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EKS 513 EKS 515k EKS 515 EKX 513 EKX 515k EKX 515 Operating Instructions 51058446 EKS 513 / 515k / 515 EKX 513 / 515k / 515 G 05.07 - 10.10

EKS 513 / 515k / 515 EKX 513 / 515k / 515 - · PDF fileEKS 513 EKS 515k EKS 515 EKX 513 EKX 515k EKX 515 Operating Instructions 51058446 EKS 513 / 515k / 515 EKX 513 / 515k / 515 G

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EKS 513EKS 515kEKS 515EKX 513EKX 515kEKX 515

Operating Instructions

51058446

EKS 513 / 515k / 515EKX 513 / 515k / 515

G

05.07 -

10.10

1

10

09.G

B

Declaration of Conformity

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

Additional information

Authorised signatory

Date

G EU Declaration of Conformity

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

Type Option Serial No. Year of Construction

EKS 513EKS 515kEKS 515EKX 513EKX 515kEKX 515

10

09.G

B

2

01

08.G

B

Foreword

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

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

Safety instructions and important explanations are indicated by the followinggraphics:

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

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

Z Used before notices and explanations.

t Used to indicate standard equipment.

o Used to indicate optional equipment.

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

Copyright

Copyright of these operating instructions remains with JUNGHEINRICH AG.

Jungheinrich Aktiengesellschaft

Am Stadtrand 3522047 Hamburg - GERMANY

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

www.jungheinrich.com

01

08.G

B

I 1

11

09

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Table of contents

A Correct Use and Application

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

2 Correct application .............................................................................. A 1

3 Approved application conditions ......................................................... A 1

4 Proprietor responsibilities .................................................................... A 2

5 Adding attachments and/or accessories ............................................. A 2

B Truck Description

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

1.1 Travel direction definition .................................................................... B 2

2 Assemblies and Functional Description .............................................. B 3

2.1 Truck functional description ................................................................ B 6

3 Standard version specifications .......................................................... B 10

3.1 Performance data ................................................................................ B 11

3.2 Dimensions (as per data plate) ........................................................... B 12

3.3 Mast version ........................................................................................ B 16

3.4 Engine data ......................................................................................... B 18

3.5 Weights ............................................................................................... B 18

3.6 Wheels, chassis .................................................................................. B 21

3.7 EN norms ............................................................................................ B 22

3.8 Conditions of use ................................................................................ B 23

3.9 Electrical requirements ........................................................................ B 23

4 Identification points and data plates .................................................... B 24

4.1 Truck data plate .................................................................................. B 26

4.2 Truck capacity plate ............................................................................ B 27

4.3 Attachment capacity plate (o) ............................................................ B 28

5 Stability ................................................................................................ B 28

C Transport and Commissioning

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

2 Lifting by Crane ................................................................................... C 2

2.1 Lifting by crane with mast assembled ................................................. C 2

2.2 Crane points / Strap points .................................................................. C 3

2.3 Lifting the battery by crane .................................................................. C 4

3 Securing the truck during transport ..................................................... C 5

3.1 Basic truck transport safety ................................................................. C 6

3.2 Mast transport retainer ........................................................................ C 8

3.3 Transport retaining mechanism for trucks with the mast assembled .................................................................................. C 10

11

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I 2

4 Using the Truck for the First Time ....................................................... C 11

4.1 Moving the industrial truck without a battery ....................................... C 11

4.2 Installing and removing the mast ........................................................ C 11

5 Starting the Truck ................................................................................ C 12

5.1 Mechanical tilt safety devices (t) ....................................................... C 13

5.2 Active stabiliser (o) ............................................................................. C 14

D Battery - Servicing, Recharging, Replacement

1 Safety Regulations Governing the Handling of Lead-Acid Batteries ............................................................................. D 1

2 Battery types ....................................................................................... D 2

2.1 Battery compartment dimensions ........................................................ D 3

3 Exposing the battery ........................................................................... D 4

4 Charging the Battery ........................................................................... D 6

5 Battery Removal and Installation ........................................................ D 10

5.1 Installing and removing a battery with a battery trolley (t) ................. D 11

5.2 Placing/removing batteries in the battery replacement trolley using a forklift (o) ............................................................................... D 14

5.3 Battery lock sensor (t) ....................................................................... D 18

6 On-Board Charger (o) ........................................................................ D 19

6.1 Description .......................................................................................... D 19

6.2 Different current collectors .................................................................. D 20

6.3 Operating modes ................................................................................. D 21

6.4 Different Operating Modes .................................................................. D 22

6.5 Symbols and meaning ......................................................................... D 24

6.6 On board charger maintenance instructions ....................................... D 25

7 Battery – Checking Condition and Acid Level ..................................... D 26

8 Battery Discharge Indicator "Bar Display" (t) ................................... D 27

8.1 Battery discharge monitor with bar display ......................................... D 28

8.2 Battery symbol fluorescent colours ..................................................... D 29

9 Battery Discharge Indicator "Percentage Display" (o) ....................... D 30

9.1 Battery symbol fluorescent colours ..................................................... D 30

E Operation

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

2 Controls and Displays ......................................................................... E 3

2.1 Operating and display equipment on control panel ............................. E 3

2.2 Display unit controls and displays ....................................................... E 10

2.3 Lower range symbols and pushbuttons .............................................. E 16

2.4 Truck operational status symbols ........................................................ E 22

I 3

11

09

.GB3 Starting up the truck ............................................................................ E 23

3.1 Checks and operations to be performed before starting daily operation ..................................................................................... E 23

3.2 Truck entry and exit ............................................................................. E 24

3.3 Removing the driver’s seat .................................................................. E 25

3.4 Setting up the operator position .......................................................... E 25

3.5 Adjusting the driver’s seat ................................................................... E 26

3.6 Control panel angle adjustment .......................................................... E 27

3.7 Control panel height adjustment ......................................................... E 28

3.8 To prepare the truck for operation (t) ................................................ E 28

3.9 Preparing the truck for operation with an additional access code (o) .................................................................................. E 29

3.10 ISM Access Module (o) ...................................................................... E 30

3.11 Checks and operations to be carried out when the truck is operational ....................................................................................... E 30

3.12 Referencing the main and auxiliary lift ................................................ E 32

3.13 Setting date and time .......................................................................... E 35

3.14 Operator specific settings (o) ............................................................. E 37

4 Industrial Truck Operation ................................................................... E 40

4.1 Safety regulations for truck operation ................................................. E 40

4.2 Emergency Disconnect, Travel, Steering, Braking .............................. E 44

4.3 Negotiating narrow aisles .................................................................... E 50

4.4 Diagonal travel .................................................................................... E 57

4.5 Lifting – Lowering – Reaching – Traversing outside the rack aisles ..................................................................................... E 58

4.6 Simultaneous load handler traverse and fork carriage swivel ............. E 61

4.7 Telescopic table (o) ............................................................................ E 64

4.8 Symmetrical sideshifter (o) ................................................................ E 71

4.9 Fork adjuster (o) ................................................................................. E 71

4.10 Telescopic forks (o) ............................................................................ E 72

4.11 Symmetrical sideshift with integrated fork adjuster (o) ...................... E 74

4.12 Asymmetrical sideshifter with integrated fork adjuster (o) ................. E 75

4.13 Lifting - Lowering - Traversing - Pivoting inside the rack aisles .......... E 76

4.14 Order picking and stacking .................................................................. E 77

4.15 Lifting, transporting and depositing loads ............................................ E 81

4.16 Rack Height Select with Zone Entry (o) ............................................. E 86

4.17 Horizontal positioning (o) ................................................................... E 93

4.18 Parking the truck securely ................................................................... E 107

11

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I 4

5 Troubleshooting .................................................................................. E 108

5.1 Emergency stop device ....................................................................... E 111

5.2 Driver’s cab / Aux. Lift emergency lowering ........................................ E 112

5.3 Slack chain safety device override ...................................................... E 114

5.4 Travel cutout override (o) ................................................................... E 115

5.5 Lift cutout override (o) ........................................................................ E 116

5.6 Lower cutout override (o) ................................................................... E 117

5.7 Aisle end safety device (o) ................................................................. E 118

5.8 Wire guidance emergency mode (event messages 3670 / 3752) .......... E 119

5.9 Recovering the truck from a narrow aisle / Moving the truck without a battery .................................................................................. E 121

6 Exiting the driver's cab with the rescue equipment ............................. E 131

6.1 Rescue equipment storage compartment in the driver's cab .............. E 132

6.2 Rescue equipment testing / servicing ................................................. E 132

6.3 Rescue equipment service life ............................................................ E 133

6.4 Rescue equipment storage and transportation ................................... E 133

6.5 Rescue equipment description / application (- 07.09) ......................... E 134

6.6 Rescue equipment description / application (07.09 -) ......................... E 149

7 Personal Protection System (o) ......................................................... E 165

7.1 Personal Protection System (PPS) ..................................................... E 165

7.2 Functional description ......................................................................... E 165

7.3 Cleaning the front panel of the scanners ............................................ E 167

7.4 Daily checks before starting the Personal Protection System ............. E 169

7.5 Personal Protection System ................................................................ E 170

8 EKS 513/515k/515 Stockpicker ........................................................... E 172

8.1 Control panel layout ............................................................................ E 172

8.2 EKS 513/515k/515 with load guard and walk-on pallet (o) ................ E 175

8.3 Display of stockpicking platform side and / or front gates and load direction gates ...................................................................... E 183

8.4 Additional symbols in driver's display .................................................. E 185

8.5 Lifting / depositing a load .................................................................... E 185

8.6 EKS 513/515k/515 with auxiliary lift (o) ............................................. E 193

9 Optional equipment ............................................................................. E 194

9.1 Rear view mirror (o) ........................................................................... E 194

9.2 Rider mode (in the driver's cab) (o) ................................................... E 195

9.3 Weigher (o) ........................................................................................ E 197

9.4 Using a work platform (o) ................................................................... E 198

9.5 Fire extinguisher (o) ........................................................................... E 204

9.6 Closed driver's cab (o) ....................................................................... E 205

9.7 Camera system (o) ............................................................................ E 213

I 5

11

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.GBF Industrial Truck Maintenance

1 Operational Safety and Environmental Protection .............................. F 1

2 Maintenance safety regulations .......................................................... F 1

3 Servicing and Inspection ..................................................................... F 7

4 Maintenance Checklist ........................................................................ F 8

4.1 Attachment service checklist (options) ................................................ F 14

5 Lubricants and Lubrication Schedule .................................................. F 18

5.1 Handling consumables safely ............................................................. F 18

5.2 Lubrication Schedule ........................................................................... F 20

5.3 Consumables ...................................................................................... F 21

6 Maintenance and Repairs ................................................................... F 22

6.1 Preparing the truck for maintenance and repairs ................................ F 22

6.2 Preventing the driver's cab from accidentally lowering ....................... F 23

6.3 Lift chain servicing ............................................................................... F 26

6.4 Lubricating the lift chains, cleaning and greasing the contact surfaces in the mast sections ........................................... F 26

6.5 Automatic chain lubrication (o) ........................................................... F 28

6.6 Lift chain inspection ............................................................................. F 32

6.7 Hydraulic hose lines ............................................................................ F 33

6.8 Drive panel disassembly / assembly ................................................... F 34

6.9 Checking the hydraulic oil level ........................................................... F 35

6.10 Checking electrical fuses .................................................................... F 38

6.11 Recommissioning the truck after cleaning or maintenance work ............................................................................... F 40

7 Decommissioning the industrial truck .................................................. F 42

7.1 Action to be taken before decommissioning ....................................... F 43

7.2 Action to be taken during decommissioning ........................................ F 43

7.3 Restoring the truck to service after decommissioning ......................... F 44

8 Safety tests to be performed at intervals and after unusual incidents ................................................................................ F 45

9 Final de-commissioning, disposal ....................................................... F 45

10 Human vibration measurement ........................................................... F 45

11

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I 6

1

0506

.GB

Appendix

JH Traction Battery Operating Instructions

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

1

0506

.GB

Appendix

JH Traction Battery Operating Instructions

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

0506

.GB

2

0506

.GB

2

A 1

11

09

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A Correct Use and Application

1 General

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

2 Correct application

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

– Lifting, lowering and picking loads.

– Always transport a load outside the narrow aisle as low as possible, allowing forground clearance.

– Do not carry or lift passengers.

– Do push or pull load units.

– Do not negotiate slopes or inclines.

– Do not negotiate docks.

– Do not tow trailers.

– Do not transport swinging loads.

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.

Z The industrial truck must not be used in fire or explosion endangered areas, or areasthreatened by corrosion or excessive dust. Furthermore, the truck must not beoperated in the vicinity of unprotected active components of electrical systems.

– Operation in industrial and commercial environments.

– Permissible temperature range +5 °C to +40 °C.

– The truck must only be operated on level surfaces in accordance with DIN 15185part 1.

– Safety clearances between the truck and rack to EN 1726-2 item 7.3.2.

– Minimum 100 mm safety clearance between rail guided truck and rack.

– Minimum 125 mm safety clearance between wire guided truck and rack.

Z Special equipment and authorisation are required if the truck is to be constantly usedin extreme conditions or areas at risk from explosion.

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A 2

4 Proprietor responsibilities

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

Z 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 thirdparties without the permission of the manufacturer.

5 Adding attachments and/or accessories

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

B 1

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B Truck Description

1 Application

The EKX is an electric three-way stockpicker. The EKS is an electric stockpicker.They are designed to transport and pick goods on level surfaces in accordance withDIN 15185 Part 1.

It can lift open bottom or diagonal board pallets as well as roll cages beyond the areaof the load wheels. Loads can be stacked, unstacked and transported overlong distances.

The driver's cab rises together with the load handler to provide excellent visibility andeasy access to the various rack heights.

The racks must be set up for the EKX / EKS. The safety distances stipulated byJungheinrich (e.g. EN 1726-2 item 7.3.2) must be observed.

– For rail-guided trucks a minimum safety distance of 100 mm must be maintainedbetween the rack and the truck.

– For wire-guided trucks the safety distance between the rack and the truck must beno less than 125 mm. The safety distance may however be increased if specialattachments are fitted.

Z The ground must comply with DIN 15185 Part 1.

Guide rails must be provided in the narrow aisles for the rail guidance system.Vulkollan guide wheels attached to the truck chassis guide the truck between theguide rails.

A guide wire must be routed in the ground for the wire guidance system. The signalsfrom the wire are received by sensors on the chassis and processed by the on-boardcomputer.

The capacity is shown on the data plate.

Type Capacity Load centre of gravity

EKX 513 / EKS 513 1,250 kg 600 mm

EKX 515k / EKS 515k 1,500 kg 600 mm

EKX 515 / EKS 515 1,500 kg 600 mm

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B 2

1.1 Travel direction definition

The following determinations have been made for travel direction specification:

Left

Drivedirection

Loaddirection

Right

Left

Drivedirection

Loaddirection

Right

EKX 513/515k/515

EKS 513 / 515k / 515

B 3

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2 Assemblies and Functional Description

1

2

3

4

5

6

7

12

1617

22

23

24

1920 18 15

11

9,10

8

21

13

14

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B 4

1

2

3

4

5

6

7

12

1617

22

23

24

1920 18 15

11

9,10

8

21

13

14

B 5

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1) not applicable on the EKS 513 / 515k / 515

Item Description

1 t Mast

2 t Overhead guard

3 t Auxiliary Lift1)

4 t Control panel

5 t Gates

6 t Lifting driver's cab

7 t Fork

8 t Deadman button

9 o Front sensor for wire guidance system (not shown)

10 o Front scanner for personal safety system (not shown)

11 o Rail guidance rollers in front of the load wheel

12 t Load wheel

13 t Chassis

14 o Rail guidance wheels behind the load wheel

15 t Side panel

16 o Rail guidance wheels on the drive compartment

17t Tilt safety device

o Active stabilisers

18 t Drive wheel

19 o Rear sensor for wire guidance system

20 o Personal protection system rear scanner

21 o Battery cover

22 o Mast braces

23o Automatic chain lubrication on the free lift cylinders

(DZ mast only)

24o Automatic chain lubrication on the the top mast cross member

(ZT / DZ masts)

t = Standard equipment o = Optional equipment

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B 6

2.1 Truck functional description

Safety mechanisms:

– An enclosed truck geometry with rounded edges ensures safe handling of the truck.The overhead guard protects the driver from falling objects.

– The drive wheel and the load wheels are protected by a solid skirt. A slight dangerremains for third parties, even when a drive wheel cover is used.

– The Emergency Disconnect immediately disconnects all truck movement inhazardous situations.

– Gates on either side of the cab interrupt all truck operations as soon as they areopened.

– Travelling, lifting and lowering can only be activated when the deadman buttonis pressed.

– Traverse and pivot operations can only be activated when the deadman button ispressed (EKX only).

Deadman button

After preparing the truck to operation ("Preparing the truck for operation" and"Preparing the truck for operation with an additional access code (o)" in chapter E)and closing the gates, the deadman button in the leg well:

– t =be pressed once to allow the drive to operate the truck. When the travel controlbutton is released and the truck comes to a halt the parking brake applies(prevents the truck from rolling away).

– o =be pressed and held down to allow the drive to operate the truck. Lifting and travelare inhibited if the driver takes his foot off the foot switch. Steering and brakingremain enabled. When the deadman button is released and the truck comes toa halt the parking brake applies (prevents the truck from rolling away).

Emergency Stop safety feature

– If an error is detected the truck automatically brakes to a halt. Control indicatorson the driver’s display indicate the emergency stop. Every time the truck isswitched on, the system performs a self test which only releases the parking brake(emergency stop) if the functional test is positive.

B 7

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.GBDrive:

– Vertically mounted, heavy-duty and maintenance-free threephase motor with nowear parts. The motor is directly attached to the single-wheel driving gear,ensuring rapid and trouble-free maintenance.

Brake system:

– Electronically controlled drive brake and wear-free electromagnetic multiplatebrake acting on the load wheels.

– The operator can brake the truck gently and wear-free by pulling back the travelcontrol button or by changing direction. This feeds energy into the battery(service brake).

– The electromagnetic spring pressure brake acting on the drive motor serves asa parking and handbrake.

– Depending on the lift height, the load wheel brake acting on the front axle(electro-magnetic spring pressure brake) is only activated when the EmergencyDisconnect switch is pressed or if the truck is set to emergency stop.

Steering:

– Extremely smooth steering with threephase drive system (sturdy and maintenance-free threephase motor with no wear parts).

– The manageable steering wheel is integrated within the control panel. The positionof the steered drive wheel is shown in the control panel display unit. The steeringangle is +/- 90°, offering maximum manoeuvrability in narrow aisles.

– With the mechanical rail guidance system the drive wheel can be set to the forwardposition at the press of a button (optional).

– In wire guidance mode, steering is automatically assumed by the truck controllerwhen it detects the guidance wire, and manual steering is deactivated (optional).

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B 8

Controls and displays:

– The functions are activated via ergonomic thumb movement to ensure fatigue-freeoperation without stressing the wrists; sensitive application of travel and hydraulicmovements to spare and position the goods exactly.

– Soft keys to control functions (Aux. lift raise / lower,...) and menus.

– Integrated information display unit with colour display for all important driverinformation such as steering wheel position, overall lift, truck status reports(e. g. faults), service hours, battery capacity, time and wire guidance status etc..

– Electrically adjustable control panel.

– Non-switch two-handed operating principle for maximum safety and operatingcomfort. Sensors record any contact made by the operator and feed thisinformation to the on-board computer.

Ergonomics and Comfort

– Generous entry room

– Large leg area, adjustable knee pads

– Excellent view of the load and travel lane with extremely low swivel/traverse guidesand clearview masts.

– Cushioned, adjustable and folding comfort seat.

– Individual truck programs.

– Limit position / transition damping for all hydraulic functions.

Hydraulic system:

– All hydraulic operations are controlled by a sturdy, maintenance-free AC motor withno wear parts and with a flanged low emission gear pump.

– Oil is distributed via magnetic switch valves. The varying oil requirements arecontrolled by the speed of the motor.

– During a lowering operation the hydraulic pump drives the motor which then actsas a generator (regenerative lowering). The energy produced is then fed back tothe battery.

– Extremely torsion-resistant mast for high residual capacities and minimal mast sway.

B 9

11

09

.GBElectrical system:

– Electronic system with wear-free sensors.

– Service laptop connection interface: To configure all the key truck data (end position damping, lift cutout, retardation andacceleration patterns, reach speeds, cut-outs etc.) rapidly and reliably.To read off the error log to analyse fault causes.To simulate and analyse program operations.Simple function extension by releasing code numbers.

– The controller is fitted with a CAN Bus and a constantly recording sensor system.All operations can be set using parameters. The controller provide smooth start-upand braking of the load in all limit positions through end position and intermediatedampers. The MOSFET threephase controller provides smooth starting for allmovements.

– Highly efficient threephase technology with energy retention for the traction and liftmotors provides high travel and lift speeds and better use of energy.

– Simultaneous main lift and auxiliary lift raise / lower.

– Speed recording on the wheels using traction control and drive wheel wearrecognition.

Z For drive battery options refer to “Battery Types” in Chapter D.

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B 10

Optional equipment

– Mechanical rail guidance.

– Wire guidance for precise aisle guidance with no physical load of components.

– A range of modular telescopic forks.

– “Workstation” comfort package with work lights, mirror, fan.

– Radio with CD player and MP3 interface.

– Mechanical and electrical interfaces for material flow management systems.

– Jungheinrich ISM: Information system for truck management.

– Truck prepared to receive work stations.

– Cutouts of the overhead guard.

– Modular system of lift and travel cutouts plus speed reductions.

– Faster cycles through synchronised swivel.

– RFID ground controlTransponder-based truck controller system.Permanent route measurement for precise identification of all warehouse zones.High degree of flexibility in terms of switch and safety functions (end of aisle safetydevice, lift/travel cutouts, speed reduction).Travel speed setting optimisation through ground topology.

– Integrated Jungheinrich personal safety system (PSS).

– Electric active stabilisers for maximum capacities up to large lift heights (optional).

3 Standard version specifications

Z Technical data specified in accordance with VDI 2198 / EN 1726 *.Technical modifications and additions reserved.

B 11

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3.1 Performance data

RG: Rail guidanceWG: Wire guidanceFR: free ranging

1) Available in conjunction with power package up to 12 km/h2) Available in conjunction with power package up to 0.52 m/s3) Available in conjunction with power package up to 0.4 m/s

(lift height-dependent 0.2 m/s to 0.4 m/s)

Description EKX 513EKS 513

EKX 515kEKS 515k

EKX 515EKS 515

Q (t) Capacity (where C = 600 mm) 1250 1500 1500 kg

c / D* Load centre distance 600 600 600 mm

Travel speed without load (RG) 10.5 10.5 1) 10.5 1) km/h

Travel speed with load (RG) 10.5 10.5 1) 10.5 1) km/h

Travel speed without load (WG) 9 9 9 km/h

Travel speed with load (WG) 9 9 9 km/h

Travel speed without load (free ranging)

9 9 9 km/h

Travel speed with load (free ranging) 9 9 9 km/h

Lift speed without load 0.42 0.47 2) 0.47 2) m/s

Lift speed with load 0.42 0.47 2) 0.47 2) m/s

Lower speed without load 0.45 0.45 0.45 m/s

Lower speed with load 0.45 0.45 0.45 m/s

Aux. lift speed without load 0.35 0.35 0.35 m/s

Aux. lift speed with load 0.30 0.30 0.30 m/s

Aux. lift lower speed without load 0.25 0.25 0.25 m/s

Aux. lift lower speed with load 0.30 0.30 0.30 m/s

Combined raising of main and aux. lift

0.7 0.7 0.7 m/s

Traverse speed without load 0.2 - 0.3 3) 0.2 - 0.3 3) 0.2 - 0.3 3) m/s

Traverse speed with load 0.25 3) 0.25 3) 0.25 3) m/s

Rotate without load 13 13 13 s/180°

Rotate with load 13 13 13 s/180°

Service brake Inversion / regenerative

Parking brake Electric spring brake / multi-plates

Type of traction controller AC drive control

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B 12

3.2 Dimensions (as per data plate)

AstWa

h15

h10

h3

h9

h

s

7

h6

h12

h1

h4

b6b2b1

l1

l2

l8

m2zym1

l

b5

b7

l6

b8

b14 I10

b3

e

r

c

b12

x

b9

x

B 13

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1) not applicable on the EKS 513 / 515k / 515

Z The data listed in the table (performance data, dimensions and weights) are basedon a truck with a 350 ZT mast (*).The data (performance data, dimensions and weights) on the particular truck suppliedcan be found on the data plate.

Description EKX 513EKS 513

EKX 515kEKS 515k

EKX 515EKS 515

c / D Load centre of gravity 600 600 600 mm

x Load distance 440 440 440 mm

y Wheelbase 1826 1926 2222 mm

zCentre drive wheel / counterweight(truck geometry)

280 280 280 mm

h1 Mast height retracted 2955 2955 2955 mm

h3 Lift 3500 * 3500 * 3500 * mm

h4 Mast height extended 6050 6050 6050 mm

h6 Overhead guard height 2550 2550 2550 mm

h7 Seat height / standing height 430 430 430 mm

h9 Auxiliary Lift 1) 1780 1780 1780 mm

h10

Overall lift EKX (h3 + h9) 5280 5280 5280 mm

Overall lift EKS (h3) 3500 3500 3500 mm

h12 Truck height raised 3930 3930 3930 mm

h15 Picking height (h12+1600) 5530 5530 5530 mm

AstWorking aisle width for pallets 1200 x 800

1640 1640 1640 mm

b1/ b2 Overall width 1210 / 1400 1210 / 1500 1210 / 1500 mm

b3 Fork carriage width 480 480 480 mm

b5 Outside straddle 465 465 465 mm

b6 Width across guide wheels 1500 1600 1600 mm

b7 Traverse, sideways 1300 1300 1300 mm

b8Traverse, to the side of truck centre

480 480 480 mm

b9 Outer operator position width 1440 1440 1440 mm

b12 Pallet width 800 800 800 mm

b14 Swivel/traverse frame width 1440 1440 1440 mm

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B 14

AstWa

h15

h10

h3

h9

h

s

7

h6

h12

h1

h4

b6b2b1

l1

l2

l8

m2zym1

l

b5

b7

l6

b8

b14 I10

b3

e

r

c

b12

x

b9

x

B 15

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1) Special build: l10 = 190 mm

Z The data listed in the table (performance data, dimensions and weights) are basedon a truck with a 350 ZT mast (*).The data (performance data, dimensions and weights) on the particular truck suppliedcan be found on the data plate.

Description EKX 513EKS 513

EKX 515kEKS 515k

EKX 515EKS 515

l1 Overall length w.o. load 3250 3350 3646 mm

l2 Headlength 3146 3264 3560 mm

l6 Pallet length 1200 1200 1200 mm

l8 Fork pivot point distance 904 904 904 mm

l8- xFork pivot point - toothed rack distance

464 464 464 mm

l10 Outrigger width 172 1) 172 1) 172 1) mm

s/e/l Fork dimensions50 x 120 x

120050 x 120 x

120050 x 120 x

1200mm

Wa Turning radius 2106 2206 2502 mm

m1Ground clearance with load below mast

80 80 80 mm

m2Ground clearance centre wheelbase

80 80 80 mm

rFork pivot point - pivot point distance

154 154 154 mm

-- "Driver's cab entry" width 420 420 420 mm

-- Driver’s cab ceiling height 2100 2100 2100 mm

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B 16

3.3 Mast version

3.3.1 Standard mast version with telescopic mast (ZT)

Description EKX 513EKS 513

EKX 515kEKS 515k

EKX 515EKS 515

h1 Mast height retracted 2705 - 5055 2705 - 6155 2705 - 6405 mm

h3 Lift 3000 - 7500 3000 - 9500 3000 - 10000 mm

h4 Mast height extended 5550 - 10050 5550 - 12050 5550 - 12550 mm

h10 Overall lift EKX (h3 + h9) 4780 - 9280 4780 - 11280 4780 - 11780 mm

Overall lift EKS (h3) 3000 - 7500 3000 - 9500 3000 - 10000 mm

h12 Truck height raised 3430 - 7930 3430 - 9930 3430 - 10430 mm

h15 Picking height (h12+1600) 5030 - 9530 5030 - 11530 5030 - 12030 mm

B 17

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3.3.2 Standard mast with two stage triplex mast (DZ)

Description EKX 513EKS 513

EKX 515kEKS 515k

EKX 515EKS 515

h1 Mast height retracted 2550 - 3895 2550 - 4695 2550 - 5750 mm

h3 Lift 4000 - 7500 4000 - 9500 4000 - 12500 mm

h4 Mast height extended 6550 - 10050 6550 - 12050 6550 - 15050 mm

h10 Overall lift EKX (h3 + h9) 5780 - 9280 5780 - 11280 5780 - 14280 mm

Overall lift EKS (h3) 4000 - 7500 4000 - 9500 4000 - 12500 mm

h12 Truck height raised 4430 - 7930 4430 - 9930 4430 - 12930 mm

h15 Picking height (h12+1600) 6030 - 9530 6030 - 11530 6030 - 14530 mm

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B 18

3.4 Engine data

3.5 Weights

3.5.1 Basic truck / mast weight including driver's cab and attachment

Basic truck weight

Z The weight of the basic truck (13) can be found in the following table.

1) including additional weights of 300 kg that may be installed depending onthe model

DescriptionEKX 513EKS 513

EKX 515kEKS 515k

EKX 515EKS 515

Drive motor, output at S2 60 min 7.6 kW 7.6 kW 7.6 kW

Lift motor, output at S3 25 % 20.0 kW 20.0 kW 20.0 kW

Steer motor, output at S2 60 min 1.0 kW 1.0 kW 1.0 kW

Truck Basic truck weight

EKX 513 / EKS 513 2600 kg1)

EKX 515 k / EKS 515k 2600 kg1)

EKX 515 / EKS 515 2600 kg1)

1 13

B 19

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Z The weight of the mast including the driver's cab and attachment (1) can becalculated using the formulae given below. The necessary data such as net weight(overall weight) of the truck without battery can be found on the data plate.

Formula for the EKX 513/515k/515 and EKS 513/515k/515:

B = A - 2300 kg

Example:

Required details:(see truck data plate)

– Truck type = EKX 515

– Truck net weight without battery = 5722 kg

Formula:B = A - 2300 kg = 5722 kg - 2300 kg = 3422 kg

Z The weight of the mast including the driver's cab and attachment is 3422 kg.

A Truck net weight without battery

B Mast weight including driver's cab and attachment

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B 20

3.5.2 Truck net weight / axle loads

Z The data listed in the table (performance data, dimensions and weights) are basedon a truck with a 350 ZT mast (*).The data (performance data, dimensions and weights) on the particular truck suppliedcan be found on the data plate.

DescriptionEKX 513EKS 513

EKX 515kEKS 515k

EKX 515EKS 515

Net weight incl. battery, w.o. load 6350 6750 7900 kg

Battery weight 1238 1558 2178 kg

Truck net weight without battery, see "data plate"

5112 5192 5722 kg

Axle load with load front / rear

5720 / 1880 6190 / 2060 6590 / 2810 kg

Axle load without load front / rear

3850 / 2500 3980 / 2770 4480 / 3420 kg

Battery type 3EPzS 465 4EPzS 620 6EPzS 930

B 21

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3.6 Wheels, chassis

F Accident risk from incorrect wheel disassembly/assemblyThe load / drive wheels can only be disassembled or assembled by themanufacturer's customer service department which has been trained to do this.Exceptionally, this task may be performed by a customer service organisationauthorised by the manufacturer.

EKX 513 / EKS 513

EKX 515k / EKS 515k

EKX 515 / EKS 515

Description EKX 513 / EKS 513

Tyre type Vulkollan

Wheels, front (load wheel) 380 mm x 192 mm

Wheels, rear (drive wheel) 400 mm x 160 mm

Wheels, number front (load wheel) 2

Wheels, number rear (*= driven) 1*

Description EKX 515k / EKS 515k

Tyre type Vulkollan

Wheels, front (load wheel) 380 mm x 192 mm

Wheels, rear (drive wheel) 400 mm x 160 mm

Wheels, number front (load wheel) 2

Wheels, number rear (*= driven) 1*

Description EKX 515 / EKS 515

Tyre type Vulkollan

Wheels, front (load wheel) 380 mm x 192 mm

Wheels, rear (drive wheel) 400 mm x 160 mm

Wheels, number front (load wheel) 2

Wheels, number rear (*= driven) 1*

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B 22

3.7 EN norms

Noise emission level: 68 dB(A)

in accordance with EN 12053 as harmonised withISO 4871.

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

Vibration: 1.14 m/s2 in accordance with EN 13059

Seat vibration: 0.70 m/s2

Z 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 anddifferent driver weights.

Z The vibration acceleration acting on the body in the operating position is,in accordance with standard procedures, the linearly integrated, weightedacceleration in the vertical direction. It is calculated when travelling over bumps atconstant speed. These recordings were taken on a single occasion and must not beconfused with the 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 Chapter F.

Electromagnetic compatibility (EMC)

The manufacturer confirms that equipment complies with tolerance levels forelectromagnetic emissions and resistance as well as static electricity dischargetesting in accordance with EN 12895 including the normative procedures containedtherein.

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

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

B 23

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3.8 Conditions of use

Ambient temperature: operating at 5 C to 40 C

Z Special equipment and authorisation are required if the truck is to be constantly usedin conditions of extreme temperature or air humidity fluctuations.

The truck is not authorised for use in cold stores.

The truck must only be used in an closed indoor environment. The following applies:

– Ambient temperature in 24-hour mode: max. 25 °C

– max. air humidity (inside) 70%, non-condensing.

3.9 Electrical requirements

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

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B 24

4 Identification points and data plates

F Warnings and notices such as load charts, strap points and data plates must belegible at all times. Replace if necessary.

26

D (mm)

h3 (mm) Q (kg)

mV1,5 V

25 27

28

33

2534353436

37

38

40

31

41

32

28

39

29

30

31

B 25

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Item Description

25 Strap points for crane lifting

26 Truck data plate

27 Capacity decal

28 Decal: “Abseil device”

29 Decal: “No passengers”

30 Test plaque (o)

31 "Hazard warnings in narrow aisle" notice

32 Decal: Do not step onto or beneath the load, risk of trapping

33 "Control panel unlock" notice

34 Jack contact points

35 Serial number (engraved in chassis underneath the right hand side panel)

36 Decal: Emergency drain key

37 Decal: Add hydraulic oil

38 Decal: Emergency drain

39 Company and model information

40 Decal: “Caution: Low voltage electronics system”

41 “Read operating instructions" notice

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B 26

4.1 Truck data plate

Z For truck-related queries or when ordering spare parts always quote the truck serialnumber (51). The truck's serial number (51) is indicated on the data plate (26) and isengraved on the chassis (35) (see “Identification points and data plates” inchapter B).

Item Description Item Description

50 Type 56 Manufacturer

51 Serial number 57 Min./max. battery weight (kg)

52 Rated capacity (kg) 58 Drive output (kW)

53 Battery voltage (V) 59 Load centre (mm)

54 Net weight w.o. battery (kg) 60 Year of manufacture

55 Manufacturer’s logo 61 Option

50

51

52

53

54

55

56

61

60

59

58

57

B 27

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4.2 Truck capacity plate

M Replacing the forks can cause accidents The capacity changes when the forks are replaced.

– When replacing the forks always attach an additional capacity plate to the truck.

– Trucks supplied without forks are given a capacity plate for standard forks(length: 1150 mm)

The capacity plate (27) indicates the capacity (Q kg) of the truck. The maximumcapacity is shown as a table with a given load centre of gravity D (in mm) and therequired lift height h3 (in mm).

Z The capacity plate (27) of the truck indicates the truck's capacity with the forks asoriginally supplied.

Example of how to calculate the maximum capacity:

With a load centre of gravity D of 600 mm and a maximum lift height h3 of 3600 mm.the max. capacity Q is 1105 kg.

D (mm)

h3 (mm) Q (kg)

27

4250

3600

29001250 1250 850

500 600 700

1105 1105 850

850 850 600

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B 28

4.3 Attachment capacity plate (o)

The attachment capacity plate gives the truck’s capacity Q [in kg] in conjunction withthe respective attachment. The serial number specified in the load chart must matchthe data plate of the attachment, as the specific capacity for each truck is indicatedby the manufacturer. It is shown in the same way as the truck’s capacity and can bedetermined accordingly.

For loads with a centre of gravity above 500 mm upward, the capacities are reducedby the difference of the altered centre of gravity.

5 Stability

F Loss of stability can cause accidents The stability as indicated on the load chart can only be guaranteed with thecomponents (battery, mast etc.) as shown on the data plate. Only use manufacturer-approved batteries.

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 ifused correctly.

Stability can also be affected by the following factors:

– Battery size and weight

– Wheels

– Mast

– Attachment

– Transported load (size, weight and centre of gravity)

– Ground clearance, e.g. modification of the tilt safety devices.

M Loss of stability can cause accidentsChanging the components can affect stability.

C 1

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C Transport and Commissioning

1 Transport

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

– Vertically with the mast and load handler assembled (for low heights)

– Vertically with the mast and load handler disassembled (for large truck heights)

Safety Instructions for Assembly and Commissioning

F Incorrect assembly can result in accidentsThe assembly of the truck at the application site, commissioning and driver trainingmust only be performed by the manufacturer's customer service representatives whohave been specially trained for these tasks.

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

– The truck can then be started.

– If several trucks have been delivered, make sure that always the serial numbers ofthe load handlers, masts and basic trucks match each other.

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C 2

2 Lifting by Crane

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

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

– The truck and mast should only be laden by people who are trained in handlinglifting slings and tools.

– Wear safety shoes when lifting the truck by crane.

– Do not stand under a swaying load.

– Do not walk into or stand in a hazardous area.

– Always use lifting gear with sufficient capacity (for truck weight see truck data plate).

– Always attach the crane slings to the prescribed strap points and prevent themfrom slipping.

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

– Crane slings should be fastened in such a way that they do not come into contactwith any attachments when lifting.

2.1 Lifting by crane with mast assembled

4

1

2

3

C 3

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M Only use lifting gear with sufficient capacity (for the truck weight refer to the data plate).

F The truck must only be raised by a crane without a battery, see “Battery removal andinstallation” in Chapter D.

– Park the truck securely, see “Parking the Truck Securely” in Chapter E.

– Secure the truck with wedges to prevent it from rolling away.

M Attach the crane slings to the strap points (1-4) so that the truck cannot slip.Crane slings should be fastened in such a way that they do not come into contact withany parts of the truck when it is being raised.

2.2 Crane points / Strap points

– The crane points (1) are the eyes in the mast.

– The crane points (2) are the eyes on the drive compartment.

– The strap points (3) are the two mast attachments on the side of the chassis.

– The crane points (4) are the mast's lower strap points connecting it to the chassis.

For lifting by crane, use the following crane points:

M Only use lifting gear with sufficient capacity.Fastening / quick release belts placed over lift chains and / or “sharp” edges must beprotected by a suitable support material, e.g. foam.

– Crane points for complete truck with mast assembled:points (1) and (2)

Z For the truck net weight without battery see the truck data plate.

M The basic truck with the mast assembled must only be raised by crane withouta battery, see “Battery removal and installation” in Chapter D.

– Crane points for the basic truck:points (2) and (3) (weight approx. 2,700 kg excluding battery)

Z For the weight of the basic truck see "Weights" in Chapter B.

M The basic truck must only be raised by crane without a battery, see “Battery removaland installation” in Chapter D.

F Make sure the “mast attachment upper half shells” Allen screws are torqued to therequired 205 Nm.

– Mast crane points including driver’s cab and attachment:points (1) and (4)

Z For the weight of the mast plus driver's cab and attachment see "Weights" in Chapter B.

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C 4

2.3 Lifting the battery by crane

F Batteries can be hazardousBatteries contain dissolved acid which is toxic and caustic. Avoid physical contactwith battery acid.

– Dispose of used battery acid in accordance with regulations.

– Always wear protective clothing and goggles when working with batteries.

– Do not let battery acid come into contact with skin, clothing or eyes. If necessary,rinse with plenty of clean water.

– In the event of physical damage (e.g. skin or eye contact with battery acid) call fora doctor immediately.

– Spilled battery acid should be neutralised immediately with plenty of water.

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

– Follow national guidelines and legislation.

• Remove the battery from the battery compartment,see "Battery removal and installation" in Chapter D.

Z The weight to be taken into account when lifting thebattery by crane, refer to the battery's data plate.

• Lifting the battery with crane slings:

• Attach the lifting gear to the four eyes of thebattery tray (for weight refer to the battery dataplate).

The battery can now be raised and loaded witha crane.

• Load the battery onto a pallet:

• Place the battery on a pallet.

• Attach the battery to the pallet with two tie-down straps/tension belts.

The battery can now be raised and loaded witha forklift truck.

C 5

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3 Securing the truck during transport

F Accidental movement during transportImproper fastening of the truck and mast during transport can result in seriousaccidents.

– Loading must be carried out by specially trained staff in accordance withrecommendations contained in Guidelines VDI 2700 and VDI 2703. In each casecorrect measurements must be made and appropriate safety measures adopted.

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

– The lorry / trailer must have clamp rings.

– Use wedges to prevent the truck from moving.

– Use only tensioning belts or tie-down straps or with sufficient strength.

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C 6

3.1 Basic truck transport safety

M The mast must only be disassembled or assembled by the manufacturer’s authorisedservice department.

To ensure secure transport of a disassembled EKX / EKS, use the prescribedattachment points for fastening/quick release belts.

Z Only use fastening / quick release belts with a rated capacity of > 5 to. Fastening /quick release belts placed over lift chains and / or “sharp” edges must be protectedby a suitable support material, e.g. foam.

M When transporting, always relieve the drive wheel (10) by placing the entire surfaceof a wooden beam (11) underneath the battery compartment (minimum chassiswidth) in front of the drive wheel (10). In addition, secure the load wheels (15) usinga wedge (16).

F If the truck battery is supplied in the chassis, disconnect the battery.

C 7

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To ensure secure transport of the basic truck, use the following prescribedattachment points for fastening/quick release belts.

– Guide the fastening belt / quick release belt (9) through the attachment latches (7)on the mast bracing to the truck chassis rear, and attach to the clamp rings (8).

– Guide the fastening belt / quick release belt (12) via both outriggers (14) to the truckchassis front, and attach to the clamp rings (8).

– Guide the fastening belt / quick release belt (5) via the top chassis structure (13)through the two mast attachments (6), and attach to the clamp rings (8).

M Note the cable routing and cover sharp edges with a suitable material.

5 7

88 915 10111216

6

8 14 13

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C 8

3.2 Mast transport retainer

M Use a transport retaining device (19) to prevent the driver's cab (17) from sliding.The fork carriage (18) must also be secured to prevent it from sliding.

Z Only use fastening / quick release belts with a rated capacity of > 5 to. Fastening /quick release belts placed over lift chains and / or “sharp” edges must be protectedby a suitable support material, e.g. foam.

If the mast (27) is stored on a pallet(s) (28), the pallet(s) must be fastened to the mast(27) with fastening belts / quick release belts (26). Ensure a positive fit by placinga wooden beam (22) between the bottom mast (27) and the pallet (28).

In addition, guide a fastening belt / quick release belt (24) through thedriver’s positioncarriage (17) to guide and fasten the mast (27).

17 18

28 26 27 26 2520 20 24 2023 22 21

1931

30

29

C 9

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– Secure the fastening belts / quick release belts (21, 25) to the attachment latch (23)of the mast (27) and the clamp rings (20).

“Mast top” strap point

– Stow any supplied parts (forks, guide wheels, etc.) on apallet (31) so that they cannot slip. Place the pallet (31)on the top of the mast (27) and secure it. To do this,guide the fastening belt / quick release tensioningbelt (29) over the pallet (31) and around the mast (27)and fasten it. Guide the fastening belt / quick releasefastening belt (30) over the pallet (31) and secure it tothe clamp rings (20).

– Without the pallet (31) guide the fastening belt / quick release fastening belt (30)over the mast (top) and secure it to the clamp rings (20).

M Fastening / quick release belts placed over lift chains and / or “sharp” edges must beprotected by a suitable support material, e.g. foam.

31

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C 10

3.3 Transport retaining mechanism for trucks with the mast assembled

F If the truck battery is supplied in the chassis, disconnect the battery.

M When transporting, always relieve the drive wheel (37) by placing the entire surfaceof a wooden beam (38) underneath the battery compartment (minimum chassiswidth) in front of the drive wheel (37). In addition, secure the load wheels (39) usinga wedge (40).

Z Only use fastening / quick release belts with a rated capacity of > 9 to. Fastening /quick release belts placed over lift chains and / or “sharp” edges must be protectedby a suitable support material, e.g. foam.

Attach a minimum of four fastening belts / quick release belts, two on the left and twoon the right (33,35) to the mast (34) and secure them to the clamp rings (36).

Using wooden planks, a pallet or a rubber mat (32) from the outrigger (41) to the frontof the transporter, ensure a positive fit.

32 33

36 39 38 37

34 35

364041

C 11

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4 Using the Truck for the First Time

Safety Instructions for Assembly and Commissioning

F Incorrect assembly can result in accidentsThe assembly of the truck at the application site, commissioning and driver trainingmust only be performed by the manufacturer's customer service representatives whohave been specially trained for these tasks.

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

– The truck can then be started.

– If several trucks have been delivered, make sure that always the serial numbers ofthe load handlers, masts and basic trucks match each other.

M Only operate the truck with battery current. Rectified AC current will damage theelectronic components. Cable connections to the battery (tow leads) must be lessthan 6m long and have a minimum cross-section of 50 mm2.

4.1 Moving the industrial truck without a battery

M This operation must only be performed by suitably trained maintenance personnel.

F It must not be performed on slopes or inclines (no brakes).

See also “Recovering the truck from a narrow aisle / Moving the truck withouta battery” in chapter E.

4.2 Installing and removing the mast

M The mast can only be disassembled / assembled by the manufacturer's specialistcustomer service personnel who have been trained to do this. Exceptionally, this taskmay be performed by a customer service organisation authorised by the manufacturer.

There is an additional risk of trapping when reaching and traversing in the traverse/reach section of the attachment.

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C 12

5 Starting the Truck

M Only operate the truck with battery current. Rectified AC current will damage theelectronic components. Cable connections to the battery (tow leads) must be lessthan 6 m long and have a minimum cross-section of 50 mm2.

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

– Undo the transport chain(s) (42).

– If necessary install and charge the battery,see “Battery removal and installation” and“Charging the battery” in Chapter D.

– Remove the load wheel brake transport retainersThe transport retainers release the load wheelbrakes when they are de-energised. Procedure:

• Disassemble the wheel guard by removing thethree Allen screws from the load wheels.

• Remove the transport retainers from the loadwheel brakes by removing three setscrews (42b)from the load wheel brakes (42c).

Z The load wheel brakes (42c) are now applied withoutpower.

• Store the setscrews (42b) in the plastic bagsupplied. Seal the plastic bag with a tape or similar.

• Fit the wheel guard.

• Loosen the twist grip screws (42e) under thedriver's seat (42d) and carefully move the seatforward.

• Store the plastic bag in the compartment underthe driver's seat (42d).

• Move the driver's seat back (42d) and secure it tothe driver's cab by tightening the two twist gripscrews (42e).

– Make sure all safety mechanisms are present andtest them (e.g. tilt safety devices, gates etc.).

– Start up the truck as indicated, see “Starting up theTruck” in chapter E.

42a

42b

42c

42d

42e

C 13

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5.1 Mechanical tilt safety devices (t)

Z On the EKX 513/515k/515 and EKS 513 / 515k / 515 a tilt safety device (44) can bemounted on the left or right of the truck chassis, depending on the tilt test. If a tiltsafety device (44) is used, an X is engraved on the chassis (43) on the right hand sideof the battery compartment (see “Identification Points and Data Plates” in chapter B).

M Before commissioning, check the trucks to ensure the tilt safety devices (44)are present.

Z For a new drive wheel, the distance from the tilt safety device (44) to the groundshould be 10 mm - 12 mm.

M Check that all safety devices are present and operational.

44

43

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C 14

5.2 Active stabiliser (o)

Z With industrial trucks the residual capacity can be increased by 200 kg by usingactive stabilisers (45). Nevertheless, the maximum capacity must not be exceeded. The active stabiliser (45) has a maximum setting range of 40 mm and moves tocompensate for uneven ground.

Operation:

– The active stabiliser is referenced (extend –retract) when the truck is switched on. The"Active stabiliser referencing" display (46)lights up red in the display unit.After referencing the active stabiliser movesto a distance of 10 mm to 12 mm fromthe ground.

– When the truck is idle and the attachmenthas moved from its home position, the activestabiliser moves to a distance of up to 5 mmfrom the ground, depending on the liftheight. The "Active stabiliser extended"display (47) lights up yellow in the displayunit. Attachment extends left

-> left active stabiliser extends Attachment extends right

-> right active stabiliser extends

Z An adjustment run with a maximum speed of 2.5 km/h can be carried out.

– When the attachment is back in the home position the active stabiliser moves to adistance of 10 mm to 12 mm from the ground and the "Active stabiliser extended"display (47) goes out.

M Check that all safety devices are present and operational.

45

R

46

47

D 1

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D Battery - Servicing, Recharging,

Replacement

1 Safety Regulations Governing the Handling of Lead-Acid Batteries

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

Maintenance personnel: Recharging, servicing and replacing of batteries must onlybe performed by qualified personnel. These operating instructions and themanufacturer’s instructions concerning batteries and charging stations must beobserved when carrying out the work.

Fire protection: Smoking and open flames are not permitted when handlingbatteries. Wherever an industrial truck is parked for charging there shall be noinflammable material or lubricants capable of creating sparks within 2 metres aroundthe truck. The room must be ventilated. Fire protection equipment must be on hand.

Battery maintenance: The battery cell covers must be kept dry and clean. Terminalsand cable shoes must be clean, lightly greased with terminal grease and must besecurely tightened.

M Before closing the battery cover make sure that the battery cable cannot bedamaged. There is a risk of short circuits with damaged cables.

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

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General notes on handling batteries

F Batteries can be hazardousBatteries contain dissolved acid which is toxic and caustic. Avoid physical contactwith battery acid.

• Dispose of used battery acid in accordance with regulations.

• Always wear protective clothing and goggles when working with batteries.

• Do not let battery acid come into contact with skin, clothing or eyes. If necessary,rinse with plenty of clean water.

• In the event of physical damage (e.g. skin or eye contact with battery acid) call fora doctor immediately.

• Spilled battery acid should be neutralised immediately with plenty of water.

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

• Follow national guidelines and legislation.

F Using unsuitable batteries can cause accidentsThe weight and dimensions of the battery have a considerable effect on the stabilityand capacity of the industrial truck. Changing the battery equipment requires themanufacturer’s approval, as compensating weights are required if smaller batteriesare fitted. When replacing/installing the battery make sure the battery is securelylocated in the battery compartment of the truck.

2 Battery types

The EKX / EKS can be fitted with a variety of battery types. All battery types complywith DIN 43531-A. The following table shows which combinations can be includedas standard:

Z The battery weights can be taken from the battery data plate.

Voltage Capacity Battery type Battery type Weight Truck model

80 V 465 Ah 3 E PzS 465 Single part 1,238 kgEKX 513 / EKS 51380 V

( 2 x 40 V )465 Ah 3 E PzS 465 Two part 1,250 kg

80 V 620 Ah 4 E PzS 620 Single part 1,558 kgEKX 515k / EKS 515k80 V

( 2 x 40 V )620 Ah 4 E PzS 620 Two part 1,600 kg

80 V 930 Ah 6 E PzS 930 Single part 2,178 kgEKX 515 / EKS 51580 V

( 2 x 40 V )930 Ah 6 E PzS 930 Two part 2,150 kg

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2.1 Battery compartment dimensions

F When replacing the battery equipment make sure that the dimensions, types andweights of the replacement batteries are identical to the ones previously used.

– Changing the battery equipment requires the manufacturer’s approval,as compensating weights are required if smaller batteries are fitted.

– When replacing/installing the battery make sure the battery is securely located inthe battery compartment of the truck.

Truck model Length (L) Width (W) Height (H)

EKX 513EKS 513

1,060 mm 616.5 mm 925 mm

Maximum battery height = 880 mm

EKX 515kEKS 515k

1,060 mm 716.5 mm 925 mm

Maximum battery height = 880 mm

EKX 515EKS 515

1,060 mm 1,012.5 mm 925 mm

Maximum battery height = 880 mm

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B

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3 Exposing the battery

M Trapping hazardThere is a risk of trapping when you close the battery cover.

• Make sure there is nothing between the battery cover and the truck when you closethe battery cover.

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

• Always park the truck on a level surface. In special cases the truck may need to besecured with wedges.

• Always fully lower the mast and forks.

• Select a place to park where no other people are at risk of injury fromlowering forks.

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– Park the truck securely (see “Parking the Truck Securely” in Chapter E).

– Lower the load handler to the ground.

– Turn key switch (2) to "0" (zero).

– Press the Emergency Disconnect switch (1) down.

– Lift up the battery panel (3) (see arrow direction).

M Open covers can cause injury and accidentsThe covers (battery cover, side panels, drive compartment cover etc.) must be closedduring operation.

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4 Charging the Battery

F The gases produced during charging can cause explosionsThe battery gives off a mixture of oxygen and hydrogen (electrolytic gas) duringcharging. Gassing is a chemical process. This gas mixture is highly explosive andmust not be ignited.

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

• The charger must be adapted to the battery in terms of voltage and charge capacity.

• Before charging, check all cables and plug connections for visible signs of damage.

• Ventilate the room in which the truck is being charged.

• The battery cover must be open and the battery cell surfaces must be exposedduring charging to ensure adequate ventilation.

• Do not smoke and avoid naked flames when handling batteries.

• Wherever an industrial truck is parked for charging there shall be no inflammablematerial or lubricants capable of creating sparks within 2 metres around the truck.

• Fire protection equipment must be on hand.

• Do not lay any metallic objects on battery.

• It is essential to follow the safety regulations of the battery and charger stationmanufacturers.

• Expose the battery (see “Exposing the battery” in this chapter).

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– Park the truck securely, see “Parking the Truck Securely” in Chapter E.

– Expose the battery, see “Exposing the battery” in this chapter.

– Switch off the charger.

– Set the correct charging program on the charger.

– Remove the battery connector (4).

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

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Z The charger must be adapted to the battery in terms of voltage and charge capacity.

– Connect the charger lead of the battery charger station with the battery connector (4).

– Switch on the charger.

– Charge the battery in accordance with the battery and charging stationmanufacturers' instructions.

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

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F The gases produced during charging can cause explosionsThe battery gives off a mixture of oxygen and hydrogen (electrolytic gas) duringcharging. Gassing is a chemical process. This gas mixture is highly explosive andmust not be ignited.

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

M Trapping hazardThere is a risk of trapping when you close the battery cover.

• Make sure there is nothing between the battery cover and the truck when you closethe battery cover.

– Switch off the truck once the battery is fully charged.

– Disconnect the battery charging station cable from the battery connector (4).

– Check all cables and plug connections for visible signs of damage.

M There is a risk of short circuits with damaged cables.

• Report any defects immediately to your supervisor.

• Tag out and decommission a faulty lift truck.

• Only return the truck to service when you have identified and rectified the fault.

– Attach the battery connector (4) to the truck.

M Open covers can cause injury and accidentsThe covers (battery cover, side panels, drive compartment cover etc.) must be closedduring operation.

– Close the battery cover (3).

After the battery charge the truck is ready for operation.

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5 Battery Removal and Installation

M Accident risk during battery removal and installationDue to the battery weight and acid there is a risk of trapping or scalding when thebattery is removed and installed.

• Note the "Safety regulations for handling acid batteries" section in this chapter.

• Wear safety shoes when removing and installing the battery.

• Use only batteries with insulated cells and terminal connectors.

• When replacing a battery always install the same battery type in thebattery compartment. Extra weights must not be removed and must remain in thesame position.

• Park the truck on a level surface to prevent the battery from sliding out.

• Make sure the crane slings have sufficient capacity to replace the battery.

• Use only approved battery replacement devices (battery roller stand, replacementtrolley etc.).

• Make sure the battery is securely located in the truck's battery compartment.

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5.1 Installing and removing a battery with a battery trolley (t)

Battery removal:

– Park the truck securely (see “Parking the Truck Securely” in Chapter E).

– Turn the key switch (2) to "0" (zero) and press the Emergency Disconnect switch (1).

– Lift up the battery panel (3) (see arrow direction).

– Pull the battery panels (5) up and lift them off.

– Remove the battery connector (4).

– Undo the battery retainer (9) by moving the lever (8) and remove the retainer.

– Position the battery roller stand in front of the battery compartment in such a waythat the battery (7) can be safely pushed onto the roller stand.

– Pull the battery (7) onto the side of the prepared battery transporter.

F Make sure the battery trolley is properly secured.

– Secure the battery (7) on the roller stand against accidental movement.

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Battery installation:

F A non-installed battery can result in accidentsThe weight and dimensions of the battery have a considerable effect on the stabilityand capacity of the industrial truck. Do not work on the truck without a battery installedin the battery compartment. In exceptional cases short shunting journeys arepermitted, e.g. to replace the battery.The following conditions must apply:

• The tow leads must be less than 6 m long and have a minimum cross-section of50 mm2.

• The mast fully lowered.

• No load units lifted.

• Only carry out short shunting operations at slow speed.

• This requires added concentration on the part of the operator.

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M There is a risk of trapping when you close the battery cover and fit the side panels,battery retainers, battery latches and battery.

• When you fit the battery, retainers and side panels make sure there is nothingbetween these components and the truck.

• Make sure there is nothing between the battery cover and the truck when you closethe battery cover.

Z The battery retainers (6, 9) can swap positions. This means that they can both befitted in either the left or right side of the truck’s chassis.

M To avoid pushing the battery (7) through on assembly, the battery retainer (6) mustfirst be plugged in on the opposite side.

– Position the battery roller stand with the battery (7) in front of the batterycompartment in such a way that the battery (7) can be safely pushed into the truck'sbattery compartment.

– Insert the battery retainer (6) opposite the side of entry and lock it so that thebattery (7) cannot be pushed through the battery compartment when inserted.

– Undo the battery latch on the battery roller stand.

– Push the battery (7) off the roller stand as far as the stop in the truck's batterycompartment (see arrow direction).

– Insert the battery retainer (9) in the chassis and lock it by flipping the lever (8) over.

F After replacing / fitting the battery (7), make sure that the battery (7) is well securedin the battery compartment.

– Fit the side panels (5).

M There is a risk of short circuits with damaged cables.

• Report any defects immediately to your supervisor.

• Tag out and decommission a faulty lift truck.

• Only return the truck to service when you have identified and rectified the fault.

– Attach the battery connector (4) to the truck.

– Close the battery cover (3).

F After installing again, check all cables and connectors for signs of visible damage andbefore using the truck again check that:

– the battery retainers (6, 9) are fitted and the battery retainer (9) is pulled tight by thelever (8), see "Battery lock sensor" in chapter D.

– the side panels (5) are inserted safely and the battery panel (3) is closed.

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5.2 Placing/removing batteries in the battery replacement trolley using a forklift (o)

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– Park the truck securely (see “Parking the Truck Securely” in Chapter E).

– Turn the key switch (2) to "0" (zero) and press the Emergency Disconnect switch (1).

– Lift up the battery panel (3) (see arrow direction).

– Pull the battery panels (5) up and lift them off.

– Remove the battery connector (4) (2 off).

– Remove the battery retainers (10, 12) on the left and right-hand sides of the chassis.

– Carefully pull out the batteries (7) on the left or right hand side using a forklift truck.To do this, insert the forks of the truck into the fork shoes (11) of the batteryroller stand. Raise the batteries (7) carefully until they are clear of the ground.Pull the batteries (7) carefully out of the chassis.

M When replacing batteries (7) avoid damaging the truck chassis, the batteries andbattery compartment.

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Battery installation:

F A non-installed battery can result in accidentsThe weight and dimensions of the battery have a considerable effect on the stabilityand capacity of the industrial truck. Do not work on the truck without a battery installedin the battery compartment. In exceptional cases short shunting journeys arepermitted, e.g. to replace the battery.The following conditions must apply:

• The tow leads must be less than 6 m long and have a minimum cross-section of50 mm2.

• The mast fully lowered.

• No load units lifted.

• Only carry out short shunting operations at slow speed.

• This requires added concentration on the part of the operator.

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M There is a risk of trapping when you close the battery cover and fit the side panels,battery retainers, battery latches and battery.

• When you fit the battery, retainers and side panels make sure there is nothingbetween these components and the truck.

• Make sure there is nothing between the battery cover and the truck when you closethe battery cover.

Z The battery retainers (10, 12) can swap positions. This means that they can both befitted in either the left or right side of the truck’s chassis.

M When installing the batteries (7) make sure that the forks of the truck used forassembly are located in the fork shoes (11) of the battery roller stand. In addition,the fork tips of the truck used must not project beyond the battery roller stand.

– Bring the battery (7) in front of the battery compartment.

– Raise the battery (7) so that it can be moved into the battery compartment withoutstriking any objects.

M When replacing the batteries (7) avoid damaging the truck chassis, batteries andbattery compartment.

– Move the battery (7) into the battery compartment.

– Lower the battery (7) pull the forks of the truck used for assembly carefully out ofthe fork shoes (11) of the battery roller stand.

– Insert the battery retainers (10, 12) on the left and right-hand sides of the chassis.

F After replacing / fitting the battery (7), make sure that the battery (7) is well securedin the battery compartment.

– Fit the side panels (5).

M There is a risk of short circuits with damaged cables.

• Report any defects immediately to your supervisor.

• Tag out and decommission a faulty lift truck.

• Only return the truck to service when you have identified and rectified the fault.

– Attach the battery connectors (4) to the truck (2 off).

– Close the battery cover (3).

F After installing again, check all cables and connectors for signs of visible damage andbefore using the truck again check that:

– the battery retainers (10, 12) are inserted and are secure,see "Battery lock sensor" in chapter D.

– the side panels (5) are inserted safely and the battery panel (3) is closed.

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5.3 Battery lock sensor (t)

M An unsecured battery can result in accidentsIf the battery lock is not applied in the chassis, the battery may slide out of the batterycompartment due to truck movement.

• Apply the battery latch in the chassis.

• This requires added concentration on the part of the operator.

• Only carry out short shunting operations.

During operation the “battery lock” sensors monitor if the battery retainers in thechassis have been applied.

If the battery retainer(s) is (are) not installed, the truck cannot be operated.The display unit shows the "Travel Cutout Override" (13b) and the "Battery lock notinstalled" (13a) symbols. Press the “Release unlock” pushbutton (15b) while simultaneously applying the travelcontrol knob (14) to operate the truck at inching speed (2.5 km/h).

– Turn right = Travel in load direction

– Turn left = Travel in drive direction

When the battery retainer(s) has (have) been inserted in the chassis, press thepushbutton (15a) under the "Battery lock not installed" symbol (13a) to remove thetruck's speed restriction. At the same time the "Travel cutout override" (13b) and"Battery lock not installed" (13a) symbols go out. The truck can now travel again atthe required speed.

The hydraulic functions are not restricted or altered if the battery retainer(s) is/arenot applied.

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6 On-Board Charger (o)

Z On board chargers are used to ensure longer operational times without having tochange the battery.

6.1 Description

Structure

Item Meaning

16 Reed contact

17 Current collector (different versions)

18 Charger On switch

19a Charger mains connector

19b Collector connector

20 Status indicator

21 Isolator

22 Controller (SPS)

23 Charger

16 17

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19a

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21

22 23

19b

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6.2 Different current collectors

Example 1

Closed version current collector

Example 2

Open version current collector

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6.3 Operating modes

Z The on board charger allows two different operating modes to be selected.

1. Compensation charging mode

This charging method can be carried out either at a charging station or in thenarrow aisle. It requires the truck to be switched off.

Z See item 1 "Normal charging (possible switch LED arrangements)" in "DifferentOperating Modes" in chapter D.

This charging mode should be performed weekly to preserve the life of the battery.

With this type of charge the battery is charged according to the IUIU0IU characteristiccurve. This means that when the charger is switched on the battery is charged withthe full rated current until the charging characteristics change to the constant voltagepart at 2.4 volts/cell. If the value falls below the recharge value, the system switchesto recharge current at 2.7 volts/cell constant voltage part. When the battery is fullycharged the charger switches to compensation charge at 2.23 volts/cell.

2. Charging during travel (trickle charge)

Z See item 2 "Charging during travel via current collector" in "Different OperatingModes" in chapter D.

This form of charging is used to capture peak currents which occur during stackingand to keep the battery at a constant supply voltage.

With this form of charging the battery is charged to IU characteristic curve at aconstant voltage of 2.35 volts/cell.

Z Changing characteristics during travel

After the system has switched from normal charging (charging with compensationcharge) to travel mode, the charger remains off for 10 minutes (via SPS). This isfollowed by charging at 2.23 volts/cell. If more than 100 Ah has been taken from thebattery, the system switches to 2.35 volts/cell. It switches back to 2.23 volts/cell whenthe voltage exceeds 2.35 volts/cell.

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6.4 Different Operating Modes

1. Normal charging (possible switch LED arrangements)

For charging within a conductor rail For charging at a charging station via stationary network

– Switch off the truck.

– Open the battery cover to ventilatethe battery.

– Press switch (24) to start charging.The charger on (25) and chargingon (26) indicators light up.

– The charger now charges until thebattery is fully charged and thenswitches to compensation charging.

– Take the truck out of the aisle /conductor rail to the mains connection /charging station.

– Switch off the truck.

– Remove the collector's connector.

– Plug in the main circuit connector andconnect it to the stationary mains.

– Open the battery cover to ventilate thebattery.

– Press switch (24) to start charging.The charger on (25) and chargingon (26) indicators light up.

– The charger now charges until thebattery is fully charged and thenswitches to compensation charging.

Z Travel release is not authorised during normal charging.After charging, complete the charging session by pressing the switch (24).Close the battery cover. If the battery has been charged via the stationarynetwork disconnect from the mains and re-connect the collectorto the charger.

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– Make sure the current collector is connected.

– Make sure the isolator of the respective bus bar and the charger are switched on.

– Drive the truck into the aisle / bus bar with extreme caution.

– When the current collector (17) has been aligned and the truck passes over theground sensor system, maximum travel speed is enabled again.

– If adjustable current collectors (17) are fitted, the truck’s electronic system checksthat the current collector is correctly positioned (active current collector light) andreleases travel once this has been verified.

– When the current collector (17) has been aligned with the bus bar, the reedcontact (16) is closed via a permanent magnet attached to the bus bar / rack.

– The charger now switches on (Charger On and Travel On indicators) and chargesat a constant rate of 2.35 volts per cell and a pre-determined rated current.

– If energy is recovered from the drive controllers, e.g. during regenerative lowering,braking or reversing, the charger cuts out.

– When the truck leaves the narrow aisle, the reed contact (16) opens via thepermanent magnet and the charger cuts out.

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6.5 Symbols and meaning

Charger On switch White background

Option:

Active collector indicator lamp (for two collector version)Yellow background

Charger On indicator lampYellow background

Charger fault indicator lampRed background

Charging On indicator lampGreen background

Travel mode On indicator lampGreen background

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6.6 On board charger maintenance instructions

Z Maintenance intervals are listed in the operating instructions under “Maintenancechecklist - On board chargers (o)” in chapter F.

F Electric currents can cause accidentsMaintenance and repair work to on board chargers and the live attachments(collectors etc.) can only be performed by trained specialists or electrical engineers.

• Maintenance and repair work to on board chargers and the live attachments(collectors etc.) can only be performed when the system is de-energised.For normal charging disconnect the mains plug, or for conductor rail operationrepairs disconnect the power supply to the conductor rail.

Z The owner or authorised personnel must perform a daily inspection of the conditionof the on board charger and the live attachments such as the collector, includingmechanically operating components, cables and mains connectors.

F A faulty on-board charger and live attachments can cause accidentsIf the on-board charger and the live attachments are not in a satisfactory condition,withdraw the truck from service.

• Report any defects immediately to your supervisor.

• Tag out and decommission a faulty lift truck.

• Only return the truck to service when you have identified and rectified the fault.

Z The operator / owner must check each day that the conductor rail is safe to operate.Particular attention must be paid to overhanging components which could damagethe current collector or tear it out of the bus bar. The conductor rail and its feed funnelmust not be physically damaged or twisted.

F Bus bar defects can result in accidentsIf the bus bar or feed funnel are damaged, block the lane and de-energise the busbar. Inform the customer service department.

• Report any defects immediately to your supervisor.

• Tag out and decommission the faulty lane.

• Only return the lane to service when you have identified and rectified the fault.

If the red indicator lamp is activated during charging (charger fault), notify thecustomer service department.Battery maintenance and servicing is subject to the conditions listed in the operatormanual under Item D.

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7 Battery – Checking Condition and Acid Level

F Batteries can be hazardousBatteries contain dissolved acid which is toxic and caustic. Avoid physical contactwith battery acid.

• Dispose of used battery acid in accordance with regulations.

• Always wear protective clothing and goggles when working with batteries.

• Do not let battery acid come into contact with skin, clothing or eyes. If necessary,rinse with plenty of clean water.

• In the event of physical damage (e.g. skin or eye contact with battery acid) call fora doctor immediately.

• Spilled battery acid should be neutralised immediately with plenty of water.

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

• Follow national guidelines and legislation.

– The battery manufacturer’s maintenance instructions apply.

– Check the battery housing for cracks and any spilled acid.

– Remove any oxidation remains from the battery terminals and apply an acid-freegrease to the battery terminals.

– Open the plugs and check the acid level.The acid level should be at least 10-15 mm above the top of the plates. Now closethe plugs.

– If necessary, re-charge the battery.

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8 Battery Discharge Indicator "Bar Display" (t)

When you turn the Emergency Disconnect switch toactivate it and turn the key in the key switch clockwise,the battery discharge indicator / discharge monitor willshow the residual capacity available. The lower sectionof the battery symbol is empty. It indicates the residualcapacity of the battery which is protected and cannotbe used to avoid damaging the battery.

Z The standard setting for the battery dischargeindicator / discharge monitor is based on standard batteries. When usingmaintenance-free or special batteries the display and cutout points of the batterydischarge monitor must be set by authorised specialist personnel. If this adjustmentis not made the battery may become damaged through excessive depletion.

M Excessive depletion shortens the useful life of the battery.Charge the battery in good time, see “Charging the Battery” in this chapter.

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8.1 Battery discharge monitor with bar display

When a battery is discharged to the permissible level (residual capacity) the batterysymbol in the driver's display is empty and flashes red. A display appears. Main Liftand Auxiliary Lift raising are inhibited.

Lifting is only enabled again when the connected battery:

– is at least 40% charged for a wet-cell battery.

– is at least 50% charged for a gel battery.

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8.2 Battery symbol fluorescent colours

Z The fluorescent colours of the battery symbol represent the following conditions:

Battery symbol colour Meaning

White

– Battery is charged.

Z The more bars the battery discharge indicatorshows, the greater the battery's residual capacity.

Yellow

– Battery charge recommended.

Z Depending on the battery type, the batterydischarge indicator symbol flashes when thereare one or two remaining bars.

Flashing red

– Battery charge required (charge is below residual capacity level).

– The battery discharge indicator symbols does notshow any bars.

Z Main Lift and Auxiliary Lift raising is inhibited.

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9 Battery Discharge Indicator "Percentage Display" (o)

When you turn the Emergency Disconnect switchto activate it and turn the key in the key switchclockwise, the battery discharge indicator /discharge monitor will show the residual capacityavailable as a percentage.

Z The standard setting for the battery dischargeindicator / discharge monitor is based on standard batteries. When usingmaintenance-free or special batteries the display and cutout points of the batterydischarge monitor must be set by authorised specialist personnel. If this adjustmentis not made the battery may become damaged through excessive depletion.

M Excessive depletion shortens the useful life of the battery.Charge the battery in good time, see “Charging the Battery” in this chapter.

9.1 Battery symbol fluorescent colours

If a battery is discharged to less than 31% for wet-cell batteries or 41% for gelbatteries (residual capacity), the battery symbol flashes. Main Lift and Auxiliary Liftraising are disabled below 21% for wet-cell batteries and 31% for gel batteries.

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75%

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– for wet-cell batteries (PB):

Z Lifting is only enabled again when the battery connected is at least 40% charged.

– for gel batteries:

Z Lifting is only enabled again when the battery connected is at least 50% charged.

Battery symbol colour Meaning

Black 100 % - 31 %

– Battery is charged.

Z The higher the percentage, the greater thebattery residual capacity.

Yellow 30 % - 21 % – Battery charge recommended.

Flashing red 20 % - 0 %

– Battery charge required (charge is below residual capacity level).

Z Main Lift and Auxiliary Lift raising isinhibited.

Battery symbol colour Meaning

Black 100 % - 41 %

– Battery is charged.

Z The higher the percentage, the greater thebattery residual capacity.

Yellow 40 % - 31 % – Battery charge recommended.

Flashing red 30 % - 0 %

– Battery charge required (charge is below residual capacity level).

Z Main Lift and Auxiliary Lift raising isinhibited.

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E Operation

1 Safety Regulations for the Operation of Forklift Trucks

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

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

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

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

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

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E 2

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

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

Safety devices and warning signs: Safety devices, warning signs and warninginstructions in the present operating instructions shall be strictly observed.

Z Warnings and notices such as load charts, strap points and data plates must belegible at all times. Replace if necessary.

F Removing or disabling safety devices can cause accidentsRemoving or disabling safety devices such as the Emergency Disconnect switch,deadman button, horn, warning lights, safety gates, mast guards, panels etc. canresult in accidents and injury.

– Report any defects immediately to your supervisor.

– Tag out and decommission a faulty lift truck.

– Only return the truck to service when you have identified and rectified the fault.

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2.1 Operating and display equipment on control panel

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Item Control / display Function

1 Hydraulic control button t

Controls hydraulic functions, such as Main and Aux. Lift raise and lower, fork traverse and rotate

2 Horn pushbutton t Activates the horn, releases an audible warning.

3“Switch guidance on/off” pushbutton

o

Activates wire guidance in the narrow aisleRail guidance: Sets the drive wheel to the forward position

Wire guidance:

Activates the alignment process (and frequency selection for multi-frequencies)

4“Control panel adjustment” pushbutton

t

Allows the control panel to be tilted between 130° and 180°. To do this, press down on the "Control panel adjustment" pushbutton and tilt it in the required direction.

5 Display unit tDisplays function, operating information and warning messages

6 Indicator lamp t

For manufacturer's service department only.7 Indicator lamp t

8 Indicator lamp t

9“Fork carriage rotate” pushbutton

tChanges the hydraulic control button to the “Fork carriage swivel ” function

10“Attachment traverse” pushbutton

tChanges the hydraulic control button to the “Attachment Reach” function

11 “Aux. Lift” pushbutton tSwitches the hydraulic control button to lift and lower the fork carriage without the driver’s cab

12 Travel control knob tControls the travel direction and speed of the truck

13“Main and Aux. Lift raise / lower” pushbutton

tEnables simultaneous lowering/raising of Main and Aux. Lift.

14Hand rest and contact point

t

Two-hand operation in narrow aisle(via the contacts in the traction controller and hydraulic controller handle).

15 Control panel tThe truck functions can be controlled via the control panel.

16 Gate t Prevents the driver from falling out

17 Driver's seat tTo adjust the driver's seat, see "Adjusting the driver's seat" in Chapter E.

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Item Control / display Function

18Deadman button (foot switch)

t

– Not pressed ("Deadman button not pressed"lit in the display unit, see “Display unit controlsand displays” in Chapter E):

• Travel functions are inhibited.

• Hydraulic functions are inhibited.

• Steering, driver's display and horn arereleased.

– pressed ("Deadman button not pressed"disappears, see “Display unit controls anddisplays” in Chapter E):

• Travel and hydraulic functions are released.

o

– The deadman button must be applied permanently while the truck is in operation (lifting/lowering/travelling).

– When the deadman button is released the truck brakes regeneratively to a halt (parking brake applied). The truck coasts to a stop according to the “coasting brake” parameter setting.

– For functional description see standard versions.

19Control panel height adjuster

tThe control panel height can be adjusted by 85 mm.

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Item Control / display Function

20

Key switch t

Switches the control current on and off. Removing the key prevents the truck from being switched on by unauthorised personnel.

ISM access module o

Replaces the key switch.

Releases the truck response with card or transponder.

– Time out monitoring

– Records the truck's operators (shifts)

– Operational data acquisition

21Emergency Disconnect switch

tInterrupts the main supply, all truck movement is disabled

22 Steering wheel t Steers the truck in the required direction.

23“Quit sub-menu” pushbutton

t

Changes menu: When you press the "Cancel sub-menu" button the menu currently shown in the driver's display changes to the higher-level menu.

24 Pushbutton t

Activates or confirms the function shown in the display unit (as a symbol) via the pushbutton below it. The symbol will be given a dark background.

25 Numerical keypad t Controls and settings for standard functions (e.g. setting the time) and additional functions (e.g. Rack Height Select)26

Cursor keys for special hydraulic functions

t

t = Standard equipment o = Optional equipment

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2.2 Display unit controls and displays

Upper range symbols

Item Symbol Control / display Function

30“Service hours” display

tDisplays the number of service hours since the truck was commissioned

31 “Time” display t Shows the time

32 Steer angle display tIndicates the current steer angle with reference to the centre position

32

Rail guidance: Steer angle display is replaced by the following symbols:

"Truck guided (with aisle detection)"

o

Symbol lights up as soon as the truck is automatically guided and has received an aisle signal

"Truck guided (without aisle detection)"

Symbol lights up as soon as the truck is automatically guided and has not received an aisle signal.

– Continue travelling in the narrow aisle.

– As soon as the truck receives an aislesignal the "Truck guided (without aislerecognition)" symbol is replaced by the"Truck guided (with aisle recognition)"symbol.

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32

Wire guidance: Steer angle display is replaced by the following symbols:

“Acquisition in progress”

o

Symbol lights up as soon as the truck has acquired the guide wire

"Truck guided (with aisle detection)"

Symbol lights up as soon as the truck is automatically guided on the wire and has received an aisle signal

"Truck guided (without aisle detection)"

Symbol lights up as soon as the truck is automatically guided on the wire and has not received an aisle signal

– Continue travelling in the narrow aisle.

– As soon as the truck receives an aislesignal the "Truck guided (without aislerecognition)" symbol is replaced by the"Truck guided (with aisle recognition)"symbol.

"Truck not guided"

Symbol lights up as soon as the truck on the guide wire is switched off and on with the key switch.

Continue travelling in the narrow aisle.

The "Truck not guided" symbol is replaced by the "Wire acquisition in progress" symbol.

As soon as the truck has acquired the wire and received an aisle signal, the "Truck guided (with aisle recognition)" symbol lights up.

“Deviation from guide wire”

The symbol lights up as soon as the truck moves away from the guide wire and therefore from automatic guidance

Item Symbol Control / display Function

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Item Symbol Control / display Function

33 Truck model t Indicates the truck model

34

“Overall lift" and "Referencing required” displays:

t

Shows the lift height of the forks after referencing

Main Lift - raise Requests the Main Lift to raise

Main Lift - lower Requests the Main lift to lower

Aux. lift - lift Requests Aux. Lift to lift

Aux. lift - lower Requests Aux. Lift to lower

35 Weighing system o Shows the weight of the raised load in kg

36Battery Discharge Indicator

tShows the battery charge status (bar display)

oDisplays the battery charge status (residual capacity as a percentage)

37 “Level” display tThe current display receives a dark background

38"Replace hydraulic oil" display

o

Indicates that the permissible water content level in the hydraulic oil has been exceeded. The hydraulic oil must be replaced. Contact the manufacturer's service department. The manufacturer has a service department specially trained for these tasks.

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39“Perform cycle test” display

o

Indicates that the cycle test must be performed. During this time the travel speed is restricted to 2.5 km/h. Refer to the "Personal protection system (o)"section in chapter E.

40

"Active stabiliser extended" display

o

Indicates that the active stabiliser has been extended to a distance of 5 mm from the ground when the truck is idle and the sideshifter applied. An adjustment run with a maximum speed of 2.5 km/h can be carried out.

"Active stabiliser referencing" display

oIndicates the active stabiliser is being referenced while the truck is idle.

41

Attachment in home position

tSee “Attachment in Home Position” in chapter E

“Horizontal positioning” function stacking display

o See "Horizontal positioning" in chapter E.

42“Guide wire detection” display

oWire guidance sensors that have identified the guide wire illuminate

43“Rack height select” and “horizontal positioning” function display

o

The rack height select and horizontal positioning displays and function are described in “Rack Height Select with Zone Entry” and “Horizontal Positioning” in chapter E.

Item Symbol Control / display Function

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Item Symbol Control / display Function

44 Functions tFor details see “Lower range symbols and Pushbuttons” in chapter E

45

Service mode active(wrench)

tEvent and / or information messages are shown in the display unit

Wire guidance fault o

A wire guidance antenna on the truck has left the prescribed range of the guide wire. The truck immediately undergoes an Emergency Stop (see "Wire guidance emergency mode (event message I 3670 / I 3752)" in chapter E).

46Displays possible travel speeds:

t

Rabbit:Max. travel speed

Turtle:Inching speed

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Deadman button not pressed

tTruck is ready for operation.

Deadman button not pressed

Gates not closed tTruck is ready for operation.

Gates not closed

EmergencyDisconnect switch indicator lamp pressed

tTruck is ready for operation.

Emergency Disconnect switch pressed

Release two-handed operation

o

Travel and hydraulic functions are inhibited.

– Do not touch the travel / hydrauliccontrol handles

– Do not press the deadman button

– The "Release two-handed operation"symbol fades out

– Press deadman button

– Touch the travel / hydraulic controlhandles again

Z Travel and hydraulic functions areenabled again

48

Parking brake engaged

t

Indicates the truck has come to a halt (drive wheel brake and load wheel brake engaged)

Drive wheel brake referencing

Indicates the truck has come to a halt and the drive wheel brake has been referenced

t = Standard equipment o = Optional equipment

RG = Rail guidance WG = Wire guidance

Item Symbol Control / display Function

STOP

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2.3 Lower range symbols and pushbuttons

Activate pushbutton (24) under the respective symbols (44) displayed or confirms therelated function. The symbol will be given a dark background.

Symbol Control / Display Function

Warnings

“Slack chain safety device” display

t Displayed when the slack chain safety device engages

“Slack chain safety device override” pushbutton

Bypasses the slack chain safety device to lift the driver's position freely

“Fwd./Rev. travel only” display

t Displayed when the lift cutout device is activated due to low battery capacity and only forward or reverse travel is possible.

“Acknowledge lift cutout due to battery discharge” pushbutton

Confirms lift cutout for low battery capacity and releases travel

“Lift height dependent lift cutout” display

o Displayed when the lift limit is activated

“Lift limit override” pushbutton

Overrides the lift limit. Note the maximum overhead clearance heights.

“Lower limit” display o Indicates that the automatic lowering limit has been activated.

“Lower limit override” pushbutton

Overrides the lowering limit, controlled by hydraulic control button

“Travel cutout” display o Indicates that automatic, height dependent travel cutout has been activated

“Travel cutout override” pushbutton

Overrides the automatic, height dependent travel cutout

“Aisle endsafety device” display (option)

o Indicates that the aisle end safety device has been activated. The truck brakes.

Select “Warning sub-menu” display

o Indicates that several warnings (e.g. slack chain safety device, lift cutout, set date / time, operator specific settings,…) have run out.

Select “Warning sub-menu” button

Individual warnings can be seen

Quit “warnings” sub-menu.

o Indicates that the sub-menu can be quit.

“Quit warnings sub-menu” pushbutton

Resets the sub-menu to the standard menu

"Battery lock not applied" display

t Appears when the truck has been switched on but the battery lock has not been applied. The truck can only be operated at crawl speed (2.5 km/h).

"Battery lock applied confirmation" pushbutton

Acknowledges the message when the battery lock has been applied

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Personal Protection System (PPS)

“Acknowledge cycle test” display

o Indicates that the cycle test must be performed (every 24 hours). The truck brakes and can only be operated at crawl speed (2.5 km/h).Refer to the "Personal protection system (o)" section in chapter E.

“Acknowledge cycle test” pushbutton

Launches the automatic performance of cycle test

“Warning field infringement” display

o Indicates that the warning field of the Personal Protection System has been infringed by persons / objects in the narrow aisle. The truck brakes and can only be operated at crawl speed (2.5 km/h). Refer to the "Personal Protection System (o)"section in chapter E.

“Protection field infringement” display

o Indicates that the protection field of the Personal Protection System has been infringed by persons / objects in the narrow aisle. The truck brakes to a halt.

“Protective field infringement” pushbutton

Bypasses the protective function and enables crawl speed (2.5 km/h) if there is sufficient distance from the obstacle.

Refer to the "Personal protection system (o)"section in chapter E.

Guidance systems

Displays “Select Frequency 1” (“Guidance on” sub-menu)

o Indicates that wire guidance is available with frequency 1 (similar to other frequencies, maximum 5 frequencies).

“Select Frequency 1” pushbutton (similar to other frequencies)

Activates wire guidance via frequency 1 (sub-menu is quit automatically when pressed for 1 sec.).

Symbol Control / Display Function

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Attachment fork operation

“Synchronised rotate menu change” display

t Changes the menu to “synchronised rotate” functions

“Synchronised rotate menu change” pushbutton

Activates synchronised rotate menu change

“Fork synchronised left rotate” display

t Indicates that the fork synchronised left rotate – right traverse is available

“Fork synchronised left rotate” pushbutton

Activates fork left rotate, simultaneous control of load handler right traverse via the hydraulic control button

“Automatic fork synchronised left rotate” display

o Indicates that the automatic fork synchronised left rotate – right traverse is available

“Automatic fork synchronised left rotate” pushbutton

Activates fork left rotate with simultaneous load handler right traverse

“Fork synchronised right rotate” display

t Indicates that the fork synchronised right rotate – left traverse is available

“Fork synchronised right rotate” pushbutton

Activates fork right rotate, simultaneous control of load handler left traverse via the hydraulic control button

“Automatic fork synchronised right rotate” display

o Indicates that automatic fork synchronised right rotate – left traverse is available

“Automatic fork synchronised right rotate” pushbutton

Activates fork right rotate with simultaneous automatic load handler left traverse

“Automatic fork synchronised rotate to centre position” display

o Indicates that the forks can be automatically set to the centre position (forks facing forwards)

“Automatic fork synchronised rotate to centre position” pushbutton

Activates swivelling with automatic fork stop in centre position, simultaneous automatic load handler traversing with stop at centre position

“Telescopic table fork adjuster” display

Indicates that the telescopic table forks can be adjusted

“Telescopic table fork adjuster” pushbutton

Activates the telescopic table fork adjustment, controlled via the hydraulic control button

“Single telescopic fork” display

o Indicates that the single telescopic forks can be operated

“Single telescopic fork” pushbutton

Activates the single telescopic fork, controlled via the hydraulic control button

“Telescopic table” display o Indicates that the telescopic table can be operated

“Telescopic fork” pushbutton

Activates the telescopic fork, controlled via the hydraulic control button

Symbol Control / Display Function

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“Telescopic fork - synchronised movement” display

o Indicates that “Telescopic fork - synchronised movement” is available, controlled via the hydraulic control button

“Telescopic fork - synchronised movement” pushbutton

Activates synchronised movement of the telescopic forks

“Telescopic fork - asynchronous movement (top)” display

o Indicates that “Telescopic fork - asynchronous movement (top)” is available, controlled via the hydraulic control button

“Telescopic fork - asynchronous movement (top)” pushbutton

Activates asynchronous movement (top fork) of the telescopic forks

“Telescopic fork - asynchronous movement (bottom)” display

o Indicates that “Telescopic fork - asynchronous movement (bottom)” is available, controlled via the hydraulic control button

“Telescopic fork - asynchronous movement (bottom)” pushbutton

Activates asynchronous movement (bottom fork) of the telescopic forks

“2nd stacking depth” display

o Indicates that the 2nd stacking depth is possible

“2nd stacking depth” pushbutton

Activates the 2nd stacking depth, controlled via the hydraulic control button

“Fork tilt” display o Indicates that fork tilt is possible

“Fork tilt” pushbutton Activates the fork tilt, controlled via the hydraulic control button

“Special attachment” display

o Indicates that the special attachment can be controlled

“Special attachment” pushbutton

Activates control of the special attachment, controlled via the hydraulic control button

Symbol Control / Display Function

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Fork adjuster / sideshift

“Fork adjuster / sideshift menu change” display

o Changes the display unit menu to “fork adjuster / sideshift” functions

“Fork adjuster / sideshift menu change” pushbutton

Activates fork adjuster / sideshift menu change

“Symmetrical fork adjuster” display

o Indicates that fork adjustment can be operated

“Symmetrical fork adjuster” pushbutton

Activates the fork adjuster when hydraulic control button is simultaneously applied

“Asymmetrical fork adjuster menu change” display

o Indicates that the “Asymmetrical fork adjuster” menu can be changed

“Asymmetrical fork adjuster menu change” pushbutton

Changes the display unit menu to “asymmetrical fork adjuster” functions

“Fork adjuster, left only” display

o Indicates that left only fork adjustment is possible

“Fork adjuster, left only” pushbutton

Activates left only fork adjustment, controlled via the hydraulic control button

“Fork adjuster, right only” display

o Indicates that right only fork adjustment is available

“Fork adjuster, right only” pushbutton

Activates right only fork adjustment, controlled via the hydraulic control button

“Fork sideshift” display o Indicates that fork sideshift is possible

“Fork sideshift” pushbutton

Activates the fork sideshift, controlled via the hydraulic control button

Symbol Control / Display Function

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Optional equipment

“Work lights / fan menu change” display

o Changes the display unit menu to “work lights / fan” functions

“Work lights / fan menu change” pushbutton

Activates the work lights / fan menu change

“Overhead guard work lights” display

o Indicates that the overhead guard work lights can be switched on / off.

“Overhead guard work lights” pushbutton

Activates the overhead guard work lights

“Load handler work lights” display

o Indicates that the load handler work lights can be switched on / off.

“Load handler work lights” pushbutton

Activates the load handler work lights

“Fan” display o Indicates that the fan can be switched on / off.

“Fan” pushbutton Activates the fan

"Weigher display zero setting" display

o Indicates that the weight measurement display can be set (tared) to zero

"Weigher display zero setting" pushbutton

This pushbutton sets the weight measurement to zero

"Warehouse or stockpicking mode" display

o – Warehouse mode = Symbol has a darkbackground

– Stockpicking mode = Symbol has a lightbackground

Z See "Horizontal positioning" inchapter E.

"Warehouse or stockpicking mode toggle" pushbutton

This pushbutton toggles between warehouse and stockpicking mode

t = Standard equipment o = Optional equipment

RG = Rail guidance WG = Wire guidance

Symbol Control / Display Function

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2.4 Truck operational status symbols

The operational status of the truck on power up is indicated by symbols in thedisplay unit.

Gates open

Deadman button not pressed

Attachment in home position, see section of the samename in chapter E.

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B3 Starting up the truck

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

3.1 Checks and operations to be performed before starting daily operation

F Damage and other truck or attachment (special equipment) defects can resultin accidents.If damage or other truck or attachment (special equipment) defects are discovered,the truck must be taken out of service until it has been repaired.

• Report any defects immediately to your supervisor.

• Tag out and decommission a faulty lift truck.

• Only return the truck to service when you have identified and rectified the fault.

– Check the whole of the outside of the truck for signs of damage and leaks.

– Check the battery attachment and wire connections for damage, make sure theyare secure.

– Check the battery connector is secure.

– Check the battery retainers are present and test them.

– Ensure the battery is securely fixed in the battery compartment.

– Check battery cover and side panels are secure and look for damage.

– Check the overhead guard for damage.

– Check the load handler for visible signs of damage such as cracks, bent or severelyworn forks.

– Check the drive wheel and load wheels for damage.

– Make sure the load chains are evenly tensioned.

– Make sure all safety mechanisms are correct and functional.

– Test the service and parking brakes.

– For rail guidance systems check the guide wheels are smooth and not damaged.

– Check static charge eliminator is present.

– Test the instruments, displays and control switches.

– Check the Personal Protection System laser scanner front panels and cleanif necessary (o).

– Carry out a cycle test on the Personal Protection System, see “Daily Checks beforestarting the Personal Protection System” in chapter E (o).

– Check that the load chart and warning labels are legible.

– Check the rescue equipment is present.

F It is prohibited for more than one person to enter the driver’s cab at a time.

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3.2 Truck entry and exit

M Safety gate trapping hazardThere is a risk of trapping when the gates are opened and closed.

• Make sure there is nothing between the cab chassis / foot compartment and thegates when the gates are opened and closed.

F Fall hazardWhen the gates are opened and the driver's cab raised, the operator risks falling outof the cab.

• Do not open the gate when the driver's cab is raised.

– Fully lower the mast / driver's cab.

– Lift up the gates.

– To enter and exit the cab, hold onto the cab chassis (50).

– Close the gates.

M No more than one person may operate the truck in the driver's cab at a time.

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B3.3 Removing the driver’s seat

M Do not loosen the twist grip screws (52) while travelling.

– To remove the driver’s seat (51), loosenthe two twist grip screws (52) underneaththe driver's seat (51).

– The driver’s seat (51) can now be lifted upcomplete with the adjusting unit.

Z The driver's seat (51) with the adjusting unitweighs approx. 45 kg.

M If the driver’s seat has seat heating, the seatheating plug connection must first beremoved before lifting out the seat.

3.4 Setting up the operator position

M Accident riskDo not adjust the driver’s seat and controlpanel during operation.

– Before operating, adjust the driver’s seat and control panel so that all the controlsare within reach and can be applied without having to strain.

– Adjust the visibility aid equipment (mirrors, camera systems etc.) so that theworking environment can be clearly seen.

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3.5 Adjusting the driver’s seat

M The driver’s seat setting must not be changed during travel.

Z The driver’s seat has a high backrest (53)and a sculpted seating area (60) providingfatigue-free operation in a seated position.The padded underside of the seat is usedto lean against when the operator isstanding.

– Pull up the adjusting lever (61) and applyor remove weight to obtain the correctseat (60) height. The setting range is120 mm.

– Loosen the setscrew (62) to adjust theheight of the armrest (55).

– The armrest (55) swivel can be adjustedvia the wheel (56).

– Push the “seat swivel adjustment”lever (58) to swivel the seat (60) 40 mmup or down.

– Apply the “seat adjustment” lever (59) topush the seat (60) 50 mm forward orback.

– To unlock the seat (60) apply the lever (57).

– The rotary button (54) for adjusting the back support is on the left hand side ofthe seat.

– The driver’s seat can optionally be equipped with seat heating. To switch the seatheating on, the seat heating switch must be turned on (position l).

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B3.6 Control panel angle adjustment

M Do not adjust the inclination of the control panel (15) during operation.Make sure the control panel is locked in position after any adjustment.

Z The control panel (15) incline can beinfinitely adjusted by up to 50° (tilt range: 130° to 180°).

– Turn the Emergency Disconnect (21) torelease it.

– Put the key in the key switch (20) andswitch the truck on.

– Press and hold down on the control paneladjustment button (4).

– Set the control panel (15) to the requiredposition.

– “Control panel adjustment” pushbutton (4).

– Make sure the control panel is locked inposition.

F In the event of malfunctions the releasepin (4a) must be kept pressed in order toadjust the tilt angle of the control panel (15).

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3.7 Control panel height adjustment

M Do not adjust the height of the control panel (15) during operation.Make sure the control panel is locked in position after any height adjustment.

Z The height of the control panel (15) can beadjusted by 85 mm.

– Release the lever (19).

– Pull the control panel in the desiredposition (up or down).

– Tighten the lever (19).

3.8 To prepare the truck for operation (t)

– Close the gates.

– Turn the Emergency Disconnect (21) torelease it.

– Put the key in the key switch (20) andturn it clockwise.

– Test the horn by pressing the “horn”pushbutton (2).

– Test the service and parking brakes.

– Carry out a test run on the mast(Main Lift and Auxiliary Lift) to adjust theheight display,see “Referencing the Main and AuxiliaryLift” in Chapter E.

F Press the Emergency Disconnect switch (21) immediately if the truck starts to moveor lift as soon as it is switched on.

Z Brief steering movements caused by steering referencing are permissible.

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B3.9 Preparing the truck for operation with an additional access code (o)

Z Optionally, the truck can be prepared for operation with an additional 5 digit accesscode. In addition to the access code the key switch is still used to switch on the truck.

– Close the gates.

– Turn the Emergency Disconnect (21) to release it.

– Put the key in the key switch (20) and turn it clockwise.

Z In the display unit (5) you will be prompted to enter your 5 digit access code.

– Press the "Select" button (78) in the cursor field.

– Enter your 5 digit access code via the numerical keypad (25) and press "OK".The cursor keys (75, 77) can be used to enter each digit of the 5-digit access code:Move the cursor key (75) one place forward or cursor key (77) one place back.Press the "CE" key to cancel entering the 5 digit access code.

Z The truck will not operate at all unless the correct access code is entered. Up to99 different access codes can be set. The individual codes can be assigned to pre-defined travel programs, steer programs and hydraulic programs (see “Operatorspecific settings” in chapter E). If no travel, steer or hydraulic operations areperformed within a factory-set interval, the display unit (5) will again ask you to enterthe 5-digit code with the numerical keypad (25).

– Test the horn by pressing the “horn” pushbutton (2).

– Test the service and parking brakes.

– Carry out a mast reference operation (main and auxiliary lift) to adjust the heightdisplay, see “Referencing Main and Auxiliary Lift” in chapter E.

F Press the Emergency Disconnect switch (21) immediately if the truck starts to moveor lift as soon as it is switched on.

Z Brief steering movements caused by steering referencing are permissible.

* ****

21 202 5 25 78

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3.10 ISM Access Module (o)

Z If the truck is equipped with an ISM access module refer to the “ISM Access Module”operator manual.

3.11 Checks and operations to be carried out when the truck is operational

F Truck defects can result in accidentsDo not use the truck if the brake system, steering and/or hydraulic systemare defective.If any damage or other truck or attachment (special equipment) defects arediscovered, the truck must be taken out of service until it has been repaired.

• Report any defects immediately to your supervisor.

• Tag out and decommission a faulty lift truck.

• Only return the truck to service when you have identified and rectified the fault.

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BProcedure

– Test warning indicators and safety devices:

– Test the Emergency Disconnect by pressing the Emergency Disconnect switch.The main circuit is disconnected and no truck operations can be performed.Now turn the Emergency Disconnect to unlock it.

– Test the horn by pressing the "horn" button.

– Test the deadman button.

– Test the side / safety gates.

– Test the service and parking brakes, see "Brakes" in Chapter E.

– Test the steering, see "Steering" in Chapter E.

– Test the hydraulic system.

– Test the lift cutouts (o), see "Lift cutout override (o)" in Chapter E.

– Test the travel functions, see "Travel" and "Negotiating narrow aisles" inChapter E.

– Test the end of aisle safety device and aisle recognition functions (o),see "End of aisle safety device (o)" in Chapter E.

– Test the travel cutouts (o), see "Travel cutout override (o)" in Chapter E.

– Test the lighting (o).

– Test the Personal Protection System (o), see "Personal Protection System(o)" in Chapter E.

– Test the front screens of the Personal Protection System laser scanners fordirt (o), and clean if necessary, see "Cleaning the laser scanner front screen"in Chapter E.

– Test the controls and displays, see "Displays and controls" in Chapter E.

– Check the hand rests (14) and handles are secure and check for damage,see "Displays and controls" in Chapter E.

– Carry out a mast reference operation to adjust the height display, see “Referencingthe Main and Auxiliary Lift” in Chapter E.

– Test the two-handed operation system in the narrow aisle, see "Negotiating narrowaisle with rail-guided trucks (o)" and "Negotiating narrow aisles with wire-guidedtrucks (o)" in Chapter E.

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3.12 Referencing the main and auxiliary lift

Z When the following symbols are displayed you must carry out a reference/test run inaccordance with the display (5), i.e. primary lift and aux. lift must be raised approx.10 cm and then lowered again. This is the only way for the controller to release all thetruck movements at full speed.

Procedure:

– Close the safety gates securely on both sides.

– Turn the Emergency Disconnect (21) to release it.

– Put the key in the key switch and switch the truck on.

– Press deadman switch (65).

Referencing: Main Lift - raise

– Raise the Main Lift approx. 10 cm via the hydrauliccontrol button (1).Left turn = lift

Z The main lift automatically stops at the top limit.

Referencing: Main Lift - lower

– Fully lower the Main Lift with the hydraulic controlbutton (1).Right turn = Lower.

65 1 5 11 1221

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Referencing: Aux. lift - lift

– Raise the auxiliary lift approx. 10 cm via the hydrauliccontrol button (1) while simultaneously pressing the“Aux. Lift” pushbutton (11). Left turn = lift

Z The Aux. Lift automatically stops at the top limit.

Referencing: Aux. lift - lower

Fully lower the auxiliary lift via the hydraulic controlbutton (1) while simultaneously pressing the “aux. lift”pushbutton (11).Right turn = Lower.

Lift cutout with referencing

F An extended mast can cause accidentsThe lift cutout is an auxiliary function designed to supportthe operator which however does not release him fromhis responsibility to stop hydraulic operations e.g. whenconfronted with an obstacle.

Pressing the “lift cutout override” pushbutton disables thelift cutout.

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Load handler referencing (fork carriage / sideshift)

If the sideshift and / or rotation of the load handler are adjusted when the truck hasbeen switched off, the "rotate reference operation" or "traverse reference operation"symbols will be shown in the display unit the next time the truck is switched on.Rotation or traverse must be referenced.

Rotating reference operation Traversing reference operation

Sideshifting is referenced by moving the sideshifter over the "attachment centre"position, see "Traverse (load handler attachment)" in Chapter E.

The rotary sensor system of the attachment is referenced by performing at least onecomplete rotation with the load handler, see "position, see "Swivel / Rotate(Fork Carriage)" in Chapter E.

Referencing is successful if the appropriate symbol goes out after referencing.

Z If one of the two symbols does not go out after referencing, contact themanufacturer’s service department.

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B3.13 Setting date and time

Selecting the “Set Date/Time” menu:

– Press the "Quit sub-menu"pushbutton (23). The “set date/time”menu now opens. The display unitshows the date and the time.

Z Truck movement is inhibited in thistruck menu.

Date and time formats:

Format Date Time

Standard setting dd.mm.yyyy hh:mm:ss

US setting mm.dd.yyyy hh:mm:ss am/pm

Abbreviations d = daym = monthy = Year

h = Hourm = minutes = second

23

12 : 0 0 : 0 0

01 . 0 5 . 2 0 07

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Setting the date / time:

– Press the “Select” pushbutton (78) inthe cursor field. The first digit in thedate display appears against a bluebackground.

– The operator can use the cursorkeys (76, 79) to choose the requiredsetting in the selected field:Cursor key (76): decrease numberCursor key (79): increase number.

Z The required number can also beentered directly via the number field ofthe numerical keypad (25).

– Use the cursor keys (75, 77) in thecursor field to select the next /previous field:Cursor key (75): next field Cursor key (77): previous field.

Z The selected field appears with a "blue"background.

– When the date and time have beenentered, the entry must be confirmedby pressing “OK” in the numericalkeypad (25).

Quitting the “Set Time” menu:

– Press pushbutton (71) below the“truck functions” symbol. The displayunit changes to the "truck functions"menu.

23 66

12 : 0 0 : 0 0

01 . 0 5 . 2 0 07

77

7925 78

76

75

71

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B3.14 Operator specific settings (o)

Selecting the “Operator Specific Settings” menu:

– Press the “quit sub-menu”pushbutton (23); the display unitshows the “sub-menu warnings” menuitem (72).

Z Truck movement is inhibited in this truckmenu.

– Now press the pushbutton (66) belowthe “sub-menu warnings” symbol (72).The display unit now shows the“operator specific settings” menuitem (80).

– Press the pushbutton (67) belowthe “operator specific settings”symbol (80). The “operator specificsettings” menu now opens.

23 66

72

80

67

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Settings in the “Operator SpecificSettings” menu:

Z Truck operations are inhibited in thismenu.

– Press the “Select” pushbutton (78) inthe cursor field. The symbol for the“Travel acceleration” user-definedsetting appears in the display unit(see table).

– The operator can toggle between func-tions using the cursor keys (75, 77):Cursor key (75): go one functionforwardCursor key (77): go one functionback.

Function order:

Functions Display

Travel Acceleration

Apron speed

Aisle Speed

Main lift- raise speed

Main lift – lower speed

Sideshift speed

Steering wheel transmission

77

7978

76

75

25

a

v

v

V

V

V

v

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B– The operator can use the cursor

keys (76, 79) to set the functions from1 (weak) to 8 (strong):Cursor key (76): weaken the setting. Cursor key (79): strengthen the setting.

Z This allows individual settings to bemade within a pre-defined area in theprogram.

– When the driver-specific settingshave been entered, the entries mustbe confirmed by pressing “OK” in thenumerical keypad (25).

M Altering travel parameters can causeaccidentsIncreasing the settings for acceleration,steering, travel, lifting and lowering canresult in accidents.

• Carry out a test run in a secureenvironment.

• This requires greater attention on thepart of the operator.

Quitting the “Driver-specific settings” menu:

– Press pushbutton (71) below the“truck functions” symbol. The displayunit changes to the "truck functions"menu.

77

7978

76

75

25

1

8

71

75

71

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4 Industrial Truck Operation

4.1 Safety regulations for truck operation

Travel routes and work areas:

Only use lanes and routes specifically designated for truck traffic. Unauthorised thirdparties must stay away from work areas. Loads must only be stored in placesspecially designated for this purpose.The truck must only be operated in work areas with sufficient lighting to avoid dangerto personnel and materials. Additional equipment is necessary to operate the truck inareas of insufficient lighting.

F Do not exceed the permissible surface and spot load limits on the travel routes.At blind spots get a second person to assist.

Z Loads must not be deposited on travel or escape routes, in front of safetymechanisms or operating equipment that must be accessible at all times.

Driving conduct:

The driver must adapt the travel speed to local conditions. The truck must be drivenat slow speed when negotiating bends or narrow passageways, when passingthrough swing doors, at blind spots and when entering and leaving the narrow aisle.The driver must always observe an adequate braking distance between the forklifttruck and the vehicle in front and must be in control of the truck at all times. Abruptstopping (except in emergencies), rapid U turns and overtaking at dangerous or blindspots are not permitted. Do not lean out or reach beyond the working andoperating area.

Do not use a mobile phone or walkie-talkie without a handsfree device whileoperating the truck.

F Truck tipover procedureIf the truck is in danger of tipping over, the driver should not jump out of the truck.He must keep the whole of his body inside the driver's cab.The driver must:

– Crouch down,

– Hold onto the operator position with both hands,

– Lean against the direction of fall.

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BVisibility when travelling outside the narrow aisle:

The driver must look in the direction of travel and must always have a clear view ofthe route ahead.

Loads that affect visibility must be positioned at the rear of the truck. If this is notpossible, a second person must walk in front of the truck as a lookout. In this caseproceed only at walking pace and pay particular attention. Stop the truck immediatelyif visual contact is lost between the lookout and the operator.

Use the mirror only to observe the traffic behind you. Should you need visibility aids(mirrors, monitors etc.) to ensure adequate visibility, practice working with thembeforehand.

Procedure and visibility when operating with a raised driver's cab and loadhandler

F Accident risk when operating with a raised driver's cab and load handlerOperating the truck with a raised driver's cab and load handler can impair the driver'svisibility. Other people can be injured in the truck's hazardous area. The hazardousarea is defined as the area in which people are at risk from the truck movement,the load handler, attachments etc. This also includes areas which can be reached byfalling loads or lowering operating equipment. Apart from the operator (in the normaloperating position) there should be no other people in the truck's hazardous area.

– When carrying out hydraulic or travel operations, make sure that nobody is presentin the hazardous area.

– Instruct other people to move out of the hazardous area of the truck.

– Stop working with the truck if people do not leave the hazardous area.

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Crash protection

The driver must not leave the operator position in a raised position. Do not climb ontoparts of the building or other trucks and do not climb over safety devices such asrailings or gates. If Euro pallets are stored lengthways it may not be possible to reachitems from the operator platform without the use of aids. The proprietor must providethe operators with suitable tools to pick the items without putting them at risk.

Load aids may only be walked on if suitable safety devices such as pallet guard andpallet tipover safety mechanisms are in place.

F Improper use of controls and components can cause the driver to fallClimbing onto the gates, control panel, driver's cab safety guard, driver's seat etc. cancause the operator to fall out of the cab.

– The operator must not climb on the gates, control panel, driver's cab guard, driver'sseat etc.

Operating with a walk-on pallet (o):

If the truck is equipped for operation with a walk-on pallet without side gates or railing,the operator must wear a restraint belt in accordance with EN 361 and aharness (2.0 m) in accordance with EN 355 (see chapter 3.1).

F It is prohibited to stop and operate racks without a base even on just one side of therack aisle. Keep a maximum distance of 0.2 m to the rack.

M Negotiating slopes and inclines: Do not negotiate slopes and inclines.

M Travelling on docks: Do not travel on docks.

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BEntering lifts:

Lifts may only be entered if they have sufficient capacity, are suitable for driving onand authorised for truck traffic by the owner. The driver must satisfy himself of theabove before entering these areas. The truck must enter lifts with the load in front andmust take up a position which does not allow it to come into contact with the walls ofthe lift shaft. Persons riding in the lift with the forklift truck must only enter the lift after the truck hascome to a rest and must leave the lift before the truck.

Work platforms

F The use of work platforms is governed by national law. In some member states theuse 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 law permits it.-Contact the national authorities before using a work platform

Nature of loads to be carried:

The operator must make sure that the load is in a satisfactory condition. Loads mustalways be positioned safely and carefully. Use suitable precautions to prevent partsof the load from tipping or falling down.

M Accident risk when transporting fluid loadsThe following hazards can arise from transporting fluid loads:Fluid sloshing out.Change of load centre of gravity due to sudden lift and travel movements and possiblecrashing of load.Truck stability can be affected by sliding or unstable loads.

– Note the instructions in the "Transporting loads" section.

M Do not transport swinging loads.

M Towing trailers: The truck must not be used to tow a trailer.

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4.2 Emergency Disconnect, Travel, Steering, Braking

4.2.1 Emergency Disconnect switch

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

Pressing the Emergency Disconnect switch

– Press the Emergency Disconnect switch (21) down.

Z All truck operations are disabled. The truck brakes to a halt. Do not use theEmergency Disconnect (21) as a service brake.

Releasing the Emergency Disconnect switch

– Turn the Emergency Disconnect switch (21) to unlock it.

Z All electrical functions are enabled and the truck is operational again (assuming thetruck was not operational before the Emergency Disconnect was pressed).

21

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B4.2.2 Travel

M Do not drive the truck unless thepanels and covers are closed andproperly locked.

The truck can be operated in 3 modes:

– Free ranging in the apron field (FR)

– Wire guided

– Rail guided (RG)

Z The operating mode used dependson the guidance system of theracking system in question.

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Travelling in the apron field

– Close the gates.

– Turn the Emergency Disconnect (21) to release it.

– Put the key in the key switch and switch the truck on.

– Press deadman switch (65).

– Carry out a mast reference operation (main and auxiliary lift) to adjust theheight display, see “Referencing Main and Auxiliary Lift” in chapter E.

– Fully lower the auxiliary lift via the hydraulic control button (1) while simultaneouslypressing the “aux. lift” pushbutton (11).Right turn = Lower.

– Lift the Main lift with the hydraulic control button (1) until the forks are clear ofthe ground.Left turn = lift

– Slowly turn the travel control knob (12) with your right thumb. Right turn = Travel in load direction (V)Turn left = Travel in drive direction (R)

– You can control the travel speed by continuing to turn or by retracting the travelcontrol knob (12)

– Use the steering wheel (22) to steer the truck in the required direction.

65 1 21 22 11

R

V

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B4.2.3 Steering

Steering outside narrow aisles:

Use the steering wheel (22) to steeroutside narrow aisles.The position of the drive wheel (82) isshown in the display unit (5).

Steering inside narrow aisles:

Z The truck is automatically guided andthe steering wheel (22) operation isdeactivated.

82

22

5

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4.2.4 Brakes

Z The truck’s brake pattern depends largely on the ground conditions. The driver musttake this into consideration when handling the truck. Brake with care to prevent theload from slipping.

The truck can brake in three different ways:

– with the service brake (t)

– with the deadman button (65) (o)

– with the Emergency Disconnect (21) (t).

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BBraking with the service brake (t)

While travelling, set the travel direction switch (12) to the zero position or the oppositetravel direction; the traction controller will cause the truck to brake.

Z The truck brakes regeneratively via the traction controller until it starts to move in theopposite direction. This method reduces energy consumption. Energy is recovered,which is controlled by the traction current controller.

Braking with the deadman button (o)

Releasing the deadman button (65) causes the truck to brake.

Z This method of braking only acts as a parking brake and not as a service brake.

Braking with the Emergency Disconnect switch (t)

Applying the Emergency Disconnect switch (21) will cause the truck to brake to a halt.

M The Emergency Disconnect switch (21) should only be used in hazardous situations.

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4.3 Negotiating narrow aisles

F Unauthorised entry of narrow aisles by other trucks or people can causeaccidentsUnauthorised personnel must not enter narrow aisles (truck lanes in racking systemswith safety distances < 500 mm), nor must any personnel cross through them.These work areas must be marked and identified accordingly.

– Carry out a daily inspection of the safety mechanisms on the truck or the rackingsystem to avoid hazards and to protect personnel.

– These must not be rendered ineffective, misused, adjusted or removed.

– Report any defects to your supervisor immediately.

– Tag out and decommission a faulty lift truck.

– Only return the truck to service when you have identified and rectified the fault.

– Tag out faulty racking systems and block them for entry.

– Only return the truck to service when you have identified and rectified the fault.

– Note DIN 15185 Part 2.

– Narrow aisles must only be entered by trucks which are designated forthis purpose.

– Before entering a narrow aisle, the driver must look for people or other trucks inthe aisle. Never enter an aisle where there are people or other trucks. If there arepeople or trucks in the aisle, stop the truck immediately.

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M A non-guided truck can cause accidentsIf an automatically guided truck is switched off and on again, the wire guidance is nolonger active when it is switched on again. The same applies if the guide system isfaulty or switched off and on again. If you continue to travel a warning sounds and thespeed is reduced.

– When starting or continuing the truck after the wire guidance has been deactivated,note the position of the drive wheel as manual steering is now activated again.

– Re-activate the wire guidance and re-align the truck. During alignment, the rearsection of the truck may veer out when it reaches the guide wire.

– If the guide system is faulty or switched off the truck can only exit the narrow aisleat crawl speed.

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4.3.1 Rail guided trucks

Z Rail-guided trucks are fitted with sensors or RFID readers. Narrow aisles must haveguide rails. These sensors activate aisle detection when the truck enters an aisle.

– Approach the aisle at reduced speed so that the truck is aligned with the narrowaisle and is within the demarcation.

Z Note the markings attached along the route (e.g. aisle centre).Travel and hydraulic operations can only be activated in the narrow aisle with two-handed control.

– Enter the narrow aisle slowly.Ensure that the truck guide wheels enter the narrow aisle guidance rails.

– Press the “Switch guidance on/off”pushbutton (3).

– The drive wheel is automaticallyset forward. The steering angledisplay (82) changes to “Truckguided” (92). Manual steering isdisabled.

3 82

92

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B– Grab the hand rest (14) in the traction

and control handle (two-handedoperation).

Z Travel and hydraulic operations canonly be activated in the narrow aisle withtwo-handed operation.

– The main lift can be raised or loweredvia the hydraulic control button (1),see "Lift – Lower (Main Lift)" inchapter E.

– The auxiliary lift can be raised or low-ered via the hydraulic controlbutton (1) while simultaneously press-ing the "Auxiliary lift" pushbutton (11),see "Lift – Lower (Auxiliary Lift)" inchapter E.

– The attachment can be rotated to theleft or right via the hydraulic controlbutton (1) and simultaneouslypressing the “Fork carriage rotate”pushbutton (9), see "Traverse(load handler attachment)" in chapter E.

– The attachment can be traversed to the left or right via the hydraulic controlbutton (1) and simultaneously pressing the “Attachment traverse” pushbutton (10),see "Swivel / rotate (fork carriage)" in chapter E.

– Turn the travel control knob (12) to change travel speed and direction: Right turn = Travel in load direction, Left turn = Travel in drive direction.

– Continue travelling along the narrow aisle at your required speed.

Leaving the narrow aisle

F You can only change from automatic to manual steering once the truck hascompletely left the narrow aisle.

To quit rail guidance:

– The truck must be removed fully from the narrow aisle.

– The truck must have come to a halt.

– the “Switch guidance on/off” pushbutton (3) must be pressed.

Z The truck guided” display (92) changes to the steer angle display (82). The truck isnow free to move again. The steer angle display (82) shows the current position ofthe drive wheel.

1 10 11 12

14 1493 82

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4.3.2 Wire guided trucks

F When starting or continuing the truck after the wire guidance has been deactivated,note the position of the drive wheel as manual steering is now activated again.If an automatically guided truck is switched off, the wire guidance is no longer activewhen it is switched on again. Accident risk If you continue to travel a warning soundsand the speed is reduced. Re-active the wire guidance by pressing the“Switch guidance on/off” pushbutton (3) and re-align the truck. During alignment,the rear part may veer out when it reaches the guidance wire.

– Approach the guidance wire (93) at an angleand at reduced speed.

Z When acquiring the wire, the truck (94) should notbe parallel to the guidance wire (93).The optimum approachment angle is between10° and 50°.

M Accident risk during wire acquisition processIf the attachment is not in the home position as thetruck acquires the wire, it can collide with theracking system. The travelspeedremains limitedto reduced speed.

Z The truck should preferably acquire the wire in theload direction, as this involves less time anddistance.

– When the truck is close to theguidance wire, switch on the wireguidance with the “Switch guidanceon/off” pushbutton (3).

– The wire acquisition signal sounds.

– When the guidance wire (93) hasbeen reached the truck isautomatically guided.

– When the guidance wire (93) isreached, acquisition ensues atreduced speed. The steer angledisplay (82) changes to “Acquisition inprogress” (95). The acquisition signalsounds.

93

94

95

3 82

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B– Inductive automatic steering takes

over and applies the truck to theguidance wire (93).

– Acquisition is complete once the truckhas been guided precisely onto theguidance wire (93). “Acquisition inprogress” (95) changes to “Truckguided” (92).

– The acquisition signal no longersounds.

– The track is now automatically guided.

Z Travel and hydraulic operations can only be activated in the narrow aisle with two-handed operation.

– Grab the hand rest (14) in the tractionand control handle (two-handed operation).

– The main lift can be raised or loweredvia the hydraulic control button (1), see"Lift – Lower (Main Lift)" in chapter E.

– The auxiliary lift can be raised or low-ered via the hydraulic controlbutton (1) while simultaneously press-ing the "Auxiliary lift" pushbutton (11),see "Lift – Lower (Auxiliary Lift)" inchapter E.

– The attachment can be rotated to theleft or right via the hydraulic control button (1) and simultaneously pressing the“Fork carriage rotate” pushbutton (9), see "Traverse (load handler attachment)" inchapter E.

– The attachment can be traversed to the left or right via the hydraulic controlbutton (1) and simultaneously pressing the “Attachment traverse” pushbutton (10),see "Swivel / rotate (fork carriage)" in chapter E.

– Turn the travel control knob (12) to change travel speed and direction: Right turn = Travel in load direction, Left turn = Travel in drive direction.

– Continue travelling along the narrow aisle at your required speed.

92

1 10 11 12

14 149

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Leaving the narrow aisle

F You can only change from automatic tomanual steering once the truck hascompletely left the narrow aisle.

To quit rail guidance:

– The truck must be removed fully fromthe narrow aisle.

– The truck must have come to a halt.

– The “Switch guidance on/off” pushbut-ton (3) must be pressed.

Z The truck guided” display (92) changesto the steer angle display (82). The truckis now free to move again. The steerangle display (82) shows the currentposition of the drive wheel.

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B4.4 Diagonal travel

Z Diagonal travel is only possible if thetruck is wire or rail guided.

Diagonal travel is possible (simultaneoustravelling and lifting / lowering) when boththe hydraulic (1) and travel (12) controlbuttons are pressed.

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4.5 Lifting – Lowering – Reaching – Traversing outside the rack aisles

F Risk of accidents during lifting and loweringOther people can be injured in the truck's hazardous area.The hazardous area is defined as the area in which people are at risk from the truckmovement, the load handler, attachments etc. This also includes areas which can bereached by falling loads or lowering operating equipment.Apart from the operator (in the normal operating position) there should be no otherpeople in the truck's hazardous area.

• Instruct other people to move out of the hazardous area of the truck. Stop workingwith the truck if people do not leave the hazardous area.

• The truck must be prevented from being used by unauthorised people if people donot leave the hazardous area despite the warning.

• Only carry loads that have been secured and positioned in accordance withregulations. Use suitable precautions to prevent parts of the load from tipping orfalling down.

• Never exceed the maximum loads specified in the capacity chart.

• Never stand underneath a raised load handler / driver's cab.

• Do not stand on the load handler.

• Do not lift other people on the load handler.

• Never reach or climb into moving truck parts.

• The driver must not leave the operator position when it is raised –do not climb ontobuilding constructions or other trucks.

F Risk of trapping when swivelling or moving the forks.Make sure there is nobody present in the danger zone when carrying out swivel,traverse or synchronised rotate movements with the load handler. Stop the truck ifpeople do not leave the hazardous area. If people do not leave the hazardous areadespite the warning, prevent the truck from being used by unauthorised people.

F Fall hazardWhen the gates are opened and the driver's cab raised, the operator risks falling outof the cab.

• Do not open the gate when the driver's cab is raised.

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B4.5.1 Lift – Lower (Main Lift)

– Press the deadman button.

– Turn the hydraulic control switch (1)Right turn = Main Lift lower. Left turn = Main Lift raise.

Z The lift and lower speeds are inproportion to how far the hydrauliccontrol button (1) is turned.

The maximum lift speed is achievedwhen the attachment is in the homeposition (see “Attachment in Home Position” in chapter E).

Z If the line break safety devices applies for an unauthorised lowering speed (> 0.6 m/s), determine the cause and if there no leakage in thehydraulic system, briefly raise the Main Lift and then lower it again slowly.

• Report any defects immediately to your supervisor.

• Tag out and decommission a faulty lift truck.

• Only return the truck to service when you have identified and rectified the fault.

• Spilled fluids must be removed immediately with an appropriate bonding agent.The bonding agent / consumable mixture must be disposed of in accordance withregulations.

4.5.2 Lift – Lower (Aux. Lift)

– Press the deadman button.

– Press the “Aux. lift” pushbutton (11)and simultaneously turn the hydrauliccontrol button (1):Left turn = Auxiliary Lift raise.Right turn = Auxiliary Lift lower.

Z The lift and lower speeds are inproportion to how far the hydrauliccontrol button (1) is turned.

1

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4.5.3 Traverse (LAM attachment)

– Press the deadman button.

– Press the “Attachment traverse”pushbutton (10) and simultaneouslyturn the hydraulic control button (1):Right turn = Traverse right.Left turn = Traverse left.

Z The traverse speed is in proportion tohow far the hydraulic control button (1)is turned.

4.5.4 Swivel / rotate (fork carriage)

– Press the deadman button.

– Press the “Fork carriage rotate”pushbutton (9) and simultaneouslyturn the hydraulic control button (1):Right turn = Swivel right.Left turn = Swivel left.

Z The swivel speed is in proportion tohow far the hydraulic control button (1) isturned.

1 10

1

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B4.5.5 Simultaneous lifting / lowering of Main and Aux. Lift

– Press the deadman button.

– Press the “Main and Aux. Liftraise / lower” pushbutton (13) onthe bottom of the travel controlhandle while simultaneouslyturning the hydraulic control button (1):Turn right = simultaneously lowerthe Main and Aux. Lift. Turn left = simultaneously raisethe Main and Aux. Lift.

Z You can stop the raising / lowering of the Auxiliary Lift by releasing the "Main and Aux.Lift raise / lower" pushbutton (13). Pressing the "Main and Aux. Lift raise / lower"pushbutton (13)" has no affect on Main Lift or diagonal travel.

Z The lift and lower speeds are in proportion to how far the hydraulic control button (1)is turned.

4.6 Simultaneous load handler traverse and fork carriage swivel

F Risk of trapping when swivelling or moving the forks.Make sure there is nobody present in the danger zone when carrying out swivel,traverse or synchronised rotate movements with the load handler. Stop the truck ifpeople do not leave the hazardous area. If people do not leave the hazardous areadespite the warning, prevent the truck from being used by unauthorised people.

Z If you move the attachment the fork carriage will swivel simultaneously. The rotatespeed cannot be changed. The traverse speed is in proportion to how far thehydraulic control button (1) is turned.

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4.6.1 Manual rotate / traverse (t)

– Press the pushbutton (24) below the“synchronised rotate menu change”symbol (96). The display changesfrom the menu item “Synchronisedrotate menu change” (96) to “Forksynchronised right/left rotate” (97, 98).

– Press the deadman button.

– Press the pushbutton (24) below the“Fork synchronised right rotate”symbol (97) while simultaneouslyturning the hydraulic control button (1). Rotate left = swivel fork carriage to theright and traverse load handler tothe left.

– Press the pushbutton (24) below the“Fork synchronised left rotate”symbol (98) while simultaneouslyturning the hydraulic control button (1):Rotate right = swivel fork carriage tothe left and traverse load handler tothe right.

4.6.2 Automatic rotate/traverse (o)

– Press the pushbutton (24) below the“synchronised rotate menu change”symbol (96). The display changes from the menu item “Synchronised rotate menuchange” (96) to “Fork synchronised right/left rotate” (97, 98).

– Press the deadman button.

– Touch the control panel hand rest (14) with your left hand.

– Press the pushbutton (24) below the “Synchronised fork right rotate” symbol (97):Swivel the fork carriage right swivel and load handler left traverse.

– Press the pushbutton (24) below the “Synchronised fork left rotate” symbol (98):Automatic fork carriage left swivel and load handler right traverse.

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B4.6.3 Synchronised rotate until forks are in centre position (o)

– Press the pushbutton (24) below the“synchronised rotate menu change”symbol (96). The display changesfrom the menu item “Synchronisedrotate menu change” (96) to“Synchronised rotate until forks incentre position” (99).

– Press the deadman button.

– Touch the control panel hand rest (14)with your left hand.

– Press the pushbutton (24) below the“Synchronised rotate until forks incentre position” symbol (99) = swivelfork carriage and traverse loadhandler in centre position.

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4.7 Telescopic table (o)

4.7.1 Telescopic table attachment traverse (o)

Z The extended limit position of the telescopic forks is limited both electrically andmechanically.

M No loads may be pushed or pressed with the telescopic forks.Raise and transport loads which are evenly distributed with both telescopic forks.

Z Maintenance intervals are listed in the operating instructions under “Maintenancechecklist – Telescopic table (o)” in chapter F.

– Press the deadman button.

– Press the “Telescopic forks attach-ment traverse” pushbutton (10) andsimultaneously turn the hydraulic con-trol button (1):Right turn = Traverse right.Left turn = Traverse left.

Z The telescopic table automatically stopsin the centre position. If you release thehydraulic control button (1) and press itagain, the telescopic table can then be moved either left or right.If the telescopic forks are not in the centre position, you can only travel, lift and lowerat reduced speed.

Z The traverse speed is in proportion to how far the hydraulic control button (1)is turned.

M The driver must check the condition and test the operation of the telescopic tableevery day.If the telescopic table is not in a proper condition, take the truck out of service andnotify the relevant customer service department.

• Report any defects immediately to your supervisor.

• Tag out and decommission a faulty lift truck.

• Only return the truck to service when you have identified and rectified the fault.

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B4.7.2 Telescopic table attachment fork adjuster (o)

M The fork spread must only be adjusted without load.No loads may be pushed or pressed with the telescopic forks.Raise and transport loads which are evenly distributed with both telescopic forks.

Z Maintenance intervals are listed in the operating instructions under “Maintenancechecklist – Telescopic table (o)” in chapter F.

– Press the deadman button.

– Press the pushbutton (24) below the“Telescopic fork adjuster” symbol (100)while simultaneously turning thehydraulic control button (1):Left turn = Traverse forks in drivedirection.Right turn = Traverse forks in loaddirection.

Z If the telescopic forks are not in thecentre position, you can only travel, liftand lower at reduced speed.

Z The traverse speed is in proportion to how far the hydraulic control button (1)is turned.

M The driver must check the condition and test the operation of the telescopic tableevery day.If the telescopic table is not in a proper condition, take the truck out of service andnotify the relevant customer service department.

• Report any defects immediately to your supervisor.

• Tag out and decommission a faulty lift truck.

• Only return the truck to service when you have identified and rectified the fault.

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4.7.3 Rotary telescopic table (o)

Z Maintenance intervals are listed in the operating instructions under “Maintenancechecklist – Telescopic table (o)” in chapter F.

M No loads may be pushed or pressed with the telescopic forks.Raise and transport loads which are evenly distributed with both telescopic forks.

Z The rotation of the rotary table is limited both electrically and mechanically.

– Press the deadman button.

– Press the “Fork carriage rotate”pushbutton (9) and simultaneouslyturn the hydraulic control button (1) toturn the rotary table in or out of thestockpicking position:Right turn = Turn telescopic table right.Left turn = Turn telescopic table left.

Z If the telescopic forks are not in thecentre position, you can only travel, liftand lower at reduced speed.

Z The rotation speed is in proportion to how far the hydraulic control button (1) is turned.

M The driver must check the condition and test the operation of the telescopic tableevery day.If the telescopic table is not in a proper condition, take the truck out of service andnotify the relevant customer service department.

• Report any defects immediately to your supervisor.

• Tag out and decommission a faulty lift truck.

• Only return the truck to service when you have identified and rectified the fault.

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BPallet lifting from the left

If a pallet is lifted from the left hand rackside, to enable stockpicking the rotarytable must be rotated 90° clockwise andextended in the direction of the cabin(stockpicking position)..

* Note the fork marking. The fork mustbe rotated in the corresponding directionbefore discharging a pallet.

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Pallet lifting from the right

If a pallet is lifted from the right hand rackside, to enable stockpicking the rotarytable must be rotated 90° anti-clockwiseand extended in the direction of thecabin (stockpicking position).

* Note the fork marking. The fork mustbe rotated in the corresponding directionbefore discharging a pallet.

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BRe-positioning (180°)

If a pallet is taken from one side of a rack, it can be repositioned by rotating the rotarytable 180°.

* Note the fork marking. The fork must be rotated in the appropriate direction beforedischarging a pallet.

Example: removing a pallet from the right.

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4.7.4 Telescopic table – forks individually moving (o)

Z Maintenance intervals are listed in the operating instructions under “Maintenancechecklist – Telescopic table (o)” in chapter F.

M No loads may be pushed or pressed with the telescopic forks.

– Press the deadman button.

– Press the “Telescopic forks attach-ment traverse” pushbutton (10) andsimultaneously turn the hydraulic con-trol button (1):Right turn = Traverse right.Left turn = Traverse left.

– Use the pushbuttons (24) to decidewhich forks can be traversed.

– A different telescopic fork can be se-lected by pressing the pushbutton (24)below the symbols (101, 102, 103).The choice of telescopic forks canonly be made if both telescopic forksare in the centre position. The display unit shows which telescopic forks can be se-lected and hence traversed.

F Always take into account the charge on the telescopic table when choosing thetelescopic forks.An individual telescopic fork must not be chosen when the load on the two telescopicforks is overlapping, i.e. when laden with a wire box.

Z The telescopic table automatically stops in the centre position. If you release thehydraulic control button (1) and press it again, the telescopic table can then be movedeither left or right.If the telescopic forks are not in the centre position, you can only travel, lift and lowerat reduced speed.

Z The traverse speed is in proportion to how far the hydraulic control button (1)is turned.

M The driver must check the condition and test the operation of the telescopic tableevery day.If the telescopic table is not in a proper condition, take the truck out of service andnotify the relevant customer service department.

• Report any defects immediately to your supervisor.

• Tag out and decommission a faulty lift truck.

• Only return the truck to service when you have identified and rectified the fault.

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B4.8 Symmetrical sideshifter (o)

– Press the deadman button.

– Press the pushbutton (24) below the“Fork sideshift” symbol (104) whilesimultaneously turning the hydrauliccontrol button (1): Left turn = Traverse forks in drivedirection.Right turn = Traverse forks in loaddirection.

Z The speed of movement is proportionalto the turn of hydraulic control button (1).

4.9 Fork adjuster (o)

Z Maintenance intervals are listed in the operating instructions under “Maintenancechecklist – Fork adjuster (o)” in chapter F.

– Press the deadman button.

– Press the pushbutton (24) below the“Fork adjuster” symbol (105) whilesimultaneously turning the hydrauliccontrol button (1). Turn left = increase the range.Turn right = reduce the range.

Z The forks cannot be adjusted individually.

M The fork spread can only be adjustedwithout load.

Z The speed of movement is proportional to the turn of hydraulic control button (1).

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4.10 Telescopic forks (o)

Z Telescopic forks are used to achieve a greater stacking depth (single telescopic forks)or double-deep storage (double telescopic forks on narrow aisle trucks).

4.10.1 Single telescopic forks (o)

Z Maintenance intervals are listed in the operating instructions under “Maintenancechecklist – Telescopic forks (o)” in chapter F.

– Press the deadman button.

– Press the “Attachment traverse”pushbutton (10) and simultaneouslyturn the hydraulic control button (1):Right turn = Traverse right.Left turn = Traverse left.

– If the attachment has been extendedas far as the limit position, the forkscan be extended further by pressingthe pushbutton (24) below the “singletelescopic fork” symbol (106) andsimultaneously turning the hydrauliccontrol button (1).Right turn = Extend further to the right.Left turn = Extend further to the left.

– The forks can be retracted to the home position by pressing the pushbutton (24)below the “single telescopic fork” symbol (106) and simultaneously turning thehydraulic control button (1). When the forks have been retracted, the attachmentcan be retracted to the home position by pressing the “Traverse attachment”pushbutton (10) and simultaneously turning the hydraulic control button (1).

Z The traverse speed is in proportion to how far the hydraulic control button (1)is turned.

4.10.2 Double telescopic forks (o)

Z Maintenance intervals are listed in the operating instructions under “Maintenancechecklist – Telescopic forks (o)” in chapter F.

– Press the deadman button.

– Press the “Attachment traverse” pushbutton (10) and simultaneously turn thehydraulic control button (1):Right turn = Traverse right.Left turn = Traverse left.

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B– After traversing to the limit position

press the pushbutton (24) under the“2nd stacking depth” symbol (107)(changes to the active mode).Press the “Attachment traverse”pushbutton (10) and simultaneouslyturn the hydraulic control button (1):Right turn = Extend further to the right.Left turn = Extend further to the left.

Version A “Retract forks, then movethe attachment back to the homeposition”:

– Press “2nd stacking depth”pushbutton (107) (changes to the active mode).

– Press the “Attachment traverse” pushbutton (10) and simultaneously turn thehydraulic control button (1):Right turn = Traverse right.Left turn = Traverse left.

– When the forks have been retracted press the pushbutton (24) under the “2ndstacking depth” symbol (107) (changes to the non active mode).

– The attachment can now be retracted to the home position by pressing the“Traverse attachment” pushbutton (10) and simultaneously turning the hydrauliccontrol button (1).

Z The traverse speed is in proportion to how far the hydraulic control button (1)is turned.

Version B “Move back the attachment, then retract the forks to thehome position”:

– Press the pushbutton (24) below the “2nd stacking depth” symbol (107). (changes to active mode).

– Press the “Attachment traverse” pushbutton (10) and by simultaneously turning thehydraulic control button (1) first retract the attachment and then the forks:Right turn = Traverse right.Left turn = Traverse left.

– Now press the pushbutton (24) below the “2nd stacking depth” symbol (107)(changes to the non-active mode).

Z The traverse speed is in proportion to how far the hydraulic control button (1)is turned.

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4.11 Symmetrical sideshift with integrated fork adjuster (o)

M The fork adjuster is used to extend the forks beyond the geometry of thesideshift frame.

F Due to the special design of the sideshifter with integrated fork adjuster, the operatormust ensure that the forks and sideshifter do not extend into the area of the operatorposition.To avoid injury to personnel and damage to the truck and load, trained operators musthandle the attachment with particular care.

Z Maintenance intervals are listed in the operating instructions under “Maintenancechecklist – Symmetrical/Asymetrical sideshift with integrated fork adjuster (o)” inchapter F.

Function

– Press the pushbutton (24) below the“Fork adjuster / sideshifter menuchange” symbol (108). The displaychanges from the menu item “Forkadjuster / sideshifter” (108) to the“Fork sideshift” (104) and “Forkadjuster, symmetrical” (105) functions.

– Press the deadman button.

– Press the pushbutton (24) below the“Fork sideshift” symbol (104) whilesimultaneously turning the hydrauliccontrol button (1). Left turn = Traverse forks in drivedirection.Right turn = Traverse forks in loaddirection.

– Press the pushbutton (24) below the“Fork adjuster” symbol (105) whilesimultaneously turning the hydrauliccontrol button (1): Turn left = increase the fork spread.Turn right = decrease the fork spread.

Z The forks cannot be adjusted individually.

M The fork spread can only be adjustedwithout load.

Z The speed of movement is proportional to how far the hydraulic control button (1)is turned.

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B4.12 Asymmetrical sideshifter with integrated fork adjuster (o)

Z Maintenance intervals are listed in the operating instructions under “Maintenancechecklist – Symmetrical / Asymetrical sideshifter with integrated fork adjuster (o)” inchapter F.

Home position right, forks swivelled to the left

Z The asymmetrical arrangement of the attachment enables the forks to be adjusted inthis position as far as the driver’s cab, for stockpicking.

F In this position the attachment / raised load can damage the operator position.Be careful when adjusting the sideshifter and fork adjuster.

Home position left, forks swivelled to the right

Z For transporting pallets up to 3.3 m long. The sideshifter and forks cannot be adjustedas far as the cab for stockpicking purposes.

Function

– Press the deadman button.

– Press the pushbutton (24) below the“Fork adjuster / sideshift menuchange” symbol (108). The displaychanges from the menu item “Forkadjuster / sideshifter” (108) to the“Fork sideshift” (104) and “Forkadjuster, symmetrical” (105) functions.

– Press the pushbutton (24) below the“Fork sideshift” symbol (104) whilesimultaneously turning the hydrauliccontrol button (1). Left turn = Traverse forks in drivedirection.Right turn = Traverse forks in loaddirection.

– Press the pushbutton (24) below the“Fork adjuster” symbol (105) whilesimultaneously turning the hydrauliccontrol button (1): Turn left = increase the fork spread.Turn right = decrease the fork spread.

Z The forks cannot be adjusted individually.

M The fork spread can only be adjusted without load.

Z The speed of movement is proportional to how far the hydraulic control button (1)is turned.

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4.13 Lifting - Lowering - Traversing - Pivoting inside the rack aisles

F Risk of trapping when traversing or rotating with the forks.Make sure there is nobody present in the danger zone when carrying out swivel,traverse or synchronised rotate movements with the load handler.

F Risk of accidents during lifting and loweringOther people can be injured in the truck's hazardous area.The hazardous area is defined as the area in which people are at risk from the truckmovement, the load handler, attachments etc. This also includes areas which can bereached by falling loads or lowering operating equipment.Apart from the operator (in the normal operating position) there should be no otherpeople in the truck's hazardous area.

• Instruct other people to move out of the hazardous area of the truck. Stop workingwith the truck if people do not leave the hazardous area.

• The truck must be prevented from being used by unauthorised people if people donot leave the hazardous area despite the warning.

• Only carry loads that have been secured and positioned in accordance withregulations. Use suitable precautions to prevent parts of the load from tipping orfalling down.

• Never exceed the maximum loads specified in the capacity chart.

• Never stand underneath a raised load handler / driver's cab.

• Do not stand on the load handler.

• Do not lift other people on the load handler.

• Never reach or climb into moving truck parts.

• The driver must not leave the operator position when it is raised –do not climb ontobuilding constructions or other trucks.

F Fall hazardWhen the gates are opened and the driver's cab raised, the operator risks falling outof the cab.

• Do not open the gate when the driver's cab is raised.

Z Lifting and lowering inside narrow aisles requires two-handed operation.Otherwise, operation is the same as for outside the aisles.

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B4.14 Order picking and stacking

F Unsecured and incorrectly positioned loads can cause accidentsBefore lifting a load unit the driver must make sure that it has been correctly palletisedand does not exceed the truck’s capacity.

• Instruct other people to move out of the hazardous area of the truck. Stop workingwith the truck if people do not leave the hazardous area.

• Only carry loads that have been correctly secured and positioned. Use suitableprecautions to prevent parts of the load from tipping or falling down.

• Damaged loads must not be transported.

• Never exceed the maximum loads specified in the capacity chart.

• Never stand underneath a raised load handler / driver's cab.

• Do not stand on the load handler.

• Do not lift other people on the load handler.

• Check the fork spread before lifting the load and adjust if necessary.

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

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4.14.1 Adjusting the forks

F Incorrect fork adjustment cancause accidentsTo lift the load securely, the forksmust be spread as far apart aspossible and positioned centrallywith respect to the fork carriage.The load centre of gravity must becentrally aligned between the forks.

F Unsecured forks can causeaccidentsCheck the stop retainer (113) ispresent. Do not operate the truck ifthe stop retainer is missing (113).

– Lift up the locking lever (110).

– Push the forks (111) into the correct position on the fork carriage (112).

– Apply the locking lever (110) down and move the forks (111) until the locking pinengages in a notch.

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B4.14.2 Replacing the forks

F Faulty forks can cause accidentsFaulty forks can cause the load to crash.

• Do not operate the truck with faulty forks.

• If one fork tine is damaged, both fork tines must be replaced.

• Report any defects immediately to your supervisor.

• Tag out faulty forks and withdraw them from use.

M Injury risk when replacing forksYou can injure your legs when replacing the forks.

• Wear safety shoes when replacing the forks.

• Always push the forks away from your body, never towards it.

• Secure heavy forks with lifting slings and a crane before pushing them down fromthe fork carriage.

• After replacing the forks fit the stop retainer and make sure it is seated correctly.

F Using two different forks can cause accidentsAssembling forks of different types will affect the stability of the truck.

• Use only the same type of fork that has been approved by the manufacturer.

• Always replace forks in pairs.

• The fork tine dimensions must match.

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Disassembling the forks

– Park the truck securely.

– Lower the mast.

– Raise the auxiliary lift slightly so that theforks are no longer touching the ground.

– Disassemble the stop retainer (113).

– Lift up the locking lever (110).

– Carefully push the forks (111) off the forkcarriage (112).

– The forks (111) are now dismantled fromthe fork carriage (112) and can bereplaced.

Assembling the forks

– Park the truck securely.

– Lower the mast.

– Raise the fork carriage so that the fork tine can be pushed onto the fork carriage.

– Disassemble the stop retainer (113).

– Carefully push the forks (111) onto the fork carriage (112).

– Adjust the forks (111), see "Adjusting the forks" in Chapter E.

– Apply the locking lever (110) down and move the forks (111) until the locking pinengages in a notch.

F Unsecured forks can cause accidentsCheck the stop retainer (113) is present. Do not operate the truck if the stop retaineris missing (113).

– Fit the stop retainer (113) and make sure it is secure.

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B4.15 Lifting, transporting and depositing loads

F Unsecured and incorrectly positioned loads can cause accidents Before lifting a load unit the driver must make sure that it has been correctly palletisedand does not exceed the truck’s capacity.

• Instruct other people to move out of the hazardous area of the truck. Stop workingwith the truck if people do not leave the hazardous area.

• Only carry loads that have been correctly secured and positioned. Use suitableprecautions to prevent parts of the load from tipping or falling down.

• Do not transport loads other than on the authorised load handler.

• Damaged loads must not be transported.

• If the stacked load obscures forward visibility, you must travel in reverse.

• Make sure you have enough visibility when reversing.

• Never exceed the maximum loads specified in the capacity chart.

• Never stand underneath a raised load handler.

• Do not stand on the load handler.

• Do not lift other people on the load handler.

• Do not reach through the mast.

• Check the fork spread before lifting the load and adjust if necessary.

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

F Ensure there are no other people standing underneath the raised load anddriver's cab.

• Do not stand on the load handler.

• Do not lift other people on the load handler.

• Instruct other people to move out of the hazardous area of the truck.

• Never stand underneath a raised and unsecured load handler / driver's cab.

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4.15.1 Lifting a load from the side (EKX only)

– Check the fork spread for the palletand adjust if necessary.

– Press the deadman button.

– Drive the truck carefully up to thestorage location

M The forks should be evenly laden.The weight of the load unit should notexceed the truck's capacity.

– Slowly insert the forks into the palletuntil the fork back touches the load orthe pallet.

Z The load unit must not extend by morethan 50 mm beyond the fork tips.

– Raise the load slightly until it restsfreely on the forks.

– Retract the forks.

M The ground surface must be in goodcondition to ensure this works correctly.

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B4.15.2 Lifting a load from the front

– Check the fork spread for the palletand adjust if necessary.

– Press the deadman button.

– Set the attachment to the centreposition and position the forks at rightangles (90°) to the truck.

– Raise or lower the load handler so thatthe forks can enter the pallet withoutstriking it.

M The forks should be evenly laden.The weight of the load unit should notexceed the truck's capacity.

– Slowly insert the forks into the palletuntil the fork shank touches the load orthe pallet.

Z The load unit must not extend by morethan 50 mm beyond the fork tips.

– Raise the load slightly until it restsfreely on the forks.

– Make sure you can see behind youand that you have sufficient space tomove. Now reverse the truck slowlyuntil the load is clear (e.g. out ofthe rack).

– Bring the load to the home position,(see “Attachment in Home position”section in Chapter E.)

M The ground surface must be in goodcondition to ensure this works correctly.

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4.15.3 Transporting loads

– Press the deadman button.

– Raise the load slightly.

Z Always transport a load outside the rackaisle as low as possible, allowing forground clearance.

– Always transport loads with both forks.When transporting heavy loadsalways ensure that both forks carrythe same weight.

– Accelerate gradually.

– Travel at a constant speed. Adaptyour travel speed to the conditions ofthe route and the load you aretransporting.

– Always be prepared to brake. Brakegently in normal circumstances. Onlystop suddenly in dangerous situations.

– Reduce speed accordingly on narrowbends.

– Watch out for other traffic at crossingsand passageways.

– Always travel with a lookout at blindspots.

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B4.15.4 Depositing loads

– Press the deadman button.

– Drive carefully up to the storagelocation.

M Before depositing a load, the driver mustensure that the storage location issuitable for storing the load (size andcapacity).

Z Loads must not be deposited on travel orescape routes, in front of safetymechanisms or operating equipmentthat must be accessible at all times.

– Raise the load handler so that the loadcan enter the storage location withoutstriking any objects.

– Carefully push / insert the load in itsstorage location.

– Carefully lower the load handler sothat the forks are clear of the load.

M Avoid placing the load down suddenlyto avoid damaging the load and theload aid.

– Make sure you can see behind youand that you have sufficient spaceto move.

– Carefully remove the load handlerfrom the load.

– Fully lower the load handler.

– If required, set the attachment to thehome (standard) position.

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4.16 Rack Height Select with Zone Entry (o)

To lift or deposit loads in pre-selected warehouse locations, the truck must beadapted to the warehouse setup. The work required to do this must only be performedby trained field engineers from the manufacturer's service department.

In addition to the current lift height, the following symbols are displayed:

Z A load sensor between the forks identifies if there is a load on the forks

Symbol

Function

AttachmentTelescopictable

Attachment or telescopic table in home position without load

Attachment or telescopic table in home position with load

Lower / raise attachment or telescopic table without load

Lower / raise attachment or telescopic table with load

Traverse attachment or telescopic table without load to the left / right

Traverse attachment or telescopic table with load to the left / right

Zone selection / area selection

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B4.16.1 Entering area recognition (zones)

– Press the “Select” pushbutton (78) inthe cursor field.

– The zones are entered via thenumerical keypad (25).

– If an incorrect entry is made it can bedeleted by pressing the “CE” push-button in the numerical keypad (25).

– After the zone has been entered,it must be stored by pressing the “OK”pushbutton in the numericalkeypad (25).

Z The selected zone is now shown in thedisplay unit above the “zone selection”symbol.

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4.16.2 Rack number entry (lift height)

– The zones are entered via the numerical keypad (25).

– After the rack number has been entered, it must be stored by pressing the “OK”pushbutton in the numerical keypad (25).

Z The rack number can be entered as a single digit (0 - 9) or a 2-digit number (00-64).For a 2-digit entry, the first number entered is used as a multiple of ten, the secondas a unit position.

– If an incorrect entry is made it can be deleted by pressing the “CE” pushbutton inthe numerical keypad (25).

Z The entered rack number is now shown in the display unit. Depending on the currentlift height, the nominal direction (Raise or Lower) is indicated with an arrow.

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B4.16.3 Raising or depositing a load in pre-selected warehouse locations with Rack

Height Select:

– Grab the hand rests (14) on the control panel (two-handed operation).

– Press the deadman button.

– Enter the respective narrow aisle.

– Enter the zone with the numerical keypad (25). see “Entering zone recognition” in chapter E.

– Enter the rack number with the numerical keypad (25), see “Rack number entry (lift height)” in chapter E.

– When the required rack number has been entered it can approached by turning thehydraulic control button (1) in the displayed direction.Right turn = lower. Left turn = lift.

– To approach the nominal height manually (t):

– The hydraulic control button (1) must be pressed and held down until therequired height has been reached (automatic stop).

Z The lift and lower speeds are in proportion to how far the hydraulic control button (1)is turned.

– If the rack number entered is not reached with Main Lift, use the Auxiliary Lift toreach the remaining height.

– To approach the nominal height automatically (o):

– Grab the hand rests (14) on the control panel (two-handed operation).

– Turn the travel control knob (12) to the left or right and hold it in position.The nominal height is then approached automatically in the optimum manner,depending on how far away the warehouse location is.

Z The truck movements can be stopped by releasing the travel control knob (12) or thehand rests (14) on the control panel, or by pressing the Emergency Disconnect switch.

Z The rack height entered is approached with the Main Lift. If the entered lift height cannot be positioned with the Main Lift extended orfully lowered, Auxiliary Lift is used to reach the remaining height.

Stacking operation:

General procedure:

– Retrieval: Extend - Raise - Retract

– Stacking: Extend - Rest - Lower - Retract

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The following variants are possible depending on the design:

Stackingprocedure not active

– Grab the hand rests in the control panel (two-handed operation).

– Press the deadman button.

– When the selected height is reached, the Rack Height Selectcommand disappears from the display unit.

– The operator can now start manual stacking and retrieval,see “Lifting – Lowering – Traversing – Swivelling outside rack aisles”,in Chapter E.

Stackingoperation not active with feedback to radio data transmissionterminal

– Grab the hand rests in the control panel (two-handed operation).

– Press the deadman button.

– Stacking / retrieval can be performed when the selected nominalheight has been reached.

– The operator can now start manual stacking and retrieval,see “Lifting – Lowering – Traversing – Swivelling outside rack aisles”,in Chapter E.

Z The message "Order processed" to the radio data transmissionterminal is only issued when the attachment has abandoned andreturned to the home position.

Manual stacking operation

– Grab the hand rests in the control panel (two-handed operation).

– Press the deadman button.

– Stacking / retrieval can be performed when the selected nominalheight has been reached.

– Stacking and unstacking are prescribed to the driver in the display unitvia the load sensor.

– The operator can now start manual stacking and retrieval,see “Lifting – Lowering – Traversing – Swivelling outside rack aisles”,in Chapter E.

– On reaching the respective limit position (traverse / lift height reached),the next stage can follow if the hydraulic control button (1) is in neutral.

Z All hydraulic speeds can be determined by the operator via thehydraulic control button (1).

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If during positioning another rack is selected, this is displayed for approx. 1 secondand stored in an intermediate log. At the end of the stacking operation the rack isautomatically taken from the intermediate log (this does not apply to the “Stacking notactive” variant).

Z Stacking can be cancelled by pressing the “CE” key in the numerical keypad (25).No "Order processed" message is sent to the radio data transmission terminal.

Automaticstacking operation with the hydraulic control button (1) (version A)

– Grab the hand rests in the control panel (two-handed operation).

– Press the deadman button.

– When the selected nominal height has been reached, throughout theentire stacking operation the direction must be applied and maintainedby the hydraulic control button (1) as follows:

– "Left" stacking operation = turn the hydraulic control button (1) tothe left.

– "Right" stacking operation = turn the hydraulic control button (1) tothe right.

Z All functions can be stopped by releasing the hydraulic controlbutton (1). The stacking operation continues when the hydrauliccontrol button (1) is pressed again.

Automaticstacking operation with the hydraulic control button (1) (version B)

– Grab the hand rests in the control panel (two-handed operation).

– Press the deadman button.

– When the selected nominal height has been reached, throughout theentire stacking operation the direction must be applied and maintainedby the hydraulic control button (1) as follows:

– "Left" stacking operation = turn the hydraulic control button (1) tothe left.

– "Right" stacking operation = turn the hydraulic control button (1) tothe right.

Z All functions can be stopped by releasing the hydraulic controlbutton (1). The stacking operation continues when the hydrauliccontrol button (1) is pressed again.

– Pressing one of the "Auxiliary Lift" (11), "Attachment traverse" (10) or"Fork carriage rotate" (9) pushbuttons cancels the automatic stackingoperation.

Z The driver is notified of this via an audible signal.

– After the cancellation the operator must carry out traversing, lifting andlowering manually, see "Manual stacking operation".

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The following symbols appear in thedisplay unit for “left” stacking operation:

Z When stacking, after the attachment has been extended there is an interval to reducemast vibration.All automatic stacking operations can be interrupted by releasing the two-handedoperation system.

F In an emergency, press the Emergency Disconnect (21).

SymbolManual stacking operation

Stacking Retrieval

– Grab the hand rests in the control panel (two-handed operation).

– Press the deadman button.

– Press the “Attachment traverse” pushbutton (10)and simultaneously turn the hydraulic controlbutton (1) to the left.

– Rest time active.

– Grab the hand rests in the control panel(two-handed operation).

– Press the deadman button.

– Turn the hydraulic control button (1):- left = lift (retrieve)- right = lower (stack)

– Grab the hand rests in the control panel(two-handed operation).

– Press the deadman button.

– Press the “Attachment traverse” pushbutton (10)and simultaneously turn the hydraulic controlbutton (1) to the right.

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B4.17 Horizontal positioning (o)

The truck is equipped with the “Horizontal Positioning (HozPos)” function.This function supports the owner in positioning (automatic, direct targeted positioningof the pallet location) the truck in the rack and at the transfer station. In conjunctionwith the integrated rack height select with programmable fork cycles, this providesconsistent depositing and lifting of the load in the rack and at transfer stations withvery few monitored deviations.

The degree of positioning is:

– for marker detection (vertically) 5 mm and (horizontally) 12 mm.

– for warehouse navigation (vertically) 5 mm and (horizontally) 100 mm.

"Horizontal Positioning (HozPos)" offers programmable warehouse conditions.

To achieve constant insertion widths over the entire lift height, ten height-dependenttraverse adjustment values can be programmed as an option.

The aisle and fork positions are checked on entry to the aisle.

Options

– Manual targeted entry via cursor keys and via the numerical keypad.

– Targeted entry via barcode scanner on the control panel or load handler.

– Targeted entry via radio connection.

– Adjustable fork cycle (manual, function-related or automatic).

– Extension locking during travel without target or incorrect target.

Z Maintenance intervals are listed in the operating instructions under “Maintenancechecklist – Horizontal positioning (o)” in chapter F.

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4.17.1 Warehouse and stockpicking mode (o)

Z Optionally it is possible to toggle between warehouse and stockpicking mode.

Warehouse mode:

– In warehouse mode pallets can be stacked and retrieved, see "Lifting – Lowering –Traversing – Swivelling outside rack aisles”, in chapter E.

– The vertical position of the warehouse location entered is the height of the forks.This ensures that the required pallet is stacked or retrieved.

– The horizontal position of the warehouse location entered is the centre of the loadhandler. This ensures that the required pallet is stacked or retrieved.

Stockpicking mode:

– In stockpicking mode articles can be gathered together.

– The vertical position of the warehouse location entered is the picking height(raised operator height +1600 mm). This ensures that the required articles canbe picked.

– The horizontal position of the warehouse location entered is the centre of thedriver's cab. This ensures that the required articles can be picked.

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BChanging between warehouse and picking mode

– Press the “Select” pushbutton (78) inthe cursor field.

Z The display unit shows the "Warehouseor stockpicking mode" symbol (114).

– To change between warehouse andstockpicking mode press thepushbutton (24) below the"Warehouse or stockpicking mode"symbol (114).

– Warehouse mode = "Warehouseor stockpicking mode"symbol (114) has a darkbackground

– Stockpicking mode = "Warehouseor stockpicking mode"symbol (114) has a lightbackground

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4.17.2 Horizontal positioning symbols in the display unit

The following symbols are displayed along with the lift height:

Z The position of the symbols (118-124, 128, 129, 131, 132b) can be adapted tocustomer requirements. In this case the positions must then be entered so as tomatch the symbol display

Item Symbol Function / Description

115 “Travel in drive direction” symbol

116 “Travel in load direction” symbol

117 “Truck horizontally positioned” symbol

118Lightning symbol, see “Horizontal positioning error description”

119Warning symbol, see “Horizontal positioning error description”

120Question mark symbol, see “Horizontal positioning error description”

121 Rack row display, only single digit entry allowed

122Zone selection / area selectionZone display = different lift heights, only single digit entry allowed

123Position (mark) display, horizontal position in narrow aisle; single, double or three digit entries allowed

124Rack (height), rack display = lift height vertical position in aisle; single or double digit entries allowed

125Fork warning symbol, see “Horizontal positioning error description”

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125, 126,

128, 129131, 132b

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126 Turn fork right warning symbol

127 Turn fork left warning symbol

128 Area display from 0 to 8

129 Area display from A to H

130 Truck in narrow aisle / transponder recognised

131“Light button on reflector” symbol, indicates whether the position entered has been reached

132a

The “lower” or “lift” symbols indicate that vertical adjustment runs are required

132b

The "Order in memory" symbol indicates that in addition to the current order there is another order in the truck's memory

Item Symbol Function / Description

!

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Horizontal positioning error description

Item ErrorCorrection measure /Display

115 / 116

Truck has entered the wrong aisle.

Drive out of the aisle. Travel direction symbol flashing.

118 / 123

Reflex marker reached: Wrong position in aisle (marker identified without having read the corresponding transponder)

Aisle start, end or centre transponder must be passed over. Pallet location / marker and lightning symbol flash alternately.

Reflex marker not recognised, tolerance level exceeded

119 No load when unstackingStacking operation carried out as far as home position. Warning symbol lit.

119 Incorrect checksum on data entry

Order cannot be performed, re-enter data or amend order.Total symbol / warning symbol flash alternately until total key is pressed again or the order is cancelled.

120 / 121

Incorrect rack row entered with order

Check entry.Question mark / rack row symbols flash alternately.

120 / 123

Incorrect location details entered with order

Check entry.Question mark and location (marker) symbols flash alternately.

120 / 124

Incorrect rack details entered with order

Check entry.Question mark / rack (height) symbols flash alternately.

125

Forks are not in home position for the order entry

Set the attachment / forks to the home position shown.Load handler symbol / warning symbol flash alternately every 5 seconds

Wrong direction pressed for stacking

Apply the required direction.The load handler symbol flashes as long as the wrong direction is indicated.

125 / 126 / 127

Forks are not in the correct position for the stacking operation requested (error in stacking operation)

Turn forks in the direction displayed. Load handler symbol / rotation symbol flash until the correct position is reached.

--Orders cannot be entered as there is already an order in the memory.

Entry blocked.

-- Faulty data transmissionOrder not accepted. The error number is issued.

--Data transmission not repeated despite error recognition (NAK)

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B4.17.3 Horizontal positioning destination input

(manual / via barcode scanner / via data radio transmission)

Z The destination input selection can beadapted to customer requirements.

– Manual destination input: the required target is manuallyentered and confirmed.

– Destination input with barcodescanner:the target position is scanned in witha barcode scanner.

– Destination input via radio: the target is transmitted to the truckvia radio transmission.

Z A maximum of two orders can be storedin the truck’s memory.

– When the current order has beenprocessed it is deleted from thedisplay unit and the order stored in the memory is moved into the display.

– A displayed order can be deleted by pressing the “CE” pushbutton twice in thenumerical keypad (25).

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Manual target entry (default setting):

Z The position of the symbols can be adapted to customer requirements. In this casethe positions must then be entered so as to match the symbol display!

– Press the “Select” pushbutton (78) inthe cursor field.

– The “rack row” field (121) has a BLUEbackground.

– Using the numerical keypad (25)enter the rack row.

Z Only single digit entries are allowed inthe “rack row” field (121).

– Press the cursor key (75).

Z The operator can toggle betweenthe input fields using the cursorkeys (75, 77):Cursor key (75): One input field forward Cursor key (77): One input field back.

– The “position (marker)” field (123) hasa BLUE background.

– Enter the required location (marker)via the numerical keypad (25).

Z The entry in the “position (marker)” field (123) can be one, two or three-digit.

– Press the cursor key (75).

– The “rack (height)” field (124) has a BLUE background.

– Enter the required compartment (height) via the numerical keypad (25).

Z The entry in the “rack (height)” field (124) can be one or two-digit.

– Press the cursor key (75).

– The “zone selection / area selection” field (122) has a BLUE background.

– Enter the required zone / area via the numerical keypad (25).

Z Only single digit entries are allowed in the “zone selection / area selection” field (122).

– Confirm the entry of all required locations with the “OK” pushbutton in the numericalkeypad (25).

Z A maximum of 2 orders can be stored in the truck’s memory.

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BDestination input with barcode scanner

– Scan in the label with the barcode scanner.

– The target stored on the label is directly transmitted to the display unit anddisplayed.

Z A maximum of two orders can be storedin the truck’s memory.The destination entered first is shownon the driver's display as the currentorder. The second destination scannedin is stored in the truck’s memory.The "order in memory" symbol (132b) isdisplayed.

– When the current order has beenprocessed it is deleted from thedisplay unit and the order stored inthe memory is moved into the display.

– A second target can then be accepted via the barcode scanner.

Z Destinations can be inputted manually if the barcode scanner fails.

Destination input via data radio transmission

– The destination transmitted via data radio from the data terminal is received by thetruck and transmitted directly to the display unit and displayed.

– Destination input via the radio terminal is now complete. The destination can nowbe approached.

– When the current order has been performed this order is deleted from thedisplay unit.

– The truck sends a message back to the data terminal.

– Another destination can then be transmitted via the data terminal and displayed.

– Another destination can then be transmitted via radio and accepted.

– A displayed order can be deleted by pressing the “CE” key twice in the numericalkeypad.

Z Destinations can be inputted manually if the data radio fails.

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4.17.4 Stacking / retrieval after target entry

Z When the destination has been inputted, the destination can be approached. See "Negotiating narrow aisles" and "Diagonal travel" in chapter E)

Automatic horizontal and manualvertical destination approach (t)

– Grab the hand rests (14) on thecontrol panel (two-handed operation).

– Press the deadman button.

– Drive the truck into the chosen aisle.

Z An incorrect aisle will be displayed andentry will be prohibited.

– The attachment must be in the correctposition. Check the display. If neces-sary push / turn the attachment to thecorrect home position.

– Slowly turn the travel control knob (12) with your right thumb.

– Turn right = Travel in load direction

– Turn left = Travel in drive direction

– You can control the travel speed by continuing to turn or by retracting the travelcontrol knob (12)

– When you have reached the horizontal destination position the "Truck horizontallypositioned" symbol (117) is shown in the display unit and the truck stops.

Z For marker detection the display unit also shows the "Light button on reflector"symbol (131).

– Turn the hydraulic control button (1):

– Right = Main Lift lower

– Left = Main Lift raise

– Press the “Auxiliary lift” pushbutton and simultaneously turn the hydraulic controlbutton (1):

– Right = Auxiliary Lift lower

– Left = Auxiliary Lift raise

Z Horizontal adjustment runs are shown in the display unitthrough the “travel in drive direction” (115) and “travel in loaddirection” (116) symbols. Vertical adjustment runs (height inrack) are shown through the “lower” and “lift” (132a) symbols.

– When the horizontal and vertical positions have beenreached, stacking/retrieval can begin, see also “Raising ordepositing a load in pre-selected warehouse locations withRack Height Select” in chapter E.

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BAutomatic horizontal and verticaldestination approach (o)

– Grab the hand rests (14) on thecontrol panel (two-handed operation).

– Press the deadman button.

– Drive the truck into the chosen aisle.

Z An incorrect aisle will be displayed andentry will be prohibited.

– The attachment must be in the correctposition. Check the display. If neces-sary push / turn the attachment to thecorrect home position.

– Turn the travel control knob (12) to the left or right and hold it in position.

– The truck starts its automatic horizontal and vertical destination approach.

Z The truck movements can be stopped by releasing the travel control knob (12) orthe hand rests (14) on the control panel, or by pressing the Emergency Disconnectswitch.

– On reaching the warehouse location:

– the "Truck horizontally positioned" symbol (269) is shown in the display unit.

– the truck stops.

– lifting / lowering stop automatically.

– the "Lift" or "Lower" symbols (132a) fade out.

Z For marker detection the display unit also shows the "Light button on reflector"symbol (131).

– When the horizontal and vertical positions have been reached, stacking/retrievalcan begin, see also “Raising or depositing a load in pre-selected warehouselocations with Rack Height Select” in chapter E.

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4.17.5 Warehouse or stockpicking mode symbols

The following symbols (41) are shown in the display unit:

Symbols in warehouse mode with attachment

Z A load sensor between the forks detects whether there is a load on the forks.

Symbol Function

Attachment in home position without load / with load

Without load, lower / lift to reach the warehouse location

With load, lower / lift to reach the warehouse location

Without load, traverse the attachment to the left / right

With load, traverse the attachment to the left / right

Rest time without / with load

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BSymbols in warehouse mode with telescopic table

Z A load sensor between the forks detects whether there is a load on the forks.

Symbol Function

Telescopic table in home position without load / with load

Without load, lower / lift to reach the warehouse location

With load, lower / lift to reach the warehouse location

Without load, traverse the telescopic table to the left / right

With load, traverse the telescopic table to the left / right

Rest time without / with load

Telescopic table in home position without load / with load

The telescopic table can be extended to the left / right

Without load, traverse the telescopic table to the left / right into the second stacking depth, see "Double telescopic forks (o)" in chapter E

With load, traverse the telescopic table to the left / right into the second stacking depth, see "Double telescopic forks (o)" in chapter E

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Symbols in stockpicking mode

4.17.6 Picking direction position lamp (o)

On reaching the warehouse location the position lamps on the driver's cab illuminatethe warehouse location. The operator can start to pick goods in the illuminated area.

Symbol Function

Stockpicking mode active

Lower / lift to reach the warehouse location

Remove articles from the left / right warehouse location

Adjustment run display to reach the warehouse location

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B4.18 Parking the truck securely

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

F Do not park the truck on an incline. In special cases the truck may need to be securedwith wedges.Select a parking place where nobody will get caught on the lowered forks.

– Always park the truck with the mast (Main and Aux. Lift) fully lowered.

– Lower the forks to the ground.

– Set the attachment to the home (standard) position.

– Turn the truck off with the key switch (20) and remove the key.

4.18.1 Set the attachment to the home position (EKX only)

– Press the deadman button.

– Traverse the attachment (133) to the right or left limit position of the sideshiftframe (136).

– Turn the forks (135) parallel to the sideshift frame (136).

– The display unit now shows the symbol for “Attachment in home position” (134).

136

20

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133

135

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5 Troubleshooting

This chapter enables the user to identify and rectify basic faults and the effects ofincorrect operation. When trying to locate a fault, proceed in the order shown inthe table.

Fault Possible Cause ActionTruck does not start

– Battery connector not plugged in

– Check battery connector and insert if necessary.

– Gates open – Close the gates– Emergency

Disconnect pressed.– Unlock the Emergency Disconnect

– Key switch in “0” position

– Set key switch to “I”

– Battery charge too low – Check battery charge, charge battery if necessary

– Deadman button not pressed

– Press deadman button

– Faulty fuse – Check fuses– Travel cutout

activated– Press travel cutout override pushbutton

(charge battery)– Travel cutout

activated via end of aisle safety device

– Set the travel control knob to neutral and press it again.

– Chains slack – See “Slack Chain Safety Device Override” section in chapter E

Load cannot be lifted

– Truck not operational – Carry out all measures listed under “Truck does not start”.

– Battery charge too low, lift cutout

– Check battery charge, charge battery if necessary

– Insufficient hydraulic oil

– Check hydraulic oil, top up if necessary

– Chains slack – See “Slack Chain Safety Device Override” section in chapter E

– Faulty fuse – Check fuses

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Rapid travel disabled

– Load handler not in home position

– Push load handler into home position

– Main Lift / Aux. Lift raised above 0.5 m

– Lower Main Lift / Aux. Lift below 0.5 m

– WG search mode activated

– No reference run performed

– Align truck or turn off WG mode

– Perform lifting and lowering

Truck cannot be steered

– Truck not operational – Carry out all measures listed under “Truck does not start”.

– Narrow aisle mode switch pressed

– Switch off narrow aisle travel function

I 1901 – Travel control button pressed during power-up test

– Do not apply travel control button, switch truck on and off again

I 2902 – Hydraulic control button applied during power-up test

– Do not apply travel control button, switch truck on and off again

I 3670 – Truck has abandoned the guide wire

– Restore wire guidance(see "Wire guidance emergency mode (event message I 3670 / I 3752)" in chapter E).

I 3752 – Truck has abandoned the guide wire

– Restore wire guidance(see "Wire guidance emergency mode (event message I 3670 / I 3752)" in chapter E).

I 4916 – A pushbutton below the display unit and /or a pushbutton on the numerical keypad pressed during the power up test

– Do not press pushbutton, switch truck on and off again

Fault Possible Cause Action

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Z If, after carrying out the remedial action, the truck cannot be restored to operation orif a fault in the electronics system is displayed with an error code, contact themanufacturer’s service department. Further remedial work should only be carried out by the manufacturer’s trainedservice personnel. The manufacturer has a customer service department speciallytrained for these tasks. In order for customer services to respond quickly and specifically to the fault,the following information is essential:

- Truck serial number- Error number on the display unit (if applicable)- Error description- Current location of truck.

I 4917 – A pushbutton / function pre-select button (switch guidance on/off, Aux. Lift raise /lower, fork carriage rotate, traverse attachment) pressed during power up test

– Do not press the pushbutton / function pre-select button (switch guidance on/off, Aux. Lift raise / lower, fork carriage rotate, traverse attachment), switch the truck off and on again.

I 4918 – Deadman button pressed during power-up test

– Do not press the deadman button, switch truck off and on again

E 9963 – Front screen of Personal Protection System (PPS) laser scanner dirty

– Front screen of Personal Protection System (PPS) laser scanner dirty, clean

E 9901 – The Personal Protection System cycle test does not have to be performed.

– Carry out a cycle test on the Personal Protection System, see “Daily Checks before starting the Personal Protection System” in chapter E

Fault Possible Cause Action

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B5.1 Emergency stop device

When the automatic emergency stop device applies (e.g. if the wire guidance is lost,electrical steering fails) the truck brakes to a halt. Before starting again, the cause ofthe error must be identified and corrected. Start the truck again in accordance withmanufacturer’s instructions contained in these operating instructions (see “Startingup the Truck” in Chapter E).

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5.2 Driver’s cab / Aux. Lift emergency lowering

F Automatic lowering can cause accidentsIf the load handler is in the rack emergency lowering must not be performed. Due toleakage from the hydraulic system there is also the risk that the rack could bedamaged by the load handler lowering.

• Prevent the load handler from lowering further, e.g. with strong chains.

• Report any defects immediately to your supervisor.

• Arrange for trained personnel to recover the truck as soon as possible.

• Tag out and decommission a faulty lift truck.

• Only return the truck to service when you have identified and rectified the fault.

F Accident risk during emergency loweringWhen using emergency lowering, make sure that there is no one present in thedanger zone. If a second person is used to lower the load handler via the emergencylowering device, this person must consult with the driver. Both people must be in asafe area to avoid danger. Emergency lowering of the driver’s cab is prohibited whenthe load handler is in the rack.

• Set the attachment to the home position, see “Attachment in Home Position” inchapter E.

• Report any defects immediately to your supervisor.

• Tag out and decommission a faulty lift truck.

• Only return the truck to service when you have identified and rectified the fault.

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BIf necessary, a second person can be deployed to lower the cabin from the ground.

– Remove the Allen key (138) from the bracket in the centre below the strobe.

– Insert the Allen key (138) into the hole to the left below the strobe.

F Trapping risk during emergency loweringWhen an emergency lowering of the driver's cab is being performed, there isa trapping risk to the driver in the cab.

• Keep the whole of your body inside the cab.

– Using the Allen key (138):

– Turn the drain valve (137) slowly anti-clockwise:The mast / driver's cab lower.

– Turn the drain valve clockwise as far as it will go:Lowering is stopped.

F The truck may only be started again once the error has been localised and rectified.

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5.3 Slack chain safety device override

Z The slack chain safety device applies when a chain is not tensioned, or slack.For example, a chain can become slack when the load handler or the cab areattached, when the chain is loosened and/or breaks.

Raising the Main Lift when the slackchain device device is activated

Z “Main Lift lower” is disabled when theslack chain safety device is activated.

– Press the deadman button.

– Press and hold down on thepushbutton (24) below the "slackchain safety device override"symbol (145).

– Turn the hydraulic control button (1) tothe left.

– Raise the Main Lift slightly(approx. 0.25 m) until the "slack chain safety device override" symbol (145) is nolonger displayed.

– If necessary set the attachment to the home position (see “Attachment in Homeposition” section in Chapter E).

F If the "slack chain safety device override" symbol does not disappear after theMain Lift has been raised approx. 0.25m, the truck can only be started again whenthe fault has been identified and rectified.

• Report any defects immediately to your supervisor.

• Tag out and decommission a faulty lift truck.

• Only return the truck to service when you have identified and rectified the fault.

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B5.4 Travel cutout override (o)

Z The “travel cutout override” symbol (146) is illuminated in the driver's displaywhenever further travel is inhibited beyond a certain lift height or area. If however theposition of the truck needs to be adjusted with respect to the rack in order to stack orretrieve a load, proceed as follows:

F The truck can cause accidentsTravel cutout is an additional function designed to support the operator, but whichdoes not release him from any responsibility, e.g. to monitor braking at the aisle endand if necessary to apply the brakes.

Operating the truck in the event of atravel cutout

– Press the deadman button.

– Press and hold down on thepushbutton (24) below the "travelcutout override" symbol (146).

– Turn the travel control knob (12)slowly to the right:Travel in load direction.

– Turn the travel control knob (12)slowly to the left:Travel in drive direction.

– The truck can now move at crawlspeed.

Z When you have pressed the pushbutton (24) below the override symbol, varioustravel / hydraulic speeds and directions can be released. The override functions canbe adjusted by the manufacturer's customer service department.

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5.5 Lift cutout override (o)

Z If local conditions require, an automatic lift cutout can be installed to be activated froma given lift height. The automatic lift cutout, which is active from a fixed height,prevents the Main and Auxiliary Lifts from raising. The driver's display shows the"lift cutout override" symbol (149).

M An extended mast can cause accidentsThe lift cutout is an auxiliary function designed to support the operator which howeverdoes not release him from his responsibility to stop hydraulic operations e.g. whenconfronted with an obstacle.

Z The lift cutout only takes effect when referencing has been carried out(see “Referencing the Main and Auxiliary Lift” in chapter E). When referencing hasbeen completed, the height actual value is shown in the driver's display.

F Accident riskIf the lift cutout is deactivated, the driver must pay particular attention to obstacleswhen the mast is extended.

Lift cutout override

– Press the deadman button.

– Press and hold down on thepushbutton (24) below the "lift cutoutoverride" symbol (147).

– Turn the hydraulic control button (1) tothe left.

– The Main or auxiliary lift is raised. Liftcutout is deactivated.

Z The lift cutout is re-activated each timethe mast falls below the lift limit height.

Z When you have pressed thepushbutton (24) below the override symbol, various travel / hydraulic speeds anddirections can be released. The override functions can be adjusted by themanufacturer's customer service department.

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B5.6 Lower cutout override (o)

If local conditions require, an automatic lower cutout can be installed to be activatedfrom a given height. The automatic lower cutout, which is active from a fixed height,prevents the Main and Auxiliary Lifts from lowering. The driver's display shows the"lower cutout override" symbol (148).

M Risk of injury when the driver’s cab or load handler are loweredThe lower cutout is an auxiliary function designed to support the operator whichhowever does not release him from his responsibility to stop hydraulic operationse.g. when confronted with an obstacle.

Z The lower cutout only takes effect when referencing has been carried out(see “Referencing the Main and Auxiliary Lift” in chapter E). When referencing hasbeen completed, the height actual value is shown in the driver's display.

F Accident riskIf the lower cutout is deactivated, the driver must pay particular attention to obstacleswhen the driver's cab or load handler are lowered.

Lower cutout override

– Press the deadman button.

– Press and hold down on the pushbut-ton (24) below the "lower cutout over-ride" symbol (148).

– Turn the hydraulic control button (1) tothe right.

– The Main or auxiliary lift is lowered.The lower cutout is deactivated.

Z The lower cutout is re-activated eachtime the mast is raised above the lowercutout height.

Z When you have pressed the pushbutton (24) below the override symbol, varioustravel / hydraulic speeds and directions can be released. The override functions canbe adjusted by the manufacturer's customer service department.

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5.7 Aisle end safety device (o)

Trucks with the end of aisle safety device brake before the aisle exit or in the transferaisle. There are two basic versions for this:

1. Braking to a halt

2. Braking to 2.5 km/h

Other variants (affecting the subsequent travel speed, lift height etc.) are available.

F A truck without brakes can cause accidentsEnd of aisle safety braking is an additional function designed to support the operator,but which does not release him from his responsibilities such as to monitor braking atthe aisle end and if necessary to apply the brakes.

1. Braking to a halt:

When the truck passes over the aisle end safety devices (RFID, magnets,reflex markers) in the direction of the end of the aisle, it comes to a halt.

M The stopping distance depends on the travel speed.

To continue travelling:

– Briefly release the travel control knob and then apply it again.

The truck can be driven out of the narrow aisle at max. 2.5 km/h.

2. Braking to 2.5 km/h

When the truck passes over the aisle end safety devices (RFID, magnets,reflex markers) in the direction of the end of the aisle, it brakes to 2.5 km/h and canbe driven out of the narrow aisle at this speed.

M The stopping distance depends on the travel speed.

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B5.8 Wire guidance emergency mode (event messages I 3670 / I 3752)

In a wire guidance system if the truck's antenna extends beyond the pre-determined range of the guide wire, an emergency stop is immediatelyinduced. The display flashes the "wire guidance fault" symbol and displaysthe event messages "I 3670" and "I 3752".

Z If in addition to the "wire guidance fault" symbol the "screwdriver" symbol is also lit,this indicates that other faults have occurred apart from the wire guidance fault.The resulting event messages and / or information messages are shown on thedriver's display.

If the truck is travelling parallel to the guide wire, travel is not disabled.The “Acquisition in progress” display and the audible alignment signal howeverremain permanently on, warning the driver.

Automatic Emergency Stop

If during operation one of the monitors for steering control, steering system,wire guidance, the safety cutout for the traction electronic system or the powerelectronic system applies, the truck safety devices will cause the truck to stop.

To enable the truck to travel again after an Emergency Stop, carry out the following:

Z The display flashes the "wire guidance fault" symbol and displays the eventmessages "I 3670" and "I 3752".

– Determine the possible cause of the Emergency Stop and rectify it.

– Turn the Emergency Disconnect to unlock it.

Z In the driver's display the "wire guidance fault" symbol and event messages "I 3670"and "I 3752" disappear.

– Switch the automatic guidance system back on, see "Negotiating narrow aisles withwire-guided trucks (o)" in chapter E.

– Press the “switch guidance on/off” button.

– Apply the travel control knob and carefully align the truck with the guide wire.

Z The truck is now operational and aligned with the guide wire.

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Z If you cannot start the truck again after an automatic Emergency Stop, despite havingrectified the problem, turn the key switch off and on again.Carry out a mast reference operation (see “Referencing the Main and Auxiliary Lift”in Chapter E) and perform the above points.The truck is now operational again.

Z When the truck is operational again, test it with both manual steering (outside theaisle) and automatic guided steering.

Manual Emergency Stop

A manual Emergency Stop is induced when the Emergency Stop button is pressed.The truck is operational again when the Emergency Stop has been released.

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B5.9 Recovering the truck from a narrow aisle / Moving the truck without a battery

F This operation must only be performed by suitably trained maintenance personnel.When the brakes are de-activated the truck must be parked on a level surface,since the brakes are no longer effective.

M If the brakes are not working, place wedges underneath the wheels of the truck toprevent it from moving.

– Set the attachment to the home (standard) position.See “Attachment in Home Position” in Chapter E.

– Fully lower the mast (Main and auxiliary lift).

F Before recovering the truck from a narrow aisle, disconnect the battery.

Z Obtain assistance from another person. The other person must be trained andfamiliar with recovery operations.

To recover the truck from the narrow aisle, the drive wheel brake and the load wheelbrake must first be released.

M When using the truck again, check its deceleration rate.

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5.9.1 Releasing and applying the drive wheel brake

F Uncontrolled truck movementWhen the brakes are de-activated the truck must be parked on a level surface,since the brakes are no longer effective.

• Do not release the brake on slopes or inclines.

• Apply the brake again when you reach your destination.

• Do not park the truck with the brake released.

Releasing the drive wheel brake

– Switch off the truck with the key switch.

– Press the Emergency Disconnect.

– Disconnect the battery.

– Remove the drive compartment panel, see "Drive panel disassembly / assembly"in chapter F.

– Disassemble the setscrews (150) from the bracket (151) above the magneticbrake (153).

– Insert the setscrews (150) into the magnetic brake (153) above the drivemotor (154) and tighten them with the hex. nut to release the magnetic brake (153).

– The magnetic brake (153) is now released.

150

150

154

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BActivating the drive wheel brake

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

• Always park the truck on a level surface. In special cases the truck may need to besecured with wedges.

• Always fully lower the mast and forks.

• Select a place to park where no other people are at risk of injury fromlowering forks.

M If the brakes are not working, place wedges underneath the wheels of the truck toprevent it from moving.

– Use wedges to prevent the truck from moving.

– Remove the setscrews (150) from the magnetic brake (153).

– Attach the setscrews (150) to the bracket (151) above the magnetic brake (153).

– Remove the drive compartment panel, see "Drive panel disassembly / assembly"in chapter F.

– The drive wheel brake can now be applied without current.

M When using the truck again, check its deceleration rate.

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5.9.2 Releasing and applying the load wheel brake

F Uncontrolled truck movementWhen the brakes are de-activated the truck must be parked on a level surface,since the brakes are no longer effective.

• Do not release the brake on slopes or inclines.

• Apply the brake again when you reach your destination.

• Do not park the truck with the brake released.

Releasing the load wheel brake

– Switch off the truck with the key switch.

– Press the Emergency Disconnect.

– Disconnect the battery.

– Disassemble the wheel cover (159) by unscrewing three hex. bolts per loadwheel (158).

Z The load wheel (158) has five notches (157) which are arranged so that for eachposition of the load wheel (158) at least three out of nine possible thread holes (156)can be accessed by the load wheel brake.

– Loosen the twist grip screws (52) below the driver's seat (51).

– Tilt the driver’s seat (51) forward carefully.

– Remove the setscrews from the storage compartment (155) behind the driver'sseat (51).

Z For each load wheel (158), screw in three setscrews with an angle offset of 120°loosely into the thread holes (156) of the load wheel brake.

– Insert the setscrews loosely into the thread holes (156) of the load wheel brake andtighten them by no more than half a turn.

– The load wheel brake is now released.

51

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BApplying the load wheel brake

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

• Always park the truck on a level surface. In special cases the truck may need to besecured with wedges.

• Always fully lower the mast and forks.

• Select a place to park where no other people are at risk of injury fromlowering forks.

M If the brakes are not working, place wedges underneath the wheels of the truck toprevent it from moving.

– Use wedges to prevent the truck from moving.

– Remove the setscrews from the thread holes (156) of the load wheel brake.

– Store the setscrews in the storage compartment (155) behind the driver's seat (51).

– Tilt the driver's seat (51) back and attach it to the driver's cab with the twist gripscrews (52).

– Fit the wheel guard (159).

– The load wheel brake can now be applied without current.

M When using the truck again, check its deceleration rate.

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5.9.3 Steering the truck without its own drive system

M The truck may not be able to besteered if the steering system isdamaged.

F The battery must be disconnectedwhen adjusting the steering angle.

– Remove the drive compartmentpanel, see "Drive panel disas-sembly / assembly" in chapter F.

– Using an Allen key set thesteered wheel to the requireddirection via the screw in thesteer motor (160).

Z When setting an angle greaterthan 4 degrees it is advisable todischarge the wheel by raising /jacking up the truck.

F The truck may only be startedagain once the error has beenlocalised and rectified.

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B5.9.4 EKX - Recovery in load direction

– Set the attachment to the home (standard) position.See “Attachment in Home Position” in Chapter E.

– Fully lower the mast (Main and auxiliary lift).

– Switch off the truck via the key switch and disconnect the battery.

– Release the drive brake and load wheel brake, see “Releasing and activating thedrive wheel brake” and “Releasing and activating the load wheel brake” inchapter E.

– Guide the tow rope (161), tow force > 5 tonnes, around the Aux. Lift mast (139).

F The tow rope (161), tow force > 5 tonnes, must be guided around the lowest point ofthe auxiliary mast (139).

– Recover the truck carefully and slowly.

F The truck can only be steered without its own drive system when it is idle(see “Steering the Truck without its own Drive System”). Do not stand between thetow truck and the truck to be recovered during a recovery operation.After recovery, prevent the truck from accidentally moving.To do this unscrew the setscrews from the drive brake and load wheel brake andattach them to their bracket or store them in their compartments, see “Releasing andactivating the drive wheel brake” and “Releasing and activating the load wheel brake”in chapter E. If the brake is not working, secure the truck to prevent it from movingaccidentally by placing wedges against the wheels.The truck may only be started again once the error has been localised and rectified.

Drive direction

Load direction

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5.9.5 EKX - Recovery in drive direction

– Set the attachment to the home (standard) position.See “Attachment in Home Position” in Chapter E.

– Fully lower the mast (Main and auxiliary lift).

– Switch off the truck via the key switch and disconnect the battery.

– Remove the drive compartment panel, see "Drive panel disassembly / assembly"in chapter F.

– Release the drive brake and load wheel brake, see “Releasing and activating thedrive wheel brake” and “Releasing and activating the load wheel brake” inchapter E.

– Guide the tow rope (164), tow force > 5 tonnes, around the recess in the truckchassis (163) (see illustration).

M Risk of damage from the tow ropeDo not route the tow rope (164) over the tailgate (162) as the tailgate (162) is notdesigned for recovery operations and will get damaged.

– Recover the truck carefully and slowly.

F The truck can only be steered without its own drive system when it is idle(see “Steering the Truck without its own Drive System”). Do not stand between thetow truck and the truck to be recovered during a recovery operation.After recovery, prevent the truck from accidentally moving.To do this unscrew the setscrews from the drive brake and load wheel brake andattach them to their bracket or store them in their compartments, see “Releasing andactivating the drive wheel brake” and “Releasing and activating the load wheel brake”in chapter E. If the brake is not working, secure the truck to prevent it from movingaccidentally by placing wedges against the wheels.The truck may only be started again once the error has been localised and rectified.

Drive direction

Load direction

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B5.9.6 EKS - Recovery in load direction

– Fully lower the mast (Main and auxiliary lift).

– Switch off the truck via the key switch and disconnect the battery.

– Release the drive brake and load wheel brake, see “Releasing and activating thedrive wheel brake” and “Releasing and activating the load wheel brake” inchapter E.

M Risk of damage from tow ropesDuring recovery route the tow ropes to the front in such a way as to avoid damagingthe hydraulic lines, the mast cable, the mast and the driver's cab.

– Sling the tow ropes (161a,161b), tow force > 5 to, around both sides of the mastcross member (162b) (see illustration).

– Route the tow ropes (161a, 161b) around the outside of the mast (162a) and pastthe driver's cab to the front (see illustration).

– Recover the truck carefully and slowly.

F The truck can only be steered without its own drive system when it is idle(see “Steering the Truck without its own Drive System”). Do not stand between thetow truck and the truck to be recovered during a recovery operation.After recovery, prevent the truck from accidentally moving.To do this unscrew the setscrews from the drive brake and load wheel brake andattach them to their bracket or store them in their compartments, see “Releasing andactivating the drive wheel brake” and “Releasing and activating the load wheel brake”in chapter E. If the brake is not working, secure the truck to prevent it from movingaccidentally by placing wedges against the wheels.The truck may only be started again once the error has been localised and rectified.

Drive direction

Load direction

162b162163164 161b162a

161a

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5.9.7 EKS - Recovery in drive direction

– Fully lower the mast (Main and auxiliary lift).

– Switch off the truck via the key switch and disconnect the battery.

– Remove the drive compartment panel, see "Drive panel disassembly / assembly"in chapter F.

– Release the drive brake and load wheel brake, see “Releasing and activating thedrive wheel brake” and “Releasing and activating the load wheel brake” inchapter E.

– Guide the tow rope (164), tow force > 5 tonnes, around the recess in the truckchassis (163) (see illustration).

M Risk of damage from the tow ropeDo not route the tow rope (164) over the tailgate (162) as the tailgate (162) is notdesigned for recovery operations and will get damaged.

– Recover the truck carefully and slowly.

F The truck can only be steered without its own drive system when it is idle(see “Steering the Truck without its own Drive System”). Do not stand between thetow truck and the truck to be recovered during a recovery operation.After recovery, prevent the truck from accidentally moving.To do this unscrew the setscrews from the drive brake and load wheel brake andattach them to their bracket or store them in their compartments, see “Releasing andactivating the drive wheel brake” and “Releasing and activating the load wheel brake”in chapter E. If the brake is not working, secure the truck to prevent it from movingaccidentally by placing wedges against the wheels.The truck may only be started again once the error has been localised and rectified.

Drive direction

Load direction

162b162163164 161b162a

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B6 Exiting the driver's cab with the rescue equipment

Industrial trucks with a driver's cab which can be raised more than 3 m off the groundhave an emergency lowering mechanism and a rescue equipment (rescue harness /abseil device / rescue rope) for the driver which can be used to reach the groundshould the operator position be blocked.

Z If the driver’s cab cannot be lowered due to a fault, not even with the emergencylowering (see “Driver’s Cab Emergency Lowering” in chapter E), the operator mustexit the driver's cab via the emergency abseil device.

F Untrained personnel and non-serviced rescue equipment can result inaccidents and injuryThe rescue equipment (rescue harness / abseil device with rescue rope) should onlybe used by people who are physically capable, trained to use the equipment safelyand who have the required expertise.The user must have a rescue plan listing all necessary action to be taken inemergencies.

• The driver must undergo annual training in how to handle the rescue equipment.

• For the operation and service intervals of the rescue harness and the emergencyabseil device, refer to the accompanying operating instructions.

• Follow the maintenance intervals stated in rescue harness and emergency abseildevice operating instructions.

Z The Jungheinrich AG customer service department is specially trained for theseoperations.

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6.1 Rescue equipment storage compartment in the driver's cab

Z The rescue equipment is located in thestorage compartment behind the driver'sseat.

– Loosen the twist grip screws (52) on the leftand right below the driver's seat (51).

– Tilt the driver’s seat (51) forward(arrow direction).

– Remove the rescue equipment from theopen storage compartment.

6.2 Rescue equipment testing / servicing

F Unchecked rescue equipment can result in accidents

• The rescue equipment (rescue harness / abseil device and rescue rope) must beinspected by the manufacturer or an authorised person (specialist) after everyrescue operation (not practice).

The rescue equipment (rescue harness / abseil device) must be checked at leastannually by the manufacturer or an authorised person (specialist).

More regular inspections may be required if the rescue equipment is used frequentlyor is subject to heavy duty usage (e.g. environmental or industrial factors affectingthe material).

Z The Jungheinrich AG customer service department is specially trained for theseoperations.

F No modifications or additions may be made to the rescue harness and abseil device.

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B6.3 Rescue equipment service life

F No modifications or additions may be made to the rescue harness and abseil device.

6.3.1 Rescue equipment useful life

Rescue harnesses have a service life of 8 years under normal operating conditionsor if the harness is not used.

6.3.2 Rescue device service life

Rescue ropes have a useful life of 6 years under normal operating conditions or if theyare not used.

Z The exact service life of the abseil device, karabiner hook and screw lock karabinerdepend on the application and ambient conditions.

6.4 Rescue equipment storage and transportation

F Incorrectly stored rescue equipment can cause accidentsThe storage of the rescue equipment has a considerable effect on its service life.

• Store the rescue equipment in the truck's storage compartment. This is will ensurethat the equipment is protected from damp, heat and UV radiation and can bereached in emergencies.

• Avoid contact with acid, corrosive fluids and oils.

• Protect the rescue equipment from contact with sharp objects.

M Damp harness straps and/or damp rescue rope should always dry off naturally, e.g. ina well-ventilated, shady location. Do not dry wet items of equipment in tumble dryers,near fires or other heat sources.

To transport the rescue equipment always use a secure equipment bag or case toprevent damage caused by external influences.

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6.5 Rescue equipment description / application (- 07.09)

The rescue equipment consists of an RG 16-E rescue harness, an AG 10 S abseildevice and a pre-assembled rescue rope with karabiner hooks and a securedend knot.

F Improper use of the rescue equipment can cause accidentsThe rescue equipment must not be used as a fall protection restraint harness.

The rescue equipment must not be used for collecting purposes and is authorised fora pay load of up to 150 kg or 1 person.

The rescue harness consists of two leg loops, a back belt and a breast belt witha clevis type eyelet. The back belt has two shoulder straps made of elastic materialwhich prevent the operator from sliding down when used. The supporting rubberharness consist of a 45 mm wide, non-elastic harness material. The rescue harnesshas an adjustable breast belt which allows it to be adapted to suit the user. The lengthis adjusted via a body friction lock.

Z It can be used in ambient temperatures of -25°C to 80°C.The abseil equipment can be used in temperatures between -30°C and 60°C. If thedevice is used in temperatures below 0°C it must be protected against humidity toprevent freezing for example inside the equipment (brake).

F No modifications or additions may be made to the rescue harness and abseil device.

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B6.5.1 RG 16-E rescue harness

6.5.2 RG 16-E rescue harness specifications

Item Description

200 Clevis type eyelet

201 Shoulder strap

202 Longitudinally adjustable breast belt with body friction lock

203 Data plate

204 Posterior and leg belt

Type: RG 16-E

Net weight: 0.6 kg

Capacity: 150 kg

200

202

204

205

200

201

201

205

201

202

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6.5.3 RG 16-E rescue harness data plate

Item Description

206Indicates that the rescue harness should be used "for rescue purposes only"

207 Type

208 Next inspection

209 Manufacturer

210 Test plaque with details of month and year when next service is due

211 Prototype tested to EN

212 Year of manufacture

213 Factory number (manufacturer's serial number)

214 Reference number of notified test centre

215 Instruction to follow the operating instructions

0158EN 1497

XXX

XXXX

XXXXXXXXXXX XXXXXX

XXXXXXXXXXX

XXXX

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207

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B6.5.4 AG 10 S abseil device

6.5.5 AG 10 S abseil device specifications

Item Description

216Karabiner hook and union nut (attaching the abseil device to the rescue harness)

217 Test plaque

218Abseil device (with centrifugal force automatic braking for smooth abseiling)

219 Data plate

220

Brake lever

The brake lever is used by the operator to interrupt / start abseiling.

221Rescue rope (static core cladded rope)

Diameter = 9 mm.

222Karabiner hook and union nut (attaching the rescue rope to the driver's cab)

Type: AG 10 S

Equipment class: A

Permissible abseil height: max: 400 m

Permissible abseil load: 150 kg (one person)

Abseil speed: 0,7 m/s

Net weight: 1,4 kg without rescue rope

216

222

221

217

218

220

219

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6.5.6 AG 10 S abseil device data plate

Item Description

223 Prototype tested to EN

224 Type

225 Company logo / name

226 Manufacturer's address

227 Reference number of notified test centre

228 Factory number (manufacturer's serial number) / year of manufacture

229 Instruction to follow the operating instructions

230 Abseil height (rescue rope length details)

231 Abseil speed (approx. 0.7 m/s)

232 Equipment class

233

2 people (max. 225 kg / max. 100 m)

Specification of maximum abseil height with 2 people with maximum overall abseil load of 225 kg

234

Abseil load (max. 150 kg / max. 400 m)

Specification of maximum abseil height with maximum overall abseil load of 150 kg

0158

XXXXXXXXXXXXXXXX

XXXXXXXXXXXXXXXX

EN 341 / EN 1496

XXXXXXXX

XXXXXXXX

XXXXXXXX

XXXXXXXXXX

XXXXXXXXX

XXXXXXXXXX

XXX

225

231

230

226

227

229

228

232

224

233 234

223

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B6.5.7 Visual Inspection of the Rescue Equipment

The user must carry out a visual inspection of the rescue equipment (rescue harness /rescue rope / screw lock karabiner) before each operation. This will ensure that therescue equipment is operational and fit for purpose.

F Withdraw the rescue equipment from use if you find any damage or if you are in doubtas to its functionality. Return the equipment to the manufacturer or a specialistappointed by the manufacturer for inspection.

Z The Jungheinrich AG customer service department is specially trained for theseoperations.

6.5.8 Visually inspecting the RG 16-E rescue harness

The user must carry out a visual inspection of the RG 16-E rescue harness beforeeach operation. This will ensure that the RG 16-E rescue harness is operational andfit for purpose.

When carrying out a visual inspection make sure that:

– the belt material does not show any signs of damage such as chafing, cracks orloose thread ends on the seams.

– there is no damage to the locks.

– the elastic shoulder pads are not worn.

– the body friction lock is not damaged.

– the eyelet is not corroded, deformed and/or suffering from any other mechanicaldamage.

F Withdraw the RG 16-E rescue harness from use if you find any damage or if you arein doubt as to the functionality of the harness. Return the RG 16-E rescue harness tothe manufacturer or a specialist appointed by the manufacturer for inspection.

Z The Jungheinrich AG customer service department is specially trained for theseoperations.

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6.5.9 Visually inspecting the AG 10 S abseil device

The user must carry out a visual inspection of the AG 10 S abseil device before eachoperation. This will ensure that the AG 10 S abseil device is operational and fitfor purpose.

When carrying out a visual inspection make sure that:

– The data plate is present and legible.

– the abseil device is not corroded, deformed and/or suffering from any othermechanical damage.

– The abseil device does not have excessive traces of wear.

– All cheese head screws are present and tight.

– The integrated length of the screws shows if one of the screws is loose. If a loosescrew is found during the inspection it must be tightened with an appropriatewrench (accessories set). If not all the screws are present, withdraw the abseildevice from service.

– the abseil device does not have excessive traces of wear.

– There is no wear / abrasion on the rope inlet and outlet points.

– The rope inlet and outlet points should have no more than 2 mm abrasion(detected by finger), otherwise the abseil device must be withdrawn from use.

Z Worn material has a frayed, smooth and shiny surface. Abrasion causes a cleartrough formation in the material.

F Withdraw the AG 10 S abseil device from use if you find any damage or if you are indoubt as to the functionality of the abseil device. Return the AG 10 S abseil device tothe manufacturer or a specialist appointed by the manufacturer for inspection.

Z The Jungheinrich AG customer service department is specially trained for theseoperations.

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B6.5.10 Testing the brake lever

The brake lever must always be tested and its condition checked before it is used.This will ensure that the abseil device is operational and fit for purpose.

When carrying out the visual inspection make sure the brake lever is not corroded,physically damaged, deformed and/or cracked.

In addition, test the brake lever:

– Do not apply the brake lever.

– Pull the end of the rope with the karabiner hook away from the abseil device.The rescue rope should not slip through the abseil device. If it does, withdraw theabseil device from service immediately and return it to the manufacturer ormanufacturer's authorised specialist for examination.

F Withdraw the abseil device from use if you find any damage to the brake lever or ifyou are in doubt as to the functionality of the brake lever. Return the abseil device tothe manufacturer or a specialist appointed by the manufacturer for inspection.

Z The Jungheinrich AG customer service department is specially trained for theseoperations.

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6.5.11 Test the centrifugal brake

The centrifugal brake must always be tested before it is used. This will ensure thatthe abseil device is operational and fit for purpose.

– Press the brake lever down and hold it in this position.

– Pull the end of the rope with the karabiner hook approx. 1.0 m away from the abseildevice. You should feel a resistance due to the centrifugal brake.

– Release the brake lever.

– Pull the end of the rope with the karabiner hook further away from the abseil device.The brake lever should automatically revert to the default "Stop" position.

F A non-functional centrifugal brake can cause accidentsIf the rescue rope can be pulled through the abseil device without any resistance orif the brake lever is not pushed up to the "Stop" default position, withdraw the abseildevice immediately from service and return it to the manufacturer or manufacturer'sauthorised specialist for examination.If the abseil device jams and the rescue rope cannot be pulled through the abseildevice (despite pressing the brake lever down and holding it in this position),you must also withdraw the abseil device immediately from service and return it to themanufacturer or manufacturer's authorised specialist for examination.

Z The Jungheinrich AG customer service department is specially trained for theseoperations.

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B6.5.12 Visual inspection of rescue rope with karabiner hook

The user must carry out a visual inspection of the rescue rope and karabiner hookbefore each operation. This will ensure that the rescue rope is operational and fitfor purpose.

F Withdraw the rescue rope or karabiner hook from use if you find any damage or if youare in doubt as to their functionality. Return the rescue rope and karabiner hook to themanufacturer or a specialist appointed by the manufacturer for inspection.

Z The Jungheinrich AG customer service department is specially trained for theseoperations.

Visual inspection of the karabiner hook

When carrying out the visual inspection make sure the karabiner hook isnot corroded, physically damaged, deformed and/or cracked.

Also check the functionality of the lock (catch) and the rivet on the karabiner hook.

– The union nut must open and close easily.

– The lock (catch) on the karabiner hook must be restored to its original position aftermanual opening.

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Visual inspection of the rescue rope

Check that the end knot is present and secured to the end of the rope by the cable tie.There must be a knot at the end of the rope so that the rescue rope does not run outof the abseil device during abseiling.

The stitching on the rope end with the karabiner hook must be in good condition.

When carrying out the visual inspection make sure that the rescue rope does notshow any of the following signs of physical damage, defects or heat/chemicaldamage etc.:

– Interfaces,

– Fibre damage,

– Swelling,

– Twisting,

– Excessive wear suchas fluff,

– Sheath displacement,

– Open, loose end connections,

– Loops,

– Knots,

– Burnt parts,

– Decayed parts.

Z Check the rescue rope for the above features before dropping it. Do this by letting therescue rope drop through your hands.

Z Brake dust produced from work performed on the brakes is conducted away from theabseil device via the rescue rope inlet and outlet points due to the open position ofthe brake unit in the equipment housing. In addition, material abrasion on theequipment housing (aluminium dust) caused by the equipment operation isconducted away in the same manner. This can cause the rescue rope to turn black.However, this colouration has no negative effect on the rope's properties.

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B6.5.13 Putting on the RG 16-E rescue harness

– Remove all objects from your trouser pockets.

– Remove the lead seal.

– Remove the rescue equipment from the equipment bag or case.

– Carry out a visual inspection of the rescue equipment, see previous section:"Visual Inspection of the Rescue Equipment".

– The back belt must be facing the back and the legstraps facing the front.

– Hold the rescue harness in front of your body withone hand on the clevis type eyelet.

– To facilitate handling, place the rescue harnessgently on the ground and using your free hand pullthe back belt gently backwards.

– Put both legs in the leg straps, one after the other.

– Meanwhile keep holding onto the clevis type eyeleton the breast belt.

– Pull up the clevis type eyelets on the breast belt toposition the leg straps directly under your bottom.

– Now put on the two elastic shoulder straps. Theseprevent the operator from slipping out when usingthe belt.

– The back belt is automatically positioned when thetwo shoulder straps are in place.

– Adjusting the breast belt enables the rescueharness to be adapted to the operator's body size.The harness material can be pulled tighter at theloose end through the body friction lock.

– Make sure the rescue harness is comfortable andnot fitted too tight against the body.

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6.5.14 Exiting the driver's cab with the rescue equipment

– Switch off the truck with the key switch (20).

– Take the abseil device (218) and rescue harness from out of the storagecompartment, see "Rescue equipment storage compartment in the driver's cab" inChapter E.

Z The assembled rescue equipment is ready for use on breaking the seal, removal fromthe equipment bag or case and after carrying out a visual inspection of the belt, abseildevice and rescue rope.

– Carry out a visual inspection of the rescue harness, abseil device, rescue rope andscrew lock karabiner, see "Visual Inspection of the Rescue Equipment" inchapter E.

– Put on the rescue harness, see "Putting on the RG 16-E rescue harness" inChapter E.

– Insert the karabiner hook (222) of the rescue rope (221) into the eyelet (to EN 795)on the overhead guard (139) and secure it with the union nut.

– Insert the karabiner hook (216) of the abseil device (218) into the eyelet on therescue harness and secure it with the union nut. Make sure that the descendingperson can operate the abseil device (218) while abseiling.

139 20 21

216 218 220 221 222

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F Insufficient rescue rope can result in accidentsThe rope must reach the ground, otherwise you must not abseil down it.

F Rescue rope can tear, resulting in accidentsThe rope must pass over fixed objects. It must not pass over sharp edges.

• Use a border guard for abseiling over sharp edges.

• Store the rescue equipment in the truck's storage compartment. This will ensurethat the rescue rope is protected from damp, heat and UV radiation.

• Avoid contact with acid, corrosive fluids and oils.

• Protect the rescue equipment from contact with sharp objects.

216

218

220

221

222

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Abseiling

– Throw the rescue rope (221) down to the ground so that it is free of knots(except for the end knot).

– Pull the rescue rope (221) taut. The rescue rope (221) should be free to run in andout of the rope inlet and outlet points on the abseil device.

M Risk of accidents from abseiling

• Always use the rescue harness to abseil.

• Avoid slack rope to keep the fall distance as short as possible.

• Do not fall into loose rescue rope or jump from the operator position into therescue rope.

• Watch out for obstacles when abseiling.

Z Make sure that the person exiting the driver's cab does so slowly to avoid swingingon the rescue rope.

– Exit with both feet firmly on the edge and facing towards the truck.

Z The default position of the brake lever (220) on the abseil device (218) is “Stop”,which indicates that the device is not ready to descend.

– To abseil, press the brake lever (220) on the abseil device (218) down.

Z The abseil speed is automatically governed by a centrifugal brake.

– To stop abseiling, release the brake lever (220). The brake lever (220)automatically reverts to the default "Stop" position. Abseiling is interrupted.

M When abseiling take care to avoid obstacles.

F Unchecked rescue equipment can result in accidentsThe rescue equipment (rescue harness / abseil device and rescue rope) must beinspected by the manufacturer or an authorised person (specialist) after every rescueoperation (not practice).

216

218

220

221

222

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B6.6 Rescue equipment description / application (07.09 -)

The rescue equipment consists of an ARG 30 rescue harness, a MARK 1 abseildevice, a connector (OVALINK 8 screw lock karabiner ) and a pre-assembled rescuerope with karabiner hooks and a secured end knot.

The rescue equipment must not be used for collecting purposes and is authorised fora pay load of 30 - 150 kg or 1 person.

F Improper use of the rescue equipment can cause accidentsThe rescue equipment must not be used as a fall protection restraint harness.

F No modifications or additions may be made to the rescue harness and abseil device.

6.6.1 ARG 30 rescue harness

If the driver's cab cannot be lowered due to a fault, the ARG 30 rescue harness inconjunction with the abseil kit (abseil device and rescue rope) can be used to rescueindividual people from the faulty truck.

The ARG 30 rescue harness consists of two adjustable leg and should straps, a cheststrap with a D ring and a back strap with a D ring. The supporting rubber harnessconsist of a 45 mm wide harness material.

Adjust the chest and leg straps to achieve optimum adjustment of the ARG 30 rescueharness. The length of the chest strap / leg straps can be adjusted with clip-onbuckles.

Z The temperature-dependent application area of the ARG 30 rescue harness rangesfrom ambient temperatures of -23 °C to +60 °C.

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6.6.2 ARG 30 rescue harness specifications

Item Description

250 Adjustable shoulder straps

251 D ring on chest strap

252 D ring on back strap

253 Data plate, see "RG 30-E rescue harness data plate" in Chapter E.

254 Clip-on buckles

255 Adjustable leg straps

Type: ARG 30

Net weight: 1.2 kg

Capacity: One person

Size: UNISIZE

Norm: EN 361

250

251

252

253

254

255

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B6.6.3 ARG 30 rescue harness data plate

Item Description

256 Serial number

257 Note: Read operating instructions

258 Type

259 Prototype tested to EN

260 Year of manufacture

261 Manufacturer

262 CE mark

263 Next inspection

264 Manufacturer’s part number

256 257

258

259

262

260

261

263

264

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6.6.4 Service life of the MARK 1 abseil device with rescue rope and OVALINK 8 screwlock karabiner

If the driver's cab cannot be lowered due to a fault, the MARK 1 abseil device andrescue rope can be used in conjunction with the ARG 30 rescue harness to rescueindividual people from the faulty truck. The MARK 1 abseil device and rescue ropemust not be used for collecting purposes.

The MARK 1 abseil device consists of a main body to which the controls and brakeunit are attached. The bottom area of the body contains a D-ring to which a fastener(OVALINK 8 screw lock karabiner) can be attached in accordance with EN 362.The MARK 1 abseil device is authorised for a pay load of 30 - 150 kg, i.e. 1 person.

One end of the rescue rope has a karabiner hook while the other has an end knot.The end knot is secured by a cable tie and prevents the rescue rope from running outof the abseil device. The rescue rope data plate is located below a transparentprotective hose on the rope end of the karabiner hook.

The OVALINK 8 screw lock karabiner (in accordance with EN 362) is used to connectthe "MARK 1" abseil device to the ARG 30 rescue harness. The lock is secured witha threadlocker to prevent it from releasing accidentally during operation.

Z The temperature-dependent application range for the MARK 1 abseil device,rescue rope and OVALINK 8 screw lock karabiner varies from -35 °C to +60 °C.

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6.6.5 MARK 1 abseil device specifications

Item Description

265Rescue rope with karabiner hook (to attach the MARK 1 abseil device to the truck) and secured end knot

266 Brake cam

267 MARK 1 abseil device

268 Control handle

269D ring for fastener (karabiner / screw lock karabiner)

270OVALINK 8 screw lock karabiner to attach the MARK 1 abseil device to the ARG 30 rescue harness

271 End knot

272 Cable tie

Type: MARK 1

Net weight: 0.35 kg (excl. rope)

Capacity: One person (30 kg - 150 kg)

Max. abseil height: 200 m

Rope diameter:

in accordance with EN 341: 11 mm

in accordance with EN 12841: 10 to 12 mm

Authorised rope type:Static rope in accordance with EN 1891 type A

Norm:EN 341 category A

EN 12841 Type C

269

268

265

267

266

270

265

272

271

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6.6.6 Specifications of rescue rope and karabiner hook

6.6.7 OVALINK 8 screw lock karabiner specifications

6.6.8 MARK 1 abseil device housing specifications

Type: PARALOC Static 12.0

Net weight: approx. 1.5 kg

Material: Polyamine (PA)

Length: 17.5 m

Capacity: One person

Rope diameter: 12 mm

Rope type: Semi-static rope

Norm: EN 1891 type A

Type: OVALINK 8

Net weight: approx. 0.04 kg

Capacity: One person

Dimensions: 74 x 39 mm

Norm:EN 362 / Q

EN 12275

Item Description

273 CE mark

274 Abseil device type

275 Rope diameter / max. abseil height

276 Pictogram (insert rope)

277 Prototype tested to EN

0123

DSD 30+2530-150kgmax. 200m

EN 341 CLASS AROPE 11mm

EN 12841 Type C 10 ≤ ∅ ≤ 12mm

277

276

273

275

274

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B6.6.9 Rescue rope data plate

Item Description

278 Serial number

279 Type

280 Prototype tested to EN

281 Year of manufacture

282 CE mark

283 Manufacturer

284 Manufacturer’s part number

285 Note: Read operating instructions

278

279

280281

282283

284 285

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6.6.10 Visual Inspection of the Rescue Equipment

The user must carry out a visual inspection of the rescue equipment (rescue harness /rescue rope / screw lock karabiner) before each operation. This will ensure that therescue equipment is operational and fit for purpose.

F Withdraw the rescue equipment from use if you find any damage or if you are in doubtas to its functionality. Return the equipment to the manufacturer or a specialistappointed by the manufacturer for inspection.

Z The Jungheinrich AG customer service department is specially trained for theseoperations.

6.6.11 Visual inspection of the ARG 30 rescue harness

The user must carry out a visual inspection of the ARG 30 rescue harness beforeeach operation. This will ensure that the ARG 30 rescue harness is operational andfit for purpose.

When carrying out a visual inspection make sure that:

– the load-bearing harness material does not show any signs of damage suchas chafing, cracks or loose thread ends on the seams.

– the clip-on buckles are not corroded, physically damaged, deformed and/or cracked.

– the D rings on the chest strap and the back strap are not corroded, damaged,deformed and/or cracked.

– the data plate is present and legible.

F Withdraw the ARG 30 rescue harness from use if you find any damage or if you arein doubt as to the functionality of the harness. Return the ARG 30 rescue harness tothe manufacturer or a specialist appointed by the manufacturer for inspection.

Z The Jungheinrich AG customer service department is specially trained for theseoperations.

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B6.6.12 Visual inspection of the MARK 1 abseil device

The user must carry out a visual inspection of the MARK 1 abseil device before eachoperation. This will ensure that the MARK 1 abseil device is operational and fitfor purpose.

When carrying out a visual inspection make sure that:

– the abseil device is not corroded, deformed and/or suffering from any othermechanical damage.

– the abseil device does not have excessive traces of wear.

– the details on the abseil device are clearly legible.

– the control handle is not corroded, deformed and/or suffering from any othermechanical damage.

Also carry out a test on the control handle by pulling the rescue rope, both when thecontrol handle is not applied and pushed through. The rescue rope should not slipthrough the device.

F Withdraw the MARK 1 abseil device from use if you find any damage or if you are indoubt as to the functionality of the abseil device. Return the MARK 1 abseil device tothe manufacturer or a specialist appointed by the manufacturer for inspection.

Z The Jungheinrich AG customer service department is specially trained for theseoperations.

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6.6.13 Visual inspection of rescue rope with karabiner hook

The user must carry out a visual inspection of the rescue rope and karabiner hookbefore each operation. This will ensure that the rescue rope is operational and fitfor purpose.

F Withdraw the rescue rope or karabiner hook from use if you find any damage or if youare in doubt as to their functionality. Return the rescue rope and karabiner hook to themanufacturer or a specialist appointed by the manufacturer for inspection.

Z The Jungheinrich AG customer service department is specially trained for theseoperations.

Visual inspection of the rescue rope

Check that the end knot is present and secured to the end of the rope by the cabletie. There must be a knot at the end of the rope so that the rescue rope does not runout of the abseil device during abseiling.

The stitching on the rope end with the karabiner hook must be in good condition.

When carrying out the visual inspection make sure that the rescue rope does notshow any of the following signs of physical damage, defects or heat/chemicaldamage etc.:

– Interfaces,

– Fibre damage,

– Swelling,

– Twisting,

– excessive wear suchas fluff,

– Sheath displacement,

– Open, loose end connections,

– Loops,

– Knots,

– Burnt parts,

– Decayed parts.

Z Check the rescue rope for the above features before dropping it. Do this by letting therescue rope drop through your hands.

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BVisual inspection of the karabiner hook

When carrying out the visual inspection make sure the karabiner hook is notcorroded, physically damaged, deformed and/or cracked.

Also check the functionality of the lock (catch) and the rivet on the karabiner hook.

– The union nut must open and close easily.

– The lock (catch) on the karabiner hook must be restored to its original position aftermanual opening.

6.6.14 Visual inspection of the OVALINK 8 screw lock karabiner

The user must carry out a visual inspection of the OVALINK 8 screw lock karabinerbefore each operation. This will ensure that the screw lock karabiner is operationaland fit for purpose.

When carrying out a visual inspection make sure that:

– the screw lock karabiner is not corroded, deformed and/or suffering from any othermechanical damage.

– the threadlocker on the lock is not broken or damaged.

F Withdraw the OVALINK 8 screw lock karabiner from use if you find any damage or ifyou are in doubt as to the functionality of the screw lock karabiner. Return theOVALINK 8 screw lock karabiner to the manufacturer or a specialist appointed by themanufacturer for inspection.

Z The Jungheinrich AG customer service department is specially trained for theseoperations.

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6.6.15 Putting on the rescue harness

Preparation:

– Remove all objects from your trouser pockets.

– Remove the lead seal.

– Remove the rescue equipment from theequipment bag or case.

– Carry out a visual inspection of the rescueequipment, see "Visual Inspection of theRescue Equipment" in Chapter E.

– Hold the rescue harness in front of your bodywith one hand on the D ring.

– Open the clip-on buckles (3 off).

Put on the rescue harness:

– Put on the rescue harness like a jacket.

– Pull the leg straps forward between your legsand then up.

3x

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BAdjust the rescue harness to match the sizeof the operator's body:

– Close the clip-on buckles (2 off) on theleg straps.

– Guide the clip-on buckle on the chest strapthrough the front D ring.

– Close the clip-on buckle of the chest strap.

– Adjust the rescue harness to fit your individualsize and tighten the straps.

– Make sure the leg straps are adjusted so thatyou can push your hand flat between the legstrap and thigh. After adjusting the D ring onthe back strap you be exactly between yourshoulder blades.

– Undo the Velcro strip and hence the abseildevice from the rescue harness.

3x

4x

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6.6.16 Exiting the driver's cab with the rescue equipment

– Switch off the truck with the key switch (20).

– Take the abseil device and rescue harness out of the storage compartment in thedriver's cab, see "Rescue equipment storage compartment in the driver's cab" inChapter E.

Z The assembled rescue equipment is ready for use on breaking the seal, removal fromthe equipment bag or case and after carrying out a visual inspection.

– Carry out a visual inspection of the rescue harness, abseil device, rescue rope andscrew lock karabiner, see "Visual Inspection of the Rescue Equipment" inchapter E.

– Put on the rescue harness, see "Putting on the rescue harness" in Chapter E.

– Insert the karabiner hook of the rescue ropeinto the D ring (in accordance with EN 795) onthe overhead guard and secure it with theunion nut.

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B– Throw the rescue rope down to the ground

so that it is free of knots (except for the endknot).

F Insufficient rescue rope can result inaccidentsThe rope must reach the ground, otherwiseyou must not abseil down it.

F Rescue rope can tear, resulting inaccidentsThe rope must pass over fixed objects.It must not pass over sharp edges.

• Use a border guard for abseiling oversharp edges.

• Store the rescue equipment in the truck'sstorage compartment. This will ensurethat the rescue rope is protected fromdamp, heat and UV radiation.

• Avoid contact with acid, corrosive fluidsand oils.

• Protect the rescue equipment fromcontact with sharp objects.

Abseiling

– Pull the rescue rope taut between theoverhead guard and abseil device.The free rescue rope must be free to runin and out over the rope inlet and outletpoints on the abseil device.

M Risk of accidents from abseiling

• Always use the rescue harness to abseil.

• Avoid slack rope to keep the fall distanceas short as possible.

• Do not fall into loose rescue rope orjump from the operator position into therescue rope.

• Watch out for obstacles when abseiling.

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Z Make sure that the person exiting the driver's cabdoes so slowly to avoid swinging on therescue rope.

– Exit with both feet firmly on the edge and facingtowards the truck.

Z The default position of the control lever on theabseil device is “Stop” which indicates that thedevice is not ready to descend (see position "A").

– To abseil, push the control lever slightly towardsthe abseil device (see position"B").

Z The lowering speed depends on the weight of theuser and position of the control lever.The maximum descent speed is between 0.4m/sec. and 0.7m/sec.

– To stop abseiling, release the control lever (see position"A") or push fully in thedirection of the abseil device (see position"C").

M When abseiling take care to avoid obstacles.

F Unchecked rescue equipment can result in accidentsThe rescue equipment (rescue harness / abseil device and rescue rope) must beinspected by the manufacturer or an authorised person (specialist) after every rescueoperation (not practice).

A B C

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B7 Personal Protection System (o)

7.1 Personal Protection System (PPS)

The truck's integrated personal protection system (PSS)is designed to protect persons. The personal protectionsystem is used with industrial trucks in warehousesystems where pedestrians are not permitted to be innarrow aisles at the same time as industrial trucks

Z The PPS satisfies the requirements of BGV D 27, §28Section 2, DIN 15 185, part 2 item 3.13. The PPScorresponds to ISO 13849 PXF Level D for identifyingpersons and obstacles. The safety laser scannercorresponds to laser protection class 1. No othermeasures for screening the laser beam are required(eye protection).The laser scanner complies with the following norms:CDRH 21 CFR 1030.10 and DIN EN 60825:2001, wherethe following notice is made: “Caution – Hazardous rayexposure can result if the operating or adjusting devices used or proceduresperformed differ from those contained herein.” National / international regulations apply to the assembly and use of the safety laserscanner both for commissioning and recurrent technical inspections, in particular:

– Machinery Directive 2006 / 42 / EC

– Use of Work Equipment Directive 89 / 655 / EEC

– Accident prevention / health and safety regulations

– other relevant safety regulations

The manufacturer and operators of the machine on which the safety laser scanner isbeing used are responsible for agreeing and complying with all valid safetyregulations issued by the relevant authorities.

7.2 Functional description

– Mobile personal protection system with laser scanner based obstacle detection.

– Apron field protection / collision protection:

– Optimum integration in the truck.

– Easy adjustment / settings to match warehouse environment.

– Automatic speed reduction / stopping in front of obstacles / personnel / otherindustrial trucks.

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7.2.1 Standard functions

– Crawl speed released when scanner covered (load handler lowered).

– Crawl speed released when approaching the last pallet location at a closed narrowaisle end.

– Automatic reduction of maximum speed to 2.5 km/h before exiting the aisle.

– Additional stop at aisle end; option of temporary, confirmed, or absolute.

– Short range apron field protection (directly in front of and behind the truck – depending on travel direction).

M The personal protection system is not a collision guard in the sense of DIN 15185part 2 section 3.7.

7.2.2 Special functions depending on the ground conditions

– Aisle type identification within a warehouse.

– Speed reductions for escape routes within the lane.

– Stopping for escape routes within the lane.

– Zone change within a lane with short range recognition.

– Twin lane width recognition. Protection field change – wider monitoring field onone side.

– Option of attaching additional sensors for operator position carriage control withlower cutout on detection of persons.

7.2.3 Environmental awareness

The safety laser scanner is designed to keep environmental damage to a minimum.It uses minimal energy and resources. Always act with regard to the environment atyour place of work. Please note the following disposal information.

Disposal:

– Always dispose of unusable or irreparable equipment in accordance with yourcountry’s waste disposal regulations.

– Remove plastic parts and send the aluminium housing of the safety laser scannerfor recycling.

– Dispose of all electronic components as special waste.

– Electronic components are easy to disassemble.

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B7.3 Cleaning the front panel of the scanners

7.3.1 Preparation

Scanner under the load axle

– Secure the operator position, see “Securing the operator position“ in chapter F.

7.3.2 Cleaning the front panel

– Damp clean the front panel.

– Additionally, damp clean the connecting lug at thebottom of the front panel.

Z Dry cleaning carries the risk of static charge. More dustwill be attracted to the front screen. There is also the riskof scratching the front screen.

– Wipe the panel dry using a clean, soft woollen cloth /micro fibre cloth or a new soft paper towel.

M Do not use dirty or large fibre cleaning cloths as thesecan scratch the front screen. This could result in errorsand would require replacing.

– After cleaning, hold a light / torch against the frontpanel. Check for any contamination / scratching on the front panel, if necessaryclean again.

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7.3.3 Error displays on the seven segment display and indicator light (LED)

Z The seven segment display and the indicator light (LED) on the scanner act as thedisplay for the operator and the customer service engineer.

Z Other seven segment and indicator light (LED) error displays are relevant only to themanufacturer’s service department. Troubleshooting must only be performed by themanufacturer’s specialist service engineers. The manufacturer has a customerservice department specially trained for these tasks. In order for customer services to respond quickly and specifically to the fault,the following information is essential:

- Truck serial number- Error number on the seven segment display (if applicable)- Indicator light (LED) display.- Error description- Current location of truck.

Display LED signal DescriptionOff Protection field clear,

no object in protection fieldLit Object in protection field

Off Warning field clear, no object in warning field

Lit Object in warning field

Off Front panel cleanLit Front screen contaminated,

operation inhibited. clean front panel (see “Cleaning the front panel of scanners” in chapter E)

Flashes at one Hz (one second off,one second on)

Front screen contaminated,Operation still enabled, clean front panel (see “Cleaning the front panel of scanners” in chapter E)

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B7.4 Daily checks before starting the Personal Protection System

– Check the front screens of the personal protection system laser scanners forcontamination and clean as required.

7.4.1 Cycle test

Z To ensure the correct operation of the personal protection system a cycle test mustbe carried out every day (24 hour timer). The information message "I 9901" and the"Perform cycle test" symbol (165b) prompt you to perform the cycle test. During thistime the travel speed is restricted to 2.5 km/h . The speed restriction is only removedwhen the cycle test has been performed. In addition, each time the truck is switchedoff and on again it automatically performs the cycle test.

Cycle test:

– Switch off the truck.

– Switch on the truck.

Z When the truck has been switchedon the display unit shows the“Acknowledge cycle test”symbol (165a).

– Press the pushbutton (24) belowthe “Acknowledge cycle test”symbol (165a).

– The truck automatically performsthe cycle test.

– When the cycle test has beensuccessfully performed:

– the "Perform cycle test"symbol (165b) disappears.

– the speed restriction is removed.

– the 24 hour timer is reset and starts afresh.

165a

24

165b

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7.5 Personal Protection System

7.5.1 No obstacles / persons identified

Z If there are no persons and / or obstacles in the PPS warning or protection fields,the truck can travel at the maximum enabled speed.

7.5.2 Obstacles / persons in warning field

The display unit shows the “warning fieldinfringement” symbol (167). The travelspeed is restricted to 2.5 km/h.

Z When the obstacle is removed or theperson has left the warning field, thetruck can travel again at the maximumspeed. The “warning field infringement”symbol (167) also disappears.

166 167

24

12

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B7.5.3 Obstacles / persons in the protection field

The truck stops. You can only continue travelling by pressing the “protective fieldinfringement” symbol (166) and simultaneously turning the travel control button (12)in the required direction. The travel speed is restricted to 2.5 km/h.

F Risk of accidents and injury from the truckTravel cutout override is an additional function to ensure the position of the truck canbe adjusted despite a protection field infringement. However, it does not release theoperator from his responsibility to bring the truck to a halt in good time before itreaches any obstacles and / or persons.

Z When the obstacle is removed or the person has left the warning field, press thepushbutton (24) below the “protective field infringement” symbol (166) to continue atmaximum speed. The “protective field infringement” symbol (166) also disappears.

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8 EKS 513/515k/515 Stockpicker

The following functions described in chapter E do not apply to the EKS 513/515k/515:

– "Traverse (load hander attachment)",

– "Swivel / rotate (fork carriage)" and

– "Simultaneous load handler traverse and fork carriage swivel".

8.1 Control panel layout

Z The illustrations shown are examples and do not represent the equipment supplied.

Control panel in load direction

Z To operate the truck see "Displays andcontrols" in Chapter E.

Control panel in drive direction

Z To operate the truck see "Displays andcontrols" in Chapter E.

Control panel in drive direction with side-stance

Z To operate the truck see "Displays andcontrols" in Chapter E.

Split control panel in load direction

Z The truck is operated in exactly thesame way as detailed in "Controls andDisplays".

The truck is controlled via two control panels. The controls are described in "Split control panel controls" and the tilt / height adjustment in "Split control panel height and tilt adjustment".

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B8.1.1 Divided control panel controls

Item Description

290

Left control panel

Z The left control panel contains the steering wheel, Emergency Disconnect switch and the hydraulic control button.

291

Right control panel

Z The right control panel contains the travel control button, display unit,key switch and the keypads (e.g. numerical keypad, cursor keys,...).

292 Infinite tilt adjustment screw

293Control panel height adjusting lever (max. 170 mm)

Control panel height adjusting button (max. 170 mm)

290

292

291

292

293293

293 293

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8.1.2 Split control panel height and tilt adjustment

Split control panel tilt adjustment

M Do not adjust the inclination of the control panels (290.291) during operation.Make sure the screw (292) is locked in position after any adjustment.

– Undo the screw (292).

M Do not remove the screw (292) fully as it is also used to fasten the control panel.

– Set the control panel to the required angle.

– Tighten the screw (292).

Split control panel height adjustment

M Do not adjust the height of the control panels (290, 291) during operation.Make sure the control panel is locked in position after any height adjustment.

– Each control panel can be individually height adjusted by pressing the button (293)or by pulling the lever (293).

Z The height of each control panel can be adjusted by up to 170 mm.

E 175

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B8.2 EKS 513/515k/515 with load guard and walk-on pallet (o)

F Risk of accidents / crashing when using walk-on palletsWhen the gates are opened, the driver's cab can be raised to a fixed height up to amaximum of 1200 mm. When the gates are closed, the operator position can beraised to the maximum lift height.

• Only walk on pallets with a pallet guard (o).

• Beyond lift heights > 1200 mm the gates must be closed to enable travel, lifting andlowering (Main Lift).

• One-way pallets cannot be used as a surface to walk on.

• Good ground conditions.

• Only use pallets of a suitable size to fit a pallet guard.

8.2.1 Truck equipment - stockpicking platform without pallet lift option

Version A

– The stockpicking platform has a closed guard.

– The stockpicking platform can only be accessed from the truck.

Version B

Z The illustrations shown are examples and do notrepresent the equipment supplied.

– The stockpicking platform has a guard with sidegates (295).

– The stockpicking platform can:

– be accessed from truck.

– be accessed via the side gates (295) when thestockpicking platform is lowered.

295

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E 176

Version C

Z The illustrations shown are examples and do notrepresent the equipment supplied.

– The stockpicking platform has a guard withside (295) and front gates (296).

– The stockpicking platform can:

– be accessed from truck.

– be accessed via the side gates (295) when thestockpicking platform is lowered.

– be accessed via the front gates (296) when thestockpicking platform is lowered.

Version D

Z The illustrations shown are examples and do notrepresent the equipment supplied.

– The stockpicking platform has a guard with frontgates (296).

– The stockpicking platform can:

– be accessed from truck.

– be accessed via the front gates (296) when thestockpicking platform is lowered.

295

296

295

296

E 177

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B8.2.2 Stockpicking platform with pallet lift option (not monitored, not locked)

Version E

– The raised pallet can be accessed from the truck via the gates (298) in theload direction.

– The raised pallet has a side guard (297) but is open at the front.

Version F

– The raised pallet can be accessed from the truck. The truck does not have anygates in the load direction.

– The raised pallet has a side guard (297) but is open at the front.

298297

299

297

299

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Version G

– The raised pallet can be accessed from the truck via the gates (298) in theload direction.

– The raised pallet has a side (297) and a front guard (300).

Version H

– The raised pallet can be accessed from the truck. The truck does not have anygates in the load direction.

– The pallet has side gates (301) but is open at the front.

297

299

298

300

301

299 301

E 179

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BVersion I

– The raised pallet can be accessed from the truck via the gates (298) in theload direction.

– The pallet has side gates (301) but is open at the front.

Version J

– The raised pallet can be accessed from the truck. The truck does not have anygates in the load direction.

– The pallet has side gates (301).

– There is an option for a front guard through the gates (302).

301

299

298

301

301

299

302

301

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Version K

– The raised pallet can be accessed from the truck via the gates (298) in theload direction.

– The pallet has side gates (301).

– There is an option for a front guard through the gates (302).

Version L

– The raised pallet:

– cannot be accessed from truck.

– can be reached through the driver's cab extension (303).

301

299

302

301

298

303

E 181

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B8.2.3 Stockpicking platform with pallet lift option including pallet monitoring

and fixing

Z When pallets, pick boxes or load containers specially designed for the task are raised,they can be monitored and also fixed. The illustrations shown are examples and donot represent the equipment supplied.

Raised pallet load sensing version

Raised pallet load sensing via switches ornon-contact sensors.

Example:The "load sensing" switch (305) is locatedon the load handler between the forks.When the load sensing switch (305) ispressed, the controller is notified that apallet has been lifted.

Raised pallet mechanical stop with loadsensing version

Raised pallet load sensing via non-contactsensors.

Requirements:

– The pallet must have a pallet stopbolt (306).

– The pallet fixing / pallet stop locatingeye (307) must be located on the truck'sload handler.

305

306

307

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Claw with load sensing version

Raised pallet load sensing via switches ornon-contact sensors.

The "load sensing" switches or non-contactsensors (305) are located on the left andright sides of the load handler.

Z The claw (308) is used to fix the pallets.

Clamp with load sensing version

Raised pallet load sensing via a switch ornon-contact sensors. The "load sensing"switch or non-contact sensors (305) arelocated on the load handler.

Z The clamp (309) is used to fix the pallets.

308

305

309

305

E 183

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B8.3 Display of stockpicking platform side and / or front gates and load direction gates

Z The monitored side and / or front gates of the stockpicking platform aswell as the load direction gates are shown on the driver's display,depending on the use of the load handler (see "Display and Controls" inchapter E).

Z See also "Control Panel Controls and Displays" in chapter E.

Stockpicking platform without pallet lift option

The fitted gates are displayed as a single gate.

Stockpicking Platform with Pallet Lift Option

The fitted gates are shown like a side gate, irrespective of whether the pallet or picking box has been lifted and locked.

Stockpicking platform with panel and pallet lift option

Without a picking box raised and locked, the pallet lift panel is displayed as a single gate.

With a picking box raised and locked, the pallet lift panel is not displayed.

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E 184

8.3.1 Example: Monitored and non-monitored gates in load direction (o)

Access in the load direction is via:

– two foldaway, non-monitored gates (310)

– two monitored gates (311).

Z The gates (311) are displayed depending on whether the load handler is being used.Example:

– Without a picking box raised and locked, the gates (311) are displayedas a side gate.

– With a picking box raised and locked, the gates (311) are not displayed.

Description and operation of the gates

Without a raised and locked picking box:

– with the gate open (311) the operator position can be raised up to 1.2 m(fixed operator position height).

– When the gates (311) are closed, the operator position can be raised to themaximum lift height.

Z When the picking box is lifted and closed, the operator position can be raised to themaximum lifting height. The gates (311) are not monitored in this case.

310311 310

311

Closedgates

Opengates

E 185

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B8.4 Additional symbols in driver's display

The following symbols are displayed depending on the truck's equipment:

Z When the pallet or picking box is raised and locked by the clamp / claw, Main Lift -Auxiliary Lift lowering can only be performed using the override button at heightsbelow 10 cm. This is to avoid damaging the clamp / claw.

8.5 Lifting / depositing a load

F Ensure there are no other people standing underneath the raised load anddriver's cab.

• Do not stand on the load handler.

• Do not lift other people on the load handler.

• Instruct other people to move out of the hazardous area of the truck.

• Never stand underneath a raised and unsecured load handler / driver's cab.

Symbol Meaning

Clamp open

Clamp closed, no load clamped

Clamp closed, load clamped

Pallet / picking box raised and / or locked

Claw open

Claw closed

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E 186

F Risk of accidents / falling when using walk-on palletsWhen the gates are opened, the driver's cab can be raised to a fixed height up to amaximum of 1200 mm. When the gates are closed, the operator position can beraised to the maximum lift height.

• Only walk on pallets with a pallet guard (o).

• Beyond lift heights > 1200 mm the gates must be closed to enable travel, lifting andlowering (Main Lift).

• One-way pallets cannot be used as a surface to walk on.

• Good ground conditions.

• Only use pallets of a suitable size to fit a pallet guard.

F Risk of accidents / falling when using picking boxesWithout a raised and locked picking box, the driver's cab can be raised with open sidegates up to a maximum of 1200 mm (fixed driver's cab height).Without a raised and locked picking box, the driver's cab can be raised with closedgates for pallet lifting to the maximum lift height.When the picking box is lifted and closed, the operator position can be raised to themaximum lifting height. The gates for pallet lifting are not monitored in this case.

F Ensure there are no other people standing underneath the raised load anddriver's cab.

• Do not stand on the load handler.

• Do not lift other people on the load handler.

• Instruct other people to move out of the hazardous area of the truck.

• Never stand underneath a raised and unsecured load handler / driver's cab.

M Before a load can be deposited, the driver must ensure that the storage location issuitable for storing the load (size and capacity).

Z Loads must not be deposited on travel or escape routes, in front of safetymechanisms or plant equipment that must be accessible at all times.

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B8.5.1 Lifting / depositing a load with a mechanical lock on the forks (with or without

load-sensing)

Lifting a load with a mechanical lock on the forks (with or without load-sensing)

Requirements

– Truck prepared for operation.

– Load unit weight matches the truck's capacity.

– Forks evenly loaded.

– Good ground conditions.

Procedure

– Press the deadman button.

– Drive the truck carefully up to the load.

– Lower/raise the load handler so that theload can be lifted.

M Risk of injury and accidentsThe pallet / picking box must rest fully on theforks behind the anti-slip mechanisms (299).

– Insert the forks slowly into the pallet /picking box until:

– The fork shank is touching the load(pallet / picking box).

– The load is touching the load-sensingswitch (305) (o).

– Raise the load slightly until it rests freelyon the forks.

– Make sure you can see behind you andthat you have sufficient space to move. Now reverse the truck slowly until the loadis clear (e.g. out of the rack).

Z The load has been lifted correctly.

299

305

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E 188

Depositing a load with a mechanical lock on the forks (with or without load-sensing)

Requirements

– Truck prepared for operation.

– Load unit correctly lifted.

– Storage location suitable for the load (size and capacity).

– Good ground conditions.

Procedure

– Press the deadman button.

– Preparing to deposit the load in the rack:

– Raise or lower the load handler so that the load can be placed in the storagelocation without striking any objects.

– Carefully place the load in its storage location.

Z Avoid depositing the load suddenly to avoid damaging the load, load handler andthe rack.

– Carefully lower the load handler so that the forks are clear of the load.

Z When reversing make sure the goods are not damaged by the front guard or broughtcrashing down.

– Carefully remove the load handler from the load.

– Fully lower the load handler.

Z The load has been deposited correctly.

E 189

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B8.5.2 Lifting / depositing a load with a mechanical lock on the load handler

(with or without load-sensing)

Lifting a load with a mechanical lock on the load handler (with or without load-sensing)

Requirements

– Truck prepared for operation.

– Load unit weight matches the truck's capacity.

– Forks evenly loaded.

– Good ground conditions.

Procedure

Z The pallet / picking box must have a pallet stop bolt (306). The pallet retaining /pallet stop recess (307) must be located on the truck's load handler.

– Press the deadman button.

– Drive the truck carefully up to the load.

– Lower/raise the load handler so that theload can be lifted.

M Risk of injury and accidentsThe stop bolt (306) should enter the recessin the load handler (307).

– Insert the forks slowly into the pallet /picking box until:

– The fork shank is touching the load(pallet / picking box).

– The stop bolt (306) is in the recess of the load handler (307).

– The stop bolt (306) is touching the load-sensing sensor (o).

– Raise the load slightly until it rests freely on the forks.

– Make sure you can see behind you and that you have sufficient space to move.Now reverse the truck slowly until the load is clear (e.g. out of the rack).

Z The load has been correctly lifted and is mechanically (306, 307) protected againstslipping.

306

307

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Lifting a load with a mechanical lock on the load handler (with or without load-sensing)

Requirements

– Truck prepared for operation.

– Load unit correctly lifted.

– Storage location suitable for the load (size and capacity).

– Good ground conditions.

Procedure

– Press the deadman button.

– Preparing to deposit the load in the rack:

– Raise or lower the load handler so that the load can be placed in the storagelocation without striking any objects.

– Carefully bring the load to its storage location.

Z Avoid depositing the load suddenly to avoid damaging the load, load handler andthe rack.

– Lower the load handler sensitively until:

– The forks are clear of the load.

– The stop bolt (306) can be removed from the recess of the load handler (307).

Z When reversing make sure the goods are not damaged by the front guard or broughtcrashing down.

– Carefully remove the load handler from the load.

– Fully lower the load handler.

Z The load has been deposited correctly.

E 191

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B8.5.3 Lifting / depositing a load with load sensing and a clamp / claw for locking

Lifting a load with load sensing and a clamp / claw for locking

Requirements

– Truck prepared for operation.

– Load unit weight matches the truck's capacity.

– Forks evenly loaded.

– Good ground conditions.

Procedure

– Press the deadman button.

– Open the clamp / claw.

– Press the pushbutton (24) below the“clamp / claw” symbol (315/316) whilesimultaneously turning the hydrauliccontrol button (1) to the left.

– Drive the truck carefully up to the load.

– Lower/raise the load handler so that theload can be lifted.

– Insert the forks slowly into the pallet /picking box until:

– The fork shank is touching the load (pallet / picking box).

– The load is touching the load-sensing switch (o).

– Slowly raise the load until it is clear of the ground.

M Risk of injury and accidentsLock the pallet / picking box with the clamp / claw to prevent it from slipping / crashing.

– Close the clamp / claw.

– Press the pushbutton (24) below the “clamp / claw” symbol (315/316) whilesimultaneously turning the hydraulic control button (1) to the right.

Z When the pallet / picking box is locked, the load cannot be lowered down tothe ground.

– Make sure you can see behind you and that you have sufficient space to move.Now reverse the truck slowly until the load is clear (e.g. out of the rack).

The load has been lifted correctly.

315 3161

24

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E 192

Depositing a load with load-sensing and a clamp / claw for locking

Requirements

– Truck prepared for operation.

– Load unit correctly lifted.

– Storage location suitable for the load (size and capacity).

– Good ground conditions.

Procedure

– Press the deadman button.

– Preparing to deposit the load in the rack:

– Raise or lower the load handler so that the load can be placed in the storagelocation without striking any objects.

– Carefully bring the load to its storage location.

– Carefully lower the load handler to a height of approx. 10cm above the ground /rack surface.

– Open the clamp / claw.

– Press the pushbutton (24) below the “clamp / claw” symbol (315/316) whilesimultaneously turning the hydraulic control button (1) to the left.

Z Avoid depositing the load suddenly to avoid damaging the load, load handler andthe rack.

– Carefully lower the load handler so that the forks are clear of the load.

Z When reversing make sure the goods are not damaged by the front guard or broughtcrashing down.

– Carefully remove the load handler from the load.

– Fully lower the load handler.

The load has been deposited correctly.

E 193

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B8.6 EKS 513/515k/515 with auxiliary lift (o)

Z The auxiliary lift is operated as described in "Lift - Lower (Aux. Lift") in chapter E.

– Without a raised picking box the load handler can be raised approx. 450 mm withthe auxiliary lift.

– With a raised and lock picking box, raising of the auxiliary lift is inhibited when itreaches the seamless transition from the driver's cab to the pallet / picking box.

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9 Optional equipment

9.1 Rear view mirror (o)

Z Use the mirror only to observe the traffic behind you. Should you need visibility aids(mirrors, monitors etc.) to ensure adequate visibility, practice working with thembeforehand.

The rear view mirror (168) is fitted with a swivel joint. This allows the operator to setthe rear view mirror (168) to suit his individual requirements.

M An incorrectly set rear view mirror can cause accidentsIncorrectly set rear view mirrors can collide with the rack or goods during operation inthe narrow aisle.

• Adjust the rear view mirror so that the safety clearances between the truck and rackare in accordance with EN 1726-2 item 7.3.2.

• Minimum 100 mm safety clearance between rail guided truck and rack.

• Minimum 125 mm safety clearance between wire guided truck and rack.

168

E 195

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B9.2 Rider mode (in the driver's cab) (o)

In chapter E of the operating instructions: “Safety Regulations for the Operation ofForklift Trucks” the section “Unauthorised use of truck” strictly prohibits the carryingof passengers in the driver's cab and on the load handler.

M If the truck is equipped for passenger mode with an additional control panel(two-hand operation), a second person may be allowed in the driver's cab inexceptional circumstances.

• The driver must instruct the passenger how to operate in passenger mode andinform him of potential hazards.Example:Do not lean out of the driver's cab while travelling or lifting / lowering.

F A second person can only be transported if there is an additional control panel for thepassenger in the driver's cab. This control panel monitors the "two-handed operation"of the passenger.

• The additional control panel should only be added to activate passenger mode onthe truck.

• If unused, the control panel must be kept safe by an appointed person.

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9.2.1 Operation

Z The driver must check the passenger mode safety mechanisms before starting totravel. If one of the safety mechanisms is not functional, passenger mode must notbe activated. Notify the manufacturer's customer service department.

F The two-hand control switches on the additional control panel must be operational atall times.

If in exceptional circumstances, a second person is allowed to ride in the driver’s cabwith the owner’s permission, proceed as follows.

– Switch off the truck with the key switch.

– Attach the additional control panel to the side panel in the driver's cab.

– Establish an electrical connection between the truck and the additional control panel.

– Switch on the truck with the key switch.

– During operation (travel / lifting / lowering) the passenger must depress theswitches on the additional control panel with both hands (two-hand control).

Z If at any time while travelling or carrying out a hydraulic operation the two-handoperation switches installed for passenger mode are not pressed, travel and/orhydraulic operations are deactivated.

E 197

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B9.3 Weigher (o)

Z The truck can be fitted optionally with aweighing system. When the load hasbeen lifted, the weight [in kg] (187) isshown on the display unit.

M The weighing system is not a substitutefor a calibrated weigher.

9.3.1 Tare function (o)

Z The weighing system can optionally beequipped with tare function. The tarefunction sets the weigher display to zero.

Display zero setting:

– Press the deadman button.

– Without load raise the Main Liftapprox. 10 cm:

– Turn the hydraulic control button (1)to the left.

– Without load raise the Aux. Liftapprox. 10 cm:

– Press the “Aux. Lift”pushbutton (11) and simultane-ously turn the hydraulic controlbutton (1) to the left.

– Press the "Quit sub-menu"pushbutton (23).

Z Truck movement is inhibited in thistruck menu.

– The display unit shows the "Weigher display zero setting" symbol (189).

– Press the pushbutton (24) next to the "Weigher display zero setting" symbol (189).

– Press the pushbutton (71) below the “truck functions” symbol (190). The displayunit changes to the "truck functions" menu.

– The weight measurement in the driver's display unit is zero (187).

kgXX187

kg0

0

23 24

72

71

1891

187

190 11

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E 198

9.4 Using a work platform (o)

The truck's operating instructions, chapter E “Safety Regulations for the Operation ofForklift Trucks”, item “Unauthorised use of truck” strictly prohibit the carrying ofpassengers (travel and lifting) in the operator position and on the load handler.

If the truck is equipped for use with a detachable, authorised work platform, inexceptional circumstances a person who has been authorised by the proprietormay be carried in the work platform. The driver must instruct the passenger how to operate the work platform and pointout the hazards. Example: do not lean out of the work platform while travelling or lifting / lowering.

Z Operate the work platform only at reduced travel / hydraulic speeds!

M The work platform authorised for this truck must be connected mechanically andelectrically to the truck during operation. To do this, the work platform has a locking mechanism (86, 87) attached to the truck'sload handler and a connection cable (84) leading to the truck.

Z The work platform is equipped with an additional control panel (83) to enable two-hand operation for the passenger. The connection of the work platform (86) and theclosed gate (85a) are constantly monitored.

Z Maintenance intervals are listed in the operating instructions under “Maintenancechecklist – Work platform (o)” in chapter F.

83

8485a

86

90

8791

85b

8384

85a

86

87

8889

E 199

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B9.4.1 Operation

Z The work platform is authorised for one person only. If a second person is to becarried in the work platform, it must be fitted with an additional two-hand controlsystem.The operators must be instructed by the driver in how to operate the system and therisks involved.Example: do not lean out of the work platform while travelling or lifting / lowering.

If in exceptional circumstances, approved by the proprietor, the work platform is to belifted and an operator carried in it, proceed as follows:

9.4.2 Lifting the work platform

F The work platform must be lifted in such a way that at all times during travel, lifting orlowering, eye contact is maintained between the driver and the operator of thework platform.

M The work platform for the telescopic table can only be lifted from the left hand side(viewed in the load direction).

83

8485a

86

90

8791

85b

8384

85a

86

87

8889

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– Insert the forks fully in the fork guide (88, 90) of the work platform.

– Raise the work platform slightly until it is clear of the ground.

– Attachment:

– Now make sure that the lock (87) of the work platform is properly engaged in thestop (86) on the load handler.

– Push back the attachment to the standard position.

– Telescopic table:

– Push back the telescopic forks with the work platform to the standard position.

– Now make sure that the lock (87) of the work platform is properly engaged in thestop (86) on the truck.

– Using a bolt (86) prevent the work platform lock (87) from loosening.

Z The display unit shows the "work platform / stockpicking box raised andsecured" symbol. The raised and locked work platform is monitored by non-contact sensors.

– Connect the cable (84) of the work platform to the truck. Travel and hydraulicoperations are now only possible when the two-hand operation system (83) ispressed and the access gate (85a) is closed.

Z "Traversing" and / or "rotating" of the attachment are inhibited when the work platformhas been lifted and connected electrically. If the cable (84) is not connected to thetruck after the work platform has been lifted, all travel, lifting and lowering functionsare disabled.

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B9.4.3 Operating the work platform

F The driver must check the work platform safety mechanisms before starting to travel.Do not use the work platform if one of the safety mechanisms is not working.Notify the manufacturer’s customer service department.

• Report any defects immediately to your supervisor.

• Tag out and decommission a faulty lift truck.

• Only return the work platform to service when you have identified and rectifiedthe fault.

F The access gate to the work platform must be kept closed at all times while the truckis in operation. The passenger in the work platform must press the control panelswitches with both hands (two-handed operation) while travel, lifting or lowering.

Z If at any time while travelling or carrying out a hydraulic operation the two-handoperation switches installed in the work platform are not pressed, travel and/orhydraulic operations are deactivated. If at any time while travelling or carrying out a hydraulic operation the accessgate (85a) is opened, travel and hydraulic operations are disabled.

– The access gate (85a) can be opened via the switch in the work platform. In theevent of a fault the access gate (85a) can be opened with the key (85b) supplied.

83

8485a

86

90

8791

85b

8384

85a

86

87

8889

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E 202

M The driver must never leave the truck while there are people in the raised workplatform.

F Never disable the "work platform raised" switch, the "two-handed operation" switch orthe gate switch.No additional climbing aids (such as ladders, stools etc.) may be used in thework platform.Before starting (travel / lifting / lowering) the operator(s) must ensure that no objectsare protruding out of the work platform and that any objects they have taken with themare securely fixed.The work platform must not be accessed or left while in a raised position.Do not exceed the maximum load for the work platform. This can be found on thedata plate.

E 203

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B9.4.4 Lowering the work platform

– Disconnect the cable (84) of the work platform from the truck.

– Attachment:Extend the attachment and lower the work platform. Disconnect the locking mechanism (86, 87) between the work platform andthe truck.Telescopic table:Disconnect the locking mechanism (86, 87) between the work platform andthe truck. Extend the telescopic forks and lower the working platform.

– Retract the attachment / telescopic forks.

83

8485a

86

90

8791

85b

8384

85a

86

87

8889

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E 204

9.5 Fire extinguisher (o)

Z The fire extinguisher (171) can be attachedto the operator position or overhead guard.

– Open the lock (170).

– Pull the fire extinguisher (171) out of itsbracket (169) - see arrow direction.

Z To operate, refer to the illustrations on thefire extinguisher (171).

169

170

171

E 205

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B9.6 Closed driver's cab (o)

The truck can be fitted optionally with a closed driver's cab. In an emergency you canleave the driver's cab via the egress system.

9.6.1 Entering / exiting the driver's cab

Z On trucks fitted with a closed driver's cab, both doors can be closed.

174

172 173

175

176

177

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E 206

Opening and locking the cab door

Procedure

– To open the cab door (174):

– insert the key in the door lock (172).

– turn the key anti-clockwise as far as the stop.

– To lock the cab door (174):

– insert the key in the door lock (172).

– Turn the key clockwise as far as it will go:

Opening the door from the outside and the inside

Procedure

– To open the cab door (174) from the outside:

– lock the cab door (174).

– push the door lock (172) in and open the cab door (174) inwards.

– To open the cab door (174) from the inside:

– Push the handle (177) as far as the stop in the arrow direction.

– open the cab door (174) inwards.

Z The monitored cab doors are shown in the driver's display like a gate(see "Displays and controls" in Chapter E).

Entering / exiting the driver's cab

F Fall hazardWhen the cab door is open and the driver's cab raised, the operator risks falling outof the cab.

• Do not open the cab door when the driver's cab is raised.

– Fully lower the mast / driver's cab.

– Open the cab door.

– To enter and exit the cab, hold onto the cab chassis.

– Close the cab door from the inside.

M No more than one person may operate the truck in the driver's cab at a time.

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B9.6.2 Roof hatch

Opening / closing the roof hatch

Procedure

– Turn the lever (176) to:

– close and lock the roof hatch (175).

– open the roof hatch (175) by approx. 10°. This position allows the driver's cabto be ventilated

– open the roof hatch (175) fully by approx. 85°.

M Accident risk when the roof hatch is full openedWhen the roof hatch is fully opened the operator is not protected from falling objects.

• Do not open the roof hatch fully during operation.

• Do not perform any travel or hydraulic operations when the roof hatch is open.

174

172 173

175

176

177

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9.6.3 Exiting a closed driver's cab

Industrial trucks with a driver's cab which can be raised more than 3 m off the groundhave an emergency lowering mechanism and a rescue equipment (rescue harness /abseil device / rescue rope) for the driver which can be used to reach the groundshould the operator position be blocked.

Z See "Exiting the driver's cab with the rescue equipment" in chapter E.

Z If the driver’s cab cannot be lowered due to a fault, not even with the emergencylowering (see “Driver’s Cab Emergency Lowering” in chapter E), the operator mustexit the driver's cab via the emergency abseil device.

F Untrained personnel and non-serviced rescue equipment can result inaccidents and injuryThe rescue equipment (rescue harness / abseil device with rescue rope) should onlybe used by people who are physically capable, trained to use the equipment safelyand who have the required expertise.The user must have a rescue plan listing all necessary action to be taken inemergencies.

• The driver must undergo annual training in how to handle the rescue equipment.

• For the operation and service intervals of the rescue harness and the emergencyabseil device, refer to the accompanying operating instructions.

• Follow the maintenance intervals stated in rescue harness and emergency abseildevice operating instructions.

Z The Jungheinrich AG customer service department is specially trained for theseoperations.

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BExiting the driver's cab via the cab doors

Requirement

– Sufficient space between the driver's caband rack.

Procedure

– Switch off the truck with the key switch.

– Press the Emergency Disconnect.

– Take the abseil device and rescueharness out of the storage compartmentin the driver's cab, see "Rescueequipment storage compartment in thedriver's cab" in Chapter E.

Z The assembled rescue equipment is readyfor use on breaking the seal, removal fromthe equipment bag or case and aftercarrying out a visual inspection.

– Carry out a visual inspection of the rescue harness, abseil device, rescue rope andscrew lock karabiner, see "Visual Inspection of the Rescue Equipment" inchapter E.

– Put on the rescue harness, see "Putting on the rescue harness" in Chapter E.

– Open the cab door (174).

F Risk of falling after opening the cab door.When the cab door is open and the driver's cab raised, the operator risks falling outof the cab.

• When attaching the karabiner hook of the rescue rope make sure you are standingsecurely in the driver's cab.

– Insert the karabiner hook (181) of the rescue rope into the D ring (in accordancewith EN 795) on the overhead guard (180) and secure it with the union nut.

Z Abseiling is detailed in "Exiting the driver's cab with the rescue equipment" inchapter E.

174

172 173

180

180

181

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E 210

Exiting the driver's cab via the roof hatch

Requirement

– Sufficient space to open and exit thedriver's cab via the roof hatch.

Procedure

– Switch off the truck with the key switch.

– Press the Emergency Disconnect.

– Take the abseil device and rescueharness out of the storage compartmentin the driver's cab, see "Rescueequipment storage compartment in thedriver's cab" in Chapter E.

Z The assembled rescue equipment is readyfor use on breaking the seal, removal fromthe equipment bag or case and aftercarrying out a visual inspection.

– Carry out a visual inspection of therescue harness, abseil device, rescue rope and screw lock karabiner, see "VisualInspection of the Rescue Equipment" in chapter E.

– Put on the rescue harness, see "Putting on the rescue harness" in Chapter E.

– Turn the lever (176) anti-clockwise as far as the stop to open the roof hatch (175).

– Insert the karabiner hook (181) of the rescue rope into the D ring (in accordancewith EN 795) on the overhead guard (180) and secure it with the union nut.

F Fall riskThe operator may only exit via the roof hatch once he has secured himself to thedriver's cab with the karabiner hook.

– Exiting the driver's cab via the roof hatch. The seat and backrest can be used tohelp climb out of the cab.

Z Abseiling is detailed in "Exiting the driver's cab with the rescue equipment" inchapter E.

176

181

175

180

180

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B9.6.4 Exiting the driver's cab via the front window

Z Only exit the driver's cab via the frontwindow if you cannot exit via the roof hatchor cab door.

Procedure

– Switch off the truck with the key switch.

– Press the Emergency Disconnect.

– Take the abseil device and rescueharness out of the storage compartmentin the driver's cab, see "Rescueequipment storage compartment in thedriver's cab" in Chapter E.

Z The assembled rescue equipment is readyfor use on breaking the seal, removal fromthe equipment bag or case and aftercarrying out a visual inspection.

– Carry out a visual inspection of therescue harness, abseil device, rescuerope and screw lock karabiner, see"Visual Inspection of the Rescue Equipment" in chapter E.

– Put on the rescue harness, see "Putting on the rescue harness" in Chapter E.

– Remove the emergency hammer (182) from its bracket in the driver's cab.

180

183

180

182

181

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E 212

M Risk of injury when striking the front window

• Turn your face away and close your eyes when you strike the front window.

– Strike the front window (183) with the emergency hammer (182).

– Strike out the fragmented sections of the front window (183).

M Risk of injury from broken front windowsCarefully remove any fragments / glass splinters from the front window. If they are notremoved you may cut and injure yourself when leaving the driver's cab.

• Use hand protection to remove the fragments. You can use for example the rescueharness storage container as hand protection.

F Fall riskIf there is no front window and the driver's cab raised, the operator risks falling out ofthe cab.

• When attaching the karabiner hook of the rescue rope make sure you are standingsecurely in the driver's cab.

– Insert the karabiner hook (181) of the rescue rope into the D ring (in accordancewith EN 795) on the overhead guard (180) and secure it with the union nut.

Z Abseiling is detailed in "Exiting the driver's cab with the rescue equipment" inchapter E.

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B9.7 Camera system (o)

M Accident risk from hidden work areas

• The camera system acts as an aid to assist safe operation.

• Practice travelling and working with the camera system.

• Align the camera so that the hidden work area can be seen.

Z When using the camera to reverse, the monitor automatically switches on when youengage reverse gear.

Using the camera system

– Press the button (199) on the monitor to switch the camera system on or off.

– Press the button (198) to lighten or darken the screen (day / night settings).

– Press the button (195). The screen menu opens up.

Z Pressing the button (195) several times changes the menu item (contrast, brightness,colour saturation, language, video, light reflection) or quits the menu

Adjusting the menu items

– Press the button (197) to go one step forward.

– Press the button (196) to go one step back.

Z Clean a dirty screen or vent slots with a soft cloth or brush.

195 199198197196

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F Industrial Truck Maintenance

1 Operational Safety and Environmental Protection

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

F Risk of accidents and damage to componentsAny modification to the truck, in particular the safety mechanisms, is prohibited.The operating speeds of the truck must not be increased under any circumstances.

F Only original spare parts have been passed by our quality assurance service.To ensure safe and reliable operation of the truck, use only the manufacturer'sspare parts.For safety reasons, only components which have been specially agreed by themanufacturer for this truck may be installed near the computer, controllers and wireguidance antennae. These components (computers, controllers, wire guidanceantennae) must therefore not be replaced either by similar components from othertrucks of the same series.

F Old parts, oils and fuels must be disposed of in accordance with the applicableenvironmental protection regulations. For oil changes, contact the manufacturer’s oilservice department.

On completion of inspection and service work, carry out the activities listed in the“Recommissioning the truck after cleaning or maintenance work” section(see chapter F).

2 Maintenance safety regulations

Maintenance personnel: Industrial trucks must only be serviced and maintained bythe manufacturer’s trained personnel. The manufacturer’s service department hasfield technicians specially trained for these tasks. We therefore recommend that youenter into a maintenance contract with the manufacturer’s local service centre.

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F 2

Lifting and jacking up

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

• Jack up the truck only on a level surface and prevent it from moving accidentally.

• Always use a jack with sufficient capacity. When jacking up the truck, takeappropriate 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 pointsspecially provided for this purpose, see "Identification points and data plates" inchapter B.

• When jacking up the truck, take appropriate measures to prevent it from slipping ortipping over (e.g. wedges, wooden blocks).

Z Prevent the driver's cab from accidentally lowering (see "Preventing the driver's cabfrom accidentally lowering" in Chapter F) and jack lifting points (see "Identificationpoints and data plates" in Chapter B).

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BCleaning

M Fire hazardDo not use flammable liquids to clean the industrial truck.

• Always disconnect the battery before starting cleaning work.

• Carry out all necessary safety measures to prevent sparking before cleaning(e.g. by short-circuiting).

M Risk of electrical system damageThe electrical system can be damaged if it is cleaned with water. Do not wet-cleanthe electrical system.

• Do not clean the electrical system with water.

• Clean the electrical system with weak suction or compressed air (use a compressorwith a water trap) and not a conductive, anti-static brush.

M Risk of component damage when cleaning the truckIf the truck is to be cleaned with a water jet or a high-pressure cleaner, all electricaland electronic components must be carefully covered beforehand as moisture cancause malfunctions. Do not clean with pressurised water.

Z After cleaning, carry out the activities detailed in “Recommissioning the truck aftercleaning or maintenance work” (see chapter F).

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F 4

Electrical system

M Accident risk

• Only suitably trained electricians may operate on the truck's electrical system.

• Before working on the electrical system, take all precautionary measures to avoidelectric shocks.

• Always disconnect the battery before starting cleaning operations.

F Electric currents can cause accidentsMake sure the electrical system is voltage-free before starting work on it.The capacitors in the controller must be fully discharged. The capacitors are fullydischarged after approx. 10 minutes. Before starting maintenance on the electricalsystem:

• Park the truck securely, see “Parking the Truck Securely” in Chapter E.

• Press the Emergency Disconnect.

• Disconnect the battery.

• Remove any rings or metal bracelets etc. before working on electrical components.

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BConsumables and used parts

M Consumables and used parts are an environmental hazardUsed parts and consumables must be disposed of in accordance with the applicableenvironmental protection regulations. To change the oil contact the manufacturer'scustomer service department, who have been specially trained for this task.

• Note the safety regulations when handling these materials.

Welding: To avoid damaging electric or electronic components, remove these fromthe truck before performing welding operations.

F Load bearing parts of the truck may only be welded after consultation with themanufacturer.

Settings: When repairing or replacing hydraulic, electric or electronic componentsor assemblies, always note the truck-specific settings.

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F 6

Wheels

F The use of wheels that do not comply with the manufacturer's specificationscan result in accidents.The quality of wheels affects the stability and performance of the truck.Uneven wear affects the truck's stability and increases the stopping distance.

• When replacing wheels make sure the truck is not skewed.

• Always replace wheels in pairs, i.e. left and right at the same time.

Z When replacing wheels fitted at the factory, only use the manufacturer’s originalspare parts. Otherwise the truck's rated performance cannot be ensured.

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B3 Servicing and Inspection

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

M The application conditions of an industrial truck have a considerable impact on thewear of the service components. We recommend that a Jungheinrich customer service adviser carries out anapplication analysis on site to work out specific service intervals to prevent damagedue to wear.The service intervals stated are based on single shift operation under normaloperating conditions. They must be reduced accordingly if the truck is to be used inconditions of extreme dust, temperature fluctuations or multiple shifts.

The following maintenance checklist states the tasks and intervals after which theyshould be carried out. Maintenance intervals are defined as:

W = Every 50 service hours, or at least weeklyA = Every 500 service hoursB = Every 1000 service hours, or at least annuallyC = Every 2000 service hours, or at least annually

Z W maintenance interval operations are performed by the proprietor.

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F 8

4 Maintenance Checklist

Maintenance intervals

Standard= t W A B C

Brake 1.1 Test operation t

1.2 Check effectiveness of operating and parking brakes, adjust where necessary and measure braking distance

t

1.3 Check brake lining wear on drive brake t

1.4 Check electrical connections t

1.5 Make sure the sensors are secured, not damaged, clean and operational

t

1.6 Test micro switch setting t

Electricalsystem

2.1 Check static charge eliminator is present t

2.2 Test instruments, displays and control switches t

2.3 Test electric system t

2.4 Check electrical system for frame leakage t

2.5 Test lighting t

2.6 Test warning and safety devices and cutouts t

2.7 Check fuse ratings t

2.8 Make sure wire connections are secure and check for damage

t

2.9 Test the operation of the cable guides and check for damage

t

2.10 Make sure sensors are secured, not damaged, clean and operational

t

2.11 Test micro switch setting t

2.12 Check contactors, replace any worn parts. t

2.13 Check relays, replace any worn parts. t

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Maintenance intervals

Standard= t W A B C

Power supply 3.1 Battery visual inspection t

3.2 Check battery cable connections are secure, grease terminals if necessary.

t

3.3 Make sure battery plug connections, battery cables and cell connectors are secure and check for damage; replace and clean if necessary

t

3.4 Check acid density, acid level and cell voltage t

3.5 Visually inspect Aquamatik lines and connections t

Travel 4.1 Test travel function t

4.2 Test travel switch. t

4.3 Test travel speeds t

4.4 Check motor attachment t

4.5 Make sure motor lines are secure and check for damage t

4.6 Make sure sensors are secured, not damaged, clean and operational

t

4.7 Check transmission for noise and leakage t

4.8 Check transmission oil level, top up if necessary t

4.9 Change the gear oil t

4.10 Check drive wheel / load wheel for wear and damage t

4.11 Check drive wheel / load wheel bedding and attachment t

4.12 Check rail guide rollers for wear and damage t

4.13 Check rail guide roller bedding and attachment t

4.14 Check the distance between the guide roller and the rail guidance over the entire length of the rails

t

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F 10

Maintenance intervals

Standard= t W A B C

Truck setup 5.1 Check all load bearing components for damage t

5.2 Check screw connections t

5.3 Check mast attachments (bearings and retaining screws) t

5.4 Check mast anchoring for damage (option) t

5.5 Check the truck chassis for damage. t

5.6 Make sure tilt safety devices are present and check the setting (option)

t

5.7 Check active stabilisers are present; test settings and operation (option)

t

5.8 Check the overhead guard for damage t

5.9 Test the operator platform and check for damage t

5.10 Check the cabin for damage. t

5.11 Check the mast guard for damage t

5.12 Test the gates and gas pressure dampers and check for damage

t

5.13 Test the folding seat and check for damage t

5.14 Check the step mat for damage. t

5.15 Check the indication points and labels are legible and replace if necessary

t

5.16 Check the battery rollers are present and test them. t

5.17 Check the battery retainers are present and test them. t

5.18 Make sure battery sensors are secured, not damaged, clean and operational

t

5.19 Check the battery panel and sides are secure t

5.20 Test the battery cover gas pressure springs and check for damage

t

Hydraulic operation

6.1 Test hydraulic operations t

6.2 Test Main Lift lower / raise controls t

6.3 Test Aux. Lift lower / raise controls t

6.4 Test traverse / rotate controls t

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p) Replace hydraulic hoses after 6 years' operation

Maintenance intervals

Standard= t W A B C

Hydraulic operation

6.5 Test lift and lowering speeds t

6.6 Test rotate and traverse speeds t

6.7 Test emergency lowering valve t

6.8 Check motor attachment t

6.9 Make sure motor lines are secure and check for damage t

6.10 Make sure sensors are secured, not damaged, clean and operational

t

6.11 Check the mast for damage. t

6.12 Clean rollers, guide rollers and contact surfaces in the mast sections and apply grease

M Danger of crashing!

t

6.13 Check setting of slide pieces and stops, and adjust if necessary

t

6.14 Visually inspect mast rollers and check contact surface wear level

t

6.15 Visually inspect rollers, slide pieces and stops t

6.16 Check lift chains and guides for wear, adjust and lubricate.

t

6.17 Lubricate lift chains t

6.18 Test automatic chain lubrication (option) t

6.19 Check chain bolts for damage and make sure the lockwashers / pins are present

t

6.20 Test slack chain switch t

6.21 Check valves for leaks and damage t

6.22 Test operation of pressure relief valves t

6.23 Check hydraulic cylinder and piston rods for damage and leaks and make sure they are secure

t

6.24 Check that hose and pipe lines and their connections are secure, check for leaks and damage, and tighten unions if necessary p)

t

6.25 Test hose guide and check for damage t

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Maintenance intervals

Standard= t W A B C

Hydraulic operation

6.26 Test attachment, check settings and check for damage t

6.27 Check the attachment is properly secured to the truck and the supporting member

t

6.28 Attachment: Visually inspect bearing points, guides and stops for wear and damage, lubricate these components

t

6.29 Attachment: Check the eccentric bolt setting on swivel traverse frame and adjust if necessary

t

6.30 Clean and grease toothed racks t

6.31 Lubricate rollers, guide rollers and swivel bearings on the swivel traverse fork.

t

6.32 Check the rotary / traverse hydraulic motor for leaks and damage

t

6.33 Check hydraulic oil level and top up if necessary t

6.34 Replace hydraulic oil t

6.35 Replace filter cartridge t

6.36 Replace ventilation and discharge filter on hydraulic reservoir

t

6.37 Check the fork tines and fork carriage for wear and damage

t

Steering 8.1 Test steering t

8.2 Test operation and setting of wheel setting display t

8.3 Check motor attachment t

8.4 Make sure motor lines are secure and check for damage t

8.5 Make sure sensors are secured, not damaged, clean and operational

t

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e) WG: wire guidance trucksf) For trucks with a Personal Protection System (PPS)

Maintenance intervals

Standard= t W A B C

System components

9.1 Test the wire guidance and cutout limits, adjust if necessary e)

t

9.2 Measure the current in the guide wire, adjust if necessary e)

t

9.3 Check travel on the guide wire, check maximum deviation and adjust if necessary e)

t

9.4 Check the guide wire acquisition for aisle tracking e) t

9.5 Check wire guidance Emergency Stop operation e) t

9.6 Check the laser scanner attachment on the Personal Protection System f)

t

9.7 Clean the front screens of the Personal Protection System laser scanners f)

t

9.8 Test the Personal Protection System f) t

9.9 Test the warning and protective field areas of the Personal Protection System f)

t

Sign off/Dem-onstration

10.1 Lubricate the truck according to the lubrication schedule t

10.2 Carry out a test run with / without rated load t

10.3 Demonstration after servicing t

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F 14

4.1 Attachment service checklist (options)

M Check the attachment daily for external signs of damage or defects. If necessary(for major damage such as breakage) the truck may have to be taken out of service.

• Report any defects immediately to your supervisor.

• Tag out and decommission a faulty lift truck.

• Only return the truck to service when you have identified and rectified the fault.

4.1.1 Symmetrical/asymmetrical sideshift with integrated fork adjuster checklist (o)

Z In addition to the items described in chapter F of the operating instructions,the following service items must be carried out.

4.1.2 Maintenance checklist – telescopic table (o)

Z In addition to the items described in chapter F of the operating instructions,the following service items must be carried out.

Maintenance intervals

Standard= t W A B C

Fork adjuster with sideshift

1 Clean and lubricate the fork adjuster contact surfaces t

2 Clean and lubricate the sideshift plate contact surfaces t

3 Check the hydraulic unions for leaks. t

Maintenance intervals

Standard= t W A B C

Telescopic table

1 Check anti-slip lining for damage and wear,replace if necessary.

t

2 Check chain tension, adjust if necessary t

3 Clean and lubricate chains t

4 Check rollers and telescopic shuttle table gear unit for wear and lubricate.

t

5 Clean and lubricate wear strips t

6 Lubricate all lubrication points t

7 Check switch contacts and magnetic coupling t

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B4.1.3 Maintenance checklist – telescopic forks (o)

Z In addition to the items described in chapter F of the operating instructions,the following service items must be carried out.

4.1.4 Maintenance checklist – fork adjuster (o)

Z In addition to the items described in chapter F of the operating instructions,the following service items must be carried out.

Maintenance intervals

Standard= t W A B C

Telescopic forks

1 Check chain tension, adjust if necessary t

2 Clean and lubricate chains t

3 Clean and lubricate wear strips t

4 Check outer shoe wear (a) t

5 Check contact surface on inner fork tip t

6 Replace dowel pins t

Maintenance intervals

Standard= t W A B C

Forkpositioner

1 Check chain tension, adjust if necessary t

2 Clean and lubricate the fork positioner contact surfaces t

3 Check mechanical limit stops. t

a

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F 16

4.1.5 Maintenance checklist – work platform (o)

Z In addition to the items described in chapter F of the operating instructions,the following service items must be carried out.

4.1.6 Maintenance checklist - on-board charger (o)

Z In addition to the items described in chapter F of the operating instructions,the following service items must be carried out.

Maintenance intervals

Standard= t W A B C

Work platform 1 Test the operation of the work platform and check for damage

t

2 Check the locks / stops on the truck and work platform for damage

t

3 Check the wires, connectors and switches for damage. t

Maintenance intervals

Standard= t W A B C

On board charger

1 Check current collector for damage and wear, and test operation

t

2 Check collector contacts for wear t

3 Test operation t

4 Check cable and plug connections for damage and wear t

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B4.1.7 Maintenance checklist – horizontal positioning (o)

Z In addition to the items described in chapter F of the operating instructions,the following service items must be carried out.

Maintenance intervals

Standard= t W A B C

Horizontalpositioning

1 Clean barcode scanner with an appropriate solvent t

2 Check the horizontal position reflection light barrier is secure and clean

t

3 Test operation t

4 Check cable and plug connections for damage and wear t

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5 Lubricants and Lubrication Schedule

5.1 Handling consumables safely

Handling consumables

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

F Improper handling is hazardous to health, life and the environmentConsumables can be flammable.

• Keep consumables away from hot components and naked flames.

• Always keep consumables in prescribed containers.

• Always fill consumables in clean containers.

• Do not mix different grades of consumable. The only exception to this is whenmixing is expressly stipulated in the Operating Instructions.

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

• Do not spill fluids.

• Spilled fluids must be removed immediately with an appropriate bonding agent.

• The bonding agent / consumable mixture must be disposed of in accordancewith regulations.

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

• Dispose of used oils in accordance with regulations. Store used oil safely until it canbe disposed of in accordance with regulations.

• Do not spill oil.

• Spilled fluids must be removed immediately with an appropriate bonding agent.

• The bonding agent / consumable mixture must be disposed of in accordance withregulations.

• Observe national regulations when handling oils.

• Wear safety gloves when handling oils.

• Prevent oil from coming into contact with hot motor parts.

• Do not smoke when handling oil.

• Avoid contact and digestion. If you swallow oil do not induce vomiting but call fora doctor immediately.

• Seek fresh air after breathing in oil fumes or vapours.

• If oil has come into contact with your skin, rinse your skin with water.

• If oil has come into contact with your eyes, rinse them with water and call fora doctor immediately.

• Replace oil-soaked clothing and shoes immediately.

• Consumables and used parts

M Consumables and used parts are an environmental hazardUsed parts and consumables must be disposed of in accordance with the applicableenvironmental protection regulations. To change the oil contact the manufacturer'scustomer service department, who have been specially trained for this task.

• Note the safety regulations when handling these materials.

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F 20

5.2 Lubrication Schedule

g Contact surfaces a Transmission oil drain plug

s Grease nipple c Hydraulic oil drain plug

Hydraulic oil filler neck

C

F

D

CC

G

C

C

E

F

A

E

C

B

E

F 21

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B5.3 Consumables

* Plus 2% additive 68 ID (order no. 50 307 735)

F The trucks are supplied from the factory with “HLP D22” hydraulic oil or the“Plantohyd 22 S + 2% 68 ID additive” BIO hydraulic oil. You cannot change from the Plantohyd 22 S BIO hydraulic oil to HLP D22. The sameapplies to changing from HLP D22 hydraulic oil to Plantohyd 22 S BIOhydraulic oil. Furthermore, you cannot mix HLP D22 hydraulic oil Plantohyd 22 SBIO hydraulic oil.

Code Order no.Quantity supplied

Capacity Description Application

A

51 037 49751 037 494

5 l1 l approx.

105 l

HLP D22 including 2% share of additive

68 ID Hydraulic system

51 085 361* 5 lPlantohyd 22 S

(BIO hydraulic oil)

B 51 179 177 1 lapprox.

6.6 l

British Petrolium (BP)

Enersyn EP-XF150Transmission

C14 038 650

400 g (cartridge) ---

Grease - Lithium KP2K-30

(DIN 51825)

General,Toothed racks

Mast29 201 430 1 kg

D

29 201 280 400 ml ---Chain spray

Tunfluid LT 220

Lift chains

51 079 513 120 ml ---Automatic chain

lubrication cartridge with battery pack

E 50 002 004 400 ml --- Contact spray / grease Running surfaces

F51 085 365 500 ml --- All purpose cleaner Laser scanner of

personal safety system (PSS)51 085 537 1 piece --- Cleaning cloth

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F 22

6 Maintenance and Repairs

6.1 Preparing the truck for maintenance and repairs

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

– Park the truck securely, see “Parking the Truck Securely” in Chapter E.

– Switch off the truck via the key switch (key switch in “0” position”).

– Disconnect the battery to prevent the truck from being switched on accidentally

– When working under a raised lift truck, secure it to prevent it from lowering, tippingor sliding away.

– Remove the drive compartment panel, see "Drive panel disassembly / assembly"in chapter F.

F When working under a raised load handler / driver's cab or a raised truck, securethem to prevent the truck from from lowering, tipping or sliding away. When raisingthe truck, follow the instructions in chapter C, “Transport and Commissioning”.When working on the parking brake, always secure the truck to prevent it fromaccidentally rolling away.

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B6.2 Preventing the driver's cab from accidentally lowering

Z When carrying out maintenance and repair workunder the driver's cab or load handler, the raised cabmust be prevented from accidentally lowering. Thecab must not be secured with a load on the loadhandler, to prevent people below the cab from beinginjured by falling loads. Do not perform any workunderneath the driver's cab without a cab lockingdevice in place.

– Place a step ladder next to the truck so that theraised driver's cab can be safely vacated via thestep ladder.

– Raise the operator position carriage above thefirst or second mast cross-member.

Z The first mast cross-member is located approx. 450 mm and the second approx.1800 mm above the ground. Any number of attachment heights are possible betweenthe DZ and ZT masts.

– Loosen the twist grip screws (2) under the driver's seat (1) and carefully move theseat forward.

1

2

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F 24

– Loosen the lever (7) by turning it anti-clockwise.

– Raise the pin retainer (6) slightly and flip it over to the left.(see arrow directions A and B).

– Push the fastening bolt (4) through as far as the second groove (9) (see arrowdirection C).

– Engage the pin retainer (6) in the second groove (9) (see arrow directions D and E).

– Secure the pin retainer (6) by pulling on the lever (7) (turn the lever (7) anti-clockwise).

– Slowly lower the driver's cab until the fastening bolt (4) is resting on the mast cross-member (3).

– Switch off the truck.

– Open the gate.

M Falling hazard when vacating the driver's cabMove carefully and slowly from the driver's cab onto the step ladder. The stability ofthe step ladder must be ensured at all times.

• Use only sufficiently long step ladders (at least 2m).

– Carefully exit the driver's cab via the step ladder.

– Open the battery panel.

– Disconnect the battery to prevent the truck from being switched on accidentally.

A

B D

C

E

3

4

5

6

3

6

4

7

1 1

9 8

7

F 25

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BAfter carrying out maintenance / repairs

– Re-connect the battery.

– Close the battery cover.

M Falling hazard when entering the driver's cabMove carefully and slowly from the step ladder into the driver's cab. The stability ofthe step ladder must be ensured at all times.

• Use only sufficiently long step ladders (at least 2 m).

– Enter the driver's cab securely via the step ladder.

– Close the gate.

– Switch on the truck.

– Raise the driver's cab so that the fastening bolt (4) is no longer resting on the mastcross member (3).

– Loosen the lever (7) by turning it anti-clockwise.

– Raise the pin retainer (6) and flip it over to the left (see arrow directions E and D).

– Push the fastening bolt (4) through as far as the first groove (8) (see arrowdirection C).

– Engage the pin retainer (6) in the first groove (8) (see arrow directions B and A).

– Secure the pin retainer (6) by pulling on the lever (7) (turn the lever (7) anti-clockwise).

– Carefully fold the driver's seat back (1) and fasten it by tightening the two twistgrip screws (2).

– Lower the driver's cab.

A

B D

C

E

3

4

5

6

3

6

4

7

1 1

9 8

7

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F 26

6.3 Lift chain servicing

F Non-lubricated and incorrectly cleaned lift chains can cause accidentsLift chains are safety-critical parts. They must not contain any serious contamination.Lift chains and pivot pins must always be clean and well lubricated.

• Lift chains should only be cleaned with paraffin derivatives e.g. petroleum ordiesel fuels.

• Never clean chains with steam jet high pressure cleaners, cold or chemicalcleaning agents.

• Immediately after cleaning, dry the lift chain with compressed air and apply achain spray.

• Always lubricate a chain when it is discharged.

• Lubricate a lift chain with particular care around the pulleys.

Z The intervals stated in the service checklist apply to normal duty use.More demanding conditions (dust, temperature) require more regular lift chain lubri-cation. The prescribed chain spray must be used in accordance with the instructions.Applying grease externally will not provide sufficient lubrication for the lift chains.

6.4 Lubricating the lift chains, cleaning and greasing the contact surfaces in themast sections

F Accident risk when carrying out maintenance at heightRisk of crashing and trapping when carrying out maintenance at height(e.g. lubricating the mast).

• Wear personal protective equipment.

• Use a work platform, lifting platform or safety ladder.

• Do not use a step ladder.

• Do not stand under the driver's cab and / or the attachment.

Requirements:

– Park the truck on a level surface.

– Instruct a second person to operate the truck.

– Wear personal protective equipment.

Required tools and materials

– Use a work platform, lifting platform or safety ladder

Procedure

F 27

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B

F Accident riskBe aware of the ceiling height when lifting the attachment and / or the driver's cab.

– Get the second person to fully raise the attachment and / or driver's cab.

– Switch off the truck.

– Disconnect the battery.

F Do not place the work platform, lifting platform or safety ladder under an unsecuredattachment and / or driver's cab.

• Instruct other people to move out of the hazardous area of the truck.

• Never reach or climb into moving truck parts.

• Never stand underneath a raised attachment / driver's cab.

– Position the work platform, lifting platform or safety ladder directly next to the truck.

– From the work platform, lifting platform or safety ladder:

– Lubricate the lift chains.

– Clean the stop faces in the mast sections and apply grease.

Z For the lubricant refer to "Consumables" in Chapter F.

– Remove the work platform, lifting platform or safety ladder.

– Connect the battery to the truck.

– Switch on the truck.

– Get the second person to fully lower the attachment and / or driver's cab.

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F 28

6.5 Automatic chain lubrication (o)

The trucks can optionally be fitted with an automatic chain lubrication system.The lubrication unit (10) used in automatic chain lubrication consists of a driveunit (11) and a lubrication cartridge (12). The lubrication unit (10) lubricates the liftchains over a period of one, three, six or twelve months. This interval can be set viathe drive unit (11) (see “Setting the Lubrication Interval” in this chapter). The lubricantcartridge (12) must be replaced after the set lubrication interval (see "Replacing thelubricant cartridge" in this chapter).

Z The number of lubrication units (10) used depends on the mast:

– ZT mast: two lubrication units on the top mast cross member.

– DZ mast:two lubrication units on the top mast cross member, two lubrication units on the free lift cylinders.

6.5.1 Lubricant cartridge replacement

F Accident risk when carrying out maintenance at heightRisk of falling and trapping when carrying out maintenance at height (e.g. lubricatingthe mast).

• Wear personal protective equipment.

• Use a work platform, lifting platform or safety ladder.

• Do not use a step ladder.

• Do not stand under the driver's cab and / or the attachment.

10

F 29

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BRequirements:

– Park the truck on a level surface.

– Wear personal protective equipment.

Required tools and materials

– Use a work platform, lifting platform or safety ladder

Procedure:

– Fully lower the main and auxiliary lift.

– Switch off the truck.

– Disconnect the battery.

– Position the work platform, lifting platform or safety ladder directlynext to the truck so that the lubrication unit (10) can be safelyreached.

F Danger of falling!

– Unscrew the lubrication unit (10) from its bracket.

– Screw the drive unit (11) and lubrication cartridge (12) apart.

– Insert the new battery pack in the drive unit (11).

Z When replacing the lubricant cartridge (12) a new battery pack must be inserted inthe drive unit (11) to ensure sufficient power supply during operation.

– Screw the drive unit (11) and lubrication cartridge (12) back together.

– Set the lubrication interval, see "Setting the Lubrication Interval" in this chapter.

– Remove the drain plug from the lubricant cartridge.

– Unscrew the lubrication unit (10) from its bracket.

– Turn the rotary switch from OFF to ON.

Z A permanently lit red light for 25 seconds indicates that the automatic chainlubrication is working correctly.

– Remove the work platform, lifting platform or safety ladder.

– Connect the battery to the truck.

– Switch on the truck.

11

12

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F 30

6.5.2 Setting the lubrication interval

The lubrication intervals can be set via the two switches on the drive unit (11).

Z After setting the interval, place the supplied stickers with the lubrication intervals onthe drive unit (11) and the installation date on the lubricant cartridge (12).

Switch setting Lubrication Interval

One month

Three months

Six months

Twelve months

F 31

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B6.5.3 Automatic chain lubrication indicator

Display Function Duration

Red permanent signal Start up 25 secs

Green flashing signal Unit working correctly 15 secs

Red flashing signal Error / fault 8 secs

Green / red flashing signal Lubricant cartridge is empty 3 secs

Red signal Lubrication 1 - 5 sec.

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F 32

6.6 Lift chain inspection

Unauthorised wear and external damage:

In accordance with official regulations, a chain is considered to be worn if it hasextended in length by 3% in the section which passes over the deflection pulley.For safety reasons, Jungheinrich advises replacing chains when they have elongatedby 2%.Replace a chain immediately if it shows external signs of damage. This type ofdamage will result in permanent breakage.

F If the truck is fitted with two lift chains, both chains must always be replaced. This isthe only way to ensure even load distribution over the two chains.

• When replacing chains the connecting bolts between the chain anchor and thechain must be replaced.

• Always use new original parts.

Z The Jungheinrich AG customer service department is specially trained for theseoperations.

F 33

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B6.7 Hydraulic hose lines

F Brittle hydraulic hose lines can cause accidentsThe hoses must be replaced every six years. The manufacturer's customer servicedepartment is specially trained to carry out these operations.

• Comply with the safety regulations for hydraulic hose lines in accordance withBGR 237.

Z The Jungheinrich AG customer service department is specially trained for theseoperations.

F Hydraulic line leaks can cause accidentsHydraulic oil can escape from leaky and faulty hydraulic lines.

• Report any defects immediately to your supervisor.

• Tag out and decommission a faulty lift truck.

• Only return the truck to service when you have identified and rectified the fault.

• Spilled fluids must be removed immediately with an appropriate bonding agent.The bonding agent / consumable mixture must be disposed of in accordance withregulations.

F Hairline cracks in the hydraulic lines can cause injury and infectionPressurised hydraulic oil can penetrate the skin through fine holes or hairline cracksin the hydraulic lines, causing severe injury.

• Call for a doctor immediately if you are injured.

• Do not touch pressurised hydraulic lines.

• Report any defects immediately to your supervisor.

• Tag out and decommission a faulty lift truck.

• Only return the truck to service when you have identified and rectified the fault.

• Spilled fluids must be removed immediately with an appropriate bonding agent.The bonding agent / consumable mixture must be disposed of in accordance withregulations.

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F 34

6.8 Drive panel disassembly / assembly

Drive panel disassembly

– Remove the Allen key (18) from thebracket in the centre below the strobe.

– Remove the two Allen screws (15, 16)using the Allen key (18).

– Tilt the drive panel (11) back and lift itout from the top (see arrow direction).

Drive panel assembly

M Trapping hazardThere is a risk of trapping when you fitthe drive compartment cover.

• Make sure there is nothing betweenthe battery cover and the truck whenyou fit the battery cover.

– Insert the drive panel (17) at an angleinto the chassis and tilt it forward.

– Attach the drive panel (17) to the truckwith the Allen screws (15, 16).

– Tighten the Allen screws (15, 16) usingthe Allen key (18).

– Fit the Allen key (18) in the bracket in the centre below the strobe.

– After cleaning or repairs restore the truck to service, see "Recommissioning thetruck after cleaning or maintenance work" in chapter F.

15

16

17

18

F 35

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B6.9 Checking the hydraulic oil level

M The hydraulic oil is pressurised during operation and is a hazard to health and tothe environment.

• Do not touch pressurised hydraulic lines.

• Dispose of used oil in accordance with regulations. Store used oil safely until it canbe disposed of in accordance with regulations.

• Do not spill hydraulic oil.

• Spilled fluids must be removed immediately with an appropriate bonding agent.

• The bonding agent / consumable mixture must be disposed of in accordancewith regulations.

• Observe national regulations when handling hydraulic oil.

• Wear safety gloves when handling hydraulic oil.

• Prevent hydraulic oil from coming into contact with hot motor parts.

• Do not smoke when handling hydraulic oil.

• Avoid contact and digestion. If you swallow oil do not induce vomiting but call fora doctor immediately.

• Seek fresh air after breathing in oil fumes or vapours.

• If oil has come into contact with your skin, rinse your skin with water.

• If oil has come into contact with your eyes, rinse them with water and call fora doctor immediately.

• Replace oil-soaked clothing and shoes immediately.

F Hydraulic line leaks can cause accidentsHydraulic oil can escape from leaky and faulty hydraulic lines.

• Report any defects immediately to your supervisor.

• Tag out and decommission a faulty lift truck.

• Only return the truck to service when you have identified and rectified the fault.

• Spilled fluids must be removed immediately with an appropriate bonding agent.The bonding agent / consumable mixture must be disposed of in accordance withregulations.

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F 36

6.9.1 Checking the hydraulic oil level and replenishing if necessary

Requirements

– Park the truck on a level surface.

– Fully lower the main and auxiliary lift.

– Prepare the truck for maintenanceand repairs (see "Preparing the truckfor maintenance and repairs" in thischapter).

– Remove the drive compartment panel,see "Drive panel disassembly /assembly" in chapter F.

Procedure

– Turn the breather (19) and dipstick (21)anti-clockwise out of the hydraulicreservoir (22).

– The hydraulic oil should level betweenthe "MIN" and "MAX" marks on the dipstick (21).

21

19

22

F 37

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M Overfilling the hydraulic reservoir can result in damageThe hydraulic oil should not be above the "MAX" mark on the dipstick, as anyescaping oil can damage the hydraulic system.

– If the hydraulic oil level is below the "MIN" mark on the dipstick (21), add approx.3.75 litres of new hydraulic oil in accordance with the consumables table to reachthe upper "MAX" mark on the dipstick (21). The hydraulic reservoir (22) is now full.

– Trucks with bio hydraulic oil have a warning notice on the hydraulicreservoir: “Add bio hydraulic oil only”. In this case you may only use“Plantohyd 22 S” bio hydraulic oil to replenish the hydraulic reservoir.

– Trucks with normal hydraulic oil have a warning notice on the hydraulicreservoir: “Add hydraulic oil”. In this case use only the "HLP D22including 2% content additive 68 ID" hydraulic oil to fill the hydraulicreservoir.

F You cannot change from “Plantohyd 22 S” BIO hydraulic oil to HLP D22. The sameapplies to changing from HLP D22 hydraulic oil to Plantohyd 22 S BIO hydraulic oil.Furthermore, you cannot mix HLP D22 hydraulic oil with Plantohyd 22 S BIOhydraulic oil.

– Turn the breather (19) and dipstick (21) clockwise into the hydraulic reservoir (22).

– Fit the drive compartment panel, see "Drive panel disassembly / assembly" inchapter F.

– After cleaning or repairs restore the truck to service, see "Recommissioning thetruck after cleaning or maintenance work" in chapter F.

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F 38

6.10 Checking electrical fuses

F Electric fuses must only be checked and replaced by authorized personnel.

F Electric currents can cause accidentsMake sure the electrical system is voltage-free before starting work on it.The capacitors in the controller must be fully discharged. The capacitors are fullydischarged after approx. 10 minutes. Before starting maintenance on the electricalsystem:

• Park the truck securely, see “Parking the Truck Securely” in Chapter E.

• Press the Emergency Disconnect.

• Disconnect the battery.

• Remove any rings or metal bracelets etc. before working on electrical components.

M The use of incorrect fuses can cause fire and damage componentsThe use of incorrect fuses can damage the electrical system and result in fire.The safety and functionality of the truck cannot be ensured.

• Use only fuses with the prescribed rated current, see "Fuse Ratings" in chapter F.

– Prepare the truck for maintenance and repairs (see section of the same name in chapter F).

– Remove the drive compartment panel, see "Drive panel disassembly / assembly"in chapter F.

– Loosen connector XS7 (35) from the fuse holder (25) and remove it.

– Disassemble the fuse holder (25) by unscrewing the six hex. socket screws. The fuseholder (25) can now be removed from the drive compartment computer (34).

– Check all the fuses in accordance with the table; replace if necessary.

F Only use the rating indicated on the controller/fuse.

Z Assembly of the fuse holder (25) is the reverse order of disassembly.

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B6.10.1 Fuse ratings

M Torque the locknuts on the fuses 1F11 (36), 3F10 (37) and 2F15 (38) to 10 Nm.

Item Description To protect: Rating

26 5F1 Control fuse 80 V 10 A

27 7F3 DC/DC converter control fuse 10 A

28 7F7 PSS scanner control fuse 10 A

29 6F6 ISM data recorder control fuse 10 A

31 F1.2 Control fuse 80 V 10 A

32 1F3 Combi controller control fuse 10 A

33 F2.1 Control fuse 80 V 10 A

36 1F11Travel threephase controller

(AC-3 Power Control U8)250 A

37 3F10Steering threephase controller

(AC-3 Power Control U8)35 A

38 2F15Hydraulic system threephase

controller(AC-3 Power Control U8)

325 A

F_6F6F_7F7

F_F1.2F_1F3F_F2.1

F_7F3F_5F1

V2

R2

R6

R12

R11

R1

R5

R9

R4R7

R3

X3

D4 D5 D6D2D1 D3

V1

R8

R10

38

37

36

35

33 32 31

25 26 27 28 29 30

34

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F 40

6.10.2 LED fuse indicators on the fuse holder

Z During operation the LED fuse indicator lamps are green (marked grey). If an LED indicator is not lit, replace the respective fuse. The other LED indicatorsreflect truck-specific operating conditions.

6.11 Recommissioning the truck after cleaning or maintenance work

The truck can only be re-commissioned after cleaning or maintenance once thefollowing procedures have been carried out:

– Re-connect the battery.

– Switch on the truck by inserting the key in the key switch and turning it as far rightas it will go.

F After cleaning or maintenance work test all the safety mechanisms to ensure they areworking correctly.

D1 D2 D3 D4 D5 D6

1Charge

circuit out7F7 7F3

24 V DC / DC 1

internal

24 V DC / DC

HeartbeatController A

2 1F3 F1.2 5F124 V

DC / DC 1external

24 V DC / DC

HeartbeatController B

3From key

switch6F6 F2.1

24 V DC / DC 2

24 V DC / DC

Not used

D1 D2 D3 D4 D5 D6

1

2

3

F 41

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BTest the safety mechanisms:

– Test the Emergency Disconnect by pressing the Emergency Disconnect switch.The main circuit is disconnected and no truck operations can be performed.Now turn the Emergency Disconnect to unlock it.

– Test the controls and displays.

– Test the horn by pressing the "horn" button.

– Test the deadman button.

– Test the steering.

– Test the gates.

– Test the front screens of the Personal Protection System laser scanners for dirt (o),and clean if necessary, see "Cleaning the laser scanner front screen" in Chapter E.

F Faulty brakes can cause accidentsAs soon as the truck has been started, test the brakes several times.

• Report any defects immediately to your supervisor.

• Tag out and decommission a faulty lift truck.

• Only return the truck to service when you have identified and rectified the fault.

– Test the service and parking brakes.

– Lubricate the truck in accordance with the lubrication schedule, see “LubricationSchedule” in chapter F.

Z If there are switching problems in the electrical system, apply contact spray to theexposed contacts and remove any oxide layers on the contacts of the controls byapplying them repeatedly.

F Electric currents from working with contact spray can cause accidentsMake sure the electrical system is voltage-free before starting work on it.The capacitors in the controller must be fully discharged. The capacitors are fullydischarged after approx. 10 minutes. Before starting maintenance work:

• Park the truck securely, see “Parking the Truck Securely” in Chapter E.

• Press the Emergency Disconnect.

• Disconnect the battery.

• Remove any rings or metal bracelets etc. before working on electrical components.

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F 42

7 Decommissioning the industrial truck

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

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

• Jack up the truck only on a level surface and prevent it from moving accidentally.

• Always use a jack with sufficient capacity. When jacking up the truck, takeappropriate 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 pointsspecially provided for this purpose, see "Identification points and data plates" inchapter B.

• When jacking up the truck, take appropriate measures to prevent it from slipping ortipping over (e.g. wedges, wooden blocks).

M When the truck is out of service it must be jacked up so that all the wheels are clearof the ground. This is the only way of ensuring that the wheels and wheel bearingsare not damaged.

Z If the truck is to be out of service for more than 6 months, agree further measures withthe manufacturer's customer service department.

F 43

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B7.1 Action to be taken before decommissioning

– Throroughly clean the truck.

– Test the brakes.

– Check the hydraulic oil level and replenish if necessary, see “Checking theHydraulic Oil Level” in chapter F.

– Apply a thin coating of oil or lubrication to all non-painted mechanical parts.

– Lubricate the truck in accordance with the lubrication schedule, see “LubricationSchedule” in chapter F.

– Charge up the battery (see “Charging the Battery” in chapter D.)

– Disconnect the battery and clean it. Apply dielectric grease to the battery terminals.

Z In addition, observe all the instructions of the battery manufacturer.

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

7.2 Action to be taken during decommissioning

Every 2 months:

– Charge up the battery, see “Charging the Battery” in chapter D.

M Battery powered trucks:It is important to regularly charge the battery as otherwise automatic discharge willresult in battery depletion. This will destroy the battery as a result of sulphurisation.

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F 44

7.3 Restoring the truck to service after decommissioning

– Thoroughly clean the truck.

– Lubricate the truck in accordance with the lubrication schedule, see "Lubrication Schedule" in chapter F.

– Clean the battery. Grease the terminal screws with delectric grease and re-connectthe battery.

– Charge up the battery, see “Charging the Battery” in chapter D.

– Check if the transmission oil contains condensate water and replace if necessary.

– Check if the hydraulic oil contains condensate water and replace if necessary.

Z The manufacturer's customer service department is specially trained to carry outthese operations.

– Start up the truck, see “Starting up the truck” in chapter E.

Z If there are switching problems in the electrical system, apply contact spray to theexposed contacts and remove any oxide layers on the contacts of the controls byapplying them repeatedly.

F Electric currents from working with contact spray can cause accidentsMake sure the electrical system is voltage-free before starting work on it.The capacitors in the controller must be fully discharged. The capacitors are fullydischarged after approx. 10 minutes. Before starting maintenance work:

• Park the truck securely, see “Parking the Truck Securely” in Chapter E.

• Press the Emergency Disconnect.

• Disconnect the battery.

• Remove any rings or metal bracelets etc. before working on electrical components.

F Faulty brakes can cause accidentsAs soon as the truck has been started, test the brakes several times.

• Report any defects immediately to your supervisor.

• Tag out and decommission a faulty lift truck.

• Only return the truck to service when you have identified and rectified the fault.

F 45

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B8 Safety tests to be performed at intervals and after unusual incidents

Z Perform a safety check in accordance with the national regulations. Jungheinrichrecommends the truck be checked to FEM guideline 4.004. Jungheinrich has a safetydepartment with trained personnel, able to carry out inspections.

The truck must be inspected at least annually or after any unusual event by a qualifiedinspector (be sure to comply with national regulations). The inspector shall assess thecondition of the truck from purely a safety viewpoint, without regard to operational oreconomic circumstances. The inspector shall be sufficiently instructed andexperienced to be able to assess the condition of the truck and the effectiveness ofthe safety mechanisms based on the technical regulations and principles governingthe inspection of forklift trucks.

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

The owner is responsible for ensuring that faults are immediately rectified.

Z A test plate is attached to the truck as proof that it has passed the safety inspection.This plate indicates the due date for the next inspection.

9 Final de-commissioning, disposal

Z Final, correct de-commissioning or disposal of the truck must be performed inaccordance with the regulations of the country of use. In particular, regulationsgoverning the disposal of batteries, fuels and electronic and electrical systems mustbe observed.

10 Human vibration measurement

Z Vibrations that affect the driver during operation over the course of the day are knownas human vibrations. Excessive human vibrations will cause the driver long termhealth problems. The European "2002/44/EC/Vibration" operator directive hastherefore been established to protect drivers. To help operators to assess the application situation, the manufacturer offers aservice of measuring these human vibrations.

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F 46

03.1

3 E

N

A

Traction Battery Appendix

Contents

A Traction Battery Appendix....................................................... 1

1 Correct Use and Application.................................................................... 22 Data plate ................................................................................................ 23 Safety Instructions, Warning Indications and other Notes....................... 34 Lead acid batteries with armour plated cells and liquid electrolyte.......... 44.1 Description............................................................................................... 44.2 Operation................................................................................................. 54.3 Servicing lead-acid batteries with armour plated cells............................. 85 PzV and PzV-BS lead-acid batteries with sealed armour plated cells..... 95.1 Description............................................................................................... 95.2 Operation................................................................................................. 105.3 Servicing PzV and PzV-BS lead-acid batteries with sealed armour plated

cells ......................................................................................................... 136 Aquamatik water replenishment system.................................................. 146.1 Water replenishment system design ....................................................... 146.2 Functional Description ............................................................................. 156.3 Adding water............................................................................................ 156.4 Water pressure ........................................................................................ 156.5 Filling time ............................................................................................... 166.6 Water quality............................................................................................ 166.7 Battery tubing .......................................................................................... 166.8 Operating temperature ............................................................................ 166.9 Cleaning measures.................................................................................. 176.10 Service mobile vehicle............................................................................. 177 Electrolyte circulation............................................................................... 187.1 Functional Description ............................................................................. 188 Cleaning batteries.................................................................................... 209 Storing the battery ................................................................................... 2210 Troubleshooting....................................................................................... 2211 Disposal................................................................................................... 22

1

2

1

2

.13

EN

Correct Use and Application

Failure to observe the operating instructions, carrying out repairs with non-originalspare parts, tampering with the battery or using electrolyte additives will invalidate thewarranty.

Observe the instructions for maintaining the safety rating during operation forbatteries in accordance with Ex I and Ex II (see relevant certification).

Data plate

1,2

4

8

10

11

6

3

5

9

7

12 13

14

15

1 Battery name2 Battery type3 Production week/year manf.4 Serial number5 Supplier number6 Rated voltage7 Rated capacity9 Battery weight in kg8 Number of cells15 Electrolyte volume in litres10 Battery number11 Manufacturer13 Manufacturer's logo12 CE mark only for batteries beyond 75 volts14 Safety instructions and warning information

03

03.1

3 E

N3

Safety Instructions, Warning Indications and other Notes

Used batteries must be treated as hazardous waste.

These batteries are marked with the recycling symbol and the sign showing a crossed-out rubbish bin, and should not be disposed of with ordinary household waste. waste.

Buy-back terms and type of recycling are to be agreed with the manufacturer as described in § 8 of the battery legislation.

Do not smoke!

No naked flames, glowing embers or sparks near the battery - fire and explosion hazard!

Avoid fire and explosion hazards and short circuits due to overheating!

Keep away from naked flames and strong heat sources.

Always wear protective clothing (e.g. safety goggles and safety gloves) when working on cells and batteries. batteries. Always wash your hands after completing the work. Use insulated tools only. Do not physically alter the battery, strike, crush, compress, notch, dent or modify it in any way. Hazardous electric voltage! The metal parts of the battery cells are permanently live. Therefore do not place any foreign objects or tools on the battery.Observe national health and safety regulations.

If the materials leak, do not inhale the fumes. Wear safety gloves.

Follow the user instructions and keep them in a visible position in the charging area.

Work on the batteries should be performed only as instructed by specialist personnel.

3

4

4

4

4.

.13

EN

Lead acid batteries with armour plated cells and liquid electrolyte

.1 Description

Jungheinrich traction batteries are lead acid batteries with armour plated cells andliquid electrolyte. The names of the traction batteries are PzS, PzB, PzS Lib and PzM.

Electrolyte

The rated density of the electrolyte assumes a temperature of 30°C and the ratedelectrolyte level is fully charged. Higher temperatures will reduce, lower temperatureswill increase the electrolyte density. The adjustment factor is ± 0.0007 kg/l per K, e.g.electrolyte density 1.28 kg/l at 45°C corresponds to a density of 1.29 kg/l at 30°C.

The electrolyte must conform to DIN 43530 Part 2 purity regulations.

1.1 Battery nominal data

1. Product Traction battery

2. Nominal voltage 2.0 V x no. of cells

3. Rated capacity C5 See data plate

4. Discharge current C5/5h

5. Nominal electrolyte density1

1. Reached within the first 10 cycles.

1.29 kg/l

6. Nominal temperature2

2. Higher temperatures shorten the useful life, lower temperatures reduce the available capacity.

30 °C

7. System rated electrolyte level up to "Max" electrolyte level marking

Limit temperature3

3. Not permissible as operating temperature.

55°C

03

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.2 Operation

2.1 Commissioning unfilled batteries

Z The operations required must be carried out by the manufacturer's customerservice department or a customer service organisation authorised by themanufacturer.

2.2 Commissioning filled and charged batteries

Checks and operations to be performed before starting daily work

Procedure• Make sure the battery is in physically good condition. • Make sure the terminals are correct (positive to positive and negative to negative)

and check that contacts on the battery terminal conducting system are secure.• Check the terminal screw torques (M10 = 23 ±1 Nm) of the terminal conductors and

connectors. • Charge up the battery.• Check the electrolyte level.

Z The electrolyte level must be above the cell baffle or the top of the separator.• Add electrolyte with distilled water up to the nominal level.

Checks completed.

2.3 Discharging the battery

Z To achieve an optimum useful life avoid operational discharge of more than 80% ofnominal capacity (full discharge). This corresponds to a minimum electrolytedensity of 1.13 kg/l at the end of the discharge. Recharge a discharged batteryimmediately.

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2.4 Charging the battery

WARNING!

The gases produced during charging can cause explosionsThe battery gives off a mixture of oxygen and hydrogen (electrolytic gas) duringcharging. Gassing is a chemical process. This gas mixture is highly explosive andmust not be ignited.Always disconnect the charger and truck before connecting or disconnecting the

charger and battery.The charger must be adapted to the battery in terms of voltage, charge capacity

and battery technology.Before charging, check all cables and plug connections for visible signs of damage.Ventilate the room in which the truck is being charged.Battery cell surfaces must remain exposed during charging in order to ensure

sufficient ventilation, see truck operating instructions, chapter D, Charging theBattery.

Do not smoke and avoid naked flames when handling batteries.Wherever an industrial truck is parked for charging there must be no inflammable

material or consumables capable of creating sparks within a minimum distance of2 m from the truck.

Fire protection equipment must be available.Do not place any metallic objects on the battery.Always follow the safety regulations of the battery and charger station

manufacturers.

NOTE

The battery must only be charged with DC current. All charging processes inaccordance with DIN 41773 and DIN 41774 are permissible.

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Z The electrolyte temperature rises by approx. 10 K during charging. Charging shouldtherefore only begin when the electrolyte temperature is below 45°C. Theelectrolyte temperature of batteries must be at least +10°C before charging.Otherwise the battery will not charge correctly. Below 10°C the battery isinsufficiently charged with standard charging systems.

Charging the battery

Requirements– Electrolyte temperature min. 10°C to max. 45°C

Procedure• Open or take off the tray lid or covers from the battery compartment.

Z Deviations are outlined in the truck's operating instructions. The plugs remain onthe cells or remain closed.

• Connect the battery to the switched off charger, ensuring the terminals are connect(positive to positive and negative to negative).

• Switch on the charger.

Battery charged

Z Charging is considered to be complete when the electrolyte density and batteryvoltage remain constant for more than 2 hours.

Compensation charging

Compensation charging is used to ensure the useful life and maintain capacity afterfull discharge and repeated insufficient charging. The maximum compensationcharge current is 5 A/100 Ah rated capacity.

Z Compensation charging should be carried out weekly.

Trickle charging

Battery trickle charging is partial charging that extends the daily application time.Higher average temperatures occur during trickle charging which reduce the usefullife of the batteries.

Z Trickle charges should only be performed when the charge level is below 60 %. Usereplacement batteries instead of regular trickle charging.

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.3 Servicing lead-acid batteries with armour plated cells

Water quality

Z The quality of the water used to fill up electrolyte must correspond to purified ordistilled water. Purified water can be produced through distillation or ionexchangers and is then suitable for the production of electrolyte.

3.1 Daily

– Charge the battery after each discharge.– After charging, check the electrolyte level.– If necessary, add purified water up to the rated level after charging.

Z The height of the electrolyte level should not be below the cell baffle or above thetop of the separator, or the "Min" and "Max" electrolyte markings respectively.

3.2 Weekly

– After re-charging, carry out a visual inspection for dirt and physical damage.– If the battery is charged regularly according to the IU characteristic, carry out a

compensation charge.

3.3 Monthly

– Towards the end of the charging process measure and record the voltages of allthe cells with the charger switched on.

– After charging measure and record the electrolyte density and the electrolytetemperature in all the cells.

– Compare the results with the previous ones.

Z If you find significant differences compared with the previous measurements ordifferences between the cells, contact the manufacturer's customer servicedepartment.

3.4 Annually

– Measure the truck insulation resistance in accordance with EN 1175-1.– Measure the battery insulation resistance in accordance with EN 1987-1.

Z In accordance with DIN EN 50272-3 the battery insulation resistance should not beless than 50 Ω per volt of rated voltage.

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PzV and PzV-BS lead-acid batteries with sealed armour plated cells

.1 Description

PzV batteries are sealed batteries with fixed electrolytes, to which no water can beadded over the entire lifespan of the battery. Relief valves are used as plugs whichare destroyed when opened. During operation the same safety requirements apply tothe sealed batteries as for batteries with liquid electrolyte. This is to avoid electricshock, explosion of the electrolyte charging gases or hazardous electrolyte burns ifthe cell vessels are destroyed.

Z PzV batteries are low gassing, but not gassing-free.

Electrolyte

The electrolyte is sulphuric acid which is fixed in gel. The density of the electrolytecannot be measured.

1.1 Battery nominal data

1. Product Traction battery

2. Nominal voltage 2.0 V x no. of cells

3. Rated capacity C5 See data plate

4. Discharge current C5/5h

5. Rated temperature 30 °C

Limit temperature1

1. Higher temperatures shorten the useful life, lower temperatures reduce the available capacity.

45°C, not permissible as operating temperature.

6. Rated density of the electrolyte Cannot be measured

7. System rated electrolyte level Cannot be measured

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.2 Operation

2.1 Commissioning

Checks and operations to be performed before starting daily work

Procedure• Make sure the battery is in physically good condition. • Make sure the terminals are correct (positive to positive and negative to negative)

and check that contacts on the battery terminal conducting system are secure.• Check the terminal screw torques (M10 = 23 ±1 Nm) of the terminal conductors and

connectors. • Re-charge the battery.• Charge the battery.

Check completed.

2.2 Discharging the battery

Z To achieve an optimum useful life avoid operational discharges of more than 60%of nominal capacity.

Z If the battery is discharged during operation by more than 80% of rated capacity theuseful life of the battery will reduce significantly. Fully or partially dischargedbatteries must be re-charged immediately and not left unattended.

2.3 Charging the battery

WARNING!

The gases produced during charging can cause explosionsThe battery gives off a mixture of oxygen and hydrogen (electrolytic gas) duringcharging. Gassing is a chemical process. This gas mixture is highly explosive andmust not be ignited.Always disconnect the charger and truck before connecting or disconnecting the

charger and battery.The charger must be adapted to the battery in terms of voltage, charge capacity

and battery technology.Before charging, check all cables and plug connections for visible signs of damage.Ventilate the room in which the truck is being charged.Battery cell surfaces must remain exposed during charging in order to ensure

sufficient ventilation, see truck operating instructions, chapter D, Charging theBattery.

Do not smoke and avoid naked flames when handling batteries.Wherever an industrial truck is parked for charging there must be no inflammable

material or consumables capable of creating sparks within a minimum distance of2 m from the truck.

Fire protection equipment must be available.Do not place any metallic objects on the battery.Always follow the safety regulations of the battery and charger station

manufacturers.

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NOTE

Charging the battery incorrectly can result in material damage.Incorrect battery charging can result in overloading of the electric wires and contacts,hazardous gas formation and electrolyte leakage from the cells.Always charge the battery with DC current.All DIN 41773 charging procedures are permitted in the format approved by the

manufacturer.Always connect the battery to a charger that is appropriate to the size and type of

the battery.If necessary have the charger checked by the manufacturer's customer service

department for suitability.Do not exceed limit currents in the gassing area in accordance with DIN EN 50272-

3.

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Charging the battery

Requirements– Electrolyte temperature between +15°C and 35°C

Procedure• Open or take off the tray lid or covers from the battery compartment.• Connect the battery to the switched off charger, ensuring the terminals are connect

(positive to positive and negative to negative). • Switch on the charger.

Z The electrolyte temperature rises by approx. 10 K during charging. If thetemperatures are permanently higher than 40°C or lower than 15°C, a temperature-dependent constant voltage control of the charger is required. The adjustmentfactor must be applied with -0.004 V/C per K.

Battery charged

Z Charging is considered to be complete when the electrolyte density and batteryvoltage remain constant for more than 2 hours.

Compensation charging

Compensation charging is used to ensure the useful life and maintain capacity afterfull discharge and repeated insufficient charging.

Z Compensation charging should be carried out weekly.

Trickle charging

Battery trickle charging is partial charging that extends the daily application time.Higher average temperatures occur during trickle charging which can reduce theuseful life of the batteries.

Z Trickle charges should only be performed when the charge level is below 50%. Usereplacement batteries instead of regular trickle charging.

Z Avoid trickle charging with PzV batteries.

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.3 Servicing PzV and PzV-BS lead-acid batteries with sealed armour plated cells

Z Do not add water!

3.1 Daily

– Charge the battery after each discharge.

3.2 Weekly

– Visually inspect for dirt and physical damage.

3.3 Every three months

– Measure and record the overall voltage.– Measure and record the individual voltages.– Compare the results with the previous ones.

Z Carry out the measurements after full charging and subsequent resting for at least5 hours.

Z If you find significant differences compared with the previous measurements ordifferences between the cells, contact the manufacturer's customer servicedepartment.

3.4 Annually

– Measure the truck insulation resistance in accordance with EN 1175-1.– Measure the battery insulation resistance in accordance with EN 1987-1.

Z In accordance with DIN EN 50272-3 the battery insulation resistance should not beless than 50 Ω per volt of rated voltage.

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Aquamatik water replenishment system

.1 Water replenishment system design

15 Water container16 Tap connection with ball cock17 Flow indicator18 Shut-off cock19 Locking coupling 20 Battery lock connector

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.2 Functional Description

The Aquamatik water replenishment system is used to adjust the rated electrolytelevel automatically on traction batteries for industrial trucks.

The battery cells are interconnected through hoses and are attached to the watersupply (e.g. water container) through a plug connection. When the shut-off cock isopened all the cells are filled with water. The Aquamatik plug controls the amount ofwater required and, at the relevant water pressures, ensures the water supply is shutoff and the valve is closed securely.

The plug systems have an optical level indicator, a diagnostic port to measure thetemperature and electrolyte density and a degassing port.

.3 Adding water

Water should be added to the batteries just before the battery is fully charged. Thisensures that the amount of water added is mixed with the electrolyte.

.4 Water pressure

The water replenishment system must be operated with a water pressure in the waterline of 0.3 bar - 1.8 bar. Any deviations from the permissible pressure ranges willaffect the operation of the systems.

Water drop

Assembly height above battery surface is between 3 - 18 m. 1 m corresponds to 0.1bar

Pressure water

The pressure regulating valve is adjusted to suit the system and must lie between 0.3- 1.8 bar.

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.5 Filling time

The filling time for a battery depends on the electrolyte level, the ambient temperatureand the filling pressure. Filling ends automatically. The water supply line must bedisconnected from the battery when the water has been filled.

.6 Water quality

Z The quality of the water used to fill up electrolyte must correspond to purified ordistilled water. Purified water can be produced through distillation or ionexchangers and is then suitable for the production of electrolyte.

.7 Battery tubing

The tubing of the individual plugs is in accordance with the existing electric circuit. Nochanges should be made.

.8 Operating temperature

Batteries with automatic water replenishment systems should only be stored in roomswith temperatures > 0°C, as otherwise the systems could freeze.

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.9 Cleaning measures

The plug systems must only be cleaned with purified water in accordance with DIN43530-4. No parts of the plugs must come into contact with solvent-based materialsor soap.

.10 Service mobile vehicle

Mobile water filling vehicle with pump and filling gun to fill individual cells. Theimmersion pump in the container generates the necessary filling pressure. Theservice mobile must be at exactly the same height as the battery base.

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Electrolyte circulation

.1 Functional Description

Electrolyte circulation ensures the supply of air during charging to mix the electrolyte,thereby preventing any acid layer, shortening the charge time (charge factor approx.1.07) and reducing the formation of gas during charging. The charger must besuitable for the battery and electrolyte circulation.

A pump in the charger produces the necessary compressed air which is introducedto the battery cells via a hose system. The electrolyte is circulated via the inlet air andthe electrolyte density level is constant over the entire length of the electrode.

Pump

In the event of a fault, e.g. if the pressure control system responds for an unknownreason, the filters must be checked and replaced if necessary.

Battery connection

A hose is attached to the pump module which together with the charge leads is routedfrom the charger to the charging connector. The air is passed on to the battery via theelectrolyte circulation coupling ducts in the connector. When routing make sure thehose is not bent.

Pressure monitoring module

The electrolyte circulation pump is activated when charging begins. The pressuremonitoring module monitors the build up of pressure during charging. This ensuresthat the required air pressure is provided for electrolyte circulation charging.

In the event of malfunctions such as:– Battery air coupling not connected to circulation module (if coupling is separate) or

faulty.– Leaky or faulty hose connections on battery or– Intake filter contaminated

a visual error message appears on the charger.

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NOTE

If an installed electrolyte circulation system is seldom used or not used at all,or if the battery is subjected to severe temperature fluctuations, the electrolytemay flow back into the hose system.Attach a separate coupling system to the air inlet line, such as: locking coupling on

the battery side and through-coupling on the air supply side.

Schematic illustration

Electrolyte circulation on the battery and air supply via the charger.

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Cleaning batteries

Batteries and trays must be cleaned in order to – maintain cell insulation and protect cells from ground or external conductive parts.– Avoid damage from corrosion and stray currents.– Avoid excessive and varying automatic discharge of the individual cells or block

batteries due to stray currents.– Avoid electric sparking due to stray currents.

When cleaning the batteries make sure that:– The assembly site chosen for cleaning is close to a drainage system for processing

the electrolytic rinsing water.– All health and safety as well as water and waste disposal regulations are observed

when disposing of used electrolyte or rinsing water.– Protective goggles and clothing are worn.– Cell plugs are not removed or opened.– Clean the plastic components of the battery, in particular the cell containers, only

with water or water-based cloths without any additives.– After cleaning, the top of the battery is dried with suitable equipment, e.g.

compressed air or cloths.– Any fluid that has entered the battery box must be suctioned off and disposed of in

accordance with the above-mentioned regulations.

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Cleaning the battery with a high pressure cleaner

Requirements– Cell connectors tight, plugged in securely– Cell plugs closed

Procedure• Follow the high pressure cleaner's user instructions.• Do not use any cleaning additives.• Observe the permissible cleaning device temperature setting of 140°C.

Z This generally ensures that the temperature does not exceed 60°C at a distance of30cm behind the outlet nozzle.

• Observe the maximum operating pressure of 50 bar.• Observe a minimum distance of 30 cm from the top of the battery.• The battery should be sprayed over its entire surface to avoid localised

overheating.Z Do not clean one spot for more than 3 seconds with the jet to avoid exceeding the

maximum battery surface temperature of 60°C.• After cleaning dry the battery surface with suitable materials e.g. compressed air or

cleaning cloths.

Battery cleaned.

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Storing the battery

NOTE

The battery should not be stored for longer than 3 months without charging asotherwise it will no longer be functional.

If the battery is to be taken out of service for a long period, it should be stored fullycharged in a dry room protected from frost. To ensure the availability of the batterythe following charges can be selected:

– Monthly compensation charge for PzS and PzB batteries or 3-monthly full chargefor PzV batteries.

– Trickle charge for a charge voltage of 2.23 volts x no. of cells for PzS, PzM and PzBbatteries or 2.25 volts x no. of cells for PzV batteries.

If the battery is to be taken out of service for a long period ( > 3 months), it should, asfar as possible, be charged to 50% of its charge level and stored in a dry roomprotected from frost.

0 Troubleshooting

If any faults are found on the battery or charger, contact the manufacturer's customerservice department immediately.

Z The operations required must be carried out by the manufacturer's customerservice department or a customer service organisation authorised by themanufacturer.

1 Disposal

Batteries marked with the recycling symbol and the sign showing acrossed-out rubbish bin should not be disposed of with ordinaryhousehold waste.

Buy-back terms and type of recycling are to be agreed with themanufacturer as described in § 8 of the battery legislation.

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