer’s approval.

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A2 A2
 B Truck Description B Truck Description
1 Application 1 Application

The ETM/V 214-325 is a three wheel electric side seat, clear view reach truck. It is The ETM/V 214-325 is a three wheel electric side seat, clear view reach truck. It is
designed for use on level floors to lift and transport goods. Open bottom pallets or designed for use on level floors to lift and transport goods. Open bottom pallets or
pallets with transverse boards can be lifted inside or outside the area of the load pallets with transverse boards can be lifted inside or outside the area of the load
wheels or roll cage. Loads can be stacked or unstacked and transported over long wheels or roll cage. Loads can be stacked or unstacked and transported over long
distances. distances.
The capacity can be obtained from the data plate. The capacity can be obtained from the data plate.

Model Capacity Load centre of Model Capacity Load centre of

gravity gravity
ETM/V 214 1400 kg 600 mm ETM/V 214 1400 kg 600 mm
ETM/V 216 1600 kg 600 mm ETM/V 216 1600 kg 600 mm
ETM/V 320 2000 kg 600 mm ETM/V 320 2000 kg 600 mm
ETM/V 325 2500 kg 600 mm ETM/V 325 2500 kg 600 mm
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B1 B1
2 Assemblies and Functional Description 2 Assemblies and Functional Description

1 1
11 11
2 2

12 13 14 12 13 14

3 3

4 4

10 10

9 9

8 8

7 6 5 7 6 5

Item Model Item Model Item Model Item Model

1 t Clearview mast 9 t Brake pedal 1 t Clearview mast 9 t Brake pedal
2 t Overhead guard 10 t Accelerator pedal 2 t Overhead guard 10 t Accelerator pedal
3 t Free lift cylinder (not with ZT mast) 11 t Battery trolley unlatch pedal 3 t Free lift cylinder (not with ZT mast) 11 t Battery trolley unlatch pedal
4 t Multi-Pilot 12 t Driver’s display 4 t Multi-Pilot 12 t Driver’s display
o Solopilot o On board computer o Solopilot o On board computer
5 t Load wheels 13 t Two stage switch key with 5 t Load wheels 13 t Two stage switch key with
spare key (service). spare key (service).
6 t Outriggers o CANCODE 6 t Outriggers o CANCODE
7 t Drive wheel o ISM Access Module 7 t Drive wheel o ISM Access Module
8 t Deadman switch 14 t EMERGENCY DISCONNECT 8 t Deadman switch 14 t EMERGENCY DISCONNECT
switch switch
t Standard Equipment o Optional Equipment t Standard Equipment o Optional Equipment
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B2 B2
 2.1 Truck 2.1 Truck

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

Safety mechanisms: A closed truck contour with rounded edges facilitates safe Safety mechanisms: A closed truck contour with rounded edges facilitates safe
handling of the ETM/V 214-325. The driver is protected by the overhead guard (2). handling of the ETM/V 214-325. The driver is protected by the overhead guard (2).
The drive wheel (7) and the load wheels (5) are protected by a solid skirt. The drive wheel (7) and the load wheels (5) are protected by a solid skirt.

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

Pressing the EMERGENCY DISCONNECT switch (14) disconnects all electrical Pressing the EMERGENCY DISCONNECT switch (14) disconnects all electrical
functions in hazardous situations. functions in hazardous situations.
Line brake safety devices in the lift cylinders limit the load lowering speed in the event Line brake safety devices in the lift cylinders limit the load lowering speed in the event
of a hydraulic system failure. of a hydraulic system failure.

Displays: Driver Display (12) with large TFT display (t) or on board computer with Displays: Driver Display (12) with large TFT display (t) or on board computer with
LCD (o), each with integrated residual time display, battery discharge indicator, lift LCD (o), each with integrated residual time display, battery discharge indicator, lift
and travel profile settings and steering angle mode display. The battery discharge and travel profile settings and steering angle mode display. The battery discharge
indicator and hourmeter are combined on the driver’s display (12). The discharge indicator and hourmeter are combined on the driver’s display (12). The discharge
indicator is designed as a monitor which cuts out lifting when the battery is indicator is designed as a monitor which cuts out lifting when the battery is
discharged, in order to avoid depletion. discharged, in order to avoid depletion.

Drive: The entire drive unit is enclosed in the truck chassis. A fixed, 6.9 kW Drive: The entire drive unit is enclosed in the truck chassis. A fixed, 6.9 kW
threephase motor governs the drive wheel (7) via a bevel spur gearbox threephase motor governs the drive wheel (7) via a bevel spur gearbox
The electronic traction controller ensures the smooth rotation of the drive motor and The electronic traction controller ensures the smooth rotation of the drive motor and
as a result smooth driving, powerful acceleration and electrically controlled braking as a result smooth driving, powerful acceleration and electrically controlled braking
with energy recovery. with energy recovery.
The degree of energy recovery can be adjusted in the driver’s display. The degree of energy recovery can be adjusted in the driver’s display.

Free Lift Speed Increase (t): For post-06/2008 trucks with lift heights over Free Lift Speed Increase (t): For post-06/2008 trucks with lift heights over
5600 mm the free lift traverse and tilt speed is raised to improve turnover. These high 5600 mm the free lift traverse and tilt speed is raised to improve turnover. These high
speeds cannot be achieved for mast lift. When you change from free lift to mast lift, speeds cannot be achieved for mast lift. When you change from free lift to mast lift,
the traverse and tilt speeds are automatically reduced. the traverse and tilt speeds are automatically reduced.

Slip control (o): The slip control system prevents the drive wheel from blocking Slip control (o): The slip control system prevents the drive wheel from blocking
during braking. This improves the truck’s steering during braking and reduces tyre during braking. This improves the truck’s steering during braking and reduces tyre
wear. wear.
When the truck accelerates it prevents the drive wheel from spinning uncontrollably When the truck accelerates it prevents the drive wheel from spinning uncontrollably
on smooth surfaces. In some circumstances the stopping distance may be extended. on smooth surfaces. In some circumstances the stopping distance may be extended.

F The stopping distance may be extended when the reversing brake is used and the
maximum speed may be restricted immediately after replacing a wheel. F The stopping distance may be extended when the reversing brake is used and the
maximum speed may be restricted immediately after replacing a wheel.
Brake system: The electric braking system consists of three independent braking Brake system: The electric braking system consists of three independent braking
systems. Applying the brake pedal results in inversion braking (plugging) in the systems. Applying the brake pedal results in inversion braking (plugging) in the
traction motor. Where required the load carrying brakes are switched on via the traction motor. Where required the load carrying brakes are switched on via the
vehicle’s brake control system. vehicle’s brake control system.
The safety brake is electrically operated and works mechanically through a The safety brake is electrically operated and works mechanically through a
compression spring applied to a magnet brake mounted on the drive unit. This brake compression spring applied to a magnet brake mounted on the drive unit. This brake
is also used for emergency braking. A warning indicator appears when the brake is is also used for emergency braking. A warning indicator appears when the brake is
applied. applied.
Faults in the steering and brake systems (which trigger an emergency stop) are Faults in the steering and brake systems (which trigger an emergency stop) are
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shown on the driver’s display or the on board computer. shown on the driver’s display or the on board computer.

B3 B3
 Emergency Stop Safety Feature: The emergency stop is controlled by the steering Emergency Stop Safety Feature: The emergency stop is controlled by the steering
and traction controllers. If an error is detected the truck automatically brakes to a halt. and traction controllers. If an error is detected the truck automatically brakes to a halt.
Control displays on the driver’s display indicate the emergency stop. Every time the Control displays on the driver’s display indicate the emergency stop. Every time the
truck is switched on, the system performs a self-diagnosis which only releases the truck is switched on, the system performs a self-diagnosis which only releases the
parking brake (emergency stop) if the functionality test is positive. parking brake (emergency stop) if the functionality test is positive.

Steering: Electrical steering which turns the transmission via a spur gear. You can Steering: Electrical steering which turns the transmission via a spur gear. You can
choose between 3 operating modes in service mode on the driver’s display or the on- choose between 3 operating modes in service mode on the driver’s display or the on-
board computer: board computer:

– 180° (o) – 180° (o)

– 360° (endless) (o) – 360° (endless) (o)
– Switch between 180 - 360° via the (t) key – Switch between 180 - 360° via the (t) key
The adjustable steering wheel acts as a steering transmitter. The adjustable steering wheel acts as a steering transmitter.

Operator position: The driver’s position is ergonomically designed with ample Operator position: The driver’s position is ergonomically designed with ample
legroom. The driver’s seat, steering arm and Multi-Pilot can be adjusted by the driver legroom. The driver’s seat, steering arm and Multi-Pilot can be adjusted by the driver
to ensure a comfortable posture. to ensure a comfortable posture.
The accelerator pedal and brake pedal are of “automotive” design. The accelerator pedal and brake pedal are of “automotive” design.

Mast reach damping (o): Damping of vibration of extended mast and speed Mast reach damping (o): Damping of vibration of extended mast and speed
reduction to inching when the load is extended beyond free lift. reduction to inching when the load is extended beyond free lift.

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

Deadman switch: The foot switch in the left foot compartment must be depressed to Deadman switch: The foot switch in the left foot compartment must be depressed to
allow the driver to operate the truck. Lifting and travelling are inhibited if the driver allow the driver to operate the truck. Lifting and travelling are inhibited if the driver
removes his foot from the foot switch. Steering and braking remain enabled. The removes his foot from the foot switch. Steering and braking remain enabled. The
deadman switch can be adjusted so that when the foot switch is released the parking deadman switch can be adjusted so that when the foot switch is released the parking
brake applies after a set time. (prevents the truck from accidentally rolling away) brake applies after a set time. (prevents the truck from accidentally rolling away)

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 1 1
11 11
2 2

12 13 14 12 13 14

3 3

4 4

10 10

9 9

8 8

7 6 5 7 6 5

Item Model Item Model Item Model Item Model

1 t Clearview mast 9 t Brake pedal 1 t Clearview mast 9 t Brake pedal
2 t Overhead guard 10 t Accelerator pedal 2 t Overhead guard 10 t Accelerator pedal
3 t Free lift cylinder (not with ZT mast) 11 t Battery trolley unlatch pedal 3 t Free lift cylinder (not with ZT mast) 11 t Battery trolley unlatch pedal
4 t Multi-Pilot 12 t Driver’s display 4 t Multi-Pilot 12 t Driver’s display
o Solopilot o On board computer o Solopilot o On board computer
5 t Load wheels 13 t Two stage switch key with 5 t Load wheels 13 t Two stage switch key with
spare key (service). spare key (service).
6 t Outriggers o CANCODE 6 t Outriggers o CANCODE
7 t Drive wheel o ISM Access Module 7 t Drive wheel o ISM Access Module
8 t Deadman switch 14 t EMERGENCY DISCONNECT 8 t Deadman switch 14 t EMERGENCY DISCONNECT
switch switch
t Standard Equipment o Optional Equipment t Standard Equipment o Optional Equipment
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 Controls and Displays Controls and Displays

Controls and displays are clearly arranged in the driver’s Controls and displays are clearly arranged in the driver’s
cab. 4 cab. 4
The logically arranged Multi Pilot (4) enable single The logically arranged Multi Pilot (4) enable single
handed operation of travel direction, lift / lower, mast handed operation of travel direction, lift / lower, mast
reach/retract, mast tilt, sideshift left and right in sideshift reach/retract, mast tilt, sideshift left and right in sideshift
mode (auxiliary hydraulics HF5 (o)) and horn. T mode (auxiliary hydraulics HF5 (o)) and horn. T

Hydraulic system: Pump unit with AC motor and low- Hydraulic system: Pump unit with AC motor and low-
noise precision high pressure pump. The system is noise precision high pressure pump. The system is
controlled via the Multi-Pilot (4). U controlled via the Multi-Pilot (4). U

Electrical System: 48 volt, twin cable system. Standard Electrical System: 48 volt, twin cable system. Standard
electronic drive, lift and steering control system. electronic drive, lift and steering control system.
The electronic drive control provides infinite travel speed The electronic drive control provides infinite travel speed
control and enables plugging when changing direction. control and enables plugging when changing direction.
Travel and lift parameters can be set as required via the driver’s display (12). Warning Travel and lift parameters can be set as required via the driver’s display (12). Warning
displays, operator error messages and service functions can also be shown on the displays, operator error messages and service functions can also be shown on the
driver’s display. (For battery types, see Chapter D.) driver’s display. (For battery types, see Chapter D.)

2.2 Load handling 2.2 Load handling

Mast support: The mast support is mounted on support rollers. A single telescopic Mast support: The mast support is mounted on support rollers. A single telescopic
reach cylinder extends and retracts the support. The mast support rails are bolted on reach cylinder extends and retracts the support. The mast support rails are bolted on
to the outriggers (6). to the outriggers (6).

Mast: The trucks are equipped with fork tilt devices or telescopic clearview masts Mast: The trucks are equipped with fork tilt devices or telescopic clearview masts
positioned in the mast support. Adjustable side rollers and slide pieces take up the positioned in the mast support. Adjustable side rollers and slide pieces take up the
lateral pressure exerted on the fork carriage if the load is positioned on one side. The lateral pressure exerted on the fork carriage if the load is positioned on one side. The
forks are fitted to the fork carriage and are adjustable. With the two stage Triplex mast forks are fitted to the fork carriage and are adjustable. With the two stage Triplex mast
(DZ) a short, offset free lift cylinder (3) initially lifts the load carriage (free lift) without (DZ) a short, offset free lift cylinder (3) initially lifts the load carriage (free lift) without
changing the overall height of the truck. With the telescopic mast (ZT) the free lift is changing the overall height of the truck. With the telescopic mast (ZT) the free lift is
limited to 80 mm. limited to 80 mm.

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

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B6 B6
 3 Standard Version Specifications 3 Standard Version Specifications

Z Technical data specified in accordance with VDI 2198.

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

3.1 Performance Data 3.1 Performance Data

ETM/V 214/216 ETM/V 214/216

Model ETM/V 214 ETM/V 216 Model ETM/V 214 ETM/V 216
Q Capacity (where C = 600 mm) 1400 1600 kg Q Capacity (where C = 600 mm) 1400 1600 kg
c Load centre of gravity distance 600 600 mm c Load centre of gravity distance 600 600 mm
Travel Speed 14.0 / 14.0 14.0 / 14.0 km/h Travel Speed 14.0 / 14.0 14.0 / 14.0 km/h
Drive, fork direction Drive, fork direction
Lift Speed 0.44 / 0.70 0.42 / 0.70 m/s Lift Speed 0.44 / 0.70 0.42 / 0.70 m/s
w / w.o. load (±10%) w / w.o. load (±10%)
Lower Speed 0.50 / 0.50 0.50 / 0.50 m/s Lower Speed 0.50 / 0.50 0.50 / 0.50 m/s
w / w.o. load (-15%) w / w.o. load (-15%)
Traverse speed 0.08 - 0.21) m/s Traverse speed 0.08 - 0.21) m/s
Gradeability w / w.o. load 9/13 8/12 % Gradeability w / w.o. load 9/13 8/12 %
Max. gradeability (5 min rating) 10/15 10/15 % Max. gradeability (5 min rating) 10/15 10/15 %
w / w.o. load w / w.o. load
Acceleration with / without load 4.8/4.4 4.8/4.4 s Acceleration with / without load 4.8/4.4 4.8/4.4 s
Drive motor, output S2 = 60min 6.9 6.9 kW Drive motor, output S2 = 60min 6.9 6.9 kW
Lift motor, output at S3 15% 10/142) 10/142) kW Lift motor, output at S3 15% 10/142) 10/142) kW
1) Free lift traverse speed 1) Free lift traverse speed
2) For regenerative lowering 2) For regenerative lowering
option option
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 ETM/V 320/325 ETM/V 320/325

Model ETM/V 320 ETM/V 325 Model ETM/V 320 ETM/V 325
Q Capacity (where C = 600 mm) 2000 2500 kg Q Capacity (where C = 600 mm) 2000 2500 kg
c Load centre of gravity distance 600 600 mm c Load centre of gravity distance 600 600 mm
c Load centre of gravity for special trucks 800 800 mm c Load centre of gravity for special trucks 800 800 mm
Travel Speed 14.0 / 14.0 14.0 / 14.0 km/h Travel Speed 14.0 / 14.0 14.0 / 14.0 km/h
Drive, fork direction Drive, fork direction
Hubgeschwindigkeit 0.32 / 0.60 0.30 / 0.60 m/s Hubgeschwindigkeit 0.32 / 0.60 0.30 / 0.60 m/s
mit / ohne Last (±10%) mit / ohne Last (±10%)
Lower Speed 0.50 / 0.50 0.50 / 0.50 m/s Lower Speed 0.50 / 0.50 0.50 / 0.50 m/s
w / w.o. load (-15%) w / w.o. load (-15%)
Traverse speed 0.08 - 0.11) m/s Traverse speed 0.08 - 0.11) m/s
Gradeability w / w.o. load 7 / 11 6 / 10 % Gradeability w / w.o. load 7 / 11 6 / 10 %
Max. gradeability (5 min rating) 10 / 15 10 / 15 % Max. gradeability (5 min rating) 10 / 15 10 / 15 %
mit / ohne Last mit / ohne Last
Acceleration with / without load 5.3/4.6 5.4/4.6 s Acceleration with / without load 5.3/4.6 5.4/4.6 s
Drive motor, output S2 = 60min 6.9 6.9 kW Drive motor, output S2 = 60min 6.9 6.9 kW
Lift motor, output at S3 15% 10/142) 10/142) kW Lift motor, output at S3 15% 10/142) 10/142) kW
1) Free lift traverse speed 1) Free lift traverse speed
2) For regenerative lowering option 2) For regenerative lowering option

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 3.2 Dimensions 3.2 Dimensions

(All dimensions in mm) (All dimensions in mm)

ETM/V 214/216 ETM/V 214/216

Model ETM 214 ETV 214 ETM 216 ETV 216 Model ETM 214 ETV 214 ETM 216 ETV 216
s Lowered fork height 40 40 s Lowered fork height 40 40
h6 Height above overhead guard 2150 2150 h6 Height above overhead guard 2150 2150
l1 Overall lengtha) 2418 2346 2418 l1 Overall lengtha) 2418 2346 2418
l4 Reach 550 622 600 l4 Reach 550 622 600
l7 Length over Outriggers 1792 1842 l7 Length over Outriggers 1792 1842
b1/ Overall width 1120 1270 1120 1270 b1/ Overall width 1120 1270 1120 1270
b2 b2
Wa Turning radius 1613 1663 Wa Turning radius 1613 1663
Ast Aisle width 2701 2650 2715 Ast Aisle width 2701 2650 2715
800 x 1200 traverse pallets 2468b) 2396b) 2468b) 800 x 1200 traverse pallets 2468b) 2396b) 2468b)
Ast Aisle width 2757 2692 2762 Ast Aisle width 2757 2692 2762
1000 x 1200 longitudinal pallets 2668b) 2596b) 2668b) 1000 x 1200 longitudinal pallets 2668b) 2596b) 2668b)
Net weight see truck data plate Net weight see truck data plate

a)Fork length 1,150 mm a)Fork length 1,150 mm

b)Applies to 420 Ah battery. Other battery sizes will change this reading. b)Applies to 420 Ah battery. Other battery sizes will change this reading.

ETM/V 320/325 ETM/V 320/325

Model ETM 320 ETV 320 ETM 325 ETV 325 Model ETM 320 ETV 320 ETM 325 ETV 325
s Lowered fork height 50 50 s Lowered fork height 50 50
h6 Height above overhead guard 2150 2150 h6 Height above overhead guard 2150 2150
l1 Overall length a) 2547 2459 2547 l1 Overall length a) 2547 2459 2547
l4 Reach 536 624 703 736 l4 Reach 536 624 703 736
l7 Length over Outriggers 1920 2075 l7 Length over Outriggers 1920 2075
b1/ Overall width 1140 1290 1198 1348 b1/ Overall width 1140 1290 1198 1348
b2 1120 1270 1120 1270 b2 1120 1270 1120 1270
Wa Turning radius 1710 1865 Wa Turning radius 1710 1865
Ast Aisle width 2822 2758 2867 2845 Ast Aisle width 2822 2758 2867 2845
800 x 1200 traverse pallets 2597b) 2509b) 2442b) 2564b) 800 x 1200 traverse pallets 2597b) 2509b) 2442b) 2564b)
Ast Aisle width 2883 2804 2899 2870 Ast Aisle width 2883 2804 2899 2870
1000 x 1200 longitudinal pallets 2797b) 2709b) 2642b) 2764b) 1000 x 1200 longitudinal pallets 2797b) 2709b) 2642b) 2764b)
Net weight see truck data plate Net weight see truck data plate

a)Fork length 1,150 mm a)Fork length 1,150 mm

b)Applies to 560 Ah battery. Other battery sizes will change this reading. b)Applies to 560 Ah battery. Other battery sizes will change this reading.
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B9 B9
 h4 h4

h3 h3
h1 h1
l4 l l4 l
h6 h6
h2 h2

c c

Q Q

s s

l7 l7
l1 l1

b2 b1 b2 b1

Wa Wa
a a a a
2 2 2 2
Ast Ast
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B 10 B 10
 3.3 Standard mast version dimensions 3.3 Standard mast version dimensions

ETM/V 214/216 ETM/V 214/216

Model Telescopic Two stage Two stage Model Telescopic Two stage Two stage
mast (ZT) Triplex mast Triplex Mast mast (ZT) Triplex mast Triplex Mast
(DZ) (DZ) reinforced (DZ) (DZ) reinforced
h1 Height 1950 - 2700 1950 - 3540 2700 - 3950 mm h1 Height 1950 - 2700 1950 - 3540 2700 - 3950 mm
h2 Free lift 80 1306 - 2896 2056 - 3306 mm h2 Free lift 80 1306 - 2896 2056 - 3306 mm
h3 Lift 2900 - 4400 4250 - 9020 6500 - 10250 mm h3 Lift 2900 - 4400 4250 - 9020 6500 - 10250 mm
h4 Max. height 3544 - 5044 4894 - 9664 7144 - 10894 mm h4 Max. height 3544 - 5044 4894 - 9664 7144 - 10894 mm

ETM/V 320/325 ETM/V 320/325

Model Two stage Two stage Model Two stage Two stage
Triplex mast (DZ) Triplex mast Triplex mast (DZ) Triplex mast
(DZ) reinforced (DZ) reinforced
h1 Height 2050 - 3540 2700 - 4640 mm h1 Height 2050 - 3540 2700 - 4640 mm
h2 Free lift 1320 - 2810 1970 - 3910 mm h2 Free lift 1320 - 2810 1970 - 3910 mm
h3 Lift 4250 - 8720 6200 - 12020 mm h3 Lift 4250 - 8720 6200 - 12020 mm
h4 Max. height 4996 - 9466 6946 - 12766 mm h4 Max. height 4996 - 9466 6946 - 12766 mm

3.4 Weights 3.4 Weights

(All dimensions in kg) (All dimensions in kg)

Description ETM 214 ETV 214 ETM 216 ETV 216 Description ETM 214 ETV 214 ETM 216 ETV 216
Net weight incl. battery1 2925 2950 3045 3070 Net weight incl. battery1 2925 2950 3045 3070
Axle load, w.o. load front/ 1755/1170 1770/1180 1827/1218 1842/1228 Axle load, w.o. load front/ 1755/1170 1770/1180 1827/1218 1842/1228
rear rear
Axle loading forks fwd. w. 475/3806 522/3828 557/4088 / 560/4110 Axle loading forks fwd. w. 475/3806 522/3828 557/4088 / 560/4110
load front/rear load front/rear
Axle loading forks back w. 1557/2768 1566/2784 1672/2973 1681/2989 Axle loading forks back w. 1557/2768 1566/2784 1672/2973 1681/2989
load front/rear load front/rear

1)Applies to 420 Ah battery. Other battery sizes will change this reading. 1)Applies to 420 Ah battery. Other battery sizes will change this reading.

Description ETM 320 ETV 320 ETM 325 ETV 325 Description ETM 320 ETV 320 ETM 325 ETV 325
Net weight incl. battery1 3550 3650 3600 3700 Net weight incl. battery1 3550 3650 3600 3700
Axle load, w.o. load front/ 2152/1398 2212/1438 2204/1396 2264/1436 Axle load, w.o. load front/ 2152/1398 2212/1438 2204/1396 2264/1436
rear rear
Axle loading forks fwd. w. 572/4978 582/5068 592/5508 602/5598 Axle loading forks fwd. w. 572/4978 582/5068 592/5508 602/5598
load front/rear load front/rear
Axle loading forks back w. 1805/3745 1845/3805 1997/4103 2032/4168 Axle loading forks back w. 1805/3745 1845/3805 1997/4103 2032/4168
load front/rear load front/rear

1)Applies to 560 Ah battery. Other battery sizes will change this reading. 1)Applies to 560 Ah battery. Other battery sizes will change this reading.
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3.5 Wheels/tyres 3.5 Wheels/tyres

Description ETM/V 214 ETM/V 216 ETM/V 320 ETM/V 325 Description ETM/V 214 ETM/V 216 ETM/V 320 ETM/V 325
Tyre size, front 343x114 343x114 343x140 343x140 Tyre size, front 343x114 343x114 343x140 343x140
Tyre size, rear 285x100 285x100 355x106 355x135 Tyre size, rear 285x100 285x100 355x106 355x135
Wheels, number front / rear 1x/2 1x/2 1x/2 1x/2 Wheels, number front / rear 1x/2 1x/2 1x/2 1x/2
(x = driven) (x = driven)
Tyres Vulkollan® Vulkollan® Vulkollan® Vulkollan® Tyres Vulkollan® Vulkollan® Vulkollan® Vulkollan®

3.6 Battery 3.6 Battery

See battery types in chapter D. See battery types in chapter D.

3.7 Hydraulics 3.7 Hydraulics

Description ETM/V 214/216 ETM/V 320/325 Description ETM/V 214/216 ETM/V 320/325
Available working pressure for attachments 150 bar 150 bar Available working pressure for attachments 150 bar 150 bar
Oil flow for attachments 20 l/min 20 l/min Oil flow for attachments 20 l/min 20 l/min

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 3.8 Mast weights 3.8 Mast weights

The weight of the mast can be calculated using the formulae given below. 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 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 battery (lift height) can be taken from the data plate. The weight of the truck and the battery
can be found on the data plate. can be found on the data plate.

3.8.1 Mast weight calculation example 3.8.1 Mast weight calculation example
31 35 42 31 35 42

ETV 214 GNE 160 740 DZ ETV 214 GNE 160 740 DZ

xxx kg xxx kg 38 xxx kg xxx kg 38

Truck name (31): ETV-214 Truck name (31): ETV-214

Mast (42): Section reinforcement, fork tilt Mast (42): Section reinforcement, fork tilt
Mast weight = 0.74 x lift height (42) + 440 kg Mast weight = 0.74 x lift height (42) + 440 kg

Mast weight = 0.74 x 740 + 440 kg = 987.6 kg Mast weight = 0.74 x 740 + 440 kg = 987.6 kg

3.8.2 Overview of formulae to be applied 3.8.2 Overview of formulae to be applied

Truck series Design Calculation Truck series Design Calculation

ETV/ETM-214/216 ZT Weight = 0.65 x lift height + 266 kg ETV/ETM-214/216 ZT Weight = 0.65 x lift height + 266 kg
DZ hot rolled Weight = 0.63 x lift height + 325 kg DZ hot rolled Weight = 0.63 x lift height + 325 kg
DZ: large lift heights Weight = 0.74 x lift height + 370 kg DZ: large lift heights Weight = 0.74 x lift height + 370 kg
cold rolled cold rolled
DZ: fork tilt cold rolled Weight = 0.74 x lift height + 440 kg DZ: fork tilt cold rolled Weight = 0.74 x lift height + 440 kg

ETV/ETM-320/325 Standard Weight = 0.93 x lift height + 434 kg ETV/ETM-320/325 Standard Weight = 0.93 x lift height + 434 kg
Section reinforcement: Weight = 1.10 x lift height + 490 kg Section reinforcement: Weight = 1.10 x lift height + 490 kg
fork tilt and sideshifter fork tilt and sideshifter
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 h4 h4

h3 h3
h1 h1
l4 l l4 l
h6 h6
h2 h2

c c

Q Q

s s

l7 l7
l1 l1

b2 b1 b2 b1

Wa Wa
a a a a
2 2 2 2
Ast Ast
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 3.9 EN norms 3.9 EN norms

Noise emission: 68 dB(A) Noise emission: 68 dB(A)

in accordance with EN 12053 as harmonised with in accordance with EN 12053 as harmonised with
ISO 4871. ISO 4871.

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

Vibration: 0.66 m/s2 Vibration: 0.66 m/s2

In accordance with EN 13059. In accordance with EN 13059.

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

Z The vibration acceleration acting on the body in the operating position is, in
accordance with standard procedures, the linearly integrated, weighted acceleration
Z The vibration acceleration acting on the body in the operating position is, in
accordance with standard procedures, the linearly integrated, weighted acceleration
in the vertical direction. It is calculated when travelling over bumps at constant speed. in 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 the These recordings were taken uniquely on the truck and must not be confused with the
human vibrations of the "2002/44/EC/Vibrations" operator directive. The manufacturer human vibrations of the "2002/44/EC/Vibrations" operator directive. The manufacturer
offers a special service to measure these human vibrations, see "Human Vibrations" in offers a special service to measure these human vibrations, see "Human Vibrations" in
Chapter F. Chapter F.

Electromagnetic compatibility (EMC) Electromagnetic compatibility (EMC)

The manufacturer confirms the truck adheres to the limits The manufacturer confirms the truck adheres to the limits
for electromagnetic emissions and resistance as well as for electromagnetic emissions and resistance as well as
the static electricity discharge test in accordance with the static electricity discharge test in accordance with
EN 12895 as well as the standardised instructions EN 12895 as well as the standardised instructions
contained therein. contained therein.

Z No changes to electric or electronic components or their arrangement may be made

without the written agreement of the manufacturer.
Z No changes to electric or electronic components or their arrangement may be made
without the written agreement of the manufacturer.

Electrical equipment on the truck emitting non-ionised radiation (e.g. wireless data Electrical equipment on the truck emitting non-ionised radiation (e.g. wireless data
transmission) can affect operators' medical equipment (pacemakers, hearing aids transmission) can affect operators' medical equipment (pacemakers, hearing aids
etc.) and result in malfunctions. Consult with a doctor or the manufacturer of the etc.) and result in malfunctions. Consult with a doctor or the manufacturer of the
medical equipment to clarify whether it can be used near the industrial truck. medical equipment to clarify whether it can be used near the industrial truck.
3.10 Conditions of use 3.10 Conditions of use

Ambient temperature Ambient temperature

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

For constant operation below 0 °C or if there are extreme fluctuations in temperature For constant operation below 0 °C or if there are extreme fluctuations in temperature
and humidity special equipment for forklift trucks is available for which permission is and humidity special equipment for forklift trucks is available for which permission is
required. required.
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3.11 Electrical requirements 3.11 Electrical requirements

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

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 4 Identification points and data plates 4 Identification points and data plates

23 23

24 24
20, 21, 22 25 20, 21, 22 25

19 19
26 26

18 18
27 27
27a 27a
17 17

16 16
mV mV
1,5 V 1,5 V

30 28 25 30 28 25

29 28 29 28

Item Model Item Model

16 Decal: “Caution: Low voltage electronics system” 16 Decal: “Caution: Low voltage electronics system”
17 Truck data plate 17 Truck data plate
18 Test sticker (o) 18 Test sticker (o)
19 Travel direction for steering angle (o) 19 Travel direction for steering angle (o)
20 Capacity plate, capacity / sideshift 20 Capacity plate, capacity / sideshift
21 Capacity plate, Capacity / Load Centre of Gravity, Forks 21 Capacity plate, Capacity / Load Centre of Gravity, Forks
22 Capacity plate, Capacity / Load Centre of Gravity/ Lift Height 22 Capacity plate, Capacity / Load Centre of Gravity/ Lift Height
23 Notice "No standing under the load carriage" 23 Notice "No standing under the load carriage"
24 “Final inspection completed” label 24 “Final inspection completed” label
25 Strap points for crane lifting 25 Strap points for crane lifting
26 "Do not reach through the mast" warning 26 "Do not reach through the mast" warning
27 Serial no., truck without weight, see page B14 27 Serial no., truck without weight, see page B14
27a Serial no., truck with weight, see page B14 27a Serial no., truck with weight, see page B14
28 Jack contact points 28 Jack contact points
29 “Hydraulic oil filler neck” label 29 “Hydraulic oil filler neck” label
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30 Attention: Read operating instructions. 30 Attention: Read operating instructions.

31 Truck name 31 Truck name

B 17 B 17
4.1 Truck data plate 4.1 Truck data plate

31 42 31 42

32 41 32 41

33 40 33 40

34 39 34 39

35 38 35 38

37 37

36 36

Item Model Item Model Item Model Item Model

31 Model 37 Manufacturer 31 Model 37 Manufacturer
32 Serial no. 38 Min./max. battery weight (kg) 32 Serial no. 38 Min./max. battery weight (kg)
33 Rated capacity (kg) 39 Output 33 Rated capacity (kg) 39 Output
34 Battery voltage V 40 Load centre of gravity (mm) 34 Battery voltage V 40 Load centre of gravity (mm)
35 Net weight w.o. battery (kg) 41 Year of manufacture 35 Net weight w.o. battery (kg) 41 Year of manufacture
36 Manufacturer’s logo 42 Option 36 Manufacturer’s logo 42 Option

Z For queries regarding the truck or ordering spare parts please quote the truck serial
number (32). Serial number is engraved into the truck chassis.
Z For queries regarding the truck or ordering spare parts please quote the truck serial
number (32). Serial number is engraved into the truck chassis.

The serial number is located: The serial number is located:

– on trucks without a weight on the traverse wall at the bottom left of the battery – on trucks without a weight on the traverse wall at the bottom left of the battery
compartment (item 27). compartment (item 27).
– on trucks (ETM/V 320/325) with additional weight plate in the battery compartment – on trucks (ETM/V 320/325) with additional weight plate in the battery compartment
inside the left outrigger (item 27a) inside the left outrigger (item 27a)

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B 18 B 18
 4.2 Truck load chart (capacity) 4.2 Truck load chart (capacity)

F Loss of stability can cause accidents

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

The capacity plate (22) gives the capacity (Q) of the truck in kg with a vertical mast. The capacity plate (22) gives the capacity (Q) of the truck in kg with a vertical mast.
The maximum capacity is shown as a table with a standard load centre of gravity The maximum capacity is shown as a table with a standard load centre of gravity
distance * C (in mm) and the required lift height H (in mm). The arrow shape markings distance * 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 limits (42 and 43) on the inner and outer masts show the driver when the specified lift limits
have been reached. have been reached.
*) The standard load centre of gravity distance takes into account the width as well as *) The standard load centre of gravity distance takes into account the width as well as
the height of the load. the height of the load.
22 42 43 22 42 43

X.XXXX.XX.XX X.XXXX.XX.XX

4250 850 850 600 4250 850 850 600

3600 1105 1105 850 3600 1105 1105 850
2900 1250 1250 850 2900 1250 1250 850

500 600 700 500 600 700

Example of how to calculate the maximum capacity: 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 of With a load centre of gravity distance C of 600 mm and a maximum lift height H of
3600 mm. the max. capacity Q is 1105 kg. 3600 mm. the max. capacity Q is 1105 kg.

4.3 Attachment load chart 4.3 Attachment load chart

The attachment load chart gives the truck capacity Q in conjunction with the The attachment load chart gives the truck capacity Q in conjunction with the
respective attachment in kg. The serial number specified in the load chart must match respective attachment in kg. The serial number specified in the load chart must match
the data plate of the attachment, as the capacity for each truck is specifically indicated the data plate of the attachment, as the capacity for each truck is specifically indicated
by the manufacturer. It is shown in the same way as the truck capacity and can be by the manufacturer. It is shown in the same way as the truck capacity and can be
determined accordingly. determined accordingly.
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B 19 B 19
4.4 Stability 4.4 Stability

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

Stability can also be affected by the following factors: Stability can also be affected by the following factors:

– Battery size and weight, – Battery size and weight,

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

4.4.1 Wind loads 4.4.1 Wind loads

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

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

Stop the truck in both cases. Stop the truck in both cases.

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B 20 B 20
 C Transport and Commissioning C Transport and Commissioning
1 Transport 1 Transport

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

– Vertically, with the mast assembled (for low heights) – Vertically, with the mast assembled (for low heights)
– Vertically, with the mast partially assembled and leaning against the overhead – Vertically, with the mast partially assembled and leaning against the overhead
guard (for medium heights), lifting hydraulic line disconnected guard (for medium heights), lifting hydraulic line disconnected
– Vertically, with the mast dismantled (for large heights), all hydraulic lines between – Vertically, with the mast dismantled (for large heights), all hydraulic lines between
the basic truck and the mast separated. the basic truck and the mast separated.

Safety Instructions for Assembly and Commissioning Safety Instructions for Assembly and Commissioning

F On site assembly of the truck, commissioning and driver instruction may only be
carried out by personnel trained and authorised by the manufacturer
F On site assembly of the truck, commissioning and driver instruction may only be
carried out by personnel trained and authorised by the manufacturer
The hydraulic lines may only be connected to the basic truck / mast interface and the The hydraulic lines may only be connected to the basic truck / mast interface and the
truck commissioned once the mast has been properly assembled. truck commissioned once the mast has been properly assembled.
If several trucks have been delivered, make sure that the serial numbers of the load If several trucks have been delivered, make sure that the serial numbers of the load
handlers, masts and basic truck always match. handlers, masts and basic truck always match.
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C1 C1
2 Lifting by crane 2 Lifting by crane

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

F Improper lifting by crane can result in accidents

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

– Prevent the truck and mast from striking other objects when they are being raised, – 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 with and avoid any uncontrolled movement. If necessary, secure the truck and mast with
guide ropes. guide ropes.
– The truck and mast should only be laden by people who are trained in handling lift- – The truck and mast should only be laden by people who are trained in handling lift-
ing slings and tools. ing slings and tools.
– Wear safety shoes when lifting the truck by crane. – Wear safety shoes when lifting the truck by crane.
– Do not stand under a swaying load. – Do not stand under a swaying load.
– Do not walk into or stand in a hazardous area. – 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 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 – Always attach the crane slings to the prescribed strap points and prevent them
from slipping. from slipping.
– Use the lifting gear only in the prescribed load direction. – 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 with Crane slings should be fastened in such a way that they do not come into contact with
any attachments when lifting. any attachments when lifting.

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C2 C2
 2.1 Lifting the basic truck by crane 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).
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 the – In order to lift the truck with a harness wrap rope slings around the strut of the
overhead guard (1). Two strap points (2) are provided on the outriggers. overhead guard (1). Two strap points (2) are provided on the outriggers.
– Park the truck securely (see Chapter E). – Park the truck securely (see Chapter E).
– Secure the truck with wedges to prevent it from rolling away. – 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 slings
should be fastened to the harness in such a way that they do not come into contact
M Attach the crane slings to the strap points so that the truck cannot slip. Lifting slings
should be fastened to the harness in such a way that they do not come into contact
with any parts of the truck when it is being raised. with any parts of the truck when it is being raised.

1 1

2 2
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C3 C3
2.2 Lifting the basic truck and cabin by crane 2.2 Lifting the basic truck and cabin by crane

M The lifting of trucks with a weather-proof cab (o) or cold store cab (o) is subject to
restrictions. Because of the risk to the window, the crane lifting gear and rope slings
M The lifting of trucks with a weather-proof cab (o) or cold store cab (o) is subject to
restrictions. Because of the risk to the window, the crane lifting gear and rope slings
must not pass over the front door. must not pass over the front door.

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

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C4 C4
 3 Securing the truck during transport 3 Securing the truck during transport

F The truck must be securely fastened when transported on a lorry or a trailer.

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

– To fasten the truck pull the tensioning belt (3) through the guide on the overhead – To fasten the truck pull the tensioning belt (3) through the guide on the overhead
guard brace (1) and attach it to the fastening rings. guard brace (1) and attach it to the fastening rings.
– Tighten the tensioning belt with the tensioner (4). – Tighten the tensioning belt with the tensioner (4).

M Loading must be carried out by specially trained staff in accordance with

recommendations contained in Guidelines VDI 2700. In each case correct
M Loading must be carried out by specially trained staff in accordance with
recommendations contained in Guidelines VDI 2700. In each case correct
measurements must be taken and appropriate safety measures applied. measurements must be taken and appropriate safety measures applied.

1 1

3 3

4 4
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C5 C5
4 Using the truck for the first time 4 Using the truck for the first time

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

M Only operate the truck with battery current. Rectified AC current will damage the
electronic components. The battery leads (tow cable) must be less than 6m long.
M Only operate the truck with battery current. Rectified AC current will damage the
electronic 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: To prepare the truck after delivery or transport the following tasks must be carried out:
– Install battery (where required). Do not damage battery cable. – Install battery (where required). Do not damage battery cable.
– Charge the battery (see Chapter D). – Charge the battery (see Chapter D).
– If necessary, remove the transport lock from the parking brake. – If necessary, remove the transport lock from the parking brake.
– Visually inspect the truck, see "Checks Before Starting Daily Operation" in Chapter E. – Visually inspect the truck, see "Checks Before Starting Daily Operation" in Chapter E.
– Start up the truck in accordance with instructions (see Chapter E). – Start up the truck in accordance with instructions (see Chapter E).
– Test the truck, see "Testing After Daily Operation" in Chapter E. – Test the truck, see "Testing After Daily Operation" in Chapter E.
If supplied without a battery, the truck can only be steered with the steering crank If supplied without a battery, the truck can only be steered with the steering crank
(see Chapter E, “Truck Recovery”). (see Chapter E, “Truck Recovery”).

Z You may hear slight brake grinding noises after the truck is used for the first time.
Z You may hear slight brake grinding noises after the truck is used for the first time.

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C6 C6
 D Battery Maintenance, Charging & D Battery Maintenance, Charging &
Replacement Replacement
1 Safety regulations for handling acid batteries 1 Safety regulations for handling acid batteries

Park the truck securely before carrying out any work on the batteries (see Chapter E). 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 by Maintenance personnel: Batteries may only be charged, serviced or replaced by
trained personnel. The present operator manual and the manufacturer’s instructions trained personnel. The present operator manual and the manufacturer’s instructions
concerning batteries and charging stations must be observed when carrying out the concerning batteries and charging stations must be observed when carrying out the
work. work.

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

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

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

Battery Disposal: Batteries may only be disposed of in accordance with national Battery Disposal: Batteries may only be disposed of in accordance with national
environmental protection regulations or disposal laws. The manufacturer’s disposal environmental protection regulations or disposal laws. The manufacturer’s disposal
instructions must be followed. instructions 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 on F Batteries contain an acid solution which is poisonous and corrosive. Therefore,
always wear protective clothing and eye protection when carrying out work on
batteries. Above all avoid any contact with battery acid. batteries. Above all avoid any contact with battery acid.
Nevertheless, should clothing, skin or eyes come in contact with acid the affected Nevertheless, should clothing, skin or eyes come in contact with acid the affected
parts should be rinsed with plenty of clean water - where the skin or eyes are affected parts should be rinsed with plenty of clean water - where the skin or eyes are affected
call a doctor immediately. Immediately neutralise any spilled battery acid. call a doctor immediately. Immediately neutralise any spilled battery acid.

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

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

F The weight and dimensions of the battery have considerable affect on the operational
safety of the truck. Battery equipment may only be replaced with the agreement of the
F The weight and dimensions of the battery have considerable affect on the operational
safety of the truck. Battery equipment may only be replaced with the agreement of the
manufacturer. manufacturer.
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D1 D1
2 Battery types 2 Battery types

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

Capacity Standard (L) High Performance HX) Capacity Standard (L) High Performance HX)
48 V - 3PzS - battery 420 Ah 420L 450H 48 V - 3PzS - battery 420 Ah 420L 450H
48 V - 4PzS - battery 560 Ah 560L 600H 48 V - 4PzS - battery 560 Ah 560L 600H
48 V - 5PzS - battery 700 Ah 700L 750H 48 V - 5PzS - battery 700 Ah 700L 750H
48 V - 6PzS - battery 840 Ah 840L 900H 48 V - 6PzS - battery 840 Ah 840L 900H

The battery weight is indicated on the battery data plate. The battery weight is indicated on the battery data plate.

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

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D2 D2
 3 Exposing the battery 3 Exposing the battery

F Accident risk
Trapping hazard when exposing the battery. F Accident risk
Trapping hazard when exposing the battery.

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

– Prepare for operation (see Chapter E). – Prepare for operation (see Chapter E).

3 3
1 1
T T

U U

– Move the Multi Pilot (1) in the arrow direction. (U). Move the mast support as far as – Move the Multi Pilot (1) in the arrow direction. (U). Move the mast support as far as
the stop in the battery direction and release the Multi Pilot (the mast is now in its the stop in the battery direction and release the Multi Pilot (the mast is now in its
limit position). limit position).
– Again move the Multi Pilot (1) in the direction of arrow (U) and move the mast – Again move the Multi Pilot (1) in the direction of arrow (U) and move the mast
support further towards the battery as far as the stop position (preparation for support further towards the battery as far as the stop position (preparation for
unlatching the battery) and hold it in this position. unlatching the battery) and hold it in this position.
– Press on the battery unlatch pedal (2) with your right foot and hold it down. – Press on the battery unlatch pedal (2) with your right foot and hold it down.
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D3 D3
 2 2

The "battery unlatched" button (red graphic symbol) (3) lights up on the driver’s The "battery unlatched" button (red graphic symbol) (3) lights up on the driver’s
display (t) or the control light in the on-board computer display goes on (o). display (t) or the control light in the on-board computer display goes on (o).

– Move Multi-Pilot (1) towards arrow (T) and extend the mast support with the – Move Multi-Pilot (1) towards arrow (T) and extend the mast support with the
coupled battery trolley until the battery is exposed for maintenance. coupled battery trolley until the battery is exposed for maintenance.
– Release the battery unlatch pedal (2). – Release the battery unlatch pedal (2).
– Turn the EMERGENCY DISCONNECT switch and key switch off. – Turn the EMERGENCY DISCONNECT switch and key switch off.

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

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D4 D4
 4 Charging the battery 4 Charging the battery

M The gases produced during charging can cause explosions

M The gases produced during charging can cause explosions

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

– Switch the charging station and truck off first before connecting/disconnecting the – Switch the charging station and truck off first before connecting/disconnecting the
charging cable of the battery charging station to/from the battery connector. charging 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. – 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. – Before charging, check all cables and plug connections for visible signs of damage.
– Ventilate the room in which the truck is being charged. – 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- – The battery cover must be open and the battery cell surfaces must be exposed dur-
ing charging to ensure adequate ventilation. ing charging to ensure adequate ventilation.
– Do not smoke and avoid naked flames when handling batteries. – Do not smoke and avoid naked flames when handling batteries.
– Wherever an industrial truck is parked for charging there shall be no inflammable – 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. material or lubricants capable of creating sparks within 2 metres around the truck.
– Fire protection equipment must be on hand. – Fire protection equipment must be on hand.
– Do not lay any metallic objects on battery. – Do not lay any metallic objects on battery.
– It is essential to follow the safety regulations of the battery and charger station – It is essential to follow the safety regulations of the battery and charger station
manufacturers. manufacturers.
– Expose the battery (see Section 3). – Expose the battery (see Section 3).
Procedure Procedure

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

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

– Where necessary remove the insulating mat from the battery. – Where necessary remove the insulating mat from the battery.
– Connect the charger lead of the battery charger station with the battery connector. – Connect the charger lead of the battery charger station with the battery connector.
– Charge the battery in accordance with the battery and charging station – Charge the battery in accordance with the battery and charging station
manufacturers’ instructions. manufacturers’ instructions.

F It is essential to follow the safety regulations of the battery and charging station
manufacturers. F It is essential to follow the safety regulations of the battery and charging station
manufacturers.
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D5 D5
5 Battery removal and installation 5 Battery removal and installation

F Always install the battery with a cable guide

F Always install the battery with a cable guide

7 7

When a battery is installed a cable guide (7) must be fitted with the appropriate battery When a battery is installed a cable guide (7) must be fitted with the appropriate battery
cable. The battery cable length depends on the battery type. cable. The battery cable length depends on the battery type.
– Contact the manufacturer's service department when replacing the factory-fitted – Contact the manufacturer's service department when replacing the factory-fitted
battery. battery.

M Accident risk during battery removal and installation

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- Due to the battery weight and acid there is a risk of trapping or scalding when the bat-
tery is removed and installed. tery is removed and installed.
– Note the "Safety regulations for handling acid batteries" section in this chapter. – Note the "Safety regulations for handling acid batteries" section in this chapter.
– Wear safety shoes when removing and installing the battery. – Wear safety shoes when removing and installing the battery.
– Do not reach between the battery and the truck. – Do not reach between the battery and the truck.
– Use only batteries with insulated cells and terminal connectors. – Use only batteries with insulated cells and terminal connectors.
– Cover batteries with open terminals or connectors with a rubber mat. – 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. – 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. – 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 – The crane lifting gear must exert a vertical pull so that the battery container is not
compressed. compressed.
– Hooks must be fitted in such a way that when the crane lifting gear is slackened, – Hooks must be fitted in such a way that when the crane lifting gear is slackened,
it does not fall onto the battery cells. it does not fall onto the battery cells.
– Use only approved battery replacement devices (battery roller stand, replacement – Use only approved battery replacement devices (battery roller stand, replacement
trolley etc.) trolley etc.)
– Make sure the battery is securely located in the truck's battery compartment. – Make sure the battery is securely located in the truck's battery compartment.
Procedure Procedure
– Expose the battery (see Section 3). – Expose the battery (see Section 3).

F To prevent short circuits, batteries with exposed terminals or connectors must be

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

D6 D6
 Removal and Installation using a Crane Lifting Harness Removal and Installation using a Crane Lifting Harness

– Loosen and remove the retaining screw (6) from the battery lock (5). – Loosen and remove the retaining screw (6) from the battery lock (5).
– Remove the battery lock (5). – Remove the battery lock (5).
– If necessary, remove the battery cover. – If necessary, remove the battery cover.
– Strap the crane lifting harness to both sides of the battery container (4). – Strap the crane lifting harness to both sides of the battery container (4).
– Lift the battery clear and move out to the side. – Lift the battery clear and move out to the side.
Removal and installation using a battery trolley (o) Removal and installation using a battery trolley (o)

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

– Loosen and remove the retaining screw (6) from the battery lock (5). – Loosen and remove the retaining screw (6) from the battery lock (5).
– Remove the battery lock (5). – Remove the battery lock (5).
– If necessary, remove the battery cover. – If necessary, remove the battery cover.
– Lift the battery to the side on to the battery trolley – Lift the battery to the side on to the battery trolley
Installation is the reverse order of removal. Installation is the reverse order of removal.

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

4 4

6 6
5 5
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D7 D7
D8
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D8

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 E Operation E Operation
1 Safety Regulations for the Operation of Forklift Trucks 1 Safety Regulations for the Operation of Forklift Trucks

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

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

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

Unauthorised use of truck: The driver is responsible for the truck during the time it Unauthorised use of truck: The driver is responsible for the truck during the time it
is in use. The driver must prevent unauthorised persons from driving or operating the is in use. The driver must prevent unauthorised persons from driving or operating the
truck. Do not carry passengers or lift other people. truck. Do not carry passengers or lift other people.
Damage and faults: The supervisor must be immediately informed of any damage Damage and faults: The supervisor must be immediately informed of any damage
or faults to the forklift truck or attachment. Trucks which are unsafe for operation or 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. (e.g. wheel or brake problems) must not be used until they have been rectified.
Repairs: The driver must not carry out any repairs or alterations to the industrial truck Repairs: The driver must not carry out any repairs or alterations to the industrial truck
without the necessary training and authorisation to do so. The driver must never without the necessary training and authorisation to do so. The driver must never
disable or adjust safety mechanisms or switches. disable or adjust safety mechanisms or switches.

Hazardous area: A hazardous area is defined as the area in which a person is at risk Hazardous area: A hazardous area is defined as the area in which a person is at risk
due to truck movement, lifting operations, the load handler (e.g. forks or attachments) due to truck movement, lifting operations, the load handler (e.g. forks or attachments)
or the load itself. This also includes areas which can be reached by falling loads or or the load itself. This also includes areas which can be reached by falling loads or
lowering operating equipment. lowering operating equipment.

F Unauthorised persons must be kept away from the hazardous area. Where there is
danger to personnel, a warning must be sounded with sufficient notice. If F Unauthorised persons must be kept away from the hazardous area. Where there is
danger to personnel, a warning must be sounded with sufficient notice. If
unauthorised personnel are still within the hazardous area the truck shall be brought unauthorised personnel are still within the hazardous area the truck shall be brought
to a halt immediately. to a halt immediately.

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

F The truck can only be moved with or without a load when the mast support is
retracted, the mast tilted back and the load handler lowered. F The truck can only be moved with or without a load when the mast support is
retracted, the mast tilted back and the load handler lowered.
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2 Controls and Displays 2 Controls and Displays

Item Control / Display Function Item Control / Display Function

1 Key switch t Switches control current on and off. 1 Key switch t Switches control current on and off.
Removing the key prevents the truck from Removing the key prevents the truck from
being switched on by unauthorised being switched on by unauthorised
personnel. personnel.
Keypad (CANCODE) o Used to set codes and to switch on the truck 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 truck ISM Access Module o Used to set codes and to switch on the truck
2 EMERGENCY t Interrupts the supply current, deactivates all 2 EMERGENCY t Interrupts the supply current, deactivates all
DISCONNECT switch electrical functions, causing the truck to DISCONNECT switch electrical functions, causing the truck to
brake automatically. brake automatically.
3a Multi-Pilot t Function operation: 3a Multi-Pilot t Function operation:
3b Solo Pilot o – Forward / reverse travel direction 3b Solo Pilot o – Forward / reverse travel direction
– Load handler lift/lower – Load handler lift/lower
– Mast support extend / retract – Mast support extend / retract
– Mast forward or backward tilt / fork tilt – Mast forward or backward tilt / fork tilt
– Sideshift left / right – Sideshift left / right
– Horn switch – Horn switch
– Aux. hydraulics (HF5) (o) – Aux. hydraulics (HF5) (o)
4 Steering angle switch t Changes the steering range 180° / 360°. 4 Steering angle switch t Changes the steering range 180° / 360°.
5 Sideshift centre position o Moves the sideshift to the centre position. 5 Sideshift centre position o Moves the sideshift to the centre position.
switch switch
6 Forks horizontal button o Sets the forks to a horizontal position (fork tilt 6 Forks horizontal button o Sets the forks to a horizontal position (fork tilt
only) only)
7 Armrest lock t Armrest longitudinal adjustment 7 Armrest lock t Armrest longitudinal adjustment
8 Driver’s seat lock t The driver’s seat can be horizontally 8 Driver’s seat lock t The driver’s seat can be horizontally
adjusted. adjusted.
9 Weight adjustment - t Adjusts driver’s weight for optimal seat 9 Weight adjustment - t Adjusts driver’s weight for optimal seat
driver's seat cushioning driver's seat cushioning
10 Backrest adjustment t The backrest on the driver’s seat can be 10 Backrest adjustment t The backrest on the driver’s seat can be
adjusted. adjusted.
11 Accelerator pedal t Provides infinite control of travel speed. 11 Accelerator pedal t Provides infinite control of travel speed.
12 Brake pedal t Brakes the truck. 12 Brake pedal t Brakes the truck.
13 Deadman switch t – Not applied: Travel inhibited, truck 13 Deadman switch t – Not applied: Travel inhibited, truck
decelerates. decelerates.
– Applied: Travel released. – Applied: Travel released.

t = Standard equipment o = Optional Equipment t = Standard equipment o = Optional Equipment

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 3b 3b
17 17

16 16
1 2 1 2
15 15
3a 3a

18 18
4 4
14 5 14 5
6 6
7 7

13 12 11 10 9 8 13 12 11 10 9 8
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 Item Control / Display Function Item Control / Display Function
14 Override switch o Prevents damage to the truck and the load. 14 Override switch o Prevents damage to the truck and the load.
Limit switch system and lift Limit switch system and lift
height display height display
15 Steering column t Sets steering column distance and height 15 Steering column t Sets steering column distance and height
adjustment adjustment
16 Driver’s display t Displays important travel and lift parameters, 16 Driver’s display t Displays important travel and lift parameters,
selection and display of steering modes, selection and display of steering modes,
warnings, incorrect operation notes and warnings, incorrect operation notes and
service displays (see Section 6). service displays (see Section 6).
On board computer o Replaces the keyswitch. On board computer o Replaces the keyswitch.
Switches control voltage on and off. Switches control voltage on and off.
Releases truck functions via PIN code. Releases truck functions via PIN code.
17 Battery trolley unlatch pedal t Unlatches the battery trolley. 17 Battery trolley unlatch pedal t Unlatches the battery trolley.
18 Weighing button o Weighs the load. 18 Weighing button o Weighs the load.

t = Standard equipment o = Optional equipment t = Standard equipment o = Optional equipment

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 3b 3b
17 17

16 16
1 2 1 2
15 15
3a 3a

18 18
4 4
14 5 14 5
6 6
7 7

13 12 11 10 9 8 13 12 11 10 9 8
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3 Starting up the truck 3 Starting up the truck

F Before the truck can be started, operated or a load lifted, the driver must ensure that
there is nobody within the hazardous area.
F Before the truck can be started, operated or a load lifted, the driver must ensure that
there is nobody within the hazardous area.
Checks and operations to be performed before starting daily work Checks and operations to be performed before starting daily work
– Inspect the entire truck (in particular wheels, wheel bolts and load handler) – Inspect the entire truck (in particular wheels, wheel bolts and load handler)
for damage. for damage.
– Visually inspect the hydraulic system in the visible area for damage and leaks. – Visually inspect the hydraulic system in the visible area for damage and leaks.
Damaged hoses must be replaced immediately. Damaged hoses must be replaced immediately.
– Check the battery attachment and wire connections for damage and make sure – Check the battery attachment and wire connections for damage and make sure
they are secure. they are secure.
– Check the battery connector is secure. – Check the battery connector is secure.
– Check the load handler for visible signs of damage such as cracks, bent or severely – Check the load handler for visible signs of damage such as cracks, bent or severely
worn forks. worn forks.
– Check the forks. – Check the forks.
– Check the drive wheel and load wheels for damage. – Check the drive wheel and load wheels for damage.
– Check that the lift chains are evenly tensioned and damage-free. – Check that the lift chains are evenly tensioned and damage-free.
– Check that the load chart and warning labels are legible. – Check that the load chart and warning labels are legible.
– Check the fork tine retaining screw. – Check the fork tine retaining screw.
– Integrated sideshifter (o): Check the screws on the restraint system (B) and – 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. the fork locking system (A) are secure, tighten if necessary. Torque: 190 Nm.
A A A A

B B B B
Sideshifter with roller guide Sideshifter with slip-in guide Sideshifter with roller guide Sideshifter with slip-in guide

3.1 Entry and exit 3.1 Entry and exit

– To enter and exit the cab, hold onto the handle (16a). – To enter and exit the cab, hold onto the handle (16a).
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– Enter or leave the truck. – Enter or leave the truck.

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 3.2 Setting up the operator position 3.2 Setting up the operator position

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

– The driver's seat must be locked in position. – The driver's seat must be locked in position.
– Do not adjust the driver’s seat, steering column or armrest while travelling. – 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 – 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. that all the controls are within reach and can be applied without having to strain.
Adjusting the driver’s seat Adjusting the driver’s seat

Z To achieve optimal seat damping the driver’s seat must be adjusted according to the
driver’s weight.
Z To achieve optimal seat damping the driver’s seat must be adjusted according to the
driver’s weight.
The driver’s seat must be adapted to the driver’s weight. The driver’s seat must be adapted to the driver’s weight.
Adjusting the driver's weight: Adjusting the driver's weight:
– Pull the lever (9) in the direction of the 19 – Pull the lever (9) in the direction of the 19
arrow as far as the stop and then arrow as far as the stop and then
return it. return it.

Z The previous weight setting is reset to

the minimum value.
Z The previous weight setting is reset to
the minimum value.
Seat suspension setting ranges from Seat suspension setting ranges from
50 to 130 kg 50 to 130 kg
– Move lever (9) again in the direction of – Move lever (9) again in the direction of
the arrow until the corresponding the arrow until the corresponding
weight marking on the scale (18) is weight marking on the scale (18) is
reached. Then finally return the lever. 10 reached. Then finally return the lever. 10
– Sit on the driver’s seat. 8 – Sit on the driver’s seat. 8

F From the driver’s seat do not reach out

for the side wall / overhead guard.
18 9
F From the driver’s seat do not reach out
for the side wall / overhead guard.
18 9

Adjusting the backrest: Adjusting the backrest:

– Lift up locking lever (10) and adjust the incline of the backrest (19). – Lift up locking lever (10) and adjust the incline of the backrest (19).
– Release locking lever to lock the backrest in position. – Release locking lever to lock the backrest in position.
Adjusting the seat position: Adjusting the seat position:
– Pull up the locking lever (8) of the driver’s seat lock in the direction of the arrow and – Pull up the locking lever (8) of the driver’s seat lock in the direction of the arrow and
push the seat forwards or backwards to the desired position. push the seat forwards or backwards to the desired position.
– Engage locking lever (8) in position again. – Engage locking lever (8) in position again.

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

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

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

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

Z To avoid risk to health and property, check and adjust the individual driver’s seat
setting before starting up the truck. Z To avoid risk to health and property, check and adjust the individual driver’s seat
setting before starting up the truck.
The driver’s seat must be occupied in order to adjust to the driver’s weight. The driver’s seat must be occupied in order to adjust to the driver’s weight.
Adjusting the driver's weight: Adjusting the driver's weight:
6 6
– Move the lever (9) as far as – Move the lever (9) as far as
it will go in the arrow 19 it will go in the arrow 19
direction. To adjust, move 18 direction. To adjust, move 18
the lever up or down and the lever up or down and
then restore it to its home then restore it to its home
position. position.
– Move the lever up and 9 – Move the lever up and 9
down to set the seat to a down to set the seat to a
higher weight. higher weight.
– Move the lever down and – Move the lever down and
up to set the seat to a lower 7 up to set the seat to a lower 7
weight. weight.

Z The driver's weight is correct

if the arrow is in the middle of Z The driver's weight is correct
if the arrow is in the middle of
the display window (18). the display window (18).
The min. or max. weight 8 10 The min. or max. weight 8 10
setting is reached when you setting is reached when you
can feel a return stroke on the lever. can feel a return stroke on the lever.
– After adjusting the weight, move the lever back fully until it engages. – After adjusting the weight, move the lever back fully until it engages.
Adjusting the backrest: Adjusting the backrest:

F The backrest must be securely engaged in the set position. The backrest setting must
not be changed during travel. F The backrest must be securely engaged in the set position. The backrest setting must
not be changed during travel.
– Lift up locking lever (10) and adjust the incline of the backrest (19). – Lift up locking lever (10) and adjust the incline of the backrest (19).
– Release locking lever to lock the backrest in position. – Release locking lever to lock the backrest in position.
Adjusting the seat position: Adjusting the seat position:

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 seat 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 seat
setting must not be changed during travel. setting must not be changed during travel.
Do not lift the locking lever with your leg or calves. Do not lift the locking lever with your leg or calves.
– Pull up the locking lever (8) of the driver’s seat lock in the direction of the arrow and – Pull up the locking lever (8) of the driver’s seat lock in the direction of the arrow and
push the seat forwards or backwards to the desired position. push the seat forwards or backwards to the desired position.
– Engage locking lever (8) in position again. – Engage locking lever (8) in position again.
Seat heating: Seat heating:
Apply the switch (6): 1 = seat heating ON; 0 = seat heating OFF Apply the switch (6): 1 = seat heating ON; 0 = seat heating OFF
Lumbar vertebrae support: Lumbar vertebrae support:
Hand wheel (7) in position 0 = no bending in lumbar vertebrae area. 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 1 = Increased bending in upper lumbar vertebrae area.
Turn hand wheel (7) to position 2 = Increased bending in lower lumbar vertebrae area. Turn hand wheel (7) to position 2 = Increased bending in lower lumbar vertebrae area.
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 3.2.1 Using the seat belt o 3.2.1 Using the seat belt o

F Travelling without a seat belt can result

in injuries. The belt offers protection F Travelling without a seat belt can result
in injuries. The belt offers protection
against serious injury. against serious injury.

– Put on the seat belt each time before – Put on the seat belt each time before
starting the industrial truck. starting the industrial truck.
– Change the belt height setting (22) ac- – Change the belt height setting (22) ac-
cording to your body size. cording to your body size.
22 22
– Do not alter the belt setting. – Do not alter the belt setting.
– Frozen belt locks (20) or pulleys must – Frozen belt locks (20) or pulleys must
be thawed out and dried. be thawed out and dried.
– The warm air temperature must not 20 21 – The warm air temperature must not 20 21
exceed +60 °C. exceed +60 °C.
– The seat belt and seat cover must be – The seat belt and seat cover must be
checked for damage after an accident checked for damage after an accident
and replaced if necessary. and replaced if necessary.
– Damaged or non-functional belts to be – Damaged or non-functional belts to be
replaced only by contracted dealers or replaced only by contracted dealers or
branches. branches.
– Only original spare parts to be used for – Only original spare parts to be used for
retrofits or repairs. retrofits or repairs.
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3.2.2 Seat belt operating instructions 3.2.2 Seat belt operating instructions

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

F The belt must not be twisted when fastened.

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

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

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

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

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

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

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

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

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 Adjusting the steering column Adjusting the steering column

– Undo the steering column lock (15) – Undo the steering column lock (15)
and adjust the steering head (20) and adjust the steering head (20)
vertically and horizontally to the vertically and horizontally to the
required position. required position.
Now fix the steering column lock again. Now fix the steering column lock again.

20 15 20 15

Adjusting the armrest Adjusting the armrest

– Raise the armrest lock (7) and set the – Raise the armrest lock (7) and set the
armrest (21) to the required position armrest (21) to the required position
(longitudinally). (longitudinally).
– Release the armrest bar (7) again. – Release the armrest bar (7) again.

7 21 7 21
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3.3 To prepare the truck for operation 3.3 To prepare the truck for operation

– Pull up the EMERGENCY – Pull up the EMERGENCY

DISCONNECT switch (2). DISCONNECT switch (2).
– Insert the key in the key switch (1) – Insert the key in the key switch (1)
and turn it clockwise to the “I” and turn it clockwise to the “I”
position or: position or:
– for trucks without a key switch, enter – for trucks without a key switch, enter
the release code via CANCODE (1a) the release code via CANCODE (1a)
or the on-board computer. or the on-board computer.
For the CANCODE (o), enter the 16 1 2 For the CANCODE (o), enter the 16 1 2
starting PIN 2580 via the keypad (1a). starting PIN 2580 via the keypad (1a).

2 3 2 3
1 1
5 6 5 6
4 4
8 9 8 9
7 7
0 0
Set Set

16 1a 2 16 1a 2

– For the on board computer (16a) – For the on board computer (16a)
(o), enter the starting PIN 14016 2
3
(o), enter the starting PIN 14016 2
3

and confirm with OK. and confirm with OK.

DEF DEF

1 ABC
1 ABC

6 6
5 MNO
5 MNO

4GHI JKL
4GHI JKL

9 9
8 WXYZ 8 WXYZ

7 TUV
7 TUV
PQRS PQRS

OK OK
0 0
CE CE

16a 1 2 16a 1 2

BITTE PINCODE EINGEBEN BITTE PINCODE EINGEBEN

– Test horn. – Test horn.

The truck is now operational. The battery discharge monitor shows the available The truck is now operational. The battery discharge monitor shows the available
battery capacity. battery capacity.

– Check the operation of the brake and handbrake – Check the operation of the brake and handbrake
(see Section 4). (see Section 4).
– When you start up the truck the deadman switch must be applied. – When you start up the truck the deadman switch must be applied.
– Select the travel direction. – Select the travel direction.
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 – Release the parking brake with the – Release the parking brake with the
brake switch (22/22a). 22 1 2 brake switch (22/22a). 22 1 2
The truck is operational. The truck is operational.

3.4 Emergency stop device 3.4 Emergency stop device

Z The truck is fitted with an emergency

stop device. After switching on the
Z The truck is fitted with an emergency
stop device. After switching on the
EMERGENCY DISCONNECT switch (2) EMERGENCY DISCONNECT switch (2)
and the key switch (1) or entering the Pin and the key switch (1) or entering the Pin
code there follows an automatic safety code there follows an automatic safety
prompt. prompt.
Emergency stop display 22a Emergency stop display 22a

If a fault is detected in the steering or If a fault is detected in the steering or

brake system, a message is shown on brake system, a message is shown on
the driver's display (t) (16) or the on- the driver's display (t) (16) or the on-
board computer (o) (16a). 1

4GHI

PQRS
7
2
ABC

5
JKL

8
TUV
3
DEF

6
MNO

9
WXYZ
board computer (o) (16a). 1

4GHI

PQRS
7
2
ABC

5
JKL

8
TUV
3
DEF

6
MNO

9
WXYZ

OK OK
0 0
CE CE

Emergency stop activation Emergency stop activation

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

Emergency Stop Reset. Emergency Stop Reset.

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

Z If the emergency stop display appears on the driver’s display (t) or the on-board
computer (o) after repeatedly resetting the emergency stop, inform the
Z If the emergency stop display appears on the driver’s display (t) or the on-board
computer (o) after repeatedly resetting the emergency stop, inform the
manufacturer’s service department. manufacturer’s service department.

M If, after the emergency stop has been activated, the truck is in a hazardous area or
aisle, it can only be operated with the steering crank for recovery purposes
M If, after the emergency stop has been activated, the truck is in a hazardous area or
aisle, it can only be operated with the steering crank for recovery purposes
(see "Moving the truck without a battery, recovery" in chapter E). (see "Moving the truck without a battery, recovery" in chapter E).
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3.5 Testing after daily operation 3.5 Testing after daily operation

– Make sure the driver’s seat is locked in position. – Make sure the driver’s seat is locked in position.
– Test the seat belt. (The belt should block if extracted suddenly.) – Test the seat belt. (The belt should block if extracted suddenly.)
– Test the horn. – Test the horn.
– Test the controls and displays. – Test the controls and displays.
– Test the steering. – Test the steering.
– Check the steer angle display; turn the steering wheel in both directions as far as – 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. 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. – Test the lift/lower, tilt and if applicable the attachment hydraulic control functions.

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 4 Industrial Truck Operation 4 Industrial Truck Operation

4.1 Safety regulations for truck operation 4.1 Safety regulations for truck operation

Travel routes and work areas: Only use lanes and routes specifically designated for Travel routes and work areas: Only use lanes and routes specifically designated for
truck traffic. Unauthorised third parties must stay away from work areas. Loads must truck traffic. Unauthorised third parties must stay away from work areas. Loads must
only be stored in places specially designated for this purpose. Loads must not be de- only be stored in places specially designated for this purpose. Loads must not be de-
posited on travel or escape routes, in front of safety mechanisms or operating equip- posited on travel or escape routes, in front of safety mechanisms or operating equip-
ment that must be accessible at all times. ment that must be accessible at all times.

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

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

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

Negotiating slopes and inclines: Negotiating slopes or inclines is only permitted if Negotiating slopes and inclines: Negotiating slopes or inclines is only permitted if
such roads are clean and have a non-slip surface and providing such journeys are such roads are clean and have a non-slip surface and providing such journeys are
safely undertaken in accordance with the technical specifications for the truck in safely undertaken in accordance with the technical specifications for the truck in
question. The truck must always be driven with the load unit facing uphill. The question. The truck must always be driven with the load unit facing uphill. The
industrial truck must not be turned, operated at an angle or parked on inclines or industrial truck must not be turned, operated at an angle or parked on inclines or
slopes. Inclines must only be negotiated at slow speed, with the driver ready to brake slopes. Inclines must only be negotiated at slow speed, with the driver ready to brake
at any moment. at any moment.
Negotiating lifts and docks: Lifts and docks must only be used if they have sufficient Negotiating lifts and docks: Lifts and docks must only be used if they have sufficient
capacity, are suitable for driving on and authorised for truck traffic by the owner. The capacity, are suitable for driving on and authorised for truck traffic by the owner. The
driver must satisfy himself of the above before entering these areas. The truck can driver must satisfy himself of the above before entering these areas. The truck can
only be moved with or without a load when the mast support is retracted, the mast only be moved with or without a load when the mast support is retracted, the mast
tilted back and the load handler lowered. The truck must enter lifts with the load in tilted back and the load handler lowered. The truck must enter lifts with the load in
front and must take up a position which does not allow it to come into contact with the front and must take up a position which does not allow it to come into contact with the
walls of the lift shaft. walls of the lift shaft.
Persons riding in the lift with the forklift truck must only enter the lift after the truck has Persons riding in the lift with the forklift truck must only enter the lift after the truck has
come to a rest and must leave the lift before the truck. come to a rest and must leave the lift before the truck.

Work platforms: The use of work platforms is governed by national law: In some Work platforms: The use of work platforms is governed by national law: In some
member states the use of work platforms is prohibited on industrial trucks. Observe member states the use of work platforms is prohibited on industrial trucks. Observe
the applicable law. Work platforms can only be used in the country of application if the applicable law. Work platforms can only be used in the country of application if
the law permits it. Contact the national authorities before using a work platform. the 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 a Nature of loads to be carried: The operator must make sure that the load is in a
satisfactory condition. Only carry loads that are positioned safely and carefully. Use satisfactory condition. Only carry loads that are positioned safely and carefully. Use
suitable precautions, e.g. a load guard, to prevent parts of the load from tipping or suitable precautions, e.g. a load guard, to prevent parts of the load from tipping or
falling down. Prevent liquid loads from sloshing out. falling down. Prevent liquid loads from sloshing out.

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

4.2 Procedure in extraordinary situations 4.2 Procedure in extraordinary situations

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

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

– Press your upper body against back of seat. – Press your upper body against back of seat.

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

– Tilt your body in the opposite direction of fall. – Tilt your body in the opposite direction of fall.

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 4.3 Emergency Disconnect 4.3 Emergency Disconnect

F Accident risk
Applying the Emergency Disconnect switch during travel will cause the truck to decel- F Accident risk
Applying the Emergency Disconnect switch during travel will cause the truck to decel-
erate to a halt at maximum force. This may cause the load to slide off the forks. erate to a halt at maximum force. This may cause the load to slide off the forks.
There is an increased risk of accidents and injury There is an increased risk of accidents and injury
The operation of the Emergency Disconnect switch must not be affected by any ob- The operation of the Emergency Disconnect switch must not be affected by any ob-
jects placed in its way. jects placed in its way.

4.3.1 Applying the Emergency Disconnect 4.3.1 Applying the Emergency Disconnect

Procedure Procedure

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

– In hazardous situations press the Emergency Disconnect switch (2) down. – In hazardous situations press the Emergency Disconnect switch (2) down.
All electrical functions are deactivated. All electrical functions are deactivated.

The truck brakes to a halt. The truck brakes to a halt.

4.3.2 Release the Emergency Disconnect 4.3.2 Release the Emergency Disconnect

Procedure Procedure

– Turn the Emergency Disconnect switch to unlock it. – Turn the Emergency Disconnect switch to unlock it.
– All electrical functions are switched on, the truck is operational again. (Provided the – All electrical functions are switched on, the truck is operational again. (Provided the
truck was operational before the Emergency Disconnect was pressed). truck was operational before the Emergency Disconnect was pressed).
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4.4 Travel, steering, braking 4.4 Travel, steering, braking

Travel 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 when 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 when
travelling in the load direction (R). travelling in the load direction (R).

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

Z You should only travel in the load direction (R) for shunting and lifting or depositing a
load.
Z You should only travel in the load direction (R) for shunting and lifting or depositing a
load.
1 2 1 2
22 22
23 23

11 11

13 13

– Prepare the truck for operation (see Section 3.3). – Prepare the truck for operation (see Section 3.3).
– Release the parking brake with the brake switch (22). – Release the parking brake with the brake switch (22).

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

– When the truck is ready for use press the travel switch (23) in the direction of the – When the truck is ready for use press the travel switch (23) in the direction of the
arrow to select the required direction(R). Keep pressing the travel switch to change arrow to select the required direction(R). Keep pressing the travel switch to change
direction. direction.
– Apply the deadman switch (13) and the accelerator pedal (11). – Apply the deadman switch (13) and the accelerator pedal (11).
The truck will start in the desired direction. The truck will start in the desired direction.

F The deadman switch (13) ensures that the driver’s feet do not jut out over the
perimeter of the truck. If it is not pressed, all electric functions are inhibited with the
F The deadman switch (13) ensures that the driver’s feet do not jut out over the
perimeter of the truck. If it is not pressed, all electric functions are inhibited with the
exception of steering, the driver’s display panel and the horn. The truck coasts to a exception of steering, the driver’s display panel and the horn. The truck coasts to a
stop according to the “coasting brake” parameter setting. stop according to the “coasting brake” parameter setting.

Z The travel speed is governed by the accelerator (11).

Z The travel speed is governed by the accelerator (11).
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 Steering Steering

Reverse steering (t) Reverse steering (t)

When travelling forward (travel in direction of entry = drive direction) steer left to turn When travelling forward (travel in direction of entry = drive direction) steer left to turn
into a left hand bend and right into a right hand bend. The position of the drive wheel into a left hand bend and right into a right hand bend. The position of the drive wheel
will be shown in the driver’s display or the on-board computer. will be shown in the driver’s display or the on-board computer.

Synchronised steering (o) Synchronised steering (o)

– When travelling forward (travel in – When travelling forward (travel in

direction of entry = drive direction) direction of entry = drive direction)
steer left to turn into a right hand bend steer left to turn into a right hand bend
and right into a left hand bend. The and right into a left hand bend. The
position of the drive wheel will be position of the drive wheel will be
shown in the driver’s display or the on- shown in the driver’s display or the on-
board computer. board computer.

Brakes Brakes

Z The truck’s braking pattern depends largely on the ground conditions. The driver must
take this into consideration when handling the truck.
Z The truck’s braking pattern depends largely on the ground conditions. The driver must
take this into consideration when handling the truck.

The truck can brake in three different ways: The truck can brake in three different ways:
– with the reversing brake – with the reversing brake
– with the coasting brake – with the coasting brake
– with the service brake – with the service brake

F If the truck is operated by several drivers (e.g. multi-shift operation) and the
parameters are individually set, pay attention to the different braking and travelling F If the truck is operated by several drivers (e.g. multi-shift operation) and the
parameters are individually set, pay attention to the different braking and travelling
patterns. When you start the truck again, test how it responds. patterns. When you start the truck again, test how it responds.
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 Braking with the Reversing Brake: Braking with the Reversing Brake:

23 23

11 11
12 12

– Press the travel direction switch (23) while travelling. It switches to the opposite – Press the travel direction switch (23) while travelling. It switches to the opposite
travel direction and the truck decelerates through the traction current controller until travel direction and the truck decelerates through the traction current controller until
it starts to move in the opposite direction. it starts to move in the opposite direction.

Z This operating method reduces energy consumption. Energy is recovered, which is

controlled by the traction current controller. Information on the energy recovered is
Z This operating method reduces energy consumption. Energy is recovered, which is
controlled by the traction current controller. Information on the energy recovered is
shown on the driver’s display or the on-board computer. shown on the driver’s display or the on-board computer.

Braking with the Coasting Brake: Braking with the Coasting Brake:

– Release accelerator while travelling. – Release accelerator while travelling.

The truck brakes through the traction The truck brakes through the traction
current controller depending on the current controller depending on the
accelerator position. accelerator position.
Braking with the service brake: Braking with the service brake:
– Depress the brake pedal (12) the full – Depress the brake pedal (12) the full
stroke. stroke.
The truck brakes with inversion current The truck brakes with inversion current
through the drive motor and possibly through the drive motor and possibly
with the electric load wheel brakes. 11 with the electric load wheel brakes. 11
When the truck has stopped the 12 When the truck has stopped the 12
mechanical handbrake is applied. mechanical handbrake is applied.

Z As of 09/2007 when the brake pedal is applied the drive brake also applies just before
the truck stops. It is released again when the brake pedal is released.
Z As of 09/2007 when the brake pedal is applied the drive brake also applies just before
the truck stops. It is released again when the brake pedal is released.
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 4.5 Adjusting the forks 4.5 Adjusting the forks

F In order to safely raise a load the forks

should be set as far apart from each 25
24 F In order to safely raise a load the forks
should be set as far apart from each 25
24
other as possible and centrally to the other as possible and centrally to the
truck. The load centre of gravity must be truck. The load centre of gravity must be
in the centre between the forks. in the centre between the forks.

– Raise the locking lever (24). 26 – Raise the locking lever (24). 26
– Push the forks (25) into the correct – Push the forks (25) into the correct
position on the fork carriage (26). position on the fork carriage (26).
– Turn the locking lever down and move – Turn the locking lever down and move
the forks until the locking pin engages the forks until the locking pin engages
in a slot. in a slot.

F The forks must be prevent from falling

with the retaining screw (26a). F The forks must be prevent from falling
with the retaining screw (26a).

– Ensure the retaining screw (26a) – Ensure the retaining screw (26a)
is secure, tighten if necessary. is secure, tighten if necessary.

26a 26a

4.6 Lifting and depositing loads 4.6 Lifting and depositing loads

M Before a load can be lifted the driver

must ensure that it is palletised in
M Before a load can be lifted the driver
must ensure that it is palletised in
accordance with regulations and that the accordance with regulations and that the
truck capacity is not exceeded. truck capacity is not exceeded.
– Insert the forks as far as possible – Insert the forks as far as possible
underneath the load. underneath the load.
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 Lifting Lifting

F Do not reach into the mast. Do not allow anyone to stand underneath a raised load.
F Do not reach into the mast. Do not allow anyone to stand underneath a raised load.
– Pull the Multi-Pilot (3a) or Solo-Pilot – Pull the Multi-Pilot (3a) or Solo-Pilot
(3b) lever (28) in direction (H). 3a (3b) lever (28) in direction (H). 3a

Z The lift speed is determined by the

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

– Apply the Multi-Pilot (3a) or Solo-Pilot S – Apply the Multi-Pilot (3a) or Solo-Pilot S
(3b) lever (28) until you reach the (3b) lever (28) until you reach the
required lift height. required lift height.

U U
H H

Z When you reach the lock (there will be a

noise from the pressure relief valve) 28 3b
Z When you reach the lock (there will be a
noise from the pressure relief valve) 28 3b
restore the control lever immediately to restore the control lever immediately to
its initial position. its initial position.
S S

H H

Mast lift speed reduction o Mast lift speed reduction o

The safety switch is an active accident The safety switch is an active accident
prevention device operating outside the free lift range, which prevents the truck from prevention device operating outside the free lift range, which prevents the truck from
accidentally accelerating with a raised load. accidentally accelerating with a raised load.

Z When the safety switch has been activated, the truck can only operate at crawl
speed.
Z When the safety switch has been activated, the truck can only operate at crawl
speed.

– Lower the load handler and set the accelerator pedal to the zero (home) position. – Lower the load handler and set the accelerator pedal to the zero (home) position.
This deactivates the safety switch and restores normal travel. This deactivates the safety switch and restores normal travel.

Lowering Lowering
– Push the Multi-Pilot (3a) or Solo-Pilot (3b) lever (28) in direction (S). – Push the Multi-Pilot (3a) or Solo-Pilot (3b) lever (28) in direction (S).

Z The lowering speed is determined by the inclination of the control lever.

Z The lowering speed is determined by the inclination of the control lever.

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

F F
3a 3a
Do not reach between the mast and the battery Do not reach between the mast and the battery
cover. cover.

– Move the Multi-Pilot (3a) or Solo Pilot (3b) T – Move the Multi-Pilot (3a) or Solo Pilot (3b) T
lever (30) in direction (T) to extend the mast lever (30) in direction (T) to extend the mast
support forward and in direction (U) to retract it. support forward and in direction (U) to retract it.

U U

Z The reach speed is determined by the

inclination of the control lever. 30 3b
Z The reach speed is determined by the
inclination of the control lever. 30 3b

T T

U U

Mast tilt Mast tilt

Multi-Pilot t: Multi-Pilot t:
32 3a 32 3a
– To tilt forward, press rocker (32) (V). – To tilt forward, press rocker (32) (V).
V V
– To tilt back, press rocker (32) (R). R – To tilt back, press rocker (32) (R). R

Solo-Pilot o: Solo-Pilot o:
31 3b 31 3b
– To tilt forward, push the Solo Pilot (3b) – To tilt forward, push the Solo Pilot (3b)
lever (31). lever (31).
– To tilt back, pull the Solo Pilot (3b) lever (31). V – To tilt back, pull the Solo Pilot (3b) lever (31). V

R R
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 Collecting, Lifting and Transporting Loads. Collecting, Lifting and Transporting Loads.

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

Mulit-Pilot t: Mulit-Pilot t:

– Position the forks horizontally: Press – Position the forks horizontally: Press
rocker switch (32), rocker (V) or (R). rocker switch (32), rocker (V) or (R).
– Approach the load. 32 3a – Approach the load. 32 3a
– Extend the mast support forward. Set – Extend the mast support forward. Set
Multi-Pilot (3a) to direction (T) Multi-Pilot (3a) to direction (T)
– Raise the forks to the correct height: S – Raise the forks to the correct height: S
Pull Multi-Pilot (3a) in direction (H). TT Pull Multi-Pilot (3a) in direction (H). TT
– Insert the forks under the load. – Insert the forks under the load.
– Lift the load clear: Pull Multi-Pilot (3a) – Lift the load clear: Pull Multi-Pilot (3a)
in direction (H). in direction (H).
– To retract the mast support: Set Multi- UU – To retract the mast support: Set Multi- UU
Pilot (3a) to direction (U). H Pilot (3a) to direction (U). H
– To lower the load in the transport – To lower the load in the transport
position: Press Multi-Pilot (3a) in position: Press Multi-Pilot (3a) in
direction (S). direction (S).
– To position the load in the tilt back – To position the load in the tilt back
position: Press rocker switch (32), rocker (R). position: Press rocker switch (32), rocker (R).
– Transport load. – Transport load.
– To place the load in a horizontal position: Press rocker switch (32) rocker (V). – To place the load in a horizontal position: Press rocker switch (32) rocker (V).
– To position the load at the correct height: Pull Multi-Pilot (3a) in direction (H) and if – 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) to necessary extend the mast support forward by setting the Multi-Pilot (3a) to
direction (T). direction (T).
– To lower the load: Press Multi-Pilot (3a) in direction (S). – To lower the load: Press Multi-Pilot (3a) in direction (S).
– To retract the mast support: Set Multi-Pilot (3a) to direction (U). – To retract the mast support: Set Multi-Pilot (3a) to direction (U).

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 Solo-Pilot o: Solo-Pilot o:

– Position the forks horizontally: Set the – Position the forks horizontally: Set the
Solo Pilot (3b) lever (31) to neutral. Solo Pilot (3b) lever (31) to neutral.
– Approach the load. 28 30 31 – Approach the load. 28 30 31
– Extend the mast support forward. – Extend the mast support forward.
Push the Solo Pilot (3b) lever (30). Push the Solo Pilot (3b) lever (30).
– Raise the forks to the correct height: 3b – Raise the forks to the correct height: 3b
Pull the Solo Pilot lever (28). Pull the Solo Pilot lever (28).
– Insert the forks under the load. – Insert the forks under the load.
– Lift the load clear: Pull the Solo Pilot – Lift the load clear: Pull the Solo Pilot
lever (28). lever (28).
– To retract the mast support: Pull the – To retract the mast support: Pull the
Solo Pilot (3b) lever (30). Solo Pilot (3b) lever (30).
– To lower the load in the transport – To lower the load in the transport
position: Push the Solo Pilot (3b) position: Push the Solo Pilot (3b)
lever (28). lever (28).
– To position the load in the tilt back – To position the load in the tilt back
position: Pull the Solo Pilot (3b) lever (31). position: Pull the Solo Pilot (3b) lever (31).
– Transport load. – Transport load.
– To place the load in a horizontal position: Push the Solo Pilot (3b) lever (31). – To place the load in a horizontal position: Push the Solo Pilot (3b) lever (31).
– To position the load at the correct height: Pull the Solo Pilot lever (28) and if – To position the load at the correct height: Pull the Solo Pilot lever (28) and if
necessary push the Solo Pilot (3b) lever (30) to extend the mast support. necessary push the Solo Pilot (3b) lever (30) to extend the mast support.
– To lower the load: Push the Solo Pilot (3b) lever (28). – To lower the load: Push the Solo Pilot (3b) lever (28).
– To retract the mast support: Pull the Solo Pilot (3b) lever (30). – To retract the mast support: Pull the Solo Pilot (3b) lever (30).
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4.7 Emergency lowering (-10/07) 4.7 Emergency lowering (-10/07)

F Keep all personnel out of the hazardous area when applying 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 emergency If the mast does not lower due to a fault in the lift controller, apply the emergency
lowering valve (27) on the back of the mast support. lowering valve (27) on the back of the mast support.

F Only operate the emergency lowering

valve when standing next to the truck.
F Only operate the emergency lowering
valve when standing next to the truck.
27 27
Never reach through the mast! Never reach through the mast!
Do not step underneath the load. Do not step underneath the load.

– Turn the EMERGENCY DISCONNECT – Turn the EMERGENCY DISCONNECT

switch and key switch off. switch and key switch off.
– Disconnect the battery connector. – Disconnect the battery connector.
– Press the red valve head down using – Press the red valve head down using
a suitable extension and hold it in this a suitable extension and hold it in this
position. The mast and load handler position. The mast and load handler
will lower slowly. will lower slowly.

F Do not operate the truck until the fault

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

4.8 Emergency lowering (10/07-) 4.8 Emergency lowering (10/07-)

F Keep all personnel out of the hazardous area when applying 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 emergency If the mast does not lower due to a fault in the lift controller, apply the emergency
lowering valve (29) on the back of the mast support. lowering valve (29) on the back of the mast support.

F Only operate the emergency lowering

valve when standing next to the truck. 29
F Only operate the emergency lowering
valve when standing next to the truck. 29
Never reach through the mast! Never reach through the mast!
Do not step underneath the load. Do not step underneath the load.
– Turn the EMERGENCY DISCONNECT – Turn the EMERGENCY DISCONNECT
switch and key switch off. switch and key switch off.
– Disconnect the battery connector. – Disconnect the battery connector.
– Undo the rotary shaft bolt (29.6 mm – Undo the rotary shaft bolt (29.6 mm
hex.bolt) max. ½ turns if necessary hex.bolt) max. ½ turns if necessary
with a suitable extension. The mast with a suitable extension. The mast
and load handler will lower slowly. If and load handler will lower slowly. If
necessary the lowering speed can be necessary the lowering speed can be
reduced by turning clockwise or the reduced by turning clockwise or the
load can be stopped. When the load has been lowered, close the emergency load can be stopped. When the load has been lowered, close the emergency
lowering valve on the rotary shaft with a torque of 4.5 Nm. lowering valve on the rotary shaft with a torque of 4.5 Nm.

F Do not operate the truck until the fault has been rectified.
F Do not operate the truck until the fault has been rectified.
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 4.9 Operating Attachments 4.9 Operating Attachments

4.9.1 Safety instructions for operating additional attachments 4.9.1 Safety instructions for operating additional attachments

Z Optionally, trucks can be fitted with one or more auxiliary hydraulic functions to oper-
ate attachments. The auxiliary hydraulic functions are referenced HF4 and HF5.
Z Optionally, trucks can be fitted with one or more auxiliary hydraulic functions to oper-
ate attachments. The auxiliary hydraulic functions are referenced HF4 and HF5.
Auxiliary hydraulic functions for exchangeable equipment are fitted with replacement Auxiliary hydraulic functions for exchangeable equipment are fitted with replacement
couplings on the fork carriage. To assemble exchangeable equipment, see "Assem- couplings on the fork carriage. To assemble exchangeable equipment, see "Assem-
bly and hydraulic ports of additional attachments” in chapter E. bly 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 only ex- F Attaching exchangeable equipment can result in accidents.
Other people can be damaged by attaching exchangeable equipment. Use only ex-
changeable equipment which has been deemed safe after a risk analysis carried out changeable equipment which has been deemed safe after a risk analysis carried out
by the owner. by the owner.

– Only use attachments with a CE mark. – Only use attachments with a CE mark.
– Only use attachments that have been designed by the attachment manufacturer for – Only use attachments that have been designed by the attachment manufacturer for
use with the respective industrial truck. use with the respective industrial truck.
– Only use attachments that have been fitted for the purpose by the owner. – 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 – Make sure the operator has been instructed in the use of the attachment and that
he uses it for its correct purpose. he uses it for its correct purpose.
– Re-assess the residual capacity of the truck and if it has been altered, attach an – Re-assess the residual capacity of the truck and if it has been altered, attach an
additional capacity plate to the truck. additional capacity plate to the truck.
– Note the attachment manufacturer’s operating instructions. – Note the attachment manufacturer’s operating instructions.
– Only use attachments that do not restrict visibility in the travel direction. – 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 analysis
to assess whether the truck needs to be fitted with auxiliary equipment such as a cam-
Z If visibility in the travel direction is impaired, the owner must carry out a risk analysis
to assess whether the truck needs to be fitted with auxiliary equipment such as a cam-
era system or mirrors. If such equipment is used, spend sufficient time practicing trav- era system or mirrors. If such equipment is used, spend sufficient time practicing trav-
elling with them. elling with them.
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 Safety instructions for sideshifter and fork adjuster attachments Safety instructions for sideshifter and fork adjuster attachments

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

– Adapt the travel speeds to the visibility and load. – Adapt the travel speeds to the visibility and load.
– Make sure you have enough visibility when travelling in the forks direction. – Make sure you have enough visibility when travelling in the forks direction.
Safety instructions for clamping attachments (e.g. baling clamps, barrel Safety instructions for clamping attachments (e.g. baling clamps, barrel
clamps, grabs etc.) clamps, grabs etc.)

M Falling loads can cause accidents

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

– Clamping attachments must only be operated on trucks will auxiliary hydraulics – Clamping attachments must only be operated on trucks will auxiliary hydraulics
HF4 or HF5. HF4 or HF5.
– When connecting the attachment make sure that the hydraulic lines of the attach- – When connecting the attachment make sure that the hydraulic lines of the attach-
ment are connected to the right ports, see "Assembly and hydraulic ports of addi- ment are connected to the right ports, see "Assembly and hydraulic ports of addi-
tional attachments” in chapter E. tional attachments” in chapter E.
– An auxiliary button for releasing the clamp opening must be used. – An auxiliary button for releasing the clamp opening must be used.
Safety instructions for rotary attachments Safety instructions for rotary attachments

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

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

– Adapt the travel speed to the load. – Adapt the travel speed to the load.
– Lift the load from the centre. – Lift the load from the centre.
Safety instructions for telescopic attachments Safety instructions for telescopic attachments

M Accident risk from increased tipover hazard and reduced residual capacity
There is a greater tipover risk with extended telescopic attachments (e.g. reach car-
M Accident risk from increased tipover hazard and reduced residual capacity
There is a greater tipover risk with extended telescopic attachments (e.g. reach car-
riages, telescopic forks, telescopic crane booms). riages, telescopic forks, telescopic crane booms).

– Only use the telescopic function for stacking and retrieving. – Only use the telescopic function for stacking and retrieving.
– Always retract the attachment fully during transport. – Always retract the attachment fully during transport.
– Adapt the travel speed to changed load centre of gravity. 0210.GB – Adapt the travel speed to changed load centre of gravity.

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E 28 E 28
 Safety notices for fork extensions: Safety notices for fork extensions:

M Unsecured and excessive fork extensions can cause accidents.

M Unsecured and excessive fork extensions can cause accidents.
– For fork extensions with an open cross sectional area, only carry loads that are rest- – For fork extensions with an open cross sectional area, only carry loads that are rest-
ing along the entire length of the fork extension. ing along the entire length of the fork extension.
– Only use fork extensions with the same fork cross section and minimum fork length – Only use fork extensions with the same fork cross section and minimum fork length
of the truck and which comply with the details on the fork extension data plate. of 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. – The basic fork length must be at least 60% of the length of the fork extension.
– Lock the fork extensions onto the basic forks. – Lock the fork extensions onto the basic forks.
– When carrying out the daily checks and operations before starting , see "Checks – When carrying out the daily checks and operations before starting , see "Checks
and operations to be performed before starting daily operation" in chapter E, also and operations to be performed before starting daily operation" in chapter E, also
check the fork extension lock. check the fork extension lock.
– Mark any fork extensions with an incomplete or faulty lock and take them out of – Mark any fork extensions with an incomplete or faulty lock and take them out of
service. service.
– Do not use trucks with an incomplete or faulty fork extension lock. Replace the fork – Do not use trucks with an incomplete or faulty fork extension lock. Replace the fork
extension. extension.
– Only restore the fork extension to service when the fault has been rectified. – 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 attachment
operator manuals.
F Observe load chart for the truck with attachment and the truck and attachment
operator manuals.

– The attachment must only be operated by trained and authorised personnel. – The attachment must only be operated by trained and authorised personnel.
– Any operation that could affect safety must be prohibited. – Any operation that could affect safety must be prohibited.
– The attachment must only be operated when fully functional. – The attachment must only be operated when fully functional.
– Check the attachment for visible signs of damage at least once a shift. – Check the attachment for visible signs of damage at least once a shift.
– Report any signs of damage immediately. – Report any signs of damage immediately.
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4.9.2 Integrated sideshift (Multi Pilot) t 4.9.2 Integrated sideshift (Multi Pilot) t

Z The references to left and right are

based on the load handler as viewed
Z The references to left and right are
based on the load handler as viewed
from the operator’s position. from the operator’s position.

Sideshift left (from driver’s position): 35 3a Sideshift left (from driver’s position): 35 3a

– Press switch (35) in direction (X1) X2 Y2 – Press switch (35) in direction (X1) X2 Y2
Sideshift right (from driver’s position): 36 Sideshift right (from driver’s position): 36

– Press switch (35) in direction (Y1). – Press switch (35) in direction (Y1).

F When extending, note reduced capacity.

(see Chapter B).
X1
Y1 F When extending, note reduced capacity.
(see Chapter B).
X1
Y1

o Hydraulic attachments o Hydraulic attachments

The control lever (36) has functions (X2) The control lever (36) has functions (X2)
and (Y2) to operate hydraulic and (Y2) to operate hydraulic
attachments (HF5) (note manufacturer’s attachments (HF5) (note manufacturer’s
operator manual). operator manual).

F Note the capacity of the attachment.

F Note the capacity of the attachment.

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

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

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E 30 E 30
 4.9.3 Integrated sideshift (Solo Pilot) o 4.9.3 Integrated sideshift (Solo Pilot) o

Z The references to left and right are

based on the load handler as viewed
Z The references to left and right are
based on the load handler as viewed
from the operator’s position. 33 34 3b from the operator’s position. 33 34 3b

Sideshift left (from driver’s position): Sideshift left (from driver’s position):

– Press switch (33) in direction (X1) X2 – Press switch (33) in direction (X1) X2
Sideshift right (from driver’s position): Sideshift right (from driver’s position):
– Press switch (33) in direction (Y1). Y2 – Press switch (33) in direction (Y1). Y2
F Note reduced capacity for extending
(see Chapter B).
F Note reduced capacity for extending
(see Chapter B).

o Hydraulic attachments
X1 o Hydraulic attachments
X1
Y1 Y1
The fourth lever (34) of the Solo Pilot The fourth lever (34) of the Solo Pilot
(3b) has functions (X2) and (Y2) to (3b) has functions (X2) and (Y2) to
operate hydraulic attachments (HF5) (see manufacturer’s operator manual). operate hydraulic attachments (HF5) (see manufacturer’s operator manual).

F Note the capacity of the attachment.

F Note the capacity of the attachment.

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

– The attachment must only be operated by trained and authorised personnel. – The attachment must only be operated by trained and authorised personnel.
– Any operation that could affect safety must be prohibited. – Any operation that could affect safety must be prohibited.
– The attachment must only be operated when fully functional. – The attachment must only be operated when fully functional.
– Check the attachment for visible signs of damage at least once a shift. – Check the attachment for visible signs of damage at least once a shift.
– Report any signs of damage immediately. – Report any signs of damage immediately.
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E 31 E 31
4.10 Parking the truck safely 4.10 Parking the truck safely

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

F Do not park the truck on a slope. The load must always be lowered to the ground.
F Do not park the truck on a slope. The load must always be lowered to the ground.
– Apply the parking brake with the brake – Apply the parking brake with the brake
switch (22/22a). 22 1 2 switch (22/22a). 22 1 2
– Lower the load completely and – Lower the load completely and
position it horizontally. position it horizontally.
– Retract the mast support fully. – Retract the mast support fully.
– Set the EMERGENCY DISCONNECT – Set the EMERGENCY DISCONNECT
switch (2) OFF. switch (2) OFF.
– Set the key switch (1) to the "0" – Set the key switch (1) to the "0"
position and remove the key. position and remove the key.

22a 22a

3 3
2 DEF
2 DEF

1 ABC
1 ABC

6 6
5 MNO
5 MNO

4GHI JKL
4GHI JKL

9 9
8 WXYZ 8 WXYZ

7 TUV
7 TUV
PQRS PQRS

OK OK
0 0
CE CE

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E 32 E 32
 5 Driver’s display (t) 5 Driver’s display (t)

The driver’s display represents the operator interface to the truck. It is both a display The driver’s display represents the operator interface to the truck. It is both a display
and control unit for the operator and the service engineer. and 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 the Press the four keys (55, 56, 57, 58) to operate the driver's display and hence the
truck. The LEDs of the 11 buttons (36 - 44, 59, 60) can show 3 conditions: active and truck. The LEDs of the 11 buttons (36 - 44, 59, 60) can show 3 conditions: active and
flashing and off. flashing and off.
All displays are shown as text or as symbols. The meaning of the various symbols is All displays are shown as text or as symbols. The meaning of the various symbols is
explained in section 6. explained in section 6.

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

Set time: Set time:

– Press the shift key (56) for 3 seconds. – Press the shift key (56) for 3 seconds.
The display (48) via the battery shows the current time. This allows you to toggle the The display (48) via the battery shows the current time. This allows you to toggle the
display between the time and the residual time. display between the time and the residual time.

– Press the shift key another 5 seconds (8 in total) until the “Set Time” menu is – Press the shift key another 5 seconds (8 in total) until the “Set Time” menu is
displayed. displayed.
– Set the hours with the “Up” (58) & “Down” (57) keys. – Set the hours with the “Up” (58) & “Down” (57) keys.
– Confirm with the shift key. – Confirm with the shift key.
– Set the minutes with the “Up” (58) & “Down” (57) keys. – 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. – 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 hour
and 12 display (SET HOUR 24 H <-> SET HOUR 12 H).
Z Keep pressing the Up and Down keys to set the time and to change between 24 hour
and 12 display (SET HOUR 24 H <-> SET HOUR 12 H).

42 43 44 45 46 47 48 49 50 42 43 44 45 46 47 48 49 50

51 51
41 52 41 52
40 40
39 53 39 53
38 38
54 54
37 37
36 36

60 59 58 57 56 55 60 59 58 57 56 55
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E 33 E 33
 Item Model Item Model
36 Warning, warning triangle (red icon), 36 Warning, warning triangle (red icon),
37 Battery unlocked (red icon), 37 Battery unlocked (red icon),
38 Overtemperature (red icon) 38 Overtemperature (red icon)
39 deadman switch not pressed (yellow icon) 39 deadman switch not pressed (yellow icon)
40 Lift limit reached (yellow icon) 40 Lift limit reached (yellow icon)
41 Forks horizontal (green icon), 41 Forks horizontal (green icon),
42 Slow travel (green icon), 42 Slow travel (green icon),
43 Sideshift horizontal (green icon) 43 Sideshift horizontal (green icon)
44 Service mode active (yellow spanner icon) 44 Service mode active (yellow spanner icon)
Service interval exceeded (flashing graphic symbol) Service interval exceeded (flashing graphic symbol)
45 Steering angle display in 30° increments in arrow form 45 Steering angle display in 30° increments in arrow form
46 180 or 360° steering mode through display of 2 or 4 circle segments 46 180 or 360° steering mode through display of 2 or 4 circle segments
47 Residual time display with on-board battery (hours : minutes) 47 Residual time display with on-board battery (hours : minutes)
48 Time display (hours : minutes) 48 Time display (hours : minutes)
49 Battery discharge status (e.g. flashing battery symbol and buzzer noise) 49 Battery discharge status (e.g. flashing battery symbol and buzzer noise)
and energy recovery display and energy recovery display
50 Discharge indicator 50 Discharge indicator
51 Set speed (drive direction) for current performance profile 51 Set speed (drive direction) for current performance profile
(in bar form 1 to 5) (in bar form 1 to 5)
52 Set speed (lift) for current performance profile 52 Set speed (lift) for current performance profile
(in bar form 1 to 5) (in bar form 1 to 5)
53 Profile number (travel / lift profile 1, 2 or 3) 53 Profile number (travel / lift profile 1, 2 or 3)
54 Warning and error messages in text format (14 segment display) and 54 Warning and error messages in text format (14 segment display) and
information messages (service hours, lift height in mm, load weight in kg) information messages (service hours, lift height in mm, load weight in kg)
55 Profile key for selecting travel and lift modes 55 Profile key for selecting travel and lift modes
56 Shift key for changing display and accessing service mode 56 Shift key for changing display and accessing service mode
57 Brake switch for applying / releasing the handbrake 57 Brake switch for applying / releasing the handbrake
58 Slow travel switch for derating the travel speed 58 Slow travel switch for derating the travel speed
59 Error STOP sign (red icon) 59 Error STOP sign (red icon)
60 Parking brake applied (red icon) 60 Parking brake applied (red icon)
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E 34 E 34
 Battery Discharge Indicator: The charge status of the battery (49) is shown on the Battery Discharge Indicator: The charge status of the battery (49) is shown on the
driver’s display. The lower section of the battery symbol is shown as being empty. It driver’s display. The lower section of the battery symbol is shown as being empty. It
indicates the residual capacity of the battery which is protected and cannot be used indicates the residual capacity of the battery which is protected and cannot be used
to avoid damaging the battery. to avoid damaging the battery.

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

49 48 49 48

61 61

62 56 62 56

When a battery is discharged to the permissible discharge level (residual capacity) When a battery is discharged to the permissible discharge level (residual capacity)
the battery symbol is displayed as being empty. the battery symbol is displayed as being empty.

Battery Discharge Monitor: If the residual capacity falls below the required level, 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. 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.
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 is Residual time display: The time remaining to reach the residual capacity is
displayed. displayed.
To display the residual time, the display (48) can be switched by holding down the To display the residual time, the display (48) can be switched by holding down the
Shift key (56) for three seconds. Shift key (56) for three seconds.

Z This allows you to toggle the display between the time and the residual time.
Z This allows you to toggle the display between the time and the residual time.
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E 35 E 35
 Hourmeter: Service hours are counted if the truck is released for operation via the Hourmeter: Service hours are counted if the truck is released for operation via the
key switch, keypad or transponder card and the deadman switch is applied. key switch, keypad or transponder card and the deadman switch is applied.
Press the Shift key (58) briefly to change the layout of the display fields (63 and 64). Press the Shift key (58) briefly to change the layout of the display fields (63 and 64).
If no lift height(o) or load weight (o) are available, the corresponding line will be If no lift height(o) or load weight (o) are available, the corresponding line will be
bypassed. bypassed.

Display field 1 (62) Display field 2 (61) Display field 1 (62) Display field 2 (61)
Service hours Load weight Service hours Load weight
Service hours Lift height Service hours Lift height
Lift height Load weight Lift height Load weight
Load weight Lift height Load weight Lift height

Z If neither the lift height, the max. lift height or the load weight are available, display
field 2 remains empty.
Z If neither the lift height, the max. lift height or the load weight are available, display
field 2 remains empty.
“Energy recovery” display for regenerative lowering and braking “Energy recovery” display for regenerative lowering and braking

During the “energy recovery” stage, the discharge indicator on the driver’s display During the “energy recovery” stage, the discharge indicator on the driver’s display
changes so that the bars in the battery container fill from bottom to top. changes 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 This takes place cyclically and irrespective of the battery’s charge status (full or
partially discharged). partially discharged).

Z The display goes out once energy recovery is complete.

Z The display goes out once energy recovery is complete.

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E 36 E 36
 5.1 Driver’s Display LED Buttons 5.1 Driver’s Display LED Buttons

SYMBOL SYMBOL
Forks horizontal (green icon), Forks horizontal (green icon),
28 3 28 3
SYMBOL SYMBOL
Sideshift centre position (green graphic symbol) Sideshift centre position (green graphic symbol)

SYMBOL SYMBOL
Lift limit reached (yellow icon), Lift limit reached (yellow icon),

SYMBOL SYMBOL
Slow travel (green icon), Slow travel (green icon),

SYMBOL SYMBOL
Deadman switch not applied (yellow icon), Deadman switch not applied (yellow icon),

SYMBOL SYMBOL
Service mode active (yellow spanner icon) Service mode active (yellow spanner icon)

SYMBOL SYMBOL
Overtemperature (red icon), Overtemperature (red icon),

SYMBOL SYMBOL
Battery unlocked (red icon), Battery unlocked (red icon),

SYMBOL SYMBOL
Parking brake applied (red icon), Parking brake applied (red icon),

SYMBOL SYMBOL
Warning, warning triangle (red icon), Warning, warning triangle (red icon),

SYMBOL SYMBOL
Error STOP sign (red icon) Error STOP sign (red icon)
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5.2 Driver Display Switches 5.2 Driver Display Switches

Travel speed derated (slow travel switch), Travel speed derated (slow travel switch),

Handbrake applied / release (brake switch), Handbrake applied / release (brake switch),

Change display to service mode (Shift key) Change display to service mode (Shift key)

Select travel and lift modes Select travel and lift modes

5.3 Driver’s Display Warning Messages 5.3 Driver’s Display Warning Messages

Display Symbol Meaning Display Symbol Meaning

INFO 02 No travel direction selected INFO 02 No travel direction selected

INFO 03 No travel release INFO 03 No travel release

INFO 04 No setpoint INFO 04 No setpoint

Battery empty, main lift cutout Battery empty, main lift cutout

Safety switch not pressed Safety switch not pressed

INFO 07 Flashing symbol INFO 07 Flashing symbol

At least 1 control not in home position when system starts At least 1 control not in home position when system starts

INFO 08 Flashing symbol INFO 08 Flashing symbol

Handbrake applied Handbrake applied

Crawl speed applied or forced by battery locking Crawl speed applied or forced by battery locking
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E 38 E 38
 Display Symbol Meaning Display Symbol Meaning
INFO 10 Drive motor overtemperature INFO 10 Drive motor overtemperature
INFO 11 Lift motor overtemperature INFO 11 Lift motor overtemperature
INFO 12 Steer motor overtemperature INFO 12 Steer motor overtemperature
INFO 16 Traction current cutout activated INFO 16 Traction current cutout activated

Lift limit reached Lift limit reached

INFO 18 Flashing symbol INFO 18 Flashing symbol

Safety height not reached Safety height not reached

INFO 22 Traction controller does not recognise electric steering INFO 22 Traction controller does not recognise electric steering

INFO 23 Controller set to diagnostic mode INFO 23 Controller set to diagnostic mode

INFO 24 Switch truck voltage off/on INFO 24 Switch truck voltage off/on

INFO 25 Flashing symbol INFO 25 Flashing symbol

Traction controller overtemperature Traction controller overtemperature

INFO 26 Flashing symbol INFO 26 Flashing symbol

Lift controller overtemperature Lift controller overtemperature

INFO 27 Flashing symbol INFO 27 Flashing symbol

Steering controller overtemperature Steering controller overtemperature

INFO 31 No accelerator pedal zero position detected on power up INFO 31 No accelerator pedal zero position detected on power up

INFO 32 No traverse distance reference on power up INFO 32 No traverse distance reference on power up
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 Display Symbol Meaning Display Symbol Meaning
INFO 54 Set truck type INFO 54 Set truck type

INFO 55 No deadman switch zero position detected on power up INFO 55 No deadman switch zero position detected on power up
HEATING Driver display warm-up phase, as the LCD cannot be read at HEATING Driver display warm-up phase, as the LCD cannot be read at
excessively low temperatures excessively low temperatures

Driver’s display error messages Driver’s display error messages

Error Error text Explanation Remedy Error Error text Explanation Remedy
1 LOW VOLTAGE Low voltage Check battery voltage, 1 LOW VOLTAGE Low voltage Check battery voltage,
charge battery charge battery
2 HIGH VOLTAGE Overvoltage Check battery voltage. 2 HIGH VOLTAGE Overvoltage Check battery voltage.
3 TEMPERAT Controller temperature Allow the controllers to 3 TEMPERAT Controller temperature Allow the controllers to
CONTR cool CONTR cool
5 ELECTR SYSTEM Overvoltage Switch off and on again, 5 ELECTR SYSTEM Overvoltage Switch off and on again,
call service department call service department
6 ACCELERATOR Analog reading out of Switch off and on again, 6 ACCELERATOR Analog reading out of Switch off and on again,
range or incompatible call service department range or incompatible call service department
with digital signal with digital signal
7 TURN OFF KEY Key switch Switch off and on again, 7 TURN OFF KEY Key switch Switch off and on again,
call service department call service department
10 MAIN CONTACTOR Main contactor faulty Switch off and on again, 10 MAIN CONTACTOR Main contactor faulty Switch off and on again,
call service department call service department
11-19 CONTROLLER Controller Failure Switch off and on again, 11-19 CONTROLLER Controller Failure Switch off and on again,
call service department call service department
21-22 CONTROLLER Controller Failure Switch off and on again, 21-22 CONTROLLER Controller Failure Switch off and on again,
call service department call service department
23 CONTROLLER Controller Failure Switch off and on again 23 CONTROLLER Controller Failure Switch off and on again
24 CONTROLLER Controller Failure Switch off and on again, 24 CONTROLLER Controller Failure Switch off and on again,
call service department call service department
25 INTERFACE / CAN No communication from Switch off and on again 25 INTERFACE / CAN No communication from Switch off and on again
interface interface
26 LIFT SENSOR Lift sensor wire breakage Switch off and on again, 26 LIFT SENSOR Lift sensor wire breakage Switch off and on again,
call service department call service department
27 STEER ANGLE Steering actual value Switch off and on again, 27 STEER ANGLE Steering actual value Switch off and on again,
sensor faulty call service department sensor faulty call service department
30 TILT SENSOR Tilt sensor wire breakage Switch off and on again, 30 TILT SENSOR Tilt sensor wire breakage Switch off and on again,
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call service department call service department

E 40 E 40
 Error Error text Explanation Remedy Error Error text Explanation Remedy
31 SIDESHIFT SENS ZH1 sensor wire breakage Switch off and on again, 31 SIDESHIFT SENS ZH1 sensor wire breakage Switch off and on again,
HF 4 call service department HF 4 call service department
32 MULTIP SENSOR ZH2 sensor wire breakage Switch off and on again, 32 MULTIP SENSOR ZH2 sensor wire breakage Switch off and on again,
HF 5 call service department HF 5 call service department
33 MULTIP SENSOR ZH3 sensor wire breakage Switch off and on again, 33 MULTIP SENSOR ZH3 sensor wire breakage Switch off and on again,
HF 6 call service department HF 6 call service department
34 CAN-BUS CANBus damaged Switch off and on again, 34 CAN-BUS CANBus damaged Switch off and on again,
call service department call service department
39 TRUCK TYPE Improbable truck type Switch off and on again, 39 TRUCK TYPE Improbable truck type Switch off and on again,
call service department call service department
40 TEMPERAT MOTOR Motor overtemperature Allow the motor to cool 40 TEMPERAT MOTOR Motor overtemperature Allow the motor to cool
down down
43 ADJUST BRAKE Adjust brake Call service department 43 ADJUST BRAKE Adjust brake Call service department
44 BRAKE DEFECT Brake controller error Call service department 44 BRAKE DEFECT Brake controller error Call service department
45 STEERING WHEEL Too many pulses from Call service department 45 STEERING WHEEL Too many pulses from Call service department
steering setpoint device steering setpoint device
46 STEERING WHEEL Steering setpoint device Call service department 46 STEERING WHEEL Steering setpoint device Call service department
incorrectly connected incorrectly connected
47 STEERING WHEEL Processor setpoints do Call service department 47 STEERING WHEEL Processor setpoints do Call service department
not match not match
48 STEERING TYPE Processor setpoints do Call service department 48 STEERING TYPE Processor setpoints do Call service department
not match not match
49 CAN BUS CAN supply interrupted; Switch off and on again, 49 CAN BUS CAN supply interrupted; Switch off and on again,
call service department call service department
50 SENSOR HORIZON Multipilot wire breakage Switch off and on again, 50 SENSOR HORIZON Multipilot wire breakage Switch off and on again,
horizontal tilter call service department horizontal tilter call service department
54 CABLE MOTOR Motor wire breakage Switch off and on again, 54 CABLE MOTOR Motor wire breakage Switch off and on again,
call service department call service department
56 CONNECTION Motor reverse polarity Switch off and on again, 56 CONNECTION Motor reverse polarity Switch off and on again,
MOTO call service department MOTO call service department
57 STEER CONTROL Motor does not turn Switch off and on again, 57 STEER CONTROL Motor does not turn Switch off and on again,
call service department call service department
58 STEER ANGLE Steering modulation Switch off and on again, 58 STEER ANGLE Steering modulation Switch off and on again,
call service department call service department
60 STEER CONTROL Swivelling bolster does Switch off and on again, 60 STEER CONTROL Swivelling bolster does Switch off and on again,
not follow steering wheel call service department not follow steering wheel call service department
directions directions
63 CONTROLLER Sensor power supply out Switch off and on again, 63 CONTROLLER Sensor power supply out Switch off and on again,
of range call service department of range call service department
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 Error Error text Explanation Remedy Error Error text Explanation Remedy
65 SWITCH MIDDLE Multipilot wire breakage Switch off and on again, 65 SWITCH MIDDLE Multipilot wire breakage Switch off and on again,
centre shifter call service department centre shifter call service department
66 SWITCH 180-360 Multipilot wire breakage Switch off and on again, 66 SWITCH 180-360 Multipilot wire breakage Switch off and on again,
180°/360° steering change call service department 180°/360° steering change call service department
67 DRIVEDIRECTION Multipilot travel direction Switch off and on again, 67 DRIVEDIRECTION Multipilot travel direction Switch off and on again,
switch setpoint device call service department switch setpoint device call service department
jams jams
68 DEADMAN KEY Safety switch wire Switch off and on again, 68 DEADMAN KEY Safety switch wire Switch off and on again,
breakage call service department breakage call service department
83 ELECTR SYSTEM 2 identical components Switch off and on again, 83 ELECTR SYSTEM 2 identical components Switch off and on again,
call service department call service department
84 RPM SENSOR Faulty speed sensor Switch off and on again, 84 RPM SENSOR Faulty speed sensor Switch off and on again,
call service department call service department
85 ELECTRIC DRIVE Power release low Switch off and on again, 85 ELECTRIC DRIVE Power release low Switch off and on again,
voltage call service department voltage call service department
86 RPM INPLAUS Improbable speed Switch off and on again, 86 RPM INPLAUS Improbable speed Switch off and on again,
call service department call service department
87 ELECTR SYSTEM Sensor wire interrupted, Switch off and on again, 87 ELECTR SYSTEM Sensor wire interrupted, Switch off and on again,
load wheel speed call service department load wheel speed call service department
sensing affected sensing affected
97 STEER CONTROL Segment beyond Switch off and on again, 97 STEER CONTROL Segment beyond Switch off and on again,
tolerance limits call service department tolerance limits call service department
98 STEER CONTROL Sensor bearing and Switch off and on again, 98 STEER CONTROL Sensor bearing and Switch off and on again,
proximity switch call service department proximity switch call service department
(segment) positions differ (segment) positions differ
100 MULTIP SOFTW Software versions in Switch off and on again, 100 MULTIP SOFTW Software versions in Switch off and on again,
Multipilot not compatible call service department Multipilot not compatible call service department
105 CABLE TEMP MOT Motor temperature gauge Switch off and on again, 105 CABLE TEMP MOT Motor temperature gauge Switch off and on again,
provides incorrect values call service department provides incorrect values call service department
106 CABLE TEMP CON Controller temperature Switch off and on again, 106 CABLE TEMP CON Controller temperature Switch off and on again,
gauge provides incorrect call service department gauge provides incorrect call service department
values values
107 ELECTR SYSTEM Key switch voltage out of Check battery voltage, 107 ELECTR SYSTEM Key switch voltage out of Check battery voltage,
range charge battery range charge battery
109 BRAKE PEDAL Brake pedal faulty Switch off and on again, 109 BRAKE PEDAL Brake pedal faulty Switch off and on again,
call service department call service department
110 CONTROLLER Current output Switch off and on again, 110 CONTROLLER Current output Switch off and on again,
multifunction controller call service department multifunction controller call service department
faulty faulty
111 CHECK STEER Traction controller does Switch off and on again, 111 CHECK STEER Traction controller does Switch off and on again,
not receive telegrams call service department not receive telegrams call service department
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from steering controller from steering controller

E 42 E 42
 Error Error text Explanation Remedy Error Error text Explanation Remedy
113 CHECK LIFT Lift controller does not Switch off and on again, 113 CHECK LIFT Lift controller does not Switch off and on again,
send lift telegrams call service department send lift telegrams call service department
115 CONTACTOR INPL Main contactor Switch off and on again, 115 CONTACTOR INPL Main contactor Switch off and on again,
improbable call service department improbable call service department
116 INIT SUCCESS After software flashing Switch off and on again, 116 INIT SUCCESS After software flashing Switch off and on again,
(field operation), the item call service department (field operation), the item call service department
number of the software is number of the software is
improbable and improbable and
parameters may also be parameters may also be
implausible. implausible.
118 CONTROLLER Steering reports Switch off and on again, 118 CONTROLLER Steering reports Switch off and on again,
emergency stop call service department emergency stop call service department

119 WEIGHT SWITCH Weigher button faulty Switch off and on again, 119 WEIGHT SWITCH Weigher button faulty Switch off and on again,
call service department call service department

120 WEIGHT SENSOR Weigher pressure sensor Switch off and on again, 120 WEIGHT SENSOR Weigher pressure sensor Switch off and on again,
faulty call service department faulty call service department

121 CONTROLLER Brake modulation Switch off and on again, 121 CONTROLLER Brake modulation Switch off and on again,
call service department call service department

122 BRAKE CONFIG Brake incorrectly Switch off and on again, 122 BRAKE CONFIG Brake incorrectly Switch off and on again,
connected call service department connected call service department
201 SENSOR Height sensor faulty Switch off and on again, 201 SENSOR Height sensor faulty Switch off and on again,
call service department call service department
203 SENSOR Height sensor evaluation Switch off and on again, 203 SENSOR Height sensor evaluation Switch off and on again,
improbable call service department improbable call service department
204 CONTROLLER Error when reading Switch off and on again, 204 CONTROLLER Error when reading Switch off and on again,
EEPROM height select call service department EEPROM height select call service department
240 CONTROLLER No height actual value on Switch off and on again, 240 CONTROLLER No height actual value on Switch off and on again,
job entry call service department job entry call service department
250 The height is invalid for Make correct entry 250 The height is invalid for Make correct entry
the warehouse level the warehouse level
entered entered
252 Wrong height select entry Make correct entry 252 Wrong height select entry Make correct entry
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E 43 E 43
6 On board computer (o) 6 On board computer (o)

The on-board computer represents the operator interface to the truck. It is both a The on-board computer represents the operator interface to the truck. It is both a
display and control unit for the operator and the customer service engineer. You can display and control unit for the operator and the customer service engineer. You can
select certain menus (67) by pressing various keys (softkeys (66)). Menu (67) shows select certain menus (67) by pressing various keys (softkeys (66)). Menu (67) shows
three conditions: Active, inactive and not available for selection (greyed out). three conditions: Active, inactive and not available for selection (greyed out).

All displays are shown in text or symbol form to allow for intuitive operation. The All displays are shown in text or symbol form to allow for intuitive operation. The
meaning of the various symbols is explained in section 7.1. meaning of the various symbols is explained in section 7.1.

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

66 67 67 66 66 67 67 66

1 2
ABC
3
DEF
1 2
ABC
3
DEF

4
GHI
5
JKL
6
MNO
4
GHI
5
JKL
6
MNO

7 8 9 7 8 9
0
km/h
PQRS TUV WXYZ

0
km/h
PQRS TUV WXYZ

CE 0 OK CE 0 OK

0009 h 08:45 0009 h 08:45

63 63

Item Model Item Model

63 Service hours 63 Service hours
66 Soft keys 66 Soft keys
67 Menus 67 Menus
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E 44 E 44
 6.1 On board computer display symbols 6.1 On board computer display symbols

ESCAPE ESCAPE
Goes to a higher level Goes to a higher level

TRAVEL PROFILE 1 TRAVEL PROFILE 1

Slow travel Slow travel

TRAVEL PROFILE 2 TRAVEL PROFILE 2

Normal travel Normal travel
Acceleration, speed etc. can be adjusted to the driver’s requirements Acceleration, speed etc. can be adjusted to the driver’s requirements
TRAVEL PROFILE 3 TRAVEL PROFILE 3
Fast travel Fast travel

LIFT MENU LIFT MENU

Parameters/Diagnosis/ Error log book Parameters/Diagnosis/ Error log book

SERVICE MENU / PARAMETER MENU SERVICE MENU / PARAMETER MENU

Video system Video system

SCROLL UP SCROLL UP
Scrolls up line by line Scrolls up line by line

SCROLL DOWN SCROLL DOWN

Scrolls down line by line Scrolls down line by line

PAGE UP PAGE UP
Scrolls up page by page Scrolls up page by page

PAGE DOWN PAGE DOWN

Scrolls down page by page Scrolls down page by page

BATTERY CHARGE STATUS BATTERY CHARGE STATUS

Operational Operational

BATTERY CHARGE STATUS BATTERY CHARGE STATUS

Operational, warning condition Operational, warning condition

BATTERY CHARGE STATUS BATTERY CHARGE STATUS

Operational, critical warning condition Operational, critical warning condition
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STOP STOP

Lifting is inhibited Lifting is inhibited

E 45 E 45
 Display symbols Display symbols

TIME TIME
08:45 08:45

SERVICE HOUR DISPLAY SERVICE HOUR DISPLAY

0009 h 0009 h

PARAMETER SELECTION PARAMETER SELECTION

Parameters: Acceleration, coasting brake, reverse brake, speed, speed in Parameters: Acceleration, coasting brake, reverse brake, speed, speed in
drive direction and speed in fork direction. drive direction and speed in fork direction.
PARAMETER SELECTION PARAMETER SELECTION
Parameters: Lift Speed Parameters: Lift Speed

STEER ANGLE DISPLAY 360° STEER ANGLE DISPLAY 360°

0
km/h
0
km/h

STEER ANGLE DISPLAY 180° STEER ANGLE DISPLAY 180°

0
km/h
0
km/h

TABULATOR TABULATOR
Jumps to next input field Jumps to next input field

WARNING SYMBOL WARNING SYMBOL

Battery unlocked! Battery unlocked!

WARNING SYMBOL WARNING SYMBOL

P Parking brake applied P Parking brake applied

SYMBOL SYMBOL
Sideshift centre position Sideshift centre position

CRAWL SPEED CRAWL SPEED

PIN ENTRY PIN ENTRY

PIN entered / current field substitute symbol / Pin input substitute symbol PIN entered / current field substitute symbol / Pin input substitute symbol

Toggle switch Toggle switch

FORKS HORIZONTAL FORKS HORIZONTAL

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E 46 E 46
 Battery Discharge Indicator: The charge status of the battery (64) is shown on the Battery Discharge Indicator: The charge status of the battery (64) is shown on the
display. display.

M The standard setting for the battery discharge indicator / discharge monitor is based
on standard batteries.
M The standard setting for the battery discharge indicator / discharge monitor is based
on standard batteries.
The display must be re-set if using maintenance-free batteries. If this adjustment is The display must be re-set if using maintenance-free batteries. If this adjustment is
not made the battery may become damaged through excessive depletion. not made the battery may become damaged through excessive depletion.
This instrument should only be adjusted by the manufacturer’s service department. This instrument should only be adjusted by the manufacturer’s service department.

1 2
ABC
3
DEF
1 2
ABC
3
DEF

4
GHI
5
JKL
6
MNO
4
GHI
5
JKL
6
MNO

7 8 9 7 8 9
0
km/h
PQRS TUV WXYZ

0
km/h
PQRS TUV WXYZ

CE 0 OK CE 0 OK

0009 h 08:45 0009 h 08:45

63 66 63 66

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

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

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

Residual time display: The battery residual time display is an option that can be Residual time display: The battery residual time display is an option that can be
activated via a parameter in service mode. activated via a parameter in service mode.

The time remaining to reach the residual capacity is displayed. The time remaining to reach the residual capacity is displayed.
The battery residual display is shown below the battery symbol (format R 00:00). The battery residual display is shown below the battery symbol (format R 00:00).
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E 47 E 47
 Hourmeter: The service hours are displayed alongside the time. The hourmeter (63) Hourmeter: The service hours are displayed alongside the time. The hourmeter (63)
shows the overall travel and lifting time. Service hours are counted if the truck is shows the overall travel and lifting time. Service hours are counted if the truck is
released for operation via the key switch, keypad or transponder card and the released for operation via the key switch, keypad or transponder card and the
deadman switch is applied. deadman switch is applied.

“Energy recovery” display for regenerative lowering and braking “Energy recovery” display for regenerative lowering and braking
During the “energy recovery” stage, the discharge indicator on the on-board computer During the “energy recovery” stage, the discharge indicator on the on-board computer
changes so that the bars in the battery container fill from bottom to top. changes 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 This takes place cyclically and irrespective of the battery’s charge status (full or
partially discharged). partially discharged).

Z The display goes out once energy recovery is complete.

Z The display goes out once energy recovery is complete.

Lift height display (o) Lift height display (o)

The onboard computer display (63) shows the current fork height in mast lift. Use the The onboard computer display (63) shows the current fork height in mast lift. Use the
toggle key (66) to change between the service hour and time display (63). When the toggle key (66) to change between the service hour and time display (63). When the
truck is switched on, service hours are displayed. truck is switched on, service hours are displayed.

Load weight (o) Load weight (o)

The onboard computer display (63) shows the current load weight after weighing (see The onboard computer display (63) shows the current load weight after weighing (see
section 2). Use the toggle key (66) to change between the service hour and time section 2). Use the toggle key (66) to change between the service hour and time
display (63). When the truck is switched on, service hours are displayed. display (63). When the truck is switched on, service hours are displayed.

Video system (o) Video system (o)

The camera is secured to the inside of the right fork. When transferring to mast lift the The camera is secured to the inside of the right fork. When transferring to mast lift the
on-board computer display automatically changes to camera display. on-board computer display automatically changes to camera display.

Z You can press the keys to override this automatic change. 0210.GB Z You can press the keys to override this automatic change.

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E 48 E 48
 7 Keypad (CANCODE) (o) 7 Keypad (CANCODE) (o)

The keypad consists of 10 digit keys, a Set key The keypad consists of 10 digit keys, a Set key
and a o key. 1 2 3 and a o key. 1 2 3
The o key indicates operating statuses via a red/ The o key indicates operating statuses via a red/
4 5 6 4 5 6
green LED. green LED.

It contains the following functions: 7 8 9 It contains the following functions: 7 8 9

– Code lock function (starting up the truck). Set 0 – Code lock function (starting up the truck). Set 0

7.1 Code Lock 7.1 Code Lock

When the correct code has been entered, the machine is ready for use. You can When the correct code has been entered, the machine is ready for use. You can
allocate an individual code to each truck, driver or group of drivers. allocate an individual code to each truck, driver or group of drivers.

Z When the truck is originally supplied, the operator code for the driver’s display and
CANCODE (o)
Z When the truck is originally supplied, the operator code for the driver’s display and
CANCODE (o)
(factory setting 2-5-8-0) or for the on-board computer (o) (factory setting 2-5-8-0) or for the on-board computer (o)
(factory setting 1-4-0-1-6) is shown on a sticker. (factory setting 1-4-0-1-6) is shown on a sticker.

M When starting the truck for the first time, change the master and operating codes.
M When starting the truck for the first time, change the master and operating codes.
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E 49 E 49
 Commissioning Commissioning

After switching on the EMERGENCY DISCONNECT switch and if necessary the key After switching on the EMERGENCY DISCONNECT switch and if necessary the key
switch, the LED (67) goes red. switch, the LED (67) goes red.

When you enter the correct operator code the LED (67) turns green. 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 code If the wrong code is entered LED (67) flashes red for two seconds. The correct code
can then be entered. can then be entered.

Z The Set key (68) has no function in operating mode

Z The Set key (68) has no function in operating mode

Switching off Switching off

69 70 71 69 70 71
Press the o-key (72) to switch off the truck. Press the o-key (72) to switch off the truck.

Z The truck can switch off automatically after a

pre-determined time. To do this the
Z The truck can switch off automatically after a
pre-determined time. To do this the
1 2 3 1 2 3
corresponding code lock parameter must be corresponding code lock parameter must be
set (refer to section 7.3). 4 5 6 set (refer to section 7.3). 4 5 6
This additional safety mechanism in no way This additional safety mechanism in no way
discharges the owner from his obligation to 7 8 9 discharges the owner from his obligation to 7 8 9
prevent the truck from being used by Set 0 72 prevent the truck from being used by Set 0 72
unauthorized parties before leaving the 68 unauthorized parties before leaving the 68
truck. The owner must therefore apply the truck. The owner must therefore apply the
power-down key each time the truck is left. power-down key each time the truck is left.
67 67

7.2 Parameters 7.2 Parameters

In programming mode you can set the code lock functions via the keypad. In programming mode you can set the code lock functions via the keypad.

Parameter Groups Parameter Groups

The parameter number is composed of three digits. The first digit refers to the The parameter number is composed of three digits. The first digit refers to the
parameter group as shown in Table 1. The second and third digits are numbered in parameter group as shown in Table 1. The second and third digits are numbered in
sequence from 00 to 99. sequence from 00 to 99.

No. Parameter Group No. Parameter Group

0xx Code Lock Settings 0xx Code Lock Settings
(Codes, travel program release, automatic cutout, etc.) (Codes, travel program release, automatic cutout, etc.)
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E 50 E 50
 7.3 Parameter Settings 7.3 Parameter Settings

To change the truck setting you must enter the master code. To change the truck setting you must enter the master code.

Z The factory setting for the master code is 7-2-9-5.

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 (see table).
M When starting the truck for the first time, change the master code (see table).

To enter the master code: To enter the master code:

– Press the o key – Press the o key

– Enter master code – Enter master code

Code Lock Parameters Code Lock Parameters

Truck setting procedure: Truck setting procedure:

– Enter the three digit parameter number, confirm with the Set key (68). – 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 – Enter the setting according to the parameter list or change and confirm with the Set
key (68). key (68).

Z If the entry is incorrect, the LED (67) of the o key (72) flashes red. If you enter the
parameter number again the setting can be entered or changed.
Z If the entry is incorrect, the LED (67) of the o key (72) flashes red. If you enter the
parameter number again the setting can be entered or changed.

To enter more parameters, repeat the procedure. To finish entering, press the o key (72). To enter more parameters, repeat the procedure. To finish entering, press the o key (72).
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E 51 E 51
 The following parameters may be entered. The following parameters may be entered.

Code Lock Parameter List Code Lock Parameter List

No. Function Setting range Standard Comments No. Function Setting range Standard Comments
setting Procedure setting Procedure
Code Lock Code Lock
000 Change master code 0000 - 9999 7295 (LED 69 flashes) 000 Change master code 0000 - 9999 7295 (LED 69 flashes)
The length (4-6 digits) of or Enter the current The length (4-6 digits) of or Enter the current
the master code also pre- 00000 - 99999 code the master code also pre- 00000 - 99999 code
determines the length of or determines the length of or
the operator code (4-6 000000 - 999999 Confirm (Set) the operator code (4-6 000000 - 999999 Confirm (Set)
digits). Provided the digits). Provided the
operator codes are (LED 70 flashes) operator codes are (LED 70 flashes)
programmed, only news Enter a new code programmed, only news Enter a new code
codes of the same length codes of the same length
can be entered. If the Confirm (Set) can be entered. If the Confirm (Set)
code length is to be code length is to be
changed, all operator (LED 71 flashes) changed, all operator (LED 71 flashes)
codes must first be Repeat new code codes must first be Repeat new code
deleted. deleted.
Confirm (Set) Confirm (Set)
001 Add operator code 0000 - 9999 2580 (LED 70 flashes) 001 Add operator code 0000 - 9999 2580 (LED 70 flashes)
(max. 600) or Enter a code (max. 600) or Enter a code
00000 - 99999 00000 - 99999
Confirm (Set) Confirm (Set)
or or
000000 - 999999 (LED 71 flashes) 000000 - 999999 (LED 71 flashes)
Re-enter the code Re-enter the code

Confirm (Set) Confirm (Set)

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E 52 E 52
 No. Function Setting range Standard Comments No. Function Setting range Standard Comments
setting Procedure setting Procedure
Code Lock Code Lock
002 Change user code 0000 - 9999 (LED 69 flashes) 002 Change user code 0000 - 9999 (LED 69 flashes)
or Enter the current or Enter the current
00000 - 99999 code 00000 - 99999 code
or or
Confirm (Set) Confirm (Set)
000000 - 999999 000000 - 999999
(LED 70 flashes) (LED 70 flashes)
Enter a new code Enter a new code

Confirm (Set) Confirm (Set)

(LED 71 flashes) (LED 71 flashes)

Re-enter the code Re-enter the code

confirm confirm
003 Delete user code 0000 - 9999 (LED 70 flashes) 003 Delete user code 0000 - 9999 (LED 70 flashes)
or Enter a code or Enter a code
00000 - 99999 00000 - 99999
or Confirm (Set) or Confirm (Set)
000000 - 999999 000000 - 999999
(LED 71 flashes) (LED 71 flashes)
Re-enter the code Re-enter the code

Confirm (Set) Confirm (Set)

004 Delete code memory 3265 3265 = delete 004 Delete code memory 3265 3265 = delete
(Deletes all user codes ) (Deletes all user codes )
other inputs= do not other inputs= do not
delete delete
010 Automatic timeout 00 - 31 00 00 = no cutout 010 Automatic timeout 00 - 31 00 00 = no cutout

01 to 30 = 01 to 30 =
Cutout time in Cutout time in
minutes minutes

31 = Cutout after 31 = Cutout after

10 seconds 10 seconds
LEDs 69-71 are located in key fields 1-3 (see Section 7.1) LEDs 69-71 are located in key fields 1-3 (see Section 7.1)
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E 53 E 53
 Error messages on keypad Error messages on keypad

LED (67) flashes red to indicate the following errors: LED (67) flashes red to indicate the following errors:
– New master code is already an operator code. – New master code is already an operator code.
– New operator code is already a master code. – New operator code is already a master code.
– Operator code to be changed does not exist. – Operator code to be changed does not exist.
– Tried to change the operator code to another user code that already exists. – Tried to change the operator code to another user code that already exists.
– Tried to delete an operator code that does not exist. – Tried to delete an operator code that does not exist.
– Code memory full – Code memory full

8 ISM (o) 8 ISM (o)

– If the truck is equipped with an ISM access module see “ISM Access Module” – If the truck is equipped with an ISM access module see “ISM Access Module”
operating instructions. operating instructions.

9 Changing truck parameters 9 Changing truck parameters

F Changing the truck parameters will affect the behaviour of the truck. This must be
taken into account when starting up the truck. F Changing the truck parameters will affect the behaviour of the truck. This must be
taken into account when starting up the truck.
Parameters may only be changed when the truck is idle and not lifting. Parameters may only be changed when the truck is idle and not lifting.
With the driver’s display (t) or the on-board computer (o) it is possible to change With the driver’s display (t) or the on-board computer (o) it is possible to change
certain truck parameters (acceleration, coasting brake, reverse braking, drive certain truck parameters (acceleration, coasting brake, reverse braking, drive
direction speed, fork direction speed and lift speed) and hence the truck’s direction speed, fork direction speed and lift speed) and hence the truck’s
characteristics. characteristics.
t Trucks with driver’s display and key switch 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 lift For trucks with a key switch, use the grey service spanner to access the travel and lift
parameters. parameters.
o Trucks with a driver’s display and CANCODE or on-board computer o Trucks with a driver’s display and CANCODE or on-board computer

Z Before entering the SERVICE MENU / PARAMETER MENU you will be asked for
your pin. Trucks with CANCODE (o) after factory set to PIN 7295 which the setting
Z Before entering the SERVICE MENU / PARAMETER MENU you will be asked for
your pin. Trucks with CANCODE (o) after factory set to PIN 7295 which the setting
for the on-board computer (o) is PIN 14037. for the on-board computer (o) is PIN 14037.

To switch on the truck, enter your Pin. Before entering the SERVICE MENU / 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 parameter PARAMETER MENU you will then no longer be asked for your PIN. The parameter
settings are saved under your PIN. settings are saved under your PIN.
You can set 15 different parameters (change of driver or change of program). To You can set 15 different parameters (change of driver or change of program). To
select other parameter settings, the truck must log off and on again or be switched off select other parameter settings, the truck must log off and on again or be switched off
and on again. Enter the next PIN. and on again. Enter the next PIN.

M Changes to the service mode may only be made by the manufacturer’s service
department.
M Changes to the service mode may only be made by the manufacturer’s service
department.
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E 54 E 54
 10 Troubleshooting 10 Troubleshooting

All faults or results of incorrect operation are shown on the driver’s display. Follow the All faults or results of incorrect operation are shown on the driver’s display. Follow the
instructions shown on the display. instructions shown on the display.

It may be necessary to start up the truck again. Turn the EMERGENCY It may be necessary to start up the truck again. Turn the EMERGENCY
DISCONNECT switch off and on again. DISCONNECT switch off and on again.

If the truck does not start consider the following: If the truck does not start consider the following:

Fault Probable Cause Action Fault Probable Cause Action

Truck cannot Battery not connected / Check battery connector, insert if Truck cannot Battery not connected / Check battery connector, insert if
be switched battery cable severed necessary / check cable be switched battery cable severed necessary / check cable
on EMERGENCY Unlock the EMERGENCY on EMERGENCY Unlock the EMERGENCY
DISCONNECT switch DISCONNECT switch DISCONNECT switch DISCONNECT switch
pressed. pressed.
Key switch set to "0" Set key switch to “I” Key switch set to "0" Set key switch to “I”
Faulty fuse. Check fuses. Faulty fuse. Check fuses.

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 fault
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 fault
can only be corrected by trained and qualified service engineers. can only be corrected by trained and qualified service engineers.

11 Moving the truck without a battery, recovery 11 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, since
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, since
the brakes are no longer effective. the brakes are no longer effective.

Preparing the truck for recovery Preparing the truck for recovery
– Turn the Emergency Disconnect – Turn the Emergency Disconnect
switch and key switch off. switch and key switch off.
– Prevent the truck from rolling away. – Prevent the truck from rolling away.
– Push the driver’s seat out of the guide – Push the driver’s seat out of the guide
towards the steering wheel. towards the steering wheel.
– Disconnect the plug connection. – Disconnect the plug connection.
– Remove the seat panel (the seat – Remove the seat panel (the seat
panel can be removed once the panel can be removed once the
3 mounting screws have been 3 mounting screws have been
unscrewed). unscrewed).

Ventilate the magnetic brake Ventilate the magnetic brake

F Uncontrolled truck movement

When the brakes are de-activated the truck must be parked on a level surface, since
F Uncontrolled truck movement
When the brakes are de-activated the truck must be parked on a level surface, since
the brakes are no longer effective. A de-energised truck with a released magnetic the brakes are no longer effective. A de-energised truck with a released magnetic
brake cannot be stopped with the truck's own braking system. brake cannot be stopped with the truck's own braking system.
– Do not release the brake on slopes or inclines. – Do not release the brake on slopes or inclines.
– Apply the brake again when you reach your destination. – Apply the brake again when you reach your destination.
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– Do not park the truck with the brake released. – Do not park the truck with the brake released.

E 55 E 55
 Procedure: Procedure:

– Disconnect the two-pin connector from the magnetic brake. – Disconnect the two-pin connector from the magnetic brake.
– Unscrew the brake release screws from the drive plate and insert them in the – Unscrew the brake release screws from the drive plate and insert them in the
magnetic brake holes. magnetic brake holes.
Align the drive wheel Align the drive wheel

F Steering the truck at idle tensions the drive

wheel tyre. Releasing the crank can result F Steering the truck at idle tensions the drive
wheel tyre. Releasing the crank can result
in a correcting moment. 30 in a correcting moment. 30

Procedure Procedure

Set the drive wheel to the required Set the drive wheel to the required
position, to do this: position, to do this:

– Remove the protective cap from over – Remove the protective cap from over
the centre screw on the steer motor (see the centre screw on the steer motor (see
arrow). arrow).
– Assemble the steering crank in – Assemble the steering crank in
accordance with the tool set table. accordance with the tool set table.
– Place the steering crank on the steering – Place the steering crank on the steering
transmission. transmission.
Turn the drive to the required steering Turn the drive to the required steering
position. position.
Recovering the truck Recovering the truck

F The required steering wheel position can only be adjusted when the truck is stationary.
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 the
trailer load without its own braking system. F Only use vehicles to tow the truck which have sufficient tow and brake forces for the
trailer load without its own braking system.
Always tow the truck at walking pace. Always tow the truck at walking pace.

F An unsecured truck can cause accidents

Parking the truck on an incline or with a raised load / load handler is dangerous and
F An unsecured truck can cause accidents
Parking the truck on an incline or with a raised load / load handler is dangerous and
is strictly prohibited. is strictly prohibited.

– Always park the truck on a level surface. In special cases the truck may need to be – Always park the truck on a level surface. In special cases the truck may need to be
secured with wedges. secured with wedges.
– Always fully lower the mast and forks. – Always fully lower the mast and forks.
– Select a place to park where no other people are at risk of injury from lowering forks. – Select a place to park where no other people are at risk of injury from lowering forks.
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 Procedure Procedure

– Recovering the truck in the drive – Recovering the truck in the drive
direction: Guide the tow rope, tow direction: Guide the tow rope, tow
force > 5 tonnes, around the entry force > 5 tonnes, around the entry
grips on the overhead guard, grips on the overhead guard,
as indicated in the diagram. as indicated in the diagram.

– Recovering the truck in the forks – Recovering the truck in the forks
direction: Guide the tow rope, tow direction: Guide the tow rope, tow
force > 5 tonnes, around the force > 5 tonnes, around the
mast, as indicated in the diagram. mast, as indicated in the diagram.
– Recover the truck carefully and – Recover the truck carefully and
slowly. slowly.
– When the truck reaches its – When the truck reaches its
destination, restore the brake destination, restore the brake
system to its operating condition. system to its operating condition.
Bleed the magnetic brake Bleed the magnetic brake

F The truck must not be parked with

the brakes released. The magnetic
F The truck must not be parked with
the brakes released. The magnetic
brake release must be removed. brake release must be removed.
If the brake is not working, place If the brake is not working, place
wedges underneath the wheels of wedges underneath the wheels of
the truck to prevent it from moving. the truck to prevent it from moving.

Procedure Procedure
– Restore the protective cap over – Restore the protective cap over
the centre screw on the steer the centre screw on the steer
motor (see arrow). motor (see arrow).
– Unscrew the brake release screws from the magnetic brake and insert them in the – Unscrew the brake release screws from the magnetic brake and insert them in the
drive plate holes. drive plate holes.
– Attach the two-pin connector back onto the magnetic brake. – Attach the two-pin connector back onto the magnetic brake.
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12 Optional equipment 12 Optional equipment

12.1 Headlights 12.1 Headlights

74 74

73 73
75 76 75 76

Item Model Item Model

73 o Work lights 73 o Work lights
74 o Work lights 74 o Work lights
75 o Headlights ON/OFF switch for (item 73) 75 o Headlights ON/OFF switch for (item 73)
76 o Headlights ON/OFF switch for (item 74) 76 o Headlights ON/OFF switch for (item 74)

Z The work lights are fitted with a 360º swivel link.

Z The work lights are fitted with a 360º swivel link.
12.2 Beacon / strobe 12.2 Beacon / strobe

77 77
78 78

Item Model Item Model

77 o Beacon 77 o Beacon
78 o Beacon switch ON/OFF 78 o Beacon switch ON/OFF
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 12.3 Limit switch system / electrical lift limit switch 12.3 Limit switch system / electrical lift limit switch

15 79 15 79

Item Model Item Model

15 o Override switch 15 o Override switch
79 o Symbol display sideshift in central position 79 o Symbol display sideshift in central position

o ESA 1 o ESA 1
ESA stands for End-Schalter-Anlage / 1 (Limit Switch System) 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 the The task of ESA 1 is to prevent damage to the truck and / or the load near the
outriggers caused by incorrect operation. outriggers caused by incorrect operation.
ESA 1 is only available for trucks with integrated sideshift. It operates as follows: 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 are – Only when the mast is fully extended or the fork carriage above the outriggers are
all functions released. all functions released.
– Sideshift and lowering are deactivated if the mast is not fully extended and the load – Sideshift and lowering are deactivated if the mast is not fully extended and the load
is near the outriggers. (Outrigger area = 500…600 mm is near the outriggers. (Outrigger area = 500…600 mm

Automatic centring release allows, Automatic centring release allows,

– when the sideshift is centrally positioned, the mast reach to move automatically in – when the sideshift is centrally positioned, the mast reach to move automatically in
the outrigger area. the outrigger area.
– when the sideshift is centrally positioned, the load to be lowered to the ground. – 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). – the central position on the driver’s display to be shown via a control display (79).
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 o ESA 2 with override switch o ESA 2 with override switch
ESA stands for End-Schalter-Anlage / 2 (Limit Switch System) ESA stands for End-Schalter-Anlage / 2 (Limit Switch System)

The task of the ESA 2 is to prevent damage to the truck and / or the load near the The task of the ESA 2 is to prevent damage to the truck and / or the load near the
outriggers caused by incorrect operation. outriggers caused by incorrect operation.

This also applies to trucks with features such as: This also applies to trucks with features such as:

– various attachments such as fork adjusters, baling clamps – various attachments such as fork adjusters, baling clamps
– masts with integrated sideshift – masts with integrated sideshift
– particularly sensitive loads – particularly sensitive loads
Only when the mast is extended or the fork carriage above the outriggers are all Only when the mast is extended or the fork carriage above the outriggers are all
functions released. functions released.

At outrigger height level (i.e. below a lift height of approx 500 – 600 mm) the sideshift At outrigger height level (i.e. below a lift height of approx 500 – 600 mm) the sideshift
and other hydraulic functions except for lifting and tilting (forward / backward) are and other hydraulic functions except for lifting and tilting (forward / backward) are
disabled if the mast is not extended. disabled if the mast is not extended.

Override switch Override switch

The override switch (15) is located above the steering arm and enables all functions The override switch (15) is located above the steering arm and enables all functions
when activated. when activated.

12.4 Seat heating 12.4 Seat heating

Item Model Item Model

80 o Seat heating switch 80 o Seat heating switch
81 o Seat heating display 81 o Seat heating display

81 80 81 80
12.5 12 V DC / 24 V DC transformer 12.5 12 V DC / 24 V DC transformer

Item Model Item Model

85 o 24 volt transformer switch 85 o 24 volt transformer switch
86 o 12 volt transformer switch 86 o 12 volt transformer switch

The transformers (O) can be operated via the The transformers (O) can be operated via the
switches to connect a radio system or an external switches to connect a radio system or an external
device that requires a 12 / 24 volt supply. device that requires a 12 / 24 volt supply.
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E 60 E 60
 12.6 180°/360° steering angle display 12.6 180°/360° steering angle display

0
km/h
0
km/h
0
km/h
0
km/h

82 82

4 4

Item Model Item Model

4 t 180°/360° steering switch 4 t 180°/360° steering switch
82 t 180°/360° steering switch 82 t 180°/360° steering switch

Z Press the “180°/360° steering” switch (4) to change from 180° to 360° steering. The
set range is shown in the display (82).
Z Press the “180°/360° steering” switch (4) to change from 180° to 360° steering. The
set range is shown in the display (82).

12.7 Sideshift centre position 12.7 Sideshift centre position

83 83

5 5

Item Model Item Model

5 o Sideshift centre position switch 5 o Sideshift centre position switch
83 o Sideshift centre position switch 83 o Sideshift centre position switch

Z Pressing the “sideshift centre position” switch (5) locks all other hydraulic functions
until the switch is no longer applied or the sideshift is in the target position.
Z Pressing the “sideshift centre position” switch (5) locks all other hydraulic functions
until the switch is no longer applied or the sideshift is in the target position.
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12.8 Forks horizontal button 12.8 Forks horizontal button

84 84

6 6

Item Model Item Model

6 o Forks horizontal button 6 o Forks horizontal button
84 o Forks horizontal display 84 o Forks horizontal display

Z Pressing the “forks horizontal” button (6) locks all other hydraulic functions until the
switch is no longer applied or the forks are in the horizontal target position.
Z Pressing the “forks horizontal” button (6) locks all other hydraulic functions until the
switch is no longer applied or the forks are in the horizontal target position.

12.9 Weigher 12.9 Weigher

kg kg

81 81

Item Model Item Model

81 o Weighing button 81 o Weighing button

Z When applied, the load is raised approx. 10 cm and lowered again. This process
determines the load weight which is then shown on the driver’s display. All other
Z When applied, the load is raised approx. 10 cm and lowered again. This process
determines the load weight which is then shown on the driver’s display. All other
hydraulic operations are inhibited during weighing. The button must be held throughout hydraulic operations are inhibited during weighing. The button must be held throughout
the whole process or else weighing will be interrupted. the whole process or else weighing will be interrupted.
If there is no valid reading, the display shows “- - - - kg”. If there is no valid reading, the display shows “- - - - kg”.
The weighing system is not a substitute for a calibrated weigher. The weighing system is not a substitute for a calibrated weigher.
The weighing system must not be used to lift the load freely. The weighing system must not be used to lift the load freely.
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 12.10 Clamp button 12.10 Clamp button

kg kg

81a 81a

Item Description Item Description

81a o “Clamp function release” button 81a o “Clamp function release” button

When the "Clamp function release" button (81a) is pressed and the corresponding When the "Clamp function release" button (81a) is pressed and the corresponding
hydraulic function applied simultaneously, the clamp function is activated. hydraulic function applied simultaneously, the clamp function is activated.
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12.11 Weatherproof cab 12.11 Weatherproof cab
87, 88 89 87, 88 89

90 90

100 91 100 91
99 92 99 92
101 98 93 101 98 93
97 94 97 94
96 95 96 95

Item Model Item Model

87 o Weather-proof cab Comfort 1 (no entry door) 87 o Weather-proof cab Comfort 1 (no entry door)
88 o Weather-proof cab Comfort 2 (with entry door) 88 o Weather-proof cab Comfort 2 (with entry door)
89 o Spray water reservoir (behind driver’s seat) 89 o Spray water reservoir (behind driver’s seat)
90 o Emergency hammer 90 o Emergency hammer
91 o Load side work lights 91 o Load side work lights
92 o Not used 92 o Not used
93 o Heating 93 o Heating
94 o Seat heating indicator 94 o Seat heating indicator
95 o Not used 95 o Not used
96 o Windscreen spray water pump 96 o Windscreen spray water pump
97 o Seat heating switch 97 o Seat heating switch
98 o Fan 98 o Fan
99 o Beacon 99 o Beacon
100 o Drive side work lights 100 o Drive side work lights
101 o Windscreen wiper switch 101 o Windscreen wiper switch
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 12.12 Parabolic mirror 12.12 Parabolic mirror

102 102

Item Description Item Description

102 o Parabolic mirror (adjustable) 102 o Parabolic mirror (adjustable)

The parabolic mirror is fitted with a side swivel link. The parabolic mirror is fitted with a side swivel link.
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12.13 Removable load backrest 12.13 Removable load backrest

103 103

104 104

M Trapping hazard
Wear safety gloves and safety shoes when carrying out this operation.
M Trapping hazard
Wear safety gloves and safety shoes when carrying out this operation.

Z The load backrest is heavy

Two people are required to remove and attach the load backrest.
Z The load backrest is heavy
Two people are required to remove and attach the load backrest.

Load backrest disassembly Load backrest disassembly

– Loosen the screws (104) – Loosen the screws (104)

– Remove the load backrest from the fork carriage and put it down securely. – Remove the load backrest from the fork carriage and put it down securely.
Load backrest assembly Load backrest assembly

– Attach the load backrest to the top rail of the fork carriage (103). – Attach the load backrest to the top rail of the fork carriage (103).
– Fit the bolts and tighten them with a torque wrench. – Fit the bolts and tighten them with a torque wrench.

Z Torque = 85 Nm
Z Torque = 85 Nm
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 12.14 Rack Height Select 12.14 Rack Height Select

“Rack Height Select” window “Rack Height Select” window

Z If the truck is equipped with an Rack Height Select, see the "Rack Height Select"
operating instructions.
Z If the truck is equipped with an Rack Height Select, see the "Rack Height Select"
operating instructions.

105 105

106 107 106 107

– Press the "Rack Height Select" key to – Press the "Rack Height Select" key to
call the “Rack Height Select” (105) dis- call the “Rack Height Select” (105) dis-
play/input window. play/input window.

Z On pressing the key the display/input

window (right) appears.
Z On pressing the key the display/input
window (right) appears.

“Lift Height Display” window “Lift Height Display” window

– Activate the lift height display by – Activate the lift height display by
pressing the "Operating hours/lift pressing the "Operating hours/lift
height" key (107). height" key (107).

Z On pressing the key the display (106) toggles between operating hours and lift height
in mm.
Z On pressing the key the display (106) toggles between operating hours and lift height
in mm.
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12.15 ISM access module 12.15 ISM access module

The access module replaces the key switch on a truck. The transponders replace the The access module replaces the key switch on a truck. The transponders replace the
key and are held in front of the access module to log on. When you leave the truck key and are held in front of the access module to log on. When you leave the truck
press the red button to log off. The truck can only be used again if an authorised trans- press the red button to log off. The truck can only be used again if an authorised trans-
ponder is held again in front of the access module. ponder 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.
Z If the truck is equipped with an ISM access module see the “ISM Access Module”
operating instructions.

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 12.16 Assembly and hydraulic ports of additional attachments 12.16 Assembly and hydraulic ports of additional attachments

M Incorrectly connected attachments can cause accidents.

Attachments with incorrectly connected hydraulic attachments can result in accidents.
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, specialist per- – Attachments must only be assembled and commissioned by trained, specialist per-
sonnel. sonnel.
– Note the attachment manufacturer’s operating instructions. – Note the attachment manufacturer’s operating instructions.
– Before commissioning, check the fasteners are positioned correctly and securely – Before commissioning, check the fasteners are positioned correctly and securely
and make sure they are complete. and make sure they are complete.
– Before commissioning, make sure the attachment is working correctly. – Before commissioning, make sure the attachment is working correctly.
Hydraulic ports Hydraulic ports
Requirements Requirements

– Non-pressurised hydraulic hoses. – Non-pressurised hydraulic hoses.

– The attachment directions of movement must match the controls’ direction of move- – The attachment directions of movement must match the controls’ direction of move-
ment. ment.
Procedure Procedure

– Depressurise the hydraulic hoses by switching off the truck and waiting a few minutes. – Depressurise the hydraulic hoses by switching off the truck and waiting a few minutes.
– Attach the plug connector and engage it in position. – Attach the plug connector and engage it in position.
– Mark the controls with symbols that indicate their function. – Mark the controls with symbols that indicate their function.
The attachment is now hydraulically connected. The attachment is now hydraulically connected.

Z Spilled hydraulic oil must be set using a suitable agent and disposed of in accordance
with environmental regulations. If hydraulic oil comes into contact with the skin, wash
Z Spilled hydraulic oil must be set using a suitable agent and disposed of in accordance
with environmental regulations. If hydraulic oil comes into contact with the skin, wash
it off immediately with soap and water. If it comes into contact with the eyes rinse it off immediately with soap and water. If it comes into contact with the eyes rinse
them immediately with flowing water and call for a doctor. them immediately with flowing water and call for a doctor.
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E 70
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 F Industrial Truck Maintenance F Industrial Truck Maintenance
1 Operational Safety and Environmental Protection 1 Operational Safety and Environmental Protection

The servicing and inspection duties contained in this chapter must be performed in The servicing and inspection duties contained in this chapter must be performed in
accordance with the intervals indicated in the maintenance checklists. accordance with the intervals indicated in the maintenance checklists.

F Risk of accidents and damage to component

Any modification to the forklift truck assemblies, in particular the safety mechanisms, F Risk of accidents and damage to component
Any modification to the forklift truck assemblies, in particular the safety mechanisms,
is prohibited. Do not alter the truck's operating speeds under any circumstances. is prohibited. Do not alter the truck's operating speeds under any circumstances.

Exception: Owners should only make changes or have changes made to powered Exception: Owners should only make changes or have changes made to powered
industrial trucks if the truck manufacturer is no longer operating in the field and there industrial trucks if the truck manufacturer is no longer operating in the field and there
is no successor to the business; owners must however: is no successor to the business; owners must however:

– Ensure that the changes to be made are planned, tested and performed by a spe- – Ensure that the changes to be made are planned, tested and performed by a spe-
cialist engineer in industrial trucks taking safety into account. cialist engineer in industrial trucks taking safety into account.
– Keep permanent graphic records of the plans, tests and completion of the changes – 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, – carry out and have authorised the respective changes to the capacity data plates,
decals and stickers as well as the operator and service manuals. decals and stickers as well as the operator and service manuals.
– Attach permanent and clearly visible marking to the truck indicating the types of – 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 the changes made, the date of the changes and the name and address of the
organisation responsible for the work. organisation responsible for the work.

M Only original spare parts have been certified by our quality assurance department.
To ensure safe and reliable operation of the truck, use only the manufacturer's spare
M Only original spare parts have been certified by our quality assurance department.
To ensure safe and reliable operation of the truck, use only the manufacturer's spare
parts. Used parts, oils and fuels must be disposed of in accordance with the relevant parts. Used parts, oils and fuels must be disposed of in accordance with the relevant
environmental protection regulations. For oil changes, contact the manufacturer’s environmental protection regulations. For oil changes, contact the manufacturer’s
specialist department. specialist department.

Upon completion of inspection and servicing, the tasks contained in Upon completion of inspection and servicing, the tasks contained in
the “Recommissioning” section must be performed (see chapter F). the “Recommissioning” section must be performed (see chapter F).
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F1 F1
2 Maintenance safety regulations 2 Maintenance safety regulations

Maintenance personnel Maintenance personnel

Industrial trucks must only be serviced and maintained by the manufacturer’s trained Industrial trucks must only be serviced and maintained by the manufacturer’s trained
personnel. The manufacturer’s service department has field technicians specially personnel. The manufacturer’s service department has field technicians specially
trained for these tasks. trained for these tasks.
We therefore recommend that you enter into a maintenance contract with the manu- We therefore recommend that you enter into a maintenance contract with the manu-
facturer’s local service centre. facturer’s local service centre.

Lifting and jacking up Lifting and jacking up

Lifting and jacking up the truck safely Lifting and jacking up the truck safely
In order to raise the truck, the lifting gear must only be secured to the points specially In order to raise the truck, the lifting gear must only be secured to the points specially
provided for this purpose. provided for this purpose.
You may only work under a raised load handler / raised cab if they have been secured You may only work under a raised load handler / raised cab if they have been secured
with a sufficiently strong chain or the fastening bolt. In order to raise and jack up the with a sufficiently strong chain or the fastening bolt. In order to raise and jack up the
truck safely, proceed as follows: truck safely, proceed as follows:

– Jack up the truck only on a level surface and prevent it from moving accidentally. – 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 – 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). 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- – 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. cially provided for this purpose, see "Identification points" in chapter B.
Cleaning Cleaning

Fire hazard Fire hazard

Do not use flammable liquids to clean the industrial truck. Do not use flammable liquids to clean the industrial truck.

– Always disconnect the battery before starting cleaning work. – Always disconnect the battery before starting cleaning work.
– Carry out all necessary safety measures to prevent sparking before cleaning (e.g. – Carry out all necessary safety measures to prevent sparking before cleaning (e.g.
by short-circuiting). by short-circuiting).
Risk of electrical system damage Risk of electrical system damage

The electrical system can be damaged if it is cleaned with water. Do not wet-clean The electrical system can be damaged if it is cleaned with water. Do not wet-clean
the electrical system. the electrical system.

– Do not clean the electrical system with water. – Do not clean the electrical system with water.
– Clean the electrical system with weak suction or compressed air (use a compressor – Clean the electrical system with weak suction or compressed air (use a compressor
with a water trap) and not a conductive, anti-static brush. with a water trap) and not a conductive, anti-static brush.
Risk of component damage when cleaning the truck 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 electrical If the truck is to be cleaned with a water jet or a high-pressure cleaner, all electrical
and electronic components must be carefully covered beforehand as moisture can and electronic components must be carefully covered beforehand as moisture can
cause malfunctions. Do not clean with pressurised water. cause malfunctions. Do not clean with pressurised water.

After cleaning the truck, carry out the operations detailed in the “Recommissioning” After cleaning the truck, carry out the operations detailed in the “Recommissioning”
section. section.
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 Electrical system Electrical system

M Accident risk
M Accident risk
– Only suitably trained electricians may operate on the truck's electrical system. – Only suitably trained electricians may operate on the truck's electrical system.
– Before working on the electrical system, take all precautionary measures to avoid – Before working on the electrical system, take all precautionary measures to avoid
electric shocks. electric shocks.
– Always disconnect the battery before starting cleaning operations. – Always disconnect the battery before starting cleaning operations.

M Electric currents can cause accidents

M Electric currents can cause accidents

Make sure the electrical system is voltage-free before starting work on it. Make sure the electrical system is voltage-free before starting work on it.
Before starting maintenance on the electrical system: Before starting maintenance on the electrical system:

– Park the truck securely (see “Parking the Truck Securely” in Chapter E). – Park the truck securely (see “Parking the Truck Securely” in Chapter E).
– Press the Emergency Disconnect. – Press the Emergency Disconnect.
– Disconnect the battery. – Disconnect the battery.
– Remove any rings or metal bracelets etc. before working on electrical components. – Remove any rings or metal bracelets etc. before working on electrical components.
Consumables and used parts Consumables and used parts
Consumables and use parts must be disposed of in accordance with the applicable Consumables and use parts must be disposed of in accordance with the applicable
environmental protection regulations. To change the oil contact the manufacturer's environmental protection regulations. To change the oil contact the manufacturer's
customer service department, who have been specially trained for this task. customer service department, who have been specially trained for this task.
– Note the safety regulations when handling these materials. – Note the safety regulations when handling these materials.
Welding Welding

To avoid damaging electric or electronic components, remove these from the truck To avoid damaging electric or electronic components, remove these from the truck
before performing welding operations. before performing welding operations.
Settings Settings

When repairing or replacing hydraulic, electric or electronic components or assem- When repairing or replacing hydraulic, electric or electronic components or assem-
blies, always note the truck-specific settings. blies, always note the truck-specific settings.
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 Tyre type Tyre type

M The use of wheels that do not match the manufacturer's specifications can re-
sult in accidents.
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. The quality of wheels affects the stability and performance of the truck.
Uneven wear affects the truck's stability and increases the stopping distance. Uneven wear affects the truck's stability and increases the stopping distance.
– When replacing wheels make sure the truck is not skewed. – When replacing wheels make sure the truck is not skewed.
– Always replace wheels in pairs, i.e. left and right at the same time. – 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 – When replacing wheels fitted at the factory, only use the manufacturer’s original
spare parts. Otherwise the truck's rated performance cannot be ensured. spare parts. Otherwise the truck's rated performance cannot be ensured.
Lift chains Lift chains

M Non-lubricated and incorrectly cleaned lift chains can cause accidents

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 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 and pivot pins must always be clean and well lubricated.

– Lift chains should only be cleaned with paraffin derivatives e.g. petroleum or – Lift chains should only be cleaned with paraffin derivatives e.g. petroleum or
diesel fuels. diesel fuels.
– Never clean chains with steam jet high pressure cleaners, cold or chemical – Never clean chains with steam jet high pressure cleaners, cold or chemical
cleaning agents. cleaning agents.
– Immediately after cleaning, dry the lift chain with compressed air and apply – Immediately after cleaning, dry the lift chain with compressed air and apply
a chain spray. a chain spray.
– Always lubricate a chain when it is discharged. – Always lubricate a chain when it is discharged.
– Lubricate a lift chain with particular care around the pulleys. – Lubricate a lift chain with particular care around the pulleys.
Hydraulic hoses Hydraulic hoses

M Brittle hydraulic hose lines can cause accidents

M Brittle hydraulic hose lines can cause accidents
The hoses must be replaced every six years. The manufacturer's customer service The hoses must be replaced every six years. The manufacturer's customer service
department is specially trained to carry out these operations. department is specially trained to carry out these operations.

– Comply with the safety regulations for hydraulic hose lines in accordance with – Comply with the safety regulations for hydraulic hose lines in accordance with
ZH 1/74. ZH 1/74.

M Hydraulic line leaks can cause accidents

M Hydraulic line leaks can cause accidents

Hydraulic oil can escape from leaky and faulty hydraulic lines. Hydraulic oil can escape from leaky and faulty hydraulic lines.

– Report any defects immediately to your supervisor. – Report any defects immediately to your supervisor.
– Tag out and decommission a faulty lift truck. – Tag out and decommission a faulty lift truck.
– Only return the truck to service when you have identified and rectified the fault. – 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. – Spilled fluids must be removed immediately with an appropriate bonding agent.
The bonding agent / consumable mixture must be disposed of in accordance with The bonding agent / consumable mixture must be disposed of in accordance with
regulations. regulations.
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 M Hairline cracks in the hydraulic lines can cause injury and infection
M Hairline cracks in the hydraulic lines can cause injury and infection

Pressurised hydraulic oil can penetrate the skin through fine holes or hairline cracks Pressurised hydraulic oil can penetrate the skin through fine holes or hairline cracks
in the hydraulic lines, causing severe injury. in the hydraulic lines, causing severe injury.

– Call for a doctor immediately if you are injured. – Call for a doctor immediately if you are injured.
– Do not touch pressurised hydraulic lines. – Do not touch pressurised hydraulic lines.
– Report any defects immediately to your supervisor. – Report any defects immediately to your supervisor.
– Tag out and decommission a faulty lift truck. – Tag out and decommission a faulty lift truck.
– Only return the truck to service when you have identified and rectified the fault. – 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. – Spilled fluids must be removed immediately with an appropriate bonding agent.
The bonding agent / consumable mixture must be disposed of in accordance with The bonding agent / consumable mixture must be disposed of in accordance with
regulations. regulations.

M Mast reach damping cylinder

M Mast reach damping cylinder

A A

The damping cylinder (A) contains highly pre-tensioned compression springs. Risk of The damping cylinder (A) contains highly pre-tensioned compression springs. Risk of
injury if opened incorrectly. injury if opened incorrectly.

– The mast reach damping cylinder (o) must not be opened. – The mast reach damping cylinder (o) must not be opened.
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F5 F5
3 Servicing and Inspection 3 Servicing and Inspection

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

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

wear of the service components.
M The application conditions of an industrial truck have a considerable impact on the
wear of the service components.
We recommend that a Jungheinrich customer adviser carries out an application We recommend that a Jungheinrich customer adviser carries out an application
analysis on site to work out specific service intervals to prevent damage due to wear. analysis 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 normal The service intervals stated are based on single shift operation under normal
operating conditions. They must be reduced accordingly if the truck is to be used in operating conditions. They must be reduced accordingly if the truck is to be used in
conditions of extreme dust, temperature fluctuations or multiple shifts. conditions of extreme dust, temperature fluctuations or multiple shifts.
The following maintenance checklist states the tasks and intervals after which they The following maintenance checklist states the tasks and intervals after which they
should be carried out. Maintenance intervals are defined as: should be carried out. Maintenance intervals are defined as:

W= Every 50 service hours, at least weekly W= Every 50 service hours, at least weekly
A = Every 500 service hours A = Every 500 service hours
B = Every1000 service hours, or at least annually B = Every1000 service hours, or at least annually
C = Every2000 service hours, or at least annually C = Every2000 service hours, or at least annually

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

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

– During the run-in period – after approx. 100 service hours – the owner must check – During the run-in period – after approx. 100 service hours – the owner must check
the wheel nuts/bolts and re-tighten if necessary. the wheel nuts/bolts and re-tighten if necessary.

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F6 F6
 4 ETM/V 214-325 Maintenance Checklist 4 ETM/V 214-325 Maintenance Checklist
Maintenance Intervals Maintenance Intervals
Standard = t W A B C Standard = t W A B C
Cold store = k Cold store = k
Chassis/ 1.1 Check all load bearing components for damage t Chassis/ 1.1 Check all load bearing components for damage t
Superstruc- 1.2 Check screw connections t Superstruc- 1.2 Check screw connections t
ture: ture:
1.3 Check overhead guard for damage and make sure it is secure k t 1.3 Check overhead guard for damage and make sure it is secure k t
1.4 Check driver position mounting bolts k t 1.4 Check driver position mounting bolts k t
Drive 2.1 Check transmission for noise and leakage t Drive 2.1 Check transmission for noise and leakage t
system: 2.2 Check drive plate and bolts are secure t system: 2.2 Check drive plate and bolts are secure t
2.3 Check transmission oil level t 2.3 Check transmission oil level t
2.4 Check pedal mechanism t 2.4 Check pedal mechanism t
2.5 Change transmission oil k t 2.5 Change transmission oil k t
Wheels: 3.1 Check wheels for wear and damage t Wheels: 3.1 Check wheels for wear and damage t
3.2 Check suspension and attachment k t 3.2 Check suspension and attachment k t
Steering: 4.1 Check steering toothing for wear and lubricate k t Steering: 4.1 Check steering toothing for wear and lubricate k t
4.2 Check mechanical parts of steering head t 4.2 Check mechanical parts of steering head t
4.3 Test steering t 4.3 Test steering t
Brake 5.1 Check brake lining wear except for load wheel brake a) t Brake 5.1 Check brake lining wear except for load wheel brake a) t
system: 5.2 Test operation and settings k t system: 5.2 Test operation and settings k t
5.3 Check brake mechanism k t 5.3 Check brake mechanism k t
5.4 Check brake lines are insulated and mechanical damage t 5.4 Check brake lines are insulated and mechanical damage t
5.5 Check brake lining wear limit and air gap setting and adjust t 5.5 Check brake lining wear limit and air gap setting and adjust t
if necessary if necessary
Hydraulic 6.1 Test operation t Hydraulic 6.1 Test operation t
system 6.2 Check connections and ports for leaks and damage t system 6.2 Check connections and ports for leaks and damage t
6.3 Check hydraulic cylinder for leaks and damage and make sure k t 6.3 Check hydraulic cylinder for leaks and damage and make sure k t
it is secure it is secure
6.4 Check oil level k t 6.4 Check oil level k t
6.5 Change hydraulic oil, filter cartridge and breather k t 6.5 Change hydraulic oil, filter cartridge and breather k t
6.6 Test hose guide and check for damage k t 6.6 Test hose guide and check for damage k t
6.7 Test pressure relief valve k t 6.7 Test pressure relief valve k t
6.8 Test emergency lowering valve t 6.8 Test emergency lowering valve t
6.9 Remove gauze filter from control valve and rinse t 6.9 Remove gauze filter from control valve and rinse t

M a)Clean the load wheel brake when changing load wheels. When replacing the load
wheel check the brake multi-plate wear of the load wheel brake and replace multi-
M a)Clean the load wheel brake when changing load wheels. When replacing the load
wheel check the brake multi-plate wear of the load wheel brake and replace multi-
plates as required. plates as required.
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F7 F7
 Maintenance Intervals Maintenance Intervals
Standard = t W A B C Standard = t W A B C
Cold store = k Cold store = k
Electrical 7.1 Test operation t Electrical 7.1 Test operation t
system 7.2 Make sure wire connections are secure and check for t system 7.2 Make sure wire connections are secure and check for t
damage damage
7.3 Check fuse ratings t 7.3 Check fuse ratings t
7.4 Make sure switches are secure and are operating correctly t 7.4 Make sure switches are secure and are operating correctly t
7.5 Test all warning devices and safety switches. k t 7.5 Test all warning devices and safety switches. k t
7.6 Check contactors, replace any worn parts. t 7.6 Check contactors, replace any worn parts. t
7.7 Make sure electronic components are secure and clean. t 7.7 Make sure electronic components are secure and clean. t
Electric 8.1 Check motor attachment t Electric 8.1 Check motor attachment t
motors: motors:
Battery: 9.1 Check battery cables for damage, replace if necessary. t Battery: 9.1 Check battery cables for damage, replace if necessary. t
9.2 Check battery trolley lock, setting and operation. t 9.2 Check battery trolley lock, setting and operation. t
9.3 Check acid density, acid level and cell voltage k t 9.3 Check acid density, acid level and cell voltage k t
9.4 Check terminals are securely attached, and apply grease k t 9.4 Check terminals are securely attached, and apply grease k t
9.5 Clean battery connections, make sure they are tight k t 9.5 Clean battery connections, make sure they are tight k t
Mast: 10.1 Check mast attachment t Mast: 10.1 Check mast attachment t
10.2 Check lift chains and guides for wear, adjust and lubricate k t 10.2 Check lift chains and guides for wear, adjust and lubricate k t
10.3 Check tilt cylinder suspension and attachment t 10.3 Check tilt cylinder suspension and attachment t
10.4 Check mast tilt angle t 10.4 Check mast tilt angle t
10.5 Visually inspect rollers, slide pieces and stops k t 10.5 Visually inspect rollers, slide pieces and stops k t
10.6 Check mast suspension t 10.6 Check mast suspension t
10.7 Check reach mechanism for wear and damage; if necessary t 10.7 Check reach mechanism for wear and damage; if necessary t
adjust lateral play, adjust rollers and lubricate the tracks. adjust lateral play, adjust rollers and lubricate the tracks.
10.8 Check forks and fork carriage for wear and damage k t 10.8 Check forks and fork carriage for wear and damage k t
10.9 Check free lift cylinder displacement k t 10.9 Check free lift cylinder displacement k t
10.10 Integrated sideshifter (o): Check the screws on the restraint t 10.10 Integrated sideshifter (o): Check the screws on the restraint t
system and the fork locking system are secure. system and the fork locking system are secure.
Attach- 11.1 Test operation k t Attach- 11.1 Test operation k t
ment: 11.2 Check attachment on truck and load bearing components k t ment: 11.2 Check attachment on truck and load bearing components k t
11.3 Check bearing points, guides and stops for wear and t 11.3 Check bearing points, guides and stops for wear and t
damage, grease these components. damage, grease these components.
General 12.1 Check electrical system for frame leakage t General 12.1 Check electrical system for frame leakage t
Measure- 12.2 Test travel speed and braking distance t Measure- 12.2 Test travel speed and braking distance t
ments: ments:
12.3 Test lift and lowering speeds t 12.3 Test lift and lowering speeds t
12.4 Test safety devices and cutouts t 12.4 Test safety devices and cutouts t
Lubrication: 13.1 Lubricate truck in accordance with Lubrication Schedule k t Lubrication: 13.1 Lubricate truck in accordance with Lubrication Schedule k t
Demonstra- 14.1 Test run with rated load t Demonstra- 14.1 Test run with rated load t
tion: 14.2 After carrying out maintenance, present the truck to the k t tion: 14.2 After carrying out maintenance, present the truck to the k t
supervisor. supervisor.
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F8 F8
 5 ETM/V 214-325 Maintenance Schedule 5 ETM/V 214-325 Maintenance Schedule

F E F E

G G

75 –5 Nm 75 –5 Nm

F E F E

E F E F

2,9 l Min. = 16l 2) 2,9 l Min. = 16l 2)

Max.= 29l Max.= 29l
1) 1)
B+C B A J B+C B A J
195 -10 Nm 195 -10 Nm

g Contact surfaces g Contact surfaces

s Grease nipple s Grease nipple
Hydraulic oil filler plug Hydraulic oil filler plug
c Hydraulic oil drain plug c Hydraulic oil drain plug
b Transmission oil filler neck b Transmission oil filler neck
a Transmission oil drain plug a Transmission oil drain plug
Cold Store Application Cold Store Application
1) Cold store mix ratio 1:1 1) Cold store mix ratio 1:1
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2) For capacity see section 5.3 “Tank Capacity” 2) For capacity see section 5.3 “Tank Capacity”

F9 F9
5.1 Lubricants and Lubrication Schedule 5.1 Lubricants and Lubrication Schedule

5.1.1 Handling consumables safely 5.1.1 Handling consumables safely

Handling consumables: Consumables must always be handled correctly. Handling consumables: Consumables must always be handled correctly.
Follow the manufacturer’s instructions. Follow the manufacturer’s instructions.

M Improper handling is hazardous to health, life and the environment

M Improper handling is hazardous to health, life and the environment

Consumables can be flammable. Consumables can be flammable.

– Keep consumables away from hot components and naked flames. – Keep consumables away from hot components and naked flames.
– Always keep consumables in prescribed containers. – Always keep consumables in prescribed containers.
– Always fill consumables in clean containers. – Always fill consumables in clean containers.
– Do not mix up different grades of consumable. The only exception to this is when – Do not mix up different grades of consumable. The only exception to this is when
mixing is expressly stipulated in the Operating Instructions. mixing is expressly stipulated in the Operating Instructions.

M Spilled liquids can cause slipping and endanger the environment

M Spilled liquids can cause slipping and endanger the environment
Risk of slipping from spilled liquids. The risk is greater when combined with water. Risk of slipping from spilled liquids. The risk is greater when combined with water.

– Do not spill liquids. – Do not spill liquids.

– Spilled liquids must be removed immediately with an appropriate bonding agent. – Spilled liquids must be removed immediately with an appropriate bonding agent.
– The bonding agent / consumable mixture must be disposed of in accordance with – The bonding agent / consumable mixture must be disposed of in accordance with
regulations. regulations.

M Oils (chain spray / hydraulic oil) are flammable and poisonous.

M Oils (chain spray / hydraulic oil) are flammable and poisonous.

– Dispose of used oils in accordance with regulations. Store used oil safely until it can – Dispose of used oils in accordance with regulations. Store used oil safely until it can
be disposed of in accordance with regulations be disposed of in accordance with regulations
– Do not spill oil. – Do not spill oil.
– Spilled fluids must be removed immediately with an appropriate bonding agent. – Spilled fluids must be removed immediately with an appropriate bonding agent.
– The bonding agent / consumable mixture must be disposed of in accordance with – The bonding agent / consumable mixture must be disposed of in accordance with
regulations. regulations.
– Observe national regulations when handling oils. – Observe national regulations when handling oils.
– Wear safety gloves when handling oils. – Wear safety gloves when handling oils.
– Prevent oil from coming into contact with hot motor parts. – Prevent oil from coming into contact with hot motor parts.
– Do not smoke when handling oil. – Do not smoke when handling oil.
– Avoid contact and digestion. If you swallow oil do not induce vomiting but call for – Avoid contact and digestion. If you swallow oil do not induce vomiting but call for
a doctor immediately. a doctor immediately.
– Seek fresh air after breathing in oil fumes or vapours. – 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 skin, rinse your skin with water.
– If oil has come into contact with your eyes, rinse them with water and call for a doc- – If oil has come into contact with your eyes, rinse them with water and call for a doc-
tor immediately. tor immediately.
– Replace oil-soaked clothing and shoes immediately. – Replace oil-soaked clothing and shoes immediately.
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F 10 F 10
 5.2 Consumables 5.2 Consumables

Code Order no. Package Model Used for Code Order no. Package Model Used for
quantity quantity
A 50 449 669 5.0 l HLP-D 46, Hydraulic System A 50 449 669 5.0 l HLP-D 46, Hydraulic System
DIN 51524 DIN 51524
B 29 200 680 5.0 l CLP 100, Transmission B 29 200 680 5.0 l CLP 100, Transmission
DIN 51517 DIN 51517
C 29 200 810 5.0 l HLP 10, Transmission C 29 200 810 5.0 l HLP 10, Transmission
DIN 51524 DIN 51524
E 29 201 430 1.0 kg Grease, DIN 51825 Lubrication E 29 201 430 1.0 kg Grease, DIN 51825 Lubrication
F 50 430 702 1.0 kg Grease, TTF52 Lubrication F 50 430 702 1.0 kg Grease, TTF52 Lubrication
G 29 201 280 400 ml Chain spray Chains G 29 201 280 400 ml Chain spray Chains
J 51 081 875 5 l Renolin MR 310 Hydraulic System J 51 081 875 5 l Renolin MR 310 Hydraulic System

Grease guidelines Grease guidelines

Code Saponification Dew point Worked NLG1 class Applicationte Code Saponification Dew point Worked NLG1 class Applicationte
°C penetration at mperature °C °C penetration at mperature °C
25° C 25° C
E Lithium 185 265 - 295 2 -35 / +120 E Lithium 185 265 - 295 2 -35 / +120
F -- -- 310 - 340 1 -52 / +100 F -- -- 310 - 340 1 -52 / +100
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F 11 F 11
5.3 Reservoir capacity 5.3 Reservoir capacity

ETM 214-325 ETM 214-325

ETM 214-216 ETM 320-325 ETM 214-216 ETM 320-325

Lift heights (h3) Lift heights (h3)
Marking litres Lift heights (h3) Marking litres Lift heights (h3)
ZT DZ ZT DZ
Max 25 - up to 8720 up to 11120 Max 25 - up to 8720 up to 11120
(low air cushion) (low air cushion)
V 23.5 - up to 7400 up to 9950 V 23.5 - up to 7400 up to 9950
IV. 21 - up to 6200 up to 8720 IV. 21 - up to 6200 up to 8720
III 18.5 - up to 4550 up to 6800 III 18.5 - up to 4550 up to 6800
II 16 up to 6500 - up to 5600 II 16 up to 6500 - up to 5600
I 13 - - - I 13 - - -

ETV 214-325 ETV 214-325

ETV 214-216 ETV 320-325 ETV 214-216 ETV 320-325

Lift heights (h3) Lift heights (h3)
Marking litres Lift heights (h3) Marking litres Lift heights (h3)
ZT DZ ZT DZ
Max 31.6 - - - Max 31.6 - - -
(low air cushion) (low air cushion)
V 30 - - - V 30 - - -
IV. 28 - up to 10250 up to 12020 IV. 28 - up to 10250 up to 12020
III 25 - up to 8720 up to 11120 III 25 - up to 8720 up to 11120
II 21 - up to 6200 up to 8720 II 21 - up to 6200 up to 8720
I 17 up to 4400 - up to 6200 I 17 up to 4400 - up to 6200

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F 12 F 12
 6 Maintenance Instructions 6 Maintenance Instructions

6.1 Preparing the truck for maintenance and repairs 6.1 Preparing the truck for maintenance and repairs

All necessary safety measures must be taken to avoid accidents when carrying out All necessary safety measures must be taken to avoid accidents when carrying out
maintenance and repairs. The following preparations must be made: maintenance and repairs. The following preparations must be made:

– Park the truck securely (see Chapter E). – Park the truck securely (see Chapter E).
– Disconnect the battery (1) to prevent the truck from accidentally starting. – Disconnect the battery (1) to prevent the truck from accidentally starting.

1 1

F When working under a raised load fork or a raised truck, secure them to prevent them
from lowering, tipping or sliding away. When raising the truck also refer to the F When working under a raised load fork or a raised truck, secure them to prevent them
from lowering, tipping or sliding away. When raising the truck also refer to the
instructions in the “Transport and Commissioning” section. instructions in the “Transport and Commissioning” section.
When working on the parking brake, prevent the truck from rolling away. When working on the parking brake, prevent the truck from rolling away.
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F 13 F 13
6.2 Remove seat panel 6.2 Remove seat panel

2 3 2 3
4 4

5 5

– Pull seat locking lever (2) up and push seat (3) towards the steering wheel. – Pull seat locking lever (2) up and push seat (3) towards the steering wheel.
– Disconnect the plug connection. – Disconnect the plug connection.
– Slacken collar screws (4) and remove panel (5). – Slacken collar screws (4) and remove panel (5).

Z The drive unit and hydraulic unit are now exposed for maintenance.
Z The drive unit and hydraulic unit are now exposed for maintenance.

6.3 Check the hydraulic oil level 6.3 Check the hydraulic oil level

– Preparing the truck for maintenance – Preparing the truck for maintenance
and repairs (see Section 6.1 and 6.2). and repairs (see Section 6.1 and 6.2).
– Check oil level in hydraulic tank. – Check oil level in hydraulic tank.

Z The oil level should be checked in the

hydraulic tank when the load is lowered.
Z The oil level should be checked in the
hydraulic tank when the load is lowered.
– If necessary replenish at the filler neck – If necessary replenish at the filler neck
(6) using the correct oil grade (for (6) using the correct oil grade (for
hydraulic oil specification, hydraulic oil specification,
see section 5.1). see section 5.1).
– Replace seat panel and secure with – Replace seat panel and secure with
collar screws (4). collar screws (4).
– Connect fan. – Connect fan.
– Push seat into position and engage – Push seat into position and engage
locking lever (2). 6 locking lever (2). 6
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F 14 F 14
 6.4 Opening the fuse cover 6.4 Opening the fuse cover

– Forcibly remove panel and put it to – Forcibly remove panel and put it to
one side. one side.

Z Fuses are located under the panel.

Z Fuses are located under the panel.

6.5 Opening the instrument panel cover 6.5 Opening the instrument panel cover

– Slacken the screws in mast guard (8). – Slacken the screws in mast guard (8).
7 8 7 8
Push the steering wheel towards the Push the steering wheel towards the
seat (outermost position) Remove the seat (outermost position) Remove the
panel (7). panel (7).

Z The main fuses are located under the

panel (7).
Z The main fuses are located under the
panel (7).
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F 15 F 15
6.6 Checking electrical fuses 6.6 Checking electrical fuses

– Preparing the truck for maintenance and repairs (see Section 6.4 and 6.5). – Preparing the truck for maintenance and repairs (see Section 6.4 and 6.5).
– Check rating of all fuses in accordance with table, replace if necessary. – Check rating of all fuses in accordance with table, replace if necessary.

06/2006- 06/2006-

10 10
13 13
9 9
12 12

8 8
11 14 11 14

15 16 17 1819 20 21 15 16 17 1819 20 21
11 12 11 12
10 10
9 9
8 8

-06/2006 -06/2006
22 23 24 25 26 27 28 14 13 22 23 24 25 26 27 28 14 13

Item Model Rating / type Item Model Rating / type

8a) F8 Main fuse 355 A 8a) F8 Main fuse 355 A
9b) 2F1 Pump motor fuse 250 A 9b) 2F1 Pump motor fuse 250 A
10b) 1F1 Drive motor fuse 250 A 10b) 1F1 Drive motor fuse 250 A
11c) F1 Overall control fuse 30 A 11c) F1 Overall control fuse 30 A
12c) F13 Valve / brake fuse 30 A 12c) F13 Valve / brake fuse 30 A
13c) 3F1 Steering fuse 30 A 13c) 3F1 Steering fuse 30 A
14c) 5F6 Cabin fuse 30 A 14c) 5F6 Cabin fuse 30 A
15 F17 Radio fuse 7.5 A 15 F17 Radio fuse 7.5 A
16 4F11 Driver’s display / on board computer fuse 5A 16 4F11 Driver’s display / on board computer fuse 5A
17 5F7 Overhead guard option fuse 10 A 17 5F7 Overhead guard option fuse 10 A
18 2F17 Hydraulics MFC control fuse 2A 18 2F17 Hydraulics MFC control fuse 2A
19 4F12 Aux. MFC control fuse 2A 19 4F12 Aux. MFC control fuse 2A
20 1F13 Travel / brake MFC control fuse 7.5 A 20 1F13 Travel / brake MFC control fuse 7.5 A
21 2F16 Lift controller control fuse 2A 21 2F16 Lift controller control fuse 2A
22 4F10 Fan control fuse 3A 22 4F10 Fan control fuse 3A
23 1F12 Traction controller control fuse 2A 23 1F12 Traction controller control fuse 2A
24 3F2 Power steering control fuse 3A 24 3F2 Power steering control fuse 3A
25 9F2 Seat heating control fuse 7.5 A 25 9F2 Seat heating control fuse 7.5 A
26 4F13 Aux. fuse 7.5 A 26 4F13 Aux. fuse 7.5 A
27 2F18 Hydraulics MFC fuse 10 A 27 2F18 Hydraulics MFC fuse 10 A
28 1F14 Travel / brake MFC control fuse 10 A 28 1F14 Travel / brake MFC control fuse 10 A
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a) 13 Nm, b) 8,5 Nm , c) 4,5 Nm a) 13 Nm, b) 8,5 Nm , c) 4,5 Nm

F 16 F 16
 6.7 Checking the wheel attachments. 6.7 Checking the wheel attachments.

F Accident risk from incorrect wheel disassembly/assembly

F Accident risk from incorrect wheel disassembly/assembly

The load / drive wheels can only be disassembled or assembled by the The load / drive wheels can only be disassembled or assembled by the
manufacturer's customer service department which has been trained to do this. manufacturer's customer service department which has been trained to do this.
Exceptionally, this task may be performed by a customer service organisation Exceptionally, this task may be performed by a customer service organisation
authorised by the manufacturer. authorised by the manufacturer.

– Park the truck securely (see Chapter E). – Park the truck securely (see Chapter E).
– Tighten the wheel bolts crosswise with a torque wrench. – Tighten the wheel bolts crosswise with a torque wrench.
Torque Torque

Load wheels (main bolt) MA = 120 Nm Load wheels (main bolt) MA = 120 Nm

Drive wheel MA = 195-10 Nm Drive wheel MA = 195-10 Nm

6.8 Recommissioning 6.8 Recommissioning

The truck may only be restored to service after cleaning or repair work, once the The truck may only be restored to service after cleaning or repair work, once the
following operations have been performed. following operations have been performed.

– Test horn. – Test horn.

– Test main switch operation. – Test main switch operation.
– Test brakes. – Test brakes.
– Lubricate the truck in accordance with the maintenance schedule. – Lubricate the truck in accordance with the maintenance schedule.

7 Decommissioning the industrial truck 7 Decommissioning the industrial truck

If the industrial truck is to be decommissioned for more than two months, e.g. for If the industrial truck is to be decommissioned for more than two months, e.g. for
operational reasons, it must be parked in a frost-free and dry location and all operational reasons, it must be parked in a frost-free and dry location and all
necessary measures must be taken before, during and after decommissioning as necessary measures must be taken before, during and after decommissioning as
described. described.

M On decommissioning the truck must be jacked up so that all the wheels are clear of
the ground. This is the only way of ensuring that the wheels and wheel bearings are
M On decommissioning the truck must be jacked up so that all the wheels are clear of
the ground. This is the only way of ensuring that the wheels and wheel bearings are
not damaged. not damaged.

If the truck is to be out of service for more than 6 months, further measures must be If the truck is to be out of service for more than 6 months, further measures must be
taken in consultation with the manufacturer’s service department. taken in consultation with the manufacturer’s service department.

7.1 Prior to decommissioning: 7.1 Prior to decommissioning:

– Thoroughly clean the truck. – Thoroughly clean the truck.

– Check the brakes. – Check the brakes.
– Check the hydraulic oil level and replenish as necessary (see Chapter F). – 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. – 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). – Lubricate the truck in accordance with the maintenance schedule (see Chapter F).
– Charge the battery (see Chapter D). – Charge the battery (see Chapter D).
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– Disconnect the battery, clean it and grease the terminals. – Disconnect the battery, clean it and grease the terminals.

F 17 F 17
Z In addition, follow the battery manufacturer’s instructions.
Z In addition, follow the battery manufacturer’s instructions.

– Spay all exposed electrical contacts with a suitable contact spray. – Spay all exposed electrical contacts with a suitable contact spray.

7.2 During decommissioning: 7.2 During decommissioning:

Every 2 months: Every 2 months:

– Charge the battery (see Chapter D). – Charge the battery (see Chapter D).

M Battery powered trucks:

The battery must be charged at regular intervals to avoid depletion of the battery
M Battery powered trucks:
The battery must be charged at regular intervals to avoid depletion of the battery
through self-discharge. The sulfatisation would destroy the battery. through self-discharge. The sulfatisation would destroy the battery.

7.3 Returning the truck to operation after decommissioning 7.3 Returning the truck to operation after decommissioning

– Thoroughly clean the truck. – Thoroughly clean the truck.

– Lubricate the truck in accordance with the maintenance schedule (see Chapter F). – Lubricate the truck in accordance with the maintenance schedule (see Chapter F).
– Clean the battery, grease the terminals and connect the battery. – Clean the battery, grease the terminals and connect the battery.
– Charge the battery (see Chapter D). – Charge the battery (see Chapter D).
– Check transmission oil for condensed water and replace if necessary. – Check transmission oil for condensed water and replace if necessary.
– Check hydraulic 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). – Start up the truck (see Chapter E).

Z Battery powered trucks:

If there are switching problems in the electrical system, apply contact spray to the
Z Battery powered trucks:
If there are switching problems in the electrical system, apply contact spray to the
exposed contacts and remove any oxide layers on the contacts of the operating exposed contacts and remove any oxide layers on the contacts of the operating
controls by applying them repeatedly. controls by applying them repeatedly.

F Perform several brake tests immediately after re-commissioning the truck.

F Perform several brake tests immediately after re-commissioning the truck.

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F 18 F 18
 8 Safety checks to be performed at regular intervals and following any unusual 8 Safety checks to be performed at regular intervals and following any unusual
incidents incidents

Z Carry out a safety check in accordance with national regulations. Junheinrich

recommends checks in accordance with FEM Guideline 4.004. Jungheinrich has a
Z Carry out a safety check in accordance with national regulations. Junheinrich
recommends checks in accordance with FEM Guideline 4.004. Jungheinrich has a
special safety department with trained personnel to carry out such checks. special safety department with trained personnel to carry out such checks.

The truck must be inspected at least annually (refer to national regulations) or after The truck must be inspected at least annually (refer to national regulations) or after
any unusual event by a qualified inspector. The inspector shall assess the condition any unusual event by a qualified inspector. The inspector shall assess the condition
of the truck from purely a safety viewpoint, without regard to operational or economic of the truck from purely a safety viewpoint, without regard to operational or economic
circumstances. The inspector shall be sufficiently instructed and experienced to be circumstances. The inspector shall be sufficiently instructed and experienced to be
able to assess the condition of the truck and the effectiveness of the safety able to assess the condition of the truck and the effectiveness of the safety
mechanisms based on the technical regulations and principles governing the mechanisms based on the technical regulations and principles governing the
inspection of forklift trucks. inspection of forklift trucks.

A thorough test of the truck must be undertaken with regard to its technical condition A thorough test of the truck must be undertaken with regard to its technical condition
from a safety aspect. The truck must also be examined for damage caused by from a safety aspect. The truck must also be examined for damage caused by
possible improper use. A test report shall be provided. The test results must be kept possible improper use. A test report shall be provided. The test results must be kept
for at least the next 2 inspections. for at least the next 2 inspections.

The owner is responsible for ensuring that faults are immediately rectified. 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.
Z A test plate is attached to the truck as proof that it has passed the safety inspection.
This plate indicates the due date for the next inspection.
9 Final de-commissioning, disposal 9 Final de-commissioning, disposal

Z Final, proper decommissioning or disposal of the truck must be performed in

accordance with the regulations of the country of application. In particular, regulations
Z Final, proper decommissioning or disposal of the truck must be performed in
accordance with the regulations of the country of application. In particular, regulations
governing the disposal of batteries, fuels and electronic and electrical systems must governing the disposal of batteries, fuels and electronic and electrical systems must
be observed. be observed.
10 Human vibration measurement 10 Human vibration measurement

Z Vibrations that affect the driver during operation over the course of the day are known
as human vibrations. Excessive human vibrations will cause the driver long term
Z Vibrations that affect the driver during operation over the course of the day are known
as human vibrations. Excessive human vibrations will cause the driver long term
health problems. The European "2002/44/EC/Vibration" operator directive has health problems. The European "2002/44/EC/Vibration" operator directive has
therefore been established to protect drivers. therefore been established to protect drivers.
To help operators to assess the application situation, the manufacturer offers a To help operators to assess the application situation, the manufacturer offers a
service of measuring these human vibrations. service of measuring these human vibrations.
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F 19 F 19
F 20
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0210.GB
 Instructions for use Instructions for use
Jungheinrich traction battery Jungheinrich traction battery
Table of contents Table of contents
1 Jungheinrich traction battery 1 Jungheinrich traction battery
with positive tubular plates type EPzS and EPzB ..........................................2-6 with positive tubular plates type EPzS and EPzB ..........................................2-6

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

Instruction for use Instruction for use

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

2 Jungheinrich traction battery 2 Jungheinrich traction battery

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

Type plate Jungheinrich traction battery............................................17 Type plate Jungheinrich traction battery............................................17
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1 1
1 Jungheinrich traction battery 1 Jungheinrich traction battery

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

Rating Data Rating Data

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

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

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

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

•No smoking! •No smoking!

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

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

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

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

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

•Dangerous electrical voltage! •Dangerous electrical voltage!

•Caution! Metal parts of the battery are always live. Do not place tools or other me- •Caution! Metal parts of the battery are always live. Do not place tools or other me-
tal objects on the battery! tal objects on the battery!
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 Ignoring the operation instructions, repair with non-original parts or using additives for Ignoring the operation instructions, repair with non-original parts or using additives for
the electrolyte will render the warranty void. the electrolyte will render the warranty void.
For batteries in classes I and II the instructions for maintaining the appropriate For batteries in classes I and II the instructions for maintaining the appropriate
protection class during operation must be complied with (see relevant certificate). protection class during operation must be complied with (see relevant certificate).

1. Commissioning filled and charged batteries. For commissioning of unfilled 1. Commissioning filled and charged batteries. For commissioning of unfilled
batteries see separate instructions! batteries see separate instructions!
The battery should be inspected to ensure it is in perfect physical condition. The battery should be inspected to ensure it is in perfect physical condition.

The charger cables must be connected to ensure a good contact, taking care that the The charger cables must be connected to ensure a good contact, taking care that the
polarity is correct. Otherwise battery, vehicle or charger could be damaged. polarity is correct. Otherwise battery, vehicle or charger could be damaged.

The specified torque loading for the polscrews of the charger cables and connectors The specified torque loading for the polscrews of the charger cables and connectors
are: are:

steel steel
M 10 23 ± 1 Nm M 10 23 ± 1 Nm

The level of the electrolyte must be checked. If it is below the antisurge baffle or the The level of the electrolyte must be checked. If it is below the antisurge baffle or the
top of the separator it must first be topped up to this height with purified water. top of the separator it must first be topped up to this height with purified water.
The battery is then charged as in item 2.2. The battery is then charged as in item 2.2.

The electrolyte should be topped up to the specified level with purified water. The electrolyte should be topped up to the specified level with purified water.

2. Operation 2. Operation

DIN EN 50272-3 «Traction batteries for industrial trucks» is the standard which ap- DIN EN 50272-3 «Traction batteries for industrial trucks» is the standard which ap-
plies to the operation traction batteries in industrial trucks. plies to the operation traction batteries in industrial trucks.

2.1 Discharging 2.1 Discharging

Be sure that all breather holes are not sealed or covered. Be sure that all breather holes are not sealed or covered.

Electrical connections (e.g. plugs) must only be made or broken in the open circuit Electrical connections (e.g. plugs) must only be made or broken in the open circuit
condition. condition.
To achieve the optimum life for the battery, operating discharges of more than 80% To achieve the optimum life for the battery, operating discharges of more than 80%
of the rated capacity should be avoided (deep discharge). of the rated capacity should be avoided (deep discharge).

This corresponds to an electrolyte specific gravity of 1.13 kg/l at the end of the di- This corresponds to an electrolyte specific gravity of 1.13 kg/l at the end of the di-
scharge. Discharged batteries must be recharged immediately and must not be left scharge. Discharged batteries must be recharged immediately and must not be left
discharged. This also applies to partially discharged batteries. discharged. This also applies to partially discharged batteries.

2.2 Charging 2.2 Charging

Only direct current must be used for charging. All charging procedures in accordance Only direct current must be used for charging. All charging procedures in accordance
with DIN 41773 and DIN 41774 are permitted. Only connect the battery assigned to with DIN 41773 and DIN 41774 are permitted. Only connect the battery assigned to
a charger, suitable for the size of battery, in order to avoid overloading of the electric a charger, suitable for the size of battery, in order to avoid overloading of the electric
cables and contacts, unacceptable gassing and the escape of electrolyte from the cables and contacts, unacceptable gassing and the escape of electrolyte from the
cells. cells.
In the gassing stage the current limits given in DIN EN 50272-3 must not be excee- In the gassing stage the current limits given in DIN EN 50272-3 must not be excee-
ded. If the charger was not purchased together with the battery it is best to have its ded. If the charger was not purchased together with the battery it is best to have its
suitability checked by the manufacturers service department. When charging, proper suitability checked by the manufacturers service department. When charging, proper
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provision must be made for venting of the charging gases. provision must be made for venting of the charging gases.

3 3
 Battery container lids and the covers of battery compartments must be opened or re- Battery container lids and the covers of battery compartments must be opened or re-
moved. The vent plugs should stay on the cells and remain closed. moved. The vent plugs should stay on the cells and remain closed.
With the charger switched off connect up the battery, ensuring that the polarity is cor- With the charger switched off connect up the battery, ensuring that the polarity is cor-
rect. (positive to positive, negative to negative). Now switch on the charger. When rect. (positive to positive, negative to negative). Now switch on the charger. When
charging the temperature of the electrolyte rises by about 10°C, so charging should charging the temperature of the electrolyte rises by about 10°C, so charging should
only begin if the electrolyte temperature is below 45°C. The electrolyte temperature only begin if the electrolyte temperature is below 45°C. The electrolyte temperature
of batteries should be at least +10°C before charging otherwise a full charge will not of batteries should be at least +10°C before charging otherwise a full charge will not
be achieved. be achieved.

A charge is finished when the specific gravity of the electrolyte and the battery voltage A charge is finished when the specific gravity of the electrolyte and the battery voltage
have remained constant for two hours. Special instructions for the operation of batte- have remained constant for two hours. Special instructions for the operation of batte-
ries in hazardous areas. This concerns batteries which are used in accordance with ries in hazardous areas. This concerns batteries which are used in accordance with
EN 50014, DIN VDE 0170/0171 Ex (in areas with a firedamp hazard) or Ex II (in po- EN 50014, DIN VDE 0170/0171 Ex (in areas with a firedamp hazard) or Ex II (in po-
tentially explosive areas). During charging and subsequent gassing the container lids tentially explosive areas). During charging and subsequent gassing the container lids
must be removed or opened so that the explosive mixture of gases loses its flamma- must be removed or opened so that the explosive mixture of gases loses its flamma-
bility due to adequate ventilation. The containers for batteries with plate protection bility due to adequate ventilation. The containers for batteries with plate protection
packs must not be closed until at least half an hour after charging has past. packs must not be closed until at least half an hour after charging has past.

2.3 Equalising charge 2.3 Equalising charge

Equalising charges are used to safeguard the life of the battery and to maintain its Equalising charges are used to safeguard the life of the battery and to maintain its
capacity. They are necessary after deep discharges, repeated incomplete recharges capacity. They are necessary after deep discharges, repeated incomplete recharges
and charges to an IU characteristic curve. Equalising charges are carried out follo- and charges to an IU characteristic curve. Equalising charges are carried out follo-
wing normal charging. The charging current must not exceed 5 A/100 Ah of rated ca- wing normal charging. The charging current must not exceed 5 A/100 Ah of rated ca-
pacity (end of charge - see point 2.2). pacity (end of charge - see point 2.2).

Watch the temperature! Watch the temperature!

2.4 Temperature 2.4 Temperature

An electrolyte temperature of 30°C is specified as the rated temperature. Higher tem- An electrolyte temperature of 30°C is specified as the rated temperature. Higher tem-
peratures shorten the life of the battery, lower temperatures reduce the capacity avai- peratures shorten the life of the battery, lower temperatures reduce the capacity avai-
lable. 55°C is the upper temperature limit and is not acceptable as an operating tem- lable. 55°C is the upper temperature limit and is not acceptable as an operating tem-
perature. perature.

2.5 Electrolyte 2.5 Electrolyte

The rated specific gravity (S. G.) of the electrolyte is related to a temperature of 30°C The rated specific gravity (S. G.) of the electrolyte is related to a temperature of 30°C
and the nominal electrolyte level in the cell in fully charged condition. Higher tempe- and the nominal electrolyte level in the cell in fully charged condition. Higher tempe-
ratures reduce the specified gravity of the electrolyte, lower temperatures increase it. ratures reduce the specified gravity of the electrolyte, lower temperatures increase it.
The temperature correction factor is -0.0007 kg/l per °C, e.g. an electrolyte specific The temperature correction factor is -0.0007 kg/l per °C, e.g. an electrolyte specific
gravity of 1.28 kg/l at 45°C corresponds to an S.G. of 1.29 kg/l at 30°C. gravity of 1.28 kg/l at 45°C corresponds to an S.G. of 1.29 kg/l at 30°C.

The electrolyte must conform to the purity regulations in DIN 43530 part 2. The electrolyte must conform to the purity regulations in DIN 43530 part 2.
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 3. Maintenance 3. Maintenance

3.1 Daily 3.1 Daily

Charge the battery after every discharge. Towards the end of charge the electrolyte Charge the battery after every discharge. Towards the end of charge the electrolyte
level should be checked and if necessary topped up to the specified level with purified level should be checked and if necessary topped up to the specified level with purified
water. The electrolyte level must not fall below the anti-surge baffle or the top of the water. The electrolyte level must not fall below the anti-surge baffle or the top of the
separator or the electrolyte „min“ level mark. separator or the electrolyte „min“ level mark.
3.2 Weekly 3.2 Weekly

Visual inspection after recharging for signs of dirt and mechanical damage. If the bat- Visual inspection after recharging for signs of dirt and mechanical damage. If the bat-
tery is charged regularly with a IU characteristic curve an equalising charge must be tery is charged regularly with a IU characteristic curve an equalising charge must be
carried out (see point 2.3). carried out (see point 2.3).

3.3 Monthly 3.3 Monthly

At the end of the charge the voltages of all cells or bloc batteries should be measured At the end of the charge the voltages of all cells or bloc batteries should be measured
with the charger switched on, and recorded. After charging has ended the specific with the charger switched on, and recorded. After charging has ended the specific
gravity and the temperature of the electrolyte in all cells should be measured and re- gravity and the temperature of the electrolyte in all cells should be measured and re-
corded. corded.

If significant changes from earlier measurements or differences between the cells or If significant changes from earlier measurements or differences between the cells or
bloc batteries are found further testing and maintenance by the service department bloc batteries are found further testing and maintenance by the service department
should be requested. should be requested.

3.4 Annually 3.4 Annually

In accordance with DIN VDE 0117 at least once per year, the insulation resistance of In accordance with DIN VDE 0117 at least once per year, the insulation resistance of
the truck and the battery must be checked by an electrical specialist. the truck and the battery must be checked by an electrical specialist.
The tests on the insulation resistance of the battery must be conducted in accordance The tests on the insulation resistance of the battery must be conducted in accordance
with DIN EN 60254-1. with DIN EN 60254-1.

The insulation resistance of the battery thus determined must not be below a value of The insulation resistance of the battery thus determined must not be below a value of
50 Ω per Volt of nominal voltage, in compliance with DIN EN 50272-3. 50 Ω per Volt of nominal voltage, in compliance with DIN EN 50272-3.

For batteries up to 20 V nominal voltage the minimum value is 1000 Ω. For batteries up to 20 V nominal voltage the minimum value is 1000 Ω.
4. Care of the battery 4. Care of the battery

The battery should always be kept clean and dry to prevent tracking currents. Clea- The battery should always be kept clean and dry to prevent tracking currents. Clea-
ning must be done in accordance with the ZVEI code of practice «The Cleaning of ning must be done in accordance with the ZVEI code of practice «The Cleaning of
Vehicle Traction batteries». Vehicle Traction batteries».

Any liquid in the battery tray must be extracted and disposed of in the prescribed man- Any liquid in the battery tray must be extracted and disposed of in the prescribed man-
ner. Damage to the insulation of the tray should be repaired after cleaning, to ensure ner. Damage to the insulation of the tray should be repaired after cleaning, to ensure
that the insulation value complies DIN EN 50272-3 and to prevent tray corrosion. If it that the insulation value complies DIN EN 50272-3 and to prevent tray corrosion. If it
is necessary to remove cells it is best to call in our service department for this. is necessary to remove cells it is best to call in our service department for this.
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 5. Storage 5. Storage

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

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

6. Malfunctions 6. Malfunctions

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

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

Back to the manufacturer! Back to the manufacturer!

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

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

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

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

1 2 1 2

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

5
11 10 Nennspannung
Nominal Voltage
5
Kapazität
Capacity
6

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

9 9

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

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

Item Designation Item Designation Item Designation Item Designation

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

* CE mark is only for batteries with a nominal voltage greater than 75 volt. * CE mark is only for batteries with a nominal voltage greater than 75 volt.
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 Aquamatic/BFS III water refilling system for Jungheinrich traction battery with Aquamatic/BFS III water refilling system for Jungheinrich traction battery with
EPzS and EPzB cells with tubular positive plates EPzS and EPzB cells with tubular positive plates
Aquamatic plug arrangement for the Operating Instructions Aquamatic plug arrangement for the Operating Instructions

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

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

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

length
stroke

stroke
length

length
stroke

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

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

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

Equipment for the Equipment for the

water refilling system water refilling system

1. Water tank 1. Water tank

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

at least 3 m

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

1. Design 1. Design

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

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

3. Function 3. Function
The quantity of water required in the refilling process is controlled by the valve located The quantity of water required in the refilling process is controlled by the valve located
in the plug in combination with the float and the float rods. In the Aquamatic System in the plug in combination with the float and the float rods. In the Aquamatic System
the existing water pressure at the valve turns off the water supply and ensures that the existing water pressure at the valve turns off the water supply and ensures that
the valve closes securely. When the maximum filling level is reached in the BFS sys- the valve closes securely. When the maximum filling level is reached in the BFS sys-
tem, the float and the float rods through a lever system close the valve with five times tem, the float and the float rods through a lever system close the valve with five times
the buoyant force and consequently interrupt the water supply reliably. the buoyant force and consequently interrupt the water supply reliably.
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 4. Filling (manual/automatic) 4. Filling (manual/automatic)

The batteries should be filled with battery water as soon as possible before the battery The batteries should be filled with battery water as soon as possible before the battery
charging comes to an end; this ensures that the refilled water quantity is mixed with charging comes to an end; this ensures that the refilled water quantity is mixed with
the electrolyte. In normal operation it is usually sufficient to fill once a week. the electrolyte. In normal operation it is usually sufficient to fill once a week.
5. Connection pressure 5. Connection pressure

The water refilling unit is to be operated in such a way that the water pressure in the The water refilling unit is to be operated in such a way that the water pressure in the
water pipe is between 0.3 bars and 1.8 bars. The Aquamatic System has an operating water pipe is between 0.3 bars and 1.8 bars. The Aquamatic System has an operating
pressure range of between 0.2 bars and 0.6 bars. The BFS system has an operating pressure range of between 0.2 bars and 0.6 bars. The BFS system has an operating
pressure range of 0.3 bars to 1.8 bars. Deviations from the pressure ranges impair pressure range of 0.3 bars to 1.8 bars. Deviations from the pressure ranges impair
the system's functional reliability. This wide pressure range permits three types of fil- the system's functional reliability. This wide pressure range permits three types of fil-
ling. ling.

5.1 Falling water 5.1 Falling water

The height of the tank is chosen to suit whichever water refilling system is used. For The height of the tank is chosen to suit whichever water refilling system is used. For
the Aquamatic System the installation height is 2 m to 6 m and for the BFS system the Aquamatic System the installation height is 2 m to 6 m and for the BFS system
the installation height is 3 m to 18 m over the battery surface. the installation height is 3 m to 18 m over the battery surface.

5.2 Pressurised water 5.2 Pressurised water

The pressure-reducing valve in the Aquamatic System is set from 0.2 bars to 0.6 bars The pressure-reducing valve in the Aquamatic System is set from 0.2 bars to 0.6 bars
and from 0.3 bars to 1.8 bars in the BFS system. and from 0.3 bars to 1.8 bars in the BFS system.

5.3 Water Refill Trolley (serviceMobil) 5.3 Water Refill Trolley (serviceMobil)

The submergible pump located in the ServiceMobil's tank generates the necessary The submergible pump located in the ServiceMobil's tank generates the necessary
filling pressure. No difference in height is permitted between the standing level of the filling pressure. No difference in height is permitted between the standing level of the
ServiceMobil and the standing level of the battery. ServiceMobil and the standing level of the battery.

6. Filling duration 6. Filling duration

The length of time needed to fill the batteries depends on the conditions under which The length of time needed to fill the batteries depends on the conditions under which
the battery is used, the ambient temperatures and the type of filling and/or the filling the battery is used, the ambient temperatures and the type of filling and/or the filling
pressure. The filling time is approx. 0.5 to 4 minutes. Where filling is manual, the wa- pressure. The filling time is approx. 0.5 to 4 minutes. Where filling is manual, the wa-
ter feed pipe must be separated from the battery after filling. ter feed pipe must be separated from the battery after filling.

7. Water quality 7. Water quality

Only refilling water which conforms in quality to DIN 43530 part 4 may be used to fill Only refilling water which conforms in quality to DIN 43530 part 4 may be used to fill
the batteries. The refilling unit (tank, pipelines, valves etc.) may not contain any kind the batteries. The refilling unit (tank, pipelines, valves etc.) may not contain any kind
of dirt which could impair the functional reliability of the Aquamatic/BFS plug. For of dirt which could impair the functional reliability of the Aquamatic/BFS plug. For
safety reasons it is recommendable to insert a filter element (optional) with a max. safety reasons it is recommendable to insert a filter element (optional) with a max.
passage opening of 100 to 300 µm into the battery's main supply pipe. passage opening of 100 to 300 µm into the battery's main supply pipe.
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 8. Battery hose connections 8. Battery hose connections

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

9. Operating temperature 9. Operating temperature

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

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

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

9.2 Float 9.2 Float

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

9.3 Cleaning 9.3 Cleaning

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

10. Accessories 10. Accessories

10.1 Flow indicator 10.1 Flow indicator

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

10.2 Plug lifter 10.2 Plug lifter

Only the appertaining special-purpose tool may be used to disassemble the plug sys- Only the appertaining special-purpose tool may be used to disassemble the plug sys-
tems (plug lifter). The greatest of care must be employed when prising out the plug to tems (plug lifter). The greatest of care must be employed when prising out the plug to
prevent any damage to the plug systems. prevent any damage to the plug systems.
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 10.2.1 Clamping ring tool 10.2.1 Clamping ring tool

The clamping ring tool is used to push on a clamping ring to increase the contact pres- The clamping ring tool is used to push on a clamping ring to increase the contact pres-
sure of the hose connection on the plugs' hose couplings and to loosen it again. sure of the hose connection on the plugs' hose couplings and to loosen it again.

10.3 Filter element 10.3 Filter element

For safety reasons a filter element (ident no.: 50307282) can be fitted into the batte- For safety reasons a filter element (ident no.: 50307282) can be fitted into the batte-
ry's main supply pipe for supplying battery water. This filter element has a maximum ry's main supply pipe for supplying battery water. This filter element has a maximum
passage cross-section of 100 to 300 µm and is designed as a bag filter. passage cross-section of 100 to 300 µm and is designed as a bag filter.

10.4 Sealing coupler 10.4 Sealing coupler

The water is supplied to the water refilling systems (Aquamatic/BFS) through a cen- The water is supplied to the water refilling systems (Aquamatic/BFS) through a cen-
tral supply pipe. This is connected to the water supply system at the battery charging tral supply pipe. This is connected to the water supply system at the battery charging
station by means of a sealing coupler system. On the battery side a closing nipple station by means of a sealing coupler system. On the battery side a closing nipple
(ident no.: 50219538) is mounted and the customer must place a sealing coupler (ident no.: 50219538) is mounted and the customer must place a sealing coupler
construction on the water supply side (obtainable under ident. no.: 50219537). construction on the water supply side (obtainable under ident. no.: 50219537).
11. Functional data 11. Functional data

PS - self-sealing pressure: Aquamatic > 1.2 bars PS - self-sealing pressure: Aquamatic > 1.2 bars

BFS system none BFS system none

D - rate of flow in the opened valve when the pressure is 0.1 bars: 350 ml/min D - rate of flow in the opened valve when the pressure is 0.1 bars: 350 ml/min
D1 - maximum permissible leakage rate in the closed valve when the pressure is at D1 - maximum permissible leakage rate in the closed valve when the pressure is at
0.1 bars: 2 ml/min 0.1 bars: 2 ml/min

T - permissible temperature range: 0° C to a maximum of 65° C T - permissible temperature range: 0° C to a maximum of 65° C

Pa - operating pressure range: 0.2 to 0.6 bars in the Aquamatic system and Pa - operating pressure range: 0.2 to 0.6 bars in the Aquamatic system and
operating pressure range: 0.3 to 1.8 bars in the BFS system. operating pressure range: 0.3 to 1.8 bars in the BFS system.

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 2 Jungheinrich traction batterie 2 Jungheinrich traction batterie

Maintenance free Jungheinrich traction batterie with positive tubular plates Maintenance free Jungheinrich traction batterie with positive tubular plates
type EPzV and EPzV-BS type EPzV and EPzV-BS

Rating Data Rating Data

1. Nominal capacity C5: See type plate 1. Nominal capacity C5: See type plate
2. Nominal voltage: 2,0 Volt x No of cells 2. Nominal voltage: 2,0 Volt x No of cells
3. Discharge current: C5/5h 3. Discharge current: C5/5h
4. Rated temperature: 30° C 4. Rated temperature: 30° C
EPzV batteries are valve-regulated batteries with an immobilised electrolyte and whe- EPzV batteries are valve-regulated batteries with an immobilised electrolyte and whe-
re a water refilling isn’t permitted during the whole battery life. Instead of a vent plug re a water refilling isn’t permitted during the whole battery life. Instead of a vent plug
there are valves used, who will be destroyed when they are opened. there are valves used, who will be destroyed when they are opened.

When operating valve-regulated lead-acid batteries the same safety requirements as When operating valve-regulated lead-acid batteries the same safety requirements as
for vented cells apply to protect against hazards from electric current, from explosion for vented cells apply to protect against hazards from electric current, from explosion
of electrolytic gas and in case of the cell container is damaged, from the corrosive of electrolytic gas and in case of the cell container is damaged, from the corrosive
electrolyte. electrolyte.

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

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

• No smoking! • No smoking!
• Do not expose batteries to naked flames, glowing embers or sparks, as it may • Do not expose batteries to naked flames, glowing embers or sparks, as it may
cause the battery to explode! cause the battery to explode!
• Acid splashes in the eyes or on the skin must be washed with water. In case of • Acid splashes in the eyes or on the skin must be washed with water. In case of
accident consult a doctor immediately! accident consult a doctor immediately!
• Clothing contaminated by acid should be washed in water. • Clothing contaminated by acid should be washed in water.

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

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

• In the normal operation of this batteries a contact with acid isn´t possible. If the • In the normal operation of this batteries a contact with acid isn´t possible. If the
cell containers are damaged, the immobilised electrolyte (gelled sulphuric acid) cell containers are damaged, the immobilised electrolyte (gelled sulphuric acid)
is corrosive like the liquid electrolyte. is corrosive like the liquid electrolyte.
• Batteries and cells are heavy! • Batteries and cells are heavy!
• Ensure secure installation! Use only suitable handling equipment e.g. lifting gear • Ensure secure installation! Use only suitable handling equipment e.g. lifting gear
in accordance with VDI 3616. in accordance with VDI 3616.

• Dangerous electrical voltage! • Dangerous electrical voltage!

• Caution! Metal parts of the battery are always live. Do not place tools or other • Caution! Metal parts of the battery are always live. Do not place tools or other
metal objects on the battery! metal objects on the battery!
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 Ignoring the operation instructions, repair with non-original parts and non authorised Ignoring the operation instructions, repair with non-original parts and non authorised
interventions will render the warranty void. interventions will render the warranty void.
For batteries in classes I and II the instructions for maintaining the appropriate For batteries in classes I and II the instructions for maintaining the appropriate
protection class during operation must be complied with (see relevant certificate). protection class during operation must be complied with (see relevant certificate).
1. Commissioning 1. Commissioning

The battery should be inspected to ensure it is in perfect physical condition. The battery should be inspected to ensure it is in perfect physical condition.

The battery end cables must have a good contact to terminals, check that the polarity The battery end cables must have a good contact to terminals, check that the polarity
is correct. is correct.

Otherwise battery, vehicle or charger could be destroyed. Otherwise battery, vehicle or charger could be destroyed.

The battery has to be charged according to item 2.2 The battery has to be charged according to item 2.2

The specified torque loading for the pole screws of the end cables and connectors The specified torque loading for the pole screws of the end cables and connectors
are: are:

steel steel
M 10 23 ± 1 Nm M 10 23 ± 1 Nm

2. Operation 2. Operation

DIN EN 50272-3 «Traction batteries for industrial trucks» is the standard which ap- DIN EN 50272-3 «Traction batteries for industrial trucks» is the standard which ap-
plies to the operation traction batteries in industrial trucks. plies to the operation traction batteries in industrial trucks.

2.1 Discharging 2.1 Discharging

Ventilation openings must not be sealed or covered. Ventilation openings must not be sealed or covered.

Electrical connections (e.g. plugs) must only be made or broken in the open circuit Electrical connections (e.g. plugs) must only be made or broken in the open circuit
condition. condition.

To achieve the optimum life for the battery, operating discharges of more than 60% To achieve the optimum life for the battery, operating discharges of more than 60%
of the rated capacity should be avoided (deep discharge). of the rated capacity should be avoided (deep discharge).

They reduce the battery life considerable. To measure the state of discharge use only They reduce the battery life considerable. To measure the state of discharge use only
the battery manufacturer recommended discharge indicators. the battery manufacturer recommended discharge indicators.

Discharged batteries must be recharged immediately and must not be left dischar- Discharged batteries must be recharged immediately and must not be left dischar-
ged. ged.

This also applies to partially discharged batteries. This also applies to partially discharged batteries.

2.2 Charging 2.2 Charging

Only direct current must be used for charging. Charging procedures according to DIN Only direct current must be used for charging. Charging procedures according to DIN
41773 and DIN 41774 must only be applied in the manufacturer approved modifica- 41773 and DIN 41774 must only be applied in the manufacturer approved modifica-
tions. Therefore only battery manufacturer approved chargers must be used. Only tions. Therefore only battery manufacturer approved chargers must be used. Only
connect the battery assigned to a charger, suitable for the size of battery, in order to connect the battery assigned to a charger, suitable for the size of battery, in order to
avoid overloading of the electric cables and contacts and unacceptable gassing of the avoid overloading of the electric cables and contacts and unacceptable gassing of the
cells. EPzV batteries have a low gas emission. cells. EPzV batteries have a low gas emission.

When charging, proper provision must be made for venting of the charging gases. When charging, proper provision must be made for venting of the charging gases.
Battery container lids and the covers of battery compartments must be opened or re- Battery container lids and the covers of battery compartments must be opened or re-
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moved. moved.

14 14
 With the charger switched off connect up the battery, ensuring that the polarity is cor- With the charger switched off connect up the battery, ensuring that the polarity is cor-
rect (positive to positive, negative to negative). Now switch on the charger. When rect (positive to positive, negative to negative). Now switch on the charger. When
charging the temperature of the battery rises by about 15° C, so charging should only charging the temperature of the battery rises by about 15° C, so charging should only
begin if the battery temperature is below 35° C. The battery temperature should be at begin if the battery temperature is below 35° C. The battery temperature should be at
least +15°C before charging otherwise a full charge will not be achieved. Are the tem- least +15°C before charging otherwise a full charge will not be achieved. Are the tem-
peratures a longer time higher than +40° C or lower than +15° C, so the chargers peratures a longer time higher than +40° C or lower than +15° C, so the chargers
need a temperatures regulated voltage. need a temperatures regulated voltage.
The correction factor is, in accordance with DIN EN 50272-1, -0,005 V/c and Kelvin. The correction factor is, in accordance with DIN EN 50272-1, -0,005 V/c and Kelvin.

Special instructions for the operation of batteries in hazardous areas. Special instructions for the operation of batteries in hazardous areas.

This concerns batteries which are used in accordance with EN 50 014, DIN VDE 0170 This concerns batteries which are used in accordance with EN 50 014, DIN VDE 0170
/ 0171 Ex I (in areas with a firedamp hazard) or Ex II (in potentially explosive areas). / 0171 Ex I (in areas with a firedamp hazard) or Ex II (in potentially explosive areas).
The attention pictograms has to be respected. The attention pictograms has to be respected.

2.3 Equalising charge 2.3 Equalising charge

Equalising charges are used to safeguard the life of the battery and to maintain its Equalising charges are used to safeguard the life of the battery and to maintain its
capacity. Equalising charges are carried out following normal charging. capacity. Equalising charges are carried out following normal charging.

They are necessary after deep discharges and repeated incomplete recharges. For They are necessary after deep discharges and repeated incomplete recharges. For
the equalising charges has to be used only the battery manufacturer prescribed char- the equalising charges has to be used only the battery manufacturer prescribed char-
gers. gers.
Watch the temperature! Watch the temperature!

2.4 Temperature 2.4 Temperature

A battery temperature of 30°C is specified as the rated temperature. Higher tempera- A battery temperature of 30°C is specified as the rated temperature. Higher tempera-
tures shorten the life of the battery, lower temperatures reduce the available capacity. tures shorten the life of the battery, lower temperatures reduce the available capacity.
45° C is the upper temperature limit and is not acceptable as an operating tempera- 45° C is the upper temperature limit and is not acceptable as an operating tempera-
ture. ture.
2.5 Electrolyte 2.5 Electrolyte

The electrolyte is immobilised in a gel. The density of the electrolyte can not be The electrolyte is immobilised in a gel. The density of the electrolyte can not be
measured. measured.

3. Maintenance 3. Maintenance

Don’t refill water! Don’t refill water!

3.1 Daily 3.1 Daily

Charge the battery immediately after every discharge. Charge the battery immediately after every discharge.
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 3.2 Weekly 3.2 Weekly

Visual inspection after recharging for signs of dirt and mechanical damage. Visual inspection after recharging for signs of dirt and mechanical damage.
3.3 Quarterly 3.3 Quarterly

After the end of the charge and a rest time of 5 h following should be measured and After the end of the charge and a rest time of 5 h following should be measured and
recorded: recorded:

• the voltages of the battery • the voltages of the battery

• the voltages of every cells • the voltages of every cells

If significant changes from earlier measurements or differences between the cells or If significant changes from earlier measurements or differences between the cells or
bloc batteries are found, further testing and maintenance by the service department bloc batteries are found, further testing and maintenance by the service department
should be requested. should be requested.

3.4 Annually 3.4 Annually

In accordance with DIN VDE 0117 at least once per year, the insulation resistance of In accordance with DIN VDE 0117 at least once per year, the insulation resistance of
the truck and the battery must be checked by an electrical specialist. the truck and the battery must be checked by an electrical specialist.
The tests on the insulation resistance of the battery must be conducted in accordance The tests on the insulation resistance of the battery must be conducted in accordance
with DIN 43539-1. with DIN 43539-1.
The insulation resistance of the battery thus determined must not be below a value of The insulation resistance of the battery thus determined must not be below a value of
50 Ω per Volt of nominal voltage, in compliance with DIN EN 50272-3. 50 Ω per Volt of nominal voltage, in compliance with DIN EN 50272-3.

For batteries up to 20 V nominal voltage the minimum value is 1000 Ω. For batteries up to 20 V nominal voltage the minimum value is 1000 Ω.

4. Care of the battery 4. Care of the battery

The battery should always be kept clean and dry to prevent tracking currents. Clea- The battery should always be kept clean and dry to prevent tracking currents. Clea-
ning must be done in accordance with the ZVEI code of practice «The Cleaning of ning must be done in accordance with the ZVEI code of practice «The Cleaning of
Vehicle Traction batteries». Vehicle Traction batteries».

Any liquid in the battery tray must be extracted and disposed of in the prescribed man- Any liquid in the battery tray must be extracted and disposed of in the prescribed man-
ner. ner.
Damage to the insulation of the tray should be repaired after cleaning, to ensure that Damage to the insulation of the tray should be repaired after cleaning, to ensure that
the insulation value complies with DIN EN 50272-3 and to prevent tray corrosion. If it the insulation value complies with DIN EN 50272-3 and to prevent tray corrosion. If it
is necessary to remove cells it is best to call our service department for this. is necessary to remove cells it is best to call our service department for this.

5. Storage 5. Storage

If batteries are taken out of service for a lengthy period they should be stored in the If batteries are taken out of service for a lengthy period they should be stored in the
fully charged condition in a dry, frost-free room. fully charged condition in a dry, frost-free room.

To ensure the battery is always ready for use a choice of charging methods can be To ensure the battery is always ready for use a choice of charging methods can be
made: made:

1. a quarterly full charging like charge as in point 2.2. If any consumer is connected 1. a quarterly full charging like charge as in point 2.2. If any consumer is connected
with, e.g. measure or controlling systems, it can be, that this charging is necessary with, e.g. measure or controlling systems, it can be, that this charging is necessary
every 14 days. every 14 days.

2. float charging at a charging voltage of 2.25 V x the number of cells. 2. float charging at a charging voltage of 2.25 V x the number of cells.
The storage time should be taken into account when considering the life of the batte- The storage time should be taken into account when considering the life of the batte-
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ry. ry.

16 16
 6. Malfunctions 6. Malfunctions

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

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

Back to the manufacturer! Back to the manufacturer!

Batteries with this sign must be recycled. Batteries with this sign must be recycled.
Batteries which are not returned for the recycling process must be Batteries which are not returned for the recycling process must be
disposed of as hazardous waste! disposed of as hazardous waste!

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

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

1 2 1 2

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

5
11 10 Nennspannung
Nominal Voltage
5
Kapazität
Capacity
6

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

9 9

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

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

Item Designation Item Designation Item Designation Item Designation

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

* CE mark is only for batteries with a nominal voltage greater than 75 volt. * CE mark is only for batteries with a nominal voltage greater than 75 volt.
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18
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