V 4467 JAG GB - Jungheinrich · 2018. 4. 27. · Jungheinrich reserves the right to alter the design, equipment and technical features of the truck. ... 3.3 Standard Hoist Frames

Operating instructions

50314468

ETM/V 214/216

G

10.03 -

10.03

1003

.GBImportant Information for Transport and Assembly of Hoist Framesfor Reach Trucks

Transport

Depending on the height of the hoist frame and local conditions three different typesof lifts may be undertaken:

– Standing with assembled hoist frame (for low heights)– Standing with partially assembled hoist frame tilted against the overhead guard (for

average height). Hydraulic hoses for lift function are disconnected– Standing, with dismantled hoist frame (for large heights) all hydraulic hoses

between the main unit and the hoist frame are disconnected.

Safety Instructions for Assembly and Commissioning

f On site assembly of the truck, commissioning and driver instruction shall only becarried out by staff trained and authorised by the manufacturer.

Only after the lifting equipment has been correctly assembled may the hydraulichoses be connected to the main unit / hoist frame interface and the truck put intooperation

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Important Information for Transport and Assembly of Hoist Framesfor Reach Trucks

Transport



average height). Hydraulic hoses for lift function are disconnected– Standing, with dismantled hoist frame (for large heights) all hydraulic hoses



f On site assembly of the truck, commissioning and driver instruction shall only becarried out by staff trained and authorised by the manufacturer.

Only after the lifting equipment has been correctly assembled may the hydraulichoses be connected to the main unit / hoist frame interface and the truck put intooperation

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

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

Safety instructions and important explanations are indicated by the followinggraphics:

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

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

Z Used before notices and explanations.

t Used to indicate standard equipment.

o Used to indicate optional equipment.

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

Copyright

Copyright of these operating instructions remains with JUNGHEINRICH AG.

Jungheinrich Aktiengesellschaft

Am Stadtrand 3522047 Hamburg - GERMANY

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

www.jungheinrich.com

0108

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

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

Safety instructions and important explanations are indicated by the followinggraphics:

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

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

Z Used before notices and explanations.

t Used to indicate standard equipment.

o Used to indicate optional equipment.

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

Copyright

Copyright of these operating instructions remains with JUNGHEINRICH AG.

Jungheinrich Aktiengesellschaft

Am Stadtrand 3522047 Hamburg - GERMANY

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

www.jungheinrich.com

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Table of ContentsA Regulatory Use of Machine

B Truck Description

1 Application ........................................................................................... B 12 Description of Assemblies and their Function .................................... B 22.1 Truck ................................................................................................... B 32.2 Placing the Load ................................................................................. B 63 Technical Data Standard Design ........................................................ B 73.1 Performance Data ............................................................................... B 73.2 Dimensions ......................................................................................... B 73.3 Standard Hoist Frames ETM/V 214/216 ............................................. B 93.4 EN Standards ...................................................................................... B 113.5 Condition for Use ................................................................................ B 114 Identification Points and Data Plates .................................................. B 124.1 Data plate, truck .................................................................................. B 134.2 Capacity Plate, Capacity / Load Centre of Gravity / Lift Height ........... B 144.3 Jack Securing Point ............................................................................ B 144.4 Notice: Observe Operator Manual ...................................................... B 14

C Transport und Commissioning

1 Transport ............................................................................................. C 12 Lifting by Crane ................................................................................... C 23 Securing the Machine for Transport. ................................................... C 34 Transport Lock, Safety Brake ............................................................. C 45 Commissioning .................................................................................... C 5

D Battery - Maintenance, Charging, Replacement

1 Safety Regulations when handling acid batteries ............................... D 12 Battery Types ...................................................................................... D 23 Exposing the Battery ........................................................................... D 23.1 Battery troley - Emergency Unlocking ................................................. D 34 Battery Charging ................................................................................. D 45 Removing and Fitting the Battery. ....................................................... D 56 Battery Discharge Display, Battery Discharge Monitor, Hourmeter .... D 66.1 Driver’s Display (t) ............................................................................. D 66.2 On Board Computer (o) ..................................................................... D 8

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Table of ContentsA Regulatory Use of Machine

B Truck Description

1 Application ........................................................................................... B 12 Description of Assemblies and their Function .................................... B 22.1 Truck ................................................................................................... B 32.2 Placing the Load ................................................................................. B 63 Technical Data Standard Design ........................................................ B 73.1 Performance Data ............................................................................... B 73.2 Dimensions ......................................................................................... B 73.3 Standard Hoist Frames ETM/V 214/216 ............................................. B 93.4 EN Standards ...................................................................................... B 113.5 Condition for Use ................................................................................ B 114 Identification Points and Data Plates .................................................. B 124.1 Data plate, truck .................................................................................. B 134.2 Capacity Plate, Capacity / Load Centre of Gravity / Lift Height ........... B 144.3 Jack Securing Point ............................................................................ B 144.4 Notice: Observe Operator Manual ...................................................... B 14

C Transport und Commissioning

1 Transport ............................................................................................. C 12 Lifting by Crane ................................................................................... C 23 Securing the Machine for Transport. ................................................... C 34 Transport Lock, Safety Brake ............................................................. C 45 Commissioning .................................................................................... C 5


1 Safety Regulations when handling acid batteries ............................... D 12 Battery Types ...................................................................................... D 23 Exposing the Battery ........................................................................... D 23.1 Battery troley - Emergency Unlocking ................................................. D 34 Battery Charging ................................................................................. D 45 Removing and Fitting the Battery. ....................................................... D 56 Battery Discharge Display, Battery Discharge Monitor, Hourmeter .... D 66.1 Driver’s Display (t) ............................................................................. D 66.2 On Board Computer (o) ..................................................................... D 8

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E Operation

1 Safety Regulations for the Operation of Fork Lift Trucks .................... E 12 Description of Operating and Display Elements ................................. E 23 Starting the Truck ................................................................................ E 63.1 How to use the safety belt (o) ............................................................ E 83.2 Preparation for Use ............................................................................. E 103.3 Emergency Stop Device ...................................................................... E 114 Operating the Forklift Truck ................................................................. E 124.1 Safety Rules when Driving .................................................................. E 124.2 Driving, Steering, Braking ................................................................... E 134.3 Fork Adjustment .................................................................................. E 164.4 Picking Up and Depositing a Load ...................................................... E 164.5 Emergency Lowering .......................................................................... E 174.6 Operating Attachments ....................................................................... E 204.7 Parking the truck safely ....................................................................... E 205 Mechanical Back Up Steering (Emergency Steering Operation) ........ E 216 Display Items ....................................................................................... E 236.1 Driver’s Display (t) ............................................................................. E 236.2 Driver display lights ............................................................................. E 266.3 On Board Computer (o) ..................................................................... E 296.4 Display Symbol for On Board Computer ............................................. E 307 Operator Keypad (CANCODE) (o) ..................................................... E 327.1 Code Key ............................................................................................ E 327.2 Parameters .......................................................................................... E 337.3 Parameter Settings ............................................................................. E 348 Changing Truck Parameters ............................................................... E 379 Troubleshooting .................................................................................. E 3810 Auxiliary Electrical System .................................................................. E 3910.1 Headlights .......................................................................................... E 3910.2 Beacon ............................................................................................... E 3910.3 Bridging Switch (ESA / electrical lift limit switch ) ............................... E 4010.4 Seat Heater ........................................................................................ E 41

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E Operation

1 Safety Regulations for the Operation of Fork Lift Trucks .................... E 12 Description of Operating and Display Elements ................................. E 23 Starting the Truck ................................................................................ E 63.1 How to use the safety belt (o) ............................................................ E 83.2 Preparation for Use ............................................................................. E 103.3 Emergency Stop Device ...................................................................... E 114 Operating the Forklift Truck ................................................................. E 124.1 Safety Rules when Driving .................................................................. E 124.2 Driving, Steering, Braking ................................................................... E 134.3 Fork Adjustment .................................................................................. E 164.4 Picking Up and Depositing a Load ...................................................... E 164.5 Emergency Lowering .......................................................................... E 174.6 Operating Attachments ....................................................................... E 204.7 Parking the truck safely ....................................................................... E 205 Mechanical Back Up Steering (Emergency Steering Operation) ........ E 216 Display Items ....................................................................................... E 236.1 Driver’s Display (t) ............................................................................. E 236.2 Driver display lights ............................................................................. E 266.3 On Board Computer (o) ..................................................................... E 296.4 Display Symbol for On Board Computer ............................................. E 307 Operator Keypad (CANCODE) (o) ..................................................... E 327.1 Code Key ............................................................................................ E 327.2 Parameters .......................................................................................... E 337.3 Parameter Settings ............................................................................. E 348 Changing Truck Parameters ............................................................... E 379 Troubleshooting .................................................................................. E 3810 Auxiliary Electrical System .................................................................. E 3910.1 Headlights .......................................................................................... E 3910.2 Beacon ............................................................................................... E 3910.3 Bridging Switch (ESA / electrical lift limit switch ) ............................... E 4010.4 Seat Heater ........................................................................................ E 41

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1 Operational Safety and Environmental Protection ............................. F 12 Safety Regulations for Mantenance .................................................... F 13 Maintenance and Inspection ............................................................... F 34 Maintenance Check List ETM/V 214/216 ........................................... F 45 Lubrication Schedule ETM/V 214/216 ................................................. F 65.1 Operating Fluids .................................................................................. F 75.2 Tank Capacity ETM/V 214/216 ........................................................... F 76 Maintenance ........................................................................................ F 86.1 Prepare truck for maintenance and repairs ......................................... F 86.2 Safety Belt Maintenance (o) ............................................................... F 86.3 Removing the seat hood ..................................................................... F 96.4 Checking the hydraulic oil level ........................................................... F 96.5 Opening the fuse cover ....................................................................... F 106.6 Removing the cover from the instrument panel .................................. F 106.7 Checking the electrical fuses. ............................................................. F 116.8 Starting the Truck Again ...................................................................... F 127 Putting the Truck Out of Service ......................................................... F 127.1 Measures to be taking before putting the truck out of service ............. F 127.2 When the truck is de-commissioned ................................................... F 127.3 Starting the truck again after de-commissioning ................................. F 138 Safety test after periodic intervals and after special occurences.

(D: UVV-Test BGV D27) ................................................................ F 13

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F Maintenance of Materials Handling Equipment

1 Operational Safety and Environmental Protection ............................. F 12 Safety Regulations for Mantenance .................................................... F 13 Maintenance and Inspection ............................................................... F 34 Maintenance Check List ETM/V 214/216 ........................................... F 45 Lubrication Schedule ETM/V 214/216 ................................................. F 65.1 Operating Fluids .................................................................................. F 75.2 Tank Capacity ETM/V 214/216 ........................................................... F 76 Maintenance ........................................................................................ F 86.1 Prepare truck for maintenance and repairs ......................................... F 86.2 Safety Belt Maintenance (o) ............................................................... F 86.3 Removing the seat hood ..................................................................... F 96.4 Checking the hydraulic oil level ........................................................... F 96.5 Opening the fuse cover ....................................................................... F 106.6 Removing the cover from the instrument panel .................................. F 106.7 Checking the electrical fuses. ............................................................. F 116.8 Starting the Truck Again ...................................................................... F 127 Putting the Truck Out of Service ......................................................... F 127.1 Measures to be taking before putting the truck out of service ............. F 127.2 When the truck is de-commissioned ................................................... F 127.3 Starting the truck again after de-commissioning ................................. F 138 Safety test after periodic intervals and after special occurences.

(D: UVV-Test BGV D27) ................................................................ F 13

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A Regulatory Use of Machine

Z The document „Guidelines for the Regulatory and Correct Use of Materials HandlingEquipment“ (VDMA) is part of the delivery of this vehicle (VDMA). It forms part of theOperator Manual and its contents should be carefully observed. National regulationsshall apply in their entirety.

The vehicle described in this instruction is a materials handling vehicle suitable forlifting and transporting loads. It must be employed, operated and maintained inaccordance with the information contained in this manual. Any other use is not inkeeping with this directive and can lead to damage to persons, machine or property.Above all overloading the machine due to excessively heavy loads or incorrectlypositioned loads must be avoided. The maximum permissible load to be lifted isdisplayed on a data plate attached to the vehicle or on the load diagram. The vehiclemust not be operated in areas exposed to the risk of fire or explosion, nor in a verydusty environment.

Duties of the Operator: In keeping with the sense of this manual the operator is anynatural or legal person who operates the vehicle or for whom it is operated by anotherperson. In special cases (e.g. leasing, hire) the operator is the person who inaccordance with the existing contractual agreement between the owner and the userof the vehicle undertakes to carry out such operating duties.The operator must ensure that the vehicle is only used in accordance with theregulations and danger to life and limb of the user or a third party is avoided.Furthermore, regulations concerning accident prevention and special safety rules aswell as guidelines for driving, maintenance and commissioning shall be observed.The operator must ensure that all users of the vehicle have read and understood thisinstruction.

M Non compliance with this instruction will render our warranty invalid. This also appliesif sub-standard work has been carried out on the vehicle by the client and /or a thirdperson without the consent of the manufacturer’s service department.

Fitting Attachments: Fitting or installing additional equipment which affects theoperation of the vehicle or enhances these functions may only be undertaken with thewritten permission of the manufacturer. Where necessary permission shall beobtained from the local authority. Local authority approval does not take precedence over manufacturer’s approval.

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A Regulatory Use of Machine

Z The document „Guidelines for the Regulatory and Correct Use of Materials HandlingEquipment“ (VDMA) is part of the delivery of this vehicle (VDMA). It forms part of theOperator Manual and its contents should be carefully observed. National regulationsshall apply in their entirety.

The vehicle described in this instruction is a materials handling vehicle suitable forlifting and transporting loads. It must be employed, operated and maintained inaccordance with the information contained in this manual. Any other use is not inkeeping with this directive and can lead to damage to persons, machine or property.Above all overloading the machine due to excessively heavy loads or incorrectlypositioned loads must be avoided. The maximum permissible load to be lifted isdisplayed on a data plate attached to the vehicle or on the load diagram. The vehiclemust not be operated in areas exposed to the risk of fire or explosion, nor in a verydusty environment.

Duties of the Operator: In keeping with the sense of this manual the operator is anynatural or legal person who operates the vehicle or for whom it is operated by anotherperson. In special cases (e.g. leasing, hire) the operator is the person who inaccordance with the existing contractual agreement between the owner and the userof the vehicle undertakes to carry out such operating duties.The operator must ensure that the vehicle is only used in accordance with theregulations and danger to life and limb of the user or a third party is avoided.Furthermore, regulations concerning accident prevention and special safety rules aswell as guidelines for driving, maintenance and commissioning shall be observed.The operator must ensure that all users of the vehicle have read and understood thisinstruction.

M Non compliance with this instruction will render our warranty invalid. This also appliesif sub-standard work has been carried out on the vehicle by the client and /or a thirdperson without the consent of the manufacturer’s service department.

Fitting Attachments: Fitting or installing additional equipment which affects theoperation of the vehicle or enhances these functions may only be undertaken with thewritten permission of the manufacturer. Where necessary permission shall beobtained from the local authority. Local authority approval does not take precedence over manufacturer’s approval.

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B Truck Description1 Application

The ETM/V 214/216 is a three wheel electric side seated, clear view reach truck. It isdesigned for use on level floors to lift and transport goods. Open bottom pallets orpalets with transverse boards can be lifted inside or outside the area of the loadwheels, and trolleys can be lifted. Loads can be stacked or unstacked andtransported over longer distances. The capacity may be obtained from the data plate.

Type Capacity Load Centre of Gravity

ETM/V 214 1,400 kg 600 mmETM/V 216 1,600 kg 600 mm

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B Truck Description1 Application

The ETM/V 214/216 is a three wheel electric side seated, clear view reach truck. It isdesigned for use on level floors to lift and transport goods. Open bottom pallets orpalets with transverse boards can be lifted inside or outside the area of the loadwheels, and trolleys can be lifted. Loads can be stacked or unstacked andtransported over longer distances. The capacity may be obtained from the data plate.

Type Capacity Load Centre of Gravity

ETM/V 214 1,400 kg 600 mmETM/V 216 1,600 kg 600 mm

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2 Description of Assemblies and their Function

Item. Description Item. Description1 t Clear View Lift Mast 10 t Accelerator2 t Overhead Guard 11 t Battery trolley unlocking3 t Free Lift Cylinder

(not with ZT-Lifting Frame)12 t Driver’s display

4 t Multi-Pilot o On board computer5 t Load Wheels 13 t Two stage switch key with

spare key (service).6 t Outriggers o CANCODE7 t Drive Wheel 14 t Emergency Stop Switch8 t Dead man pedal 15 o Safety Belt9 t Brake Pedal

t Series Equipment o Auxiliary Equipment

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2 Description of Assemblies and their Function



4 t Multi-Pilot o On board computer5 t Load Wheels 13 t Two stage switch key with

spare key (service).6 t Outriggers o CANCODE7 t Drive Wheel 14 t Emergency Stop Switch8 t Dead man pedal 15 o Safety Belt9 t Brake Pedal


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2.1 Truck

Safety Instructions: An enclosed vehicle design with rounded edges facilitates safehandling of the ETM/V 214/216. The driver is protected by the driver’s cab (2). Thedrive wheel (7) and the load wheels (5) are protected by a solid anti-crashmechanism. By activating the emergency switch all electrical power can be cut off in dangeroussituations. The driver’s display unit (12) shows the following conditions:

– Lift limit reached (o)– Slow travel– Service interval expired (service mode active)– Overtemperature– Battery latching unlocked– Parking brake applied– Forks horizontal (o)– Sideshifter in central position (o)– Dead man pedal (safety switch) not activated– System warning / system fault

Line break safety devices in the lift cylinders limit the lowering speed of the load in theevent of a hydraulic system failure.

Display Instruments: Driver display (12) with large surface display using TFTtechnology (t) or on board computer with LCD display (o), each with integratedresidual time display, battery charge status, lift and drive profile settings and steeringangle mode display.

Traction Drive: The complete drive unit is enclosed in the vehicle chassis. A 6.9 kWfixed threephase motor operates the drive wheel (7) via a bevel spur gearbox.The electronic traction current control system ensures the smooth rotation of the drivemotor and as a result smooth driving, powerful acceleration and electrically controlledbraking with energy recovery. The degree of energy recovery can be adjusted via the driver’s display unit.

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2.1 Truck

Safety Instructions: An enclosed vehicle design with rounded edges facilitates safehandling of the ETM/V 214/216. The driver is protected by the driver’s cab (2). Thedrive wheel (7) and the load wheels (5) are protected by a solid anti-crashmechanism. By activating the emergency switch all electrical power can be cut off in dangeroussituations. The driver’s display unit (12) shows the following conditions:

– Lift limit reached (o)– Slow travel– Service interval expired (service mode active)– Overtemperature– Battery latching unlocked– Parking brake applied– Forks horizontal (o)– Sideshifter in central position (o)– Dead man pedal (safety switch) not activated– System warning / system fault

Line break safety devices in the lift cylinders limit the lowering speed of the load in theevent of a hydraulic system failure.

Display Instruments: Driver display (12) with large surface display using TFTtechnology (t) or on board computer with LCD display (o), each with integratedresidual time display, battery charge status, lift and drive profile settings and steeringangle mode display.

Traction Drive: The complete drive unit is enclosed in the vehicle chassis. A 6.9 kWfixed threephase motor operates the drive wheel (7) via a bevel spur gearbox.The electronic traction current control system ensures the smooth rotation of the drivemotor and as a result smooth driving, powerful acceleration and electrically controlledbraking with energy recovery. The degree of energy recovery can be adjusted via the driver’s display unit.

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Brake Equipment: The electric braking unit consists of three independent brakingsystems. Operating the brake pedal introduces regenerative braking. Where requiredthe load wheel brakes are activated via the vehicle’s brake control system.The safety brake is electrically operated and works mechanically through acompression spring applied to a magnet brake mounted on the drive unit. This brakeis used for emergency braking. A warning light appears when the brake is applied. Faults in the steering and braking systems (emergency stop trip) are shown on thedriver’s display or the on board computer.

Emergency Stop Safety Concept: The emergency stop is controlled by the brakecontrol system.The steering control system transmits a system status signal which is monitored bythe brake control. If the signal fails to appear or a fault is identified the brakes will beapplied immediately until the machine comes to rest. Control displays on the driver’sdisplay unit indicate an emergency stop. Each time the vehicle is switched on thesystem goes through a self diagnosis programme which only releases the parkingbrake (emergency stop) if a functionality check proves to be positive.

Steering: Electrical steering is operated through a spur gear. Access to the servicemode on the driver’s display unit or the on board computer will afford a choice ofthree operating modes:

– 180° (o)– 360° (continuous) (o)– Switch between 180 - 360° via key (t)

The adjustable steering wheel serves as a steering transmitter.

Drivers Cab: The driver’s cab is designed ergonomically with ample foot room. Toachieve the correct sitting position the driver’s seat and the steering head can beadjusted by the driver.Accelerator and brake pedals are arranged as in a normal lorry.

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Brake Equipment: The electric braking unit consists of three independent brakingsystems. Operating the brake pedal introduces regenerative braking. Where requiredthe load wheel brakes are activated via the vehicle’s brake control system.The safety brake is electrically operated and works mechanically through acompression spring applied to a magnet brake mounted on the drive unit. This brakeis used for emergency braking. A warning light appears when the brake is applied. Faults in the steering and braking systems (emergency stop trip) are shown on thedriver’s display or the on board computer.

Emergency Stop Safety Concept: The emergency stop is controlled by the brakecontrol system.The steering control system transmits a system status signal which is monitored bythe brake control. If the signal fails to appear or a fault is identified the brakes will beapplied immediately until the machine comes to rest. Control displays on the driver’sdisplay unit indicate an emergency stop. Each time the vehicle is switched on thesystem goes through a self diagnosis programme which only releases the parkingbrake (emergency stop) if a functionality check proves to be positive.

Steering: Electrical steering is operated through a spur gear. Access to the servicemode on the driver’s display unit or the on board computer will afford a choice ofthree operating modes:

– 180° (o)– 360° (continuous) (o)– Switch between 180 - 360° via key (t)

The adjustable steering wheel serves as a steering transmitter.

Drivers Cab: The driver’s cab is designed ergonomically with ample foot room. Toachieve the correct sitting position the driver’s seat and the steering head can beadjusted by the driver.Accelerator and brake pedals are arranged as in a normal lorry.

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4 t Multi-Pilot o On board computer5 t Load wheels 13 t Two stage switch key with

spare key (service).6 t Outriggers o CANCODE7 t Drive wheel 14 t Emergency Stop Switch8 t Dead man pedal 15 o Safety Belt9 t Brake Pedal


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4 t Multi-Pilot o On board computer5 t Load wheels 13 t Two stage switch key with

spare key (service).6 t Outriggers o CANCODE7 t Drive wheel 14 t Emergency Stop Switch8 t Dead man pedal 15 o Safety Belt9 t Brake Pedal


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Operating and Display Elements: Operating and display elements can be clearlyidentified in the driver’s cab. The Multi-Pilot (4) enables single handed operation of functions governing directionof travel, lifting / lowering, mast forward / back, mast tilt, sideshift left or right insideshift mode (auxiliary hydraulic system HF5) (o)) and horn.On the driver’s display panel (12) the battery discharge indicator and hourmeter aregrouped together. The discharge indicator is designed as a monitor which cuts outlifting if the battery is low in order to avoid excessive discharge.

Hydraulic Equipment: Pump unit with an AC motor and a noiseless precision highpressure pump. The equipment is controlled by the Multi-Pilot (4).

Electrical Equipment: 48 volt system in the form of a twin cable system. Serieselectronic drive, lift and steering control.The electronic drive control system governs the travel rate with infinite speed controland permits regenerative braking when changing direction.Drive and lift parameters can be set via the driver’s display unit (12). Warningdisplays, operating errors and service functions can also be shown at the driver’sdisplay unit.(For possible battery types, see Chapter D.)

2.2 Placing the Load

Mast holder: The mast holder is mounted on suppert rollers. A simple telescopicpushing cylinder moves the holder backwards and forwards. The running rails for themast holder are bolted on to the outriggers (6. )

Lifting Frame: The trucks are equipped with telescopic free lift units situated in themast holder and which can be tilted. Adjustable side rollers and slide pieces take upthe pressure exerted on the fork carriage if the load is positioned on one side. Thefork arms are fitted to the fork carriage and are adjustable. With the twin lift Triplexmast (DZ) the first lift of the load carriage (free lift) is produced by a short, externallyfitted lift cylinder (3) without changing the construction height. With a telescopic mast(ZT) the free lift is limited to 80 mm due to the design.

Attachments: Hydraulic and mechanical attachments are possible.

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Operating and Display Elements: Operating and display elements can be clearlyidentified in the driver’s cab. The Multi-Pilot (4) enables single handed operation of functions governing directionof travel, lifting / lowering, mast forward / back, mast tilt, sideshift left or right insideshift mode (auxiliary hydraulic system HF5) (o)) and horn.On the driver’s display panel (12) the battery discharge indicator and hourmeter aregrouped together. The discharge indicator is designed as a monitor which cuts outlifting if the battery is low in order to avoid excessive discharge.

Hydraulic Equipment: Pump unit with an AC motor and a noiseless precision highpressure pump. The equipment is controlled by the Multi-Pilot (4).

Electrical Equipment: 48 volt system in the form of a twin cable system. Serieselectronic drive, lift and steering control.The electronic drive control system governs the travel rate with infinite speed controland permits regenerative braking when changing direction.Drive and lift parameters can be set via the driver’s display unit (12). Warningdisplays, operating errors and service functions can also be shown at the driver’sdisplay unit.(For possible battery types, see Chapter D.)

2.2 Placing the Load

Mast holder: The mast holder is mounted on suppert rollers. A simple telescopicpushing cylinder moves the holder backwards and forwards. The running rails for themast holder are bolted on to the outriggers (6. )

Lifting Frame: The trucks are equipped with telescopic free lift units situated in themast holder and which can be tilted. Adjustable side rollers and slide pieces take upthe pressure exerted on the fork carriage if the load is positioned on one side. Thefork arms are fitted to the fork carriage and are adjustable. With the twin lift Triplexmast (DZ) the first lift of the load carriage (free lift) is produced by a short, externallyfitted lift cylinder (3) without changing the construction height. With a telescopic mast(ZT) the free lift is limited to 80 mm due to the design.

Attachments: Hydraulic and mechanical attachments are possible.

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3 Technical Data Standard Design

Z Release of technical data in accordance with VDI 2198.Technical modifications and supplements reserved.

3.1 Performance Data

e)Lift height up to 6500 mm 0.15 m/sLift height up to 8300 mm 0.10 m/sLift height above 8300 mm 0.08 m/s

3.2 Dimensions

a)Fork length 800 mm; 560 Ah battery: +90 mm; 700 Ah battery: +180 mmb)Fork Length 1150 mm; 560 Ah battery: +90 mm; 700 Ah battery: +180 mmc)560 Ah battery: -72 mm; 700 Ah battery: -144 mmd) 420 Ah battery: -70 mm; 560 Ah battery: -158 mm; 700 Ah battery: -264 mme)560 Ah battery: + 90 mm; 700 Ah battery: +180 mmf) with floor covering

Description ETM/V 214 ETM/V 216Q Capacity (where C = 600 mm) 1400 1600 kgc Load Centre of Gravity 600 600 mm

Travel SpeedDrive and Fork Direction

14.0 / 14.0 14.0 / 14.0 km/h

Lift speed with / without load

0.44 / 0.70 0.42 / 0.70 m/s(±10%)

Lowering speedwith / without load

0.50 / 0.50 0.50 / 0.50 m/s(±15%)

Reach speedwith / without load

0.2e)

up to 5600 mm0.2e)

up to 5600 mm m/s

Gradeability with / without load 9/13 8/12 %Max. gradeability (5 min rating) with / without load

10/15 10/15 %

Description ETM/V 214 ETM/V 216s Lowered fork height 40 40 mmh6 Height above overhead guard 2150 2150 mm11 Overall length 2418/2346 a) 2418 b) mm41 Reach c), d) 550/622 600 mm71 Length over outrigger 1792 1842 mmb1/ b2

Overall width 1120/1270 1120/1270 mm

Wa Turning radius 1613 1663 mmAst Working aisle width e)

800 x 1200 lengthe)f)2701/26502468/2396

27152468

mm

Ast Working aisle width e)

800 x 1200 lengthe)f)2757/26922668/2592

27622668

mm

Net weight see data plate, truck

B 7

1003

.GB

3 Technical Data Standard Design

Z Release of technical data in accordance with VDI 2198.Technical modifications and supplements reserved.

3.1 Performance Data

e)Lift height up to 6500 mm 0.15 m/sLift height up to 8300 mm 0.10 m/sLift height above 8300 mm 0.08 m/s

3.2 Dimensions

a)Fork length 800 mm; 560 Ah battery: +90 mm; 700 Ah battery: +180 mmb)Fork Length 1150 mm; 560 Ah battery: +90 mm; 700 Ah battery: +180 mmc)560 Ah battery: -72 mm; 700 Ah battery: -144 mmd) 420 Ah battery: -70 mm; 560 Ah battery: -158 mm; 700 Ah battery: -264 mme)560 Ah battery: + 90 mm; 700 Ah battery: +180 mmf) with floor covering

Description ETM/V 214 ETM/V 216Q Capacity (where C = 600 mm) 1400 1600 kgc Load Centre of Gravity 600 600 mm

Travel SpeedDrive and Fork Direction

14.0 / 14.0 14.0 / 14.0 km/h

Lift speed with / without load

0.44 / 0.70 0.42 / 0.70 m/s(±10%)

Lowering speedwith / without load

0.50 / 0.50 0.50 / 0.50 m/s(±15%)

Reach speedwith / without load

0.2e)

up to 5600 mm0.2e)

up to 5600 mm m/s

Gradeability with / without load 9/13 8/12 %Max. gradeability (5 min rating) with / without load

10/15 10/15 %

Description ETM/V 214 ETM/V 216s Lowered fork height 40 40 mmh6 Height above overhead guard 2150 2150 mm11 Overall length 2418/2346 a) 2418 b) mm41 Reach c), d) 550/622 600 mm71 Length over outrigger 1792 1842 mmb1/ b2

Overall width 1120/1270 1120/1270 mm

Wa Turning radius 1613 1663 mmAst Working aisle width e)

800 x 1200 lengthe)f)2701/26502468/2396

27152468

mm

Ast Working aisle width e)

800 x 1200 lengthe)f)2757/26922668/2592

27622668

mm

Net weight see data plate, truck

1003

.GB

B 8

Ast

b5 b4 b11 b1b2

e

b3

a�2

a�2

Wa

αβ

α

β

m2

h6

h8

h7

h1

l4 lh2

h3

h4

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210 yl2 x

l7l1

1003

.GB

B 8

Ast

b5 b4 b11 b1b2

e

b3

a�2

a�2

Wa

αβ

α

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h6

h8

h7

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l4 lh2

h3

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210 yl2 x

l7l1

B 9

1003

.GB

3.3 Standard Hoist Frames ETM/V 214/216

Description Telescopic Mast (ZT)

Twin LiftTriplex Mast

(DZ)


(DZ) reinforced h1 Build Height 1950 - 2700 1950 - 3540 2700 - 3950 mm h2 Free Lift 80 1306 - 2896 2056 - 3306 mm h3 Lift 2900 - 4400 4250 - 9020 6500 - 10250 mm h4 Max.Height 3544 - 5044 4894 - 9664 7144 - 10894 mm

B 9

1003

.GB

3.3 Standard Hoist Frames ETM/V 214/216

Description Telescopic Mast (ZT)


(DZ)


(DZ) reinforced h1 Build Height 1950 - 2700 1950 - 3540 2700 - 3950 mm h2 Free Lift 80 1306 - 2896 2056 - 3306 mm h3 Lift 2900 - 4400 4250 - 9020 6500 - 10250 mm h4 Max.Height 3544 - 5044 4894 - 9664 7144 - 10894 mm

1003

.GB

B 10

Ast

b5 b4 b11 b1b2

e

b3

a�2

a�2

Wa

αβ

α

β

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h6

h8

h7

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l4 lh2

h3

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Q

210 yl2 x

l7l1

1003

.GB

B 10

Ast

b5 b4 b11 b1b2

e

b3

a�2

a�2

Wa

αβ

α

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h6

h8

h7

h1

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h3

h4

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c

Q

210 yl2 x

l7l1

B 11

1003

.GB

3.4 EN Standards

Constant Noise Level: 68 dB(A)

In accordance with EN 12053 complies with ISO 4871.

Z The constant noise level is calculated in accordance with standard guidelines andtakes into account the noise levels when driving, lifting and idling. The noise level ismeasured at the driver’s ears.

Vibration: 0.66 m/s2

In accordance with EN 13059.

Z According to standard guidelines the vibration acceleration exerted on the driver’sbody when driving is the linear integrated weighted vertical acceleration. It isascertained when driving over humps at constant speed.

Electromagnetic Compatability (EMC)

The manufacturer confirms that the truck does notexceed the limits for electromagnetic fault emission andjamming resistance. The truck has been tested for thedischarge of static electricity in accordance withEN 12895 as well as the standard instructions containedtherein.

Z Changes to electrical and electronic components and their arrangement may only bemade with the written persmission of the manufacturer.

3.5 Condition for Use

Ambient Temperature.- during operation -25 °C to +40 °C

Special equipment and authorisation is required for trucks designed to be usedconstantly below 0 °C or in conditions subject to extreme changes in temperture orair humidity.

B 11

1003

.GB

3.4 EN Standards

Constant Noise Level: 68 dB(A)

In accordance with EN 12053 complies with ISO 4871.

Z The constant noise level is calculated in accordance with standard guidelines andtakes into account the noise levels when driving, lifting and idling. The noise level ismeasured at the driver’s ears.

Vibration: 0.66 m/s2

In accordance with EN 13059.

Z According to standard guidelines the vibration acceleration exerted on the driver’sbody when driving is the linear integrated weighted vertical acceleration. It isascertained when driving over humps at constant speed.

Electromagnetic Compatability (EMC)

The manufacturer confirms that the truck does notexceed the limits for electromagnetic fault emission andjamming resistance. The truck has been tested for thedischarge of static electricity in accordance withEN 12895 as well as the standard instructions containedtherein.

Z Changes to electrical and electronic components and their arrangement may only bemade with the written persmission of the manufacturer.

3.5 Condition for Use

Ambient Temperature.- during operation -25 °C to +40 °C

Special equipment and authorisation is required for trucks designed to be usedconstantly below 0 °C or in conditions subject to extreme changes in temperture orair humidity.

1003

.GB

B 12

4 Identification Points and Data Plates

Item. Description16 Warning Sign "Caution Low Voltage Electronics "17 UVV Test Notice (D only ) 18 Drive direction when turning steering wheel19 Capacity plate, Capacity Sideshifter20 Capacity plate, Capacity / Load Centre of Gravity / Fork arms21 Capacity plate, Capacity / Load Centre of Gravity / Lift height22 Sign "Put on Safety Belt" (o)23 Notice "Do not stand under the load carriage"24 Crane loading securing points25 Notice "Do not reach through the hoist frame"26 Jack securing points27 Notice "Hydraulic oil filler neck"28 Data plate, truck29 Caution: Observe Operator Manual

19, 20, 21 24

28

17

26 24

mV1,5 V

26

29

16

22

2518

23

27

1003

.GB

B 12

4 Identification Points and Data Plates

Item. Description16 Warning Sign "Caution Low Voltage Electronics "17 UVV Test Notice (D only ) 18 Drive direction when turning steering wheel19 Capacity plate, Capacity Sideshifter20 Capacity plate, Capacity / Load Centre of Gravity / Fork arms21 Capacity plate, Capacity / Load Centre of Gravity / Lift height22 Sign "Put on Safety Belt" (o)23 Notice "Do not stand under the load carriage"24 Crane loading securing points25 Notice "Do not reach through the hoist frame"26 Jack securing points27 Notice "Hydraulic oil filler neck"28 Data plate, truck29 Caution: Observe Operator Manual

19, 20, 21 24

28

17

26 24

mV1,5 V

26

29

16

22

2518

23

27

B 13

1003

.GB

4.1 Data plate, truck

Z For queries regarding the truck or ordering spare parts please quote the vehicle serialnumber (31).

Item. Description Item. Description30 Type 36 Manufacturer31 Serial no.. 37 Battery weight min/max in kg32 Rated capacity in kg 38 Drive power33 Battery Voltage V 39 Load centre of gravity distance

in mm34 Net weight without battery in kg. 40 Year of manufacture35 Manufacturer’s logo 41 Option

36

35

3734

3833

3932

4031

4130

B 13

1003

.GB

4.1 Data plate, truck

Z For queries regarding the truck or ordering spare parts please quote the vehicle serialnumber (31).

Item. Description Item. Description30 Type 36 Manufacturer31 Serial no.. 37 Battery weight min/max in kg32 Rated capacity in kg 38 Drive power33 Battery Voltage V 39 Load centre of gravity distance

in mm34 Net weight without battery in kg. 40 Year of manufacture35 Manufacturer’s logo 41 Option

36

35

3734

3833

3932

4031

4130

1003

.GB

B 14

4.2 Capacity Plate, Capacity / Load Centre of Gravity / Lift Height

The capacity plate (22) gives the capacity (Q) of the vehicle in kg with a vertical hoistframe. In tabular form the maximum capacity is shown with a standard load centre ofgravity distance * C (in mm) and the desired lift height H (in mm). The arrows (42 and43) on the inner and outer masts show the driver when he has reached the preset liftheights shown in the load diagram.

*) The standard load centre of gravity distance not only takes into consideration theload height but also the load width.

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

4.3 Jack Securing Point

The notice "Jack securing point" (27)shows the place where the vehicle maybe lifted and chocked up (see ChapterF).

4.4 Notice: Observe Operator Manual

When commissioning (see Chapter C) and using the mechanical auxiliary steeringsystem (see Chapter E) carefully following the instructions contained in the OperatorManual.

4222 43

500 600 700

850850600

X.XXXX.XX.XX

12501105850

12501105850

290036004250

27

1003

.GB

B 14

4.2 Capacity Plate, Capacity / Load Centre of Gravity / Lift Height

The capacity plate (22) gives the capacity (Q) of the vehicle in kg with a vertical hoistframe. In tabular form the maximum capacity is shown with a standard load centre ofgravity distance * C (in mm) and the desired lift height H (in mm). The arrows (42 and43) on the inner and outer masts show the driver when he has reached the preset liftheights shown in the load diagram.

*) The standard load centre of gravity distance not only takes into consideration theload height but also the load width.

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

4.3 Jack Securing Point

The notice "Jack securing point" (27)shows the place where the vehicle maybe lifted and chocked up (see ChapterF).

4.4 Notice: Observe Operator Manual

When commissioning (see Chapter C) and using the mechanical auxiliary steeringsystem (see Chapter E) carefully following the instructions contained in the OperatorManual.

4222 43

500 600 700

850850600

X.XXXX.XX.XX

12501105850

12501105850

290036004250

27

C 1

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.GB

C Transport und Commissioning1 Transport



average height). Hydraulic hoses for lifting are disconnected– Standing, with dismantled hoist frame (for large heights) all hydraulic hoses



F On site assembly of the vehicle, commissioning and driver instruction shall only becarried out by staff trained and authorised by the manufacturer

Only when the hoist frame has been correctly assembled may the hydraulic hoses beconnected to the main unit / lift frame interface and the truck put into operation

C 1

1003

.GB

C Transport und Commissioning1 Transport



average height). Hydraulic hoses for lifting are disconnected– Standing, with dismantled hoist frame (for large heights) all hydraulic hoses



F On site assembly of the vehicle, commissioning and driver instruction shall only becarried out by staff trained and authorised by the manufacturer

Only when the hoist frame has been correctly assembled may the hydraulic hoses beconnected to the main unit / lift frame interface and the truck put into operation

1003

.GB

C 2

2 Lifting by Crane

M Only use lifting equipment with sufficient capacity. (Weight Lifted = Net Weight + Battery Weight; see data plate, truck).

– In order to lift the truck with a harness wrap slings around the strut of the overheadguard. Two suspension points (2) are located on the outriggers.

– Withdraw battery plug (1).– Secure the truck with wedges to prevent it from rolling away!

M Fasten the harness to the lifting points so that it cannot slip! Lifting slings should befastened to the harness so that when lifting they do not come into contact with anyattachments.

1

2

1003

.GB

C 2

2 Lifting by Crane

M Only use lifting equipment with sufficient capacity. (Weight Lifted = Net Weight + Battery Weight; see data plate, truck).

– In order to lift the truck with a harness wrap slings around the strut of the overheadguard. Two suspension points (2) are located on the outriggers.

– Withdraw battery plug (1).– Secure the truck with wedges to prevent it from rolling away!

M Fasten the harness to the lifting points so that it cannot slip! Lifting slings should befastened to the harness so that when lifting they do not come into contact with anyattachments.

1

2

C 3

1003

.GB

3 Securing the Machine for Transport.

F When transported on a lorry or a trailer the vehicle must be securely fastened down.The lorry or trailer must have securing rings fitted to its body.

– To secure the vehicle pass the tensioning strap (3) through the overhead guardstrut (1) and attach it to the securing rings.

– The tensioning strap must be secured by a tensioner (4).

M Loading shall be carried out by staff especially trained for that purpose in accordancewith recommendations contained in Guidelines VDI 2700 and VDI 2703. In eachcase correct measurements shall be determined and appropriate safety measuresadopted.

3

1

4

C 3

1003

.GB

3 Securing the Machine for Transport.

F When transported on a lorry or a trailer the vehicle must be securely fastened down.The lorry or trailer must have securing rings fitted to its body.

– To secure the vehicle pass the tensioning strap (3) through the overhead guardstrut (1) and attach it to the securing rings.

– The tensioning strap must be secured by a tensioner (4).

M Loading shall be carried out by staff especially trained for that purpose in accordancewith recommendations contained in Guidelines VDI 2700 and VDI 2703. In eachcase correct measurements shall be determined and appropriate safety measuresadopted.

3

1

4

1003

.GB

C 4

4 Transport Lock, Safety Brake

F If a vehicle is delivered with or without a flat battery before the vehicle is started thetransport locking device must be removed (2xM5 bolts). This device locks thecompression spring which operates the safety brake so that the vehicle has no brakeswhen there is no power. The device consists of two screws which are screwed intothe brake magnet (on the drive motor). This ensures that the spring cannot activatethe brake.

Removing the Transport Lock

– Push driver’s seat out of the guidetowards the steering wheel.

– Remove fan plug from seat hood.– Remove seat hood (see Chapter F).– Remove two-pin plug from magnetic

brake– Remove the brake release screws

from the magnetic brake and insertthem into the holes in the drive plate.

The brake can now be operated withoutcurrent. The truck can no longer bepushed without the battery.

– Connect the two-pin plug to the magnet brake.– Re-fit hood.– Connect the fan plug to the seat hood.– Position driver’s seat in guide.– Install and connect the battery– Turn on the main switch and key switch

The truck is now ready for use.

1003

.GB

C 4

4 Transport Lock, Safety Brake

F If a vehicle is delivered with or without a flat battery before the vehicle is started thetransport locking device must be removed (2xM5 bolts). This device locks thecompression spring which operates the safety brake so that the vehicle has no brakeswhen there is no power. The device consists of two screws which are screwed intothe brake magnet (on the drive motor). This ensures that the spring cannot activatethe brake.

Removing the Transport Lock

– Push driver’s seat out of the guidetowards the steering wheel.

– Remove fan plug from seat hood.– Remove seat hood (see Chapter F).– Remove two-pin plug from magnetic

brake– Remove the brake release screws

from the magnetic brake and insertthem into the holes in the drive plate.

The brake can now be operated withoutcurrent. The truck can no longer bepushed without the battery.

– Connect the two-pin plug to the magnet brake.– Re-fit hood.– Connect the fan plug to the seat hood.– Position driver’s seat in guide.– Install and connect the battery– Turn on the main switch and key switch

The truck is now ready for use.

C 5

1003

.GBMoving the truck without a battery

– Withdraw battery plug.– Push driver’s seat out of the guide towards the steering wheel.– Remove fan plug from seat hood.– Remove seat hood (see Chapter F).– Remove two-pin plug from magnetic brake– Remove the brake release screws from the drive plate and insert them into the

holes in the magnetic brake.

Z The brake is now ventilated without current. The vehicle can be pushed or pulledwithout the battery.

M After pushing operation is complete the brake release screws must be removedagain.

– Remove the brake release screws from the magnet brake and insert them into theholes in the drive plate.

– Connect the two-pin plug to the magnet brake.– Re-fit hood.– Connect the fan plug to the seat hood.– Position driver’s seat in guide.– Connect battery plug.– Switch on the main switch and key switch

Z The truck is now ready for use.

5 Commissioning

F Before commissining the machine ensure that the hydraulic hoses to the main unit/hoist frame interface have been connected.

M Operate the truck only with battery power! The AC current of the rectifier will damageelectrical components. Connecting cables to the battery (trailing cables) must be lessthan 6 metres.

To prepare the machine after delivery or transport the following tasks must be carriedout:

– Install battery (where required). Do not damage battery cable.– Charge up the battery (see Chapter D).– Where necessary remove the transport lock for the safety brake– Operate the truck as described above. (see Chapter E).

Z If delivered without a battery the truck can only be steered by means of themechanical back-up system (see Chapter E).

Z After commissioning it is possible that slight brake scrubbing noises will be heard.

C 5

1003

.GB

Moving the truck without a battery

– Withdraw battery plug.– Push driver’s seat out of the guide towards the steering wheel.– Remove fan plug from seat hood.– Remove seat hood (see Chapter F).– Remove two-pin plug from magnetic brake– Remove the brake release screws from the drive plate and insert them into the

holes in the magnetic brake.

Z The brake is now ventilated without current. The vehicle can be pushed or pulledwithout the battery.

M After pushing operation is complete the brake release screws must be removedagain.

– Remove the brake release screws from the magnet brake and insert them into theholes in the drive plate.

– Connect the two-pin plug to the magnet brake.– Re-fit hood.– Connect the fan plug to the seat hood.– Position driver’s seat in guide.– Connect battery plug.– Switch on the main switch and key switch

Z The truck is now ready for use.

5 Commissioning

F Before commissining the machine ensure that the hydraulic hoses to the main unit/hoist frame interface have been connected.

M Operate the truck only with battery power! The AC current of the rectifier will damageelectrical components. Connecting cables to the battery (trailing cables) must be lessthan 6 metres.

To prepare the machine after delivery or transport the following tasks must be carriedout:

– Install battery (where required). Do not damage battery cable.– Charge up the battery (see Chapter D).– Where necessary remove the transport lock for the safety brake– Operate the truck as described above. (see Chapter E).

Z If delivered without a battery the truck can only be steered by means of themechanical back-up system (see Chapter E).

Z After commissioning it is possible that slight brake scrubbing noises will be heard.

1003

.GB

C 6

1003

.GB

C 6

D 1

1003

.GB


1 Safety Regulations when handling acid batteries

Before any work is carried out on the batteries the truck must be safely parked(see Chapter E).

Maintenance Personnel: Batteries may only be charged, maintained or changed bystaff particularly trained for that purpose. These operating instructions andmanufacturer’s regulations concerning batteries and charging stations shall beobserved when work is being carried out.

Fire Protection: Smoking and open fires shall be avoided when working withbatteries. Where a truck is parked up for charging there shall be no inflammablematerial or operating fluids capable of sustaining a spark within a distance of 2metres around the machine. The space must be ventilated and fire protectionequipment must be on hand.

Battery Maintenance: The cell cover of the battery must be kept dry and clean.Cable posts and terminals nust be kept clean, smeared with dielectric grease and besecurely tightened. Batteries with non insulated posts must be covered with a non slipinsulation mat.

Battery Disposal: Batteries may only be disposed of in accordance with nationalEnvironmental Protection Laws or the Law governing Disposal of Hazardous Items.The manufacturer’s instructions concerning disposal must be fulfilled..

M Before closing the battery top ensure that the battery cable cannnot be damaged.

F Batteries contain dissolved acid which is poisonous and corrosive. Consequentlywhen carrying out work on batteries protective clothing and eye protection must beworn . Above all avoid any contact with battery acid.Nevertheles should clothing, skin or eyes come in contact with acid then the effectedparts should be rinsed with copious amounts of clean water - where the skin or eyesare affected a doctor must be summoned immediately. Disturbed battery acid shouldbe immediately neutralised.

M Only batteries with an enclosed chamber may be used.

F The weight and dimensions of a battery have considerable influence on theoperational safety of the truck. A change of battery equipment is only permitted on theagreement with the manufacturer.

D 1

1003

.GB


1 Safety Regulations when handling acid batteries

Before any work is carried out on the batteries the truck must be safely parked(see Chapter E).

Maintenance Personnel: Batteries may only be charged, maintained or changed bystaff particularly trained for that purpose. These operating instructions andmanufacturer’s regulations concerning batteries and charging stations shall beobserved when work is being carried out.

Fire Protection: Smoking and open fires shall be avoided when working withbatteries. Where a truck is parked up for charging there shall be no inflammablematerial or operating fluids capable of sustaining a spark within a distance of 2metres around the machine. The space must be ventilated and fire protectionequipment must be on hand.

Battery Maintenance: The cell cover of the battery must be kept dry and clean.Cable posts and terminals nust be kept clean, smeared with dielectric grease and besecurely tightened. Batteries with non insulated posts must be covered with a non slipinsulation mat.

Battery Disposal: Batteries may only be disposed of in accordance with nationalEnvironmental Protection Laws or the Law governing Disposal of Hazardous Items.The manufacturer’s instructions concerning disposal must be fulfilled..

M Before closing the battery top ensure that the battery cable cannnot be damaged.

F Batteries contain dissolved acid which is poisonous and corrosive. Consequentlywhen carrying out work on batteries protective clothing and eye protection must beworn . Above all avoid any contact with battery acid.Nevertheles should clothing, skin or eyes come in contact with acid then the effectedparts should be rinsed with copious amounts of clean water - where the skin or eyesare affected a doctor must be summoned immediately. Disturbed battery acid shouldbe immediately neutralised.

M Only batteries with an enclosed chamber may be used.

F The weight and dimensions of a battery have considerable influence on theoperational safety of the truck. A change of battery equipment is only permitted on theagreement with the manufacturer.

1003

.GB

D 2

2 Battery Types

Depending on truck application various types of batteries may be installed. The following table shows which combinations can be included as standard:

The battery weight is given on the battery data plate.

F When changing or installing a battery ensure that the battery is securely located inthe space provided.

3 Exposing the Battery

– Preparing for Operation (see Chapter E). – Tilt the Multi-Pilot (1) in arrow direction (U). Move the mast holder up to the stop

near the battery and let go of the Multi-Pilot (the mast is now in the end position).– Again tilt the Multi-Pilot (1) in the direction of arrow (U) and move the mast holder

further towards the stop position (preparation for latching battery).– Keep the Multi-Pilot (1) in the direction of arrow (U) and pull the battery truck lock.

The driver’s display panel will show (“Battery Latched" (red graphic symbol) (t) orthe control light will appear come on the board computer panel (o).

– Tilt Multi-Pilot (1) towards arrow (T) and push the mast holder with the coupledbattery trolley until the battery is clear for maintenance.

– Switch off the main switch and the key switch

F The battery plug and socket may only withdrawn or connected when the main switchand the charging equipment are switched off.

– Withdraw battery plug (2) from the socket.– Where necessary remove the insulation mat from the battery.

Z The safety switch for the battery locking system permits travel in creep modeproviding the battery trolley is uncoupled and the control display (4) is not deleted.Before the truck is started up again the battery trolley must be pushed to its leavingposition in order to uncouple the battery trolley and the mast holder. The controldisplay (4) must be out.

Capacitance Standard (L) High Performance HX)48 V - 3PzS - Battery 420 Ah 420L 450H48 V - 4PzS - Battery 560 Ah 560L 600H48 V - 5PzS - Battery 700 Ah 700L 750H

1003

.GB

D 2

2 Battery Types

Depending on truck application various types of batteries may be installed. The following table shows which combinations can be included as standard:

The battery weight is given on the battery data plate.

F When changing or installing a battery ensure that the battery is securely located inthe space provided.

3 Exposing the Battery

– Preparing for Operation (see Chapter E). – Tilt the Multi-Pilot (1) in arrow direction (U). Move the mast holder up to the stop

near the battery and let go of the Multi-Pilot (the mast is now in the end position).– Again tilt the Multi-Pilot (1) in the direction of arrow (U) and move the mast holder

further towards the stop position (preparation for latching battery).– Keep the Multi-Pilot (1) in the direction of arrow (U) and pull the battery truck lock.

The driver’s display panel will show (“Battery Latched" (red graphic symbol) (t) orthe control light will appear come on the board computer panel (o).

– Tilt Multi-Pilot (1) towards arrow (T) and push the mast holder with the coupledbattery trolley until the battery is clear for maintenance.

– Switch off the main switch and the key switch

F The battery plug and socket may only withdrawn or connected when the main switchand the charging equipment are switched off.

– Withdraw battery plug (2) from the socket.– Where necessary remove the insulation mat from the battery.

Z The safety switch for the battery locking system permits travel in creep modeproviding the battery trolley is uncoupled and the control display (4) is not deleted.Before the truck is started up again the battery trolley must be pushed to its leavingposition in order to uncouple the battery trolley and the mast holder. The controldisplay (4) must be out.

Capacitance Standard (L) High Performance HX)48 V - 3PzS - Battery 420 Ah 420L 450H48 V - 4PzS - Battery 560 Ah 560L 600H48 V - 5PzS - Battery 700 Ah 700L 750H

D 3

1003

.GB

F The truck must only be driven slowly inside the battery charging station with thebattery leading!

3.1 Battery troley - Emergency Unlocking

– Preparation for Use(see Chapter E).

– Tilt Multi-Pilot (1) towards arrow (U),move the mast holder up to the stopposition towards the battery. Releasethe Multi-Pilot (1).

– Tilt the Multi-Pilot (1) towards arrow(U) and move the mast holder furtherto the stop towards the battery

– Switch off the main switch and the keyswitch

– Remove driver’s seat and disconnectfan connection.

– Remove seat hood.(see Chapter F).

– Withdraw the lock (6) from ring (e.g.use screw driver)..

– Re-fit hood.– Re-connect fan and install driver’s seat– Switch on the main switch and key switch– Tilt Multi-Pilot (1) towards arrow (T) and push the mast holder with the coupled

battery trolley until the battery is clear for maintenance.– Control display (4) lights up– Switch off the main switch and the key switch

3

U

5

T1

2

4

6

D 3

1003

.GB

F The truck must only be driven slowly inside the battery charging station with thebattery leading!

3.1 Battery troley - Emergency Unlocking

– Preparation for Use(see Chapter E).

– Tilt Multi-Pilot (1) towards arrow (U),move the mast holder up to the stopposition towards the battery. Releasethe Multi-Pilot (1).

– Tilt the Multi-Pilot (1) towards arrow(U) and move the mast holder furtherto the stop towards the battery

– Switch off the main switch and the keyswitch

– Remove driver’s seat and disconnectfan connection.

– Remove seat hood.(see Chapter F).

– Withdraw the lock (6) from ring (e.g.use screw driver)..

– Re-fit hood.– Re-connect fan and install driver’s seat– Switch on the main switch and key switch– Tilt Multi-Pilot (1) towards arrow (T) and push the mast holder with the coupled

battery trolley until the battery is clear for maintenance.– Control display (4) lights up– Switch off the main switch and the key switch

3

U

5

T1

2

4

6

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Z Before installing the battery lock rectify the fault on the battery unlocking system.The safety switch for the battery lock only enables creep mode providing the batterytrolley is unlatched and the control light (4) is still lit. To start up the truck the batterytrolley must be in its leaving position in order to uncouple the battery trolley and themast. Control display (4) must be faded out.

4 Battery Charging

– Expose Battery (see Section 3).

F To carry out the charging procedure the top surface of the cells must be exposed inorder to guarantee adequate ventilation. No metal objects must be left on top of thebattery. Before commencing the charging process visibly check the cable andconnections for damage.

– Where required remove the insulating mat from the battery.– Connect the charging cable to the battery plug (2)– Charge the battery up in accordance with the manufacturer’s instructions for both

the battery and the charging station.

F The safety regulations provided by the battery and charging station manufacturershall be strictly observed.

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Z Before installing the battery lock rectify the fault on the battery unlocking system.The safety switch for the battery lock only enables creep mode providing the batterytrolley is unlatched and the control light (4) is still lit. To start up the truck the batterytrolley must be in its leaving position in order to uncouple the battery trolley and themast. Control display (4) must be faded out.

4 Battery Charging


F To carry out the charging procedure the top surface of the cells must be exposed inorder to guarantee adequate ventilation. No metal objects must be left on top of thebattery. Before commencing the charging process visibly check the cable andconnections for damage.

– Where required remove the insulating mat from the battery.– Connect the charging cable to the battery plug (2)– Charge the battery up in accordance with the manufacturer’s instructions for both

the battery and the charging station.

F The safety regulations provided by the battery and charging station manufacturershall be strictly observed.

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5 Removing and Fitting the Battery.


F In order to avoid a short circuit, exposed poles or connections must be covered withan rubber cover. When using a crane to change the battery ensure that there issufficient lifting capacity (see battery weight on the battery data plate fitted to batteryholder). The lifting harness must exert a vertical pull so that the battery holder is notcrushed. Hooks shall be fitted so that when the sling chains are slackened off they doimpinge on the battery cells.

Removal and Installation using a Lifting Harness

– Loosen fixing bolts (9) in the red battery retaining bracket (8)– Remove retaining bracket (8).– Couple lifting harness to battery holder (7).– Lift the battery clear and move out to the side.

Dismantling and assembling with battery trolley (o)

F The truck must lie horizontally so that when removing the battery retaining bracket thebattery itself does not roll out.

– Loosen fixing bolts (9) in the red battery retaining bracket (8)– Remove retaining bracket (8).– Lift the battery to the side on to the battery trolley

Installation to be carried out in reverse order.

F When changing the battery it may only be replaced by one of similar design. Followinginstallation the cable and connections must be visibly checked for damage and coverplates must be replaced securely.

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5 Removing and Fitting the Battery.


F In order to avoid a short circuit, exposed poles or connections must be covered withan rubber cover. When using a crane to change the battery ensure that there issufficient lifting capacity (see battery weight on the battery data plate fitted to batteryholder). The lifting harness must exert a vertical pull so that the battery holder is notcrushed. Hooks shall be fitted so that when the sling chains are slackened off they doimpinge on the battery cells.

Removal and Installation using a Lifting Harness

– Loosen fixing bolts (9) in the red battery retaining bracket (8)– Remove retaining bracket (8).– Couple lifting harness to battery holder (7).– Lift the battery clear and move out to the side.

Dismantling and assembling with battery trolley (o)

F The truck must lie horizontally so that when removing the battery retaining bracket thebattery itself does not roll out.

– Loosen fixing bolts (9) in the red battery retaining bracket (8)– Remove retaining bracket (8).– Lift the battery to the side on to the battery trolley

Installation to be carried out in reverse order.

F When changing the battery it may only be replaced by one of similar design. Followinginstallation the cable and connections must be visibly checked for damage and coverplates must be replaced securely.

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6 Battery Discharge Display, Battery Discharge Monitor, Hourmeter

6.1 Driver’s Display (t)

Battery Discharge Display: The charge status of the battery (10) is displayed in10% increments on the driver’s display unit.

M The serial setting for the battery discharge display / discharge monitor is applied tostandard batteries.

The battery must be charged when there is a battery residual capacitance of 20% forstandard batteries or 40% for maintenance free batteries.

Battery Discharge Monitor: Lifting is cut out when the residual capacity falls belowthe required level. An appropriate message will be shown on the driver’s display unit.

Z Lifting will only be restored when the connected battery is charged up to 70% ofmaximum.

Remaining Time Display: The remaining time is shown up to 20% residual capacity(for maintenance batteries 40%)

To display the remaining time the 7 segment display above battery (11) can beswitched over by activating the shift key (13) for 3 seconds.

Z It switches between actual time and time remaining.

10 11

14 13

12

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6 Battery Discharge Display, Battery Discharge Monitor, Hourmeter


Battery Discharge Display: The charge status of the battery (10) is displayed in10% increments on the driver’s display unit.

M The serial setting for the battery discharge display / discharge monitor is applied tostandard batteries.



Z Lifting will only be restored when the connected battery is charged up to 70% ofmaximum.

Remaining Time Display: The remaining time is shown up to 20% residual capacity(for maintenance batteries 40%)

To display the remaining time the 7 segment display above battery (11) can beswitched over by activating the shift key (13) for 3 seconds.

Z It switches between actual time and time remaining.

10 11

14 13

12

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1003

.GBHourmeter: Pressing the shift key (13) briefly produces other display fields (12 and14). If no lift height, maximum lift or load weight is available then the appropriate linesare by-passed.

Z If there is no lift height, maximum lift height or load weight available then the displayfield 2 remains empty.

"Energy Recovery" Display for Regenerative Lowering and Braking

During "Energy Recovery" the discharge display switches over to driver’s display sothat the bars in the battery icon fill up from 0 to 100% (from bottom to top).

This occurs in cycles irrespective of battery charge status (fully or partially charged).

Z The display goes out when energy recovery is complete.

Display Field 1 (14) Display Field 2 (12)Operating Hours Load WeightOperating Hours Lift HeightOperating Hours Max. Lift Height

Lift Height Load WeightLift Height Max. Lift Height

Load Weight Lift HeightLoad Weight Max. Lift Height

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Hourmeter: Pressing the shift key (13) briefly produces other display fields (12 and14). If no lift height, maximum lift or load weight is available then the appropriate linesare by-passed.

Z If there is no lift height, maximum lift height or load weight available then the displayfield 2 remains empty.

"Energy Recovery" Display for Regenerative Lowering and Braking

During "Energy Recovery" the discharge display switches over to driver’s display sothat the bars in the battery icon fill up from 0 to 100% (from bottom to top).

This occurs in cycles irrespective of battery charge status (fully or partially charged).


Display Field 1 (14) Display Field 2 (12)Operating Hours Load WeightOperating Hours Lift HeightOperating Hours Max. Lift Height

Lift Height Load WeightLift Height Max. Lift Height

Load Weight Lift HeightLoad Weight Max. Lift Height

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6.2 On Board Computer (o)

Battery Discharge Display: The charge status of the battery (15) is shown in 10%increments on the display.

M The serial setting of the battery discharge display / discharge monitor is applied tostandard batteries.When using maintenance free batteries the display must be set so that the symbol (T)appears after the percentage figure. If this setting is not carried out the battery maybe damaged because of excessive depletion. When adjusting the instrument the manufacturer’s service department must be calledin. .



Lfiting will only be restored when the connected battery is charged up to 70% ofmaximum.

Remaining Time Display: The Battery Remaining Time Display is an option whichcan be activated via a parameter in the service mode.

The remaining time is shown up to 20% residual capacity (for maintenance batteries40%)

Alternatively the Battery Remaining Time display is shown as a percentage figure(15) under the battery symbol (Format R 00:00).

OK0CE

8TUV

7PQRS

9WXYZ

5JKL

4GHI

6MNO

2ABC

1 3DEF

0009 h 08:45

km/h

50 % T

0

15 16

17

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D 8


Battery Discharge Display: The charge status of the battery (15) is shown in 10%increments on the display.

M The serial setting of the battery discharge display / discharge monitor is applied tostandard batteries.When using maintenance free batteries the display must be set so that the symbol (T)appears after the percentage figure. If this setting is not carried out the battery maybe damaged because of excessive depletion. When adjusting the instrument the manufacturer’s service department must be calledin. .



Lfiting will only be restored when the connected battery is charged up to 70% ofmaximum.

Remaining Time Display: The Battery Remaining Time Display is an option whichcan be activated via a parameter in the service mode.

The remaining time is shown up to 20% residual capacity (for maintenance batteries40%)

Alternatively the Battery Remaining Time display is shown as a percentage figure(15) under the battery symbol (Format R 00:00).

OK0CE

8TUV

7PQRS

9WXYZ

5JKL

4GHI

6MNO

2ABC

1 3DEF

0009 h 08:45

km/h

50 % T

0

15 16

17

D 9

1003

.GBHourmeter: The operating hours are displayed next to the clock time. The operatinghours meter (17) shows the total time of travel and lifting movements.

Display "Energy Recovery" when lowering and braking pay load

During “Energy Recovery" the discharge display on the computer switches over sothat the bars in the battery icon fill up from 0 to 100% (from bottom to top).

This occurs in cycles irrespective of battery charge condition (fully or partiallycharged).


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Hourmeter: The operating hours are displayed next to the clock time. The operatinghours meter (17) shows the total time of travel and lifting movements.

Display "Energy Recovery" when lowering and braking pay load

During “Energy Recovery" the discharge display on the computer switches over sothat the bars in the battery icon fill up from 0 to 100% (from bottom to top).

This occurs in cycles irrespective of battery charge condition (fully or partiallycharged).


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E 1

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E Operation1 Safety Regulations for the Operation of Fork Lift Trucks

Driver Authorisation: The forklift truck may only be used by auitable persons whohave been trained to drive the truck, who have proved to the owner or hisrepresentative that they can drive and handle loads and have been authorised tooperate the truck by such owner or his representative.

Driver’s Rights, Responsibilities and Regulations. The driver must be informed ofhis duties and responsibilities and be instructed in the operation of the truck and shallbe made familiar with the contents of the present Operator Manual. He must beafforded all his due rights. Safety shoes must be worn when operating pedestrian lift trucks.

Unauthorised Use of Truck: The driver is responsible for the forklift during the timeit is in use. He shall prevent unauthorised persons from driving or operating the truck.It is forbidden to carry or hoist persons.

Damage and Complaints : Damage or any complaints regarding the forklift truck orits attachments shall immediately be reported to a supervisor. Machines not safe foroperation shall not be used until they are deemed fit for use following authorisedrepair and commissioning.

Repairs: The driver must not carry out any repairs or alterations to the forklift truckwithout the necessary training and authoristion to do so. On no account shall headjust or render unusable safety equipment or switches.

Danger Areas: A danger area is defined as the area in which a person is at risk dueto truck movement, lifting operations, load lifting parts (e.g. forks or anciliaryequipment) or the load itself. This also includes areas which can be reached by fallingloads or lowering mechanical devices.

F Unauthorised persons must be kept away from the danger area. Where there isdanger to persons a warning shall be given in good time. If unauthorised persons arestill within the danger area then the truck shall be brought to rest immediately.

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

E 1

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E Operation1 Safety Regulations for the Operation of Fork Lift Trucks

Driver Authorisation: The forklift truck may only be used by auitable persons whohave been trained to drive the truck, who have proved to the owner or hisrepresentative that they can drive and handle loads and have been authorised tooperate the truck by such owner or his representative.

Driver’s Rights, Responsibilities and Regulations. The driver must be informed ofhis duties and responsibilities and be instructed in the operation of the truck and shallbe made familiar with the contents of the present Operator Manual. He must beafforded all his due rights. Safety shoes must be worn when operating pedestrian lift trucks.

Unauthorised Use of Truck: The driver is responsible for the forklift during the timeit is in use. He shall prevent unauthorised persons from driving or operating the truck.It is forbidden to carry or hoist persons.

Damage and Complaints : Damage or any complaints regarding the forklift truck orits attachments shall immediately be reported to a supervisor. Machines not safe foroperation shall not be used until they are deemed fit for use following authorisedrepair and commissioning.

Repairs: The driver must not carry out any repairs or alterations to the forklift truckwithout the necessary training and authoristion to do so. On no account shall headjust or render unusable safety equipment or switches.

Danger Areas: A danger area is defined as the area in which a person is at risk dueto truck movement, lifting operations, load lifting parts (e.g. forks or anciliaryequipment) or the load itself. This also includes areas which can be reached by fallingloads or lowering mechanical devices.

F Unauthorised persons must be kept away from the danger area. Where there isdanger to persons a warning shall be given in good time. If unauthorised persons arestill within the danger area then the truck shall be brought to rest immediately.

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

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2 Description of Operating and Display Elements

Item. Operating or Display Element

Function

1 key switch t Switches current on and off.By removing the switch the truck cannot be switched on by unauthorised persons.

Keypad (CANCODE)

o Sets the code and switches on the truck

2 Main Switch (Emergency disconnect)

t The supply current is interrupted, all electrical functions are switched off and the truck brakes are applied automatically.

3 Multi-Pilot t Function operation:– Travel forward / reverse– Lift/lower load pickup– Extend / retract mast holder– Tilt hoist fram forward or backward, fork

tilt– Sideshift left / right– Horn button– Auxiliary hydraulics (HF5) (o)

4 Steering switch t Change steering range from 180° or 360°.5 Sideshift centring switch o Sideshift positioned in centre6 Forks horizontal switch o Forks set to horizontal position (fork tilter

only)7 Lock for arm rest t Longitudinal displacement of arm rest8 Driver’s seat lock t The driver’s seat can be adjusted

horizontally9 Driver’s seat weight

adjustmentt Adjusting driver’s weight for optimal seat

cushioning10 Backrest adjustment t The driver’s seat backrest can be adjusted11 Accelerator t The traction speed is infinitely variable12 Brake Pedal t Brake applied to truck13 Dead man pedal t – Not Activated: Travel inhibited, truck

brought to rest.– Activated : Travel released

t = Series Equipment o = Auxliary Equipment

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2 Description of Operating and Display Elements


Function

1 key switch t Switches current on and off.By removing the switch the truck cannot be switched on by unauthorised persons.

Keypad (CANCODE)

o Sets the code and switches on the truck

2 Main Switch (Emergency disconnect)

t The supply current is interrupted, all electrical functions are switched off and the truck brakes are applied automatically.

3 Multi-Pilot t Function operation:– Travel forward / reverse– Lift/lower load pickup– Extend / retract mast holder– Tilt hoist fram forward or backward, fork

tilt– Sideshift left / right– Horn button– Auxiliary hydraulics (HF5) (o)

4 Steering switch t Change steering range from 180° or 360°.5 Sideshift centring switch o Sideshift positioned in centre6 Forks horizontal switch o Forks set to horizontal position (fork tilter

only)7 Lock for arm rest t Longitudinal displacement of arm rest8 Driver’s seat lock t The driver’s seat can be adjusted

horizontally9 Driver’s seat weight

adjustmentt Adjusting driver’s weight for optimal seat

cushioning10 Backrest adjustment t The driver’s seat backrest can be adjusted11 Accelerator t The traction speed is infinitely variable12 Brake Pedal t Brake applied to truck13 Dead man pedal t – Not Activated: Travel inhibited, truck

brought to rest.– Activated : Travel released


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3

14

15

4

5

6

7

89111213 10

16

17

1 2

E 3

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15

4

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7

89111213 10

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Function

14 Battery trolley unlocking t Unlocks the battery trolley15 Bridging switch o Avoids damage to forks or the load in the

outrigger area.16 Steering column

adjustmentt Adjust steering column height and distance

17 Driver display t Displays important drive and lifting parameters; selecs and displays types of steering operations, warning signs, provides information regarding incorrect operation and service displays (see Section 5)

On board computer o Replaces the key switch.Control voltage switch on – offRelease of truck functions via PIN-Code.


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Function

14 Battery trolley unlocking t Unlocks the battery trolley15 Bridging switch o Avoids damage to forks or the load in the

outrigger area.16 Steering column

adjustmentt Adjust steering column height and distance

17 Driver display t Displays important drive and lifting parameters; selecs and displays types of steering operations, warning signs, provides information regarding incorrect operation and service displays (see Section 5)

On board computer o Replaces the key switch.Control voltage switch on – offRelease of truck functions via PIN-Code.


E 5

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14

15

4

5

6

7

89111213 10

16

17

1 2

E 5

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6

7

89111213 10

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E 6

3 Starting the Truck

F Before the truck is started, operated or a load unit raised, the driver must ensure thatthere is no one standing in the danger area.

Daily tests and procedures before commencing work

– The entire truck (particularly wheels and lifting devices) to be inspected fordamage.

– Check whether the load chains are evenly tensioned– Visibly check battery and cable connections

Adjusting the driver’s seat

Z To achieve optimal seat cushioning the driver’s seat must be adjusted according tothe driver’s weight. The driver’s seat must not be occupied when being adjusted driver’s weight.

To adjust the driver's weight :

– Pull the lever (9) in the direction of thearrow and return.

Z The previous weight setting is reset tothe minimum valueSetting range of seat suspension from50 kg to 130 kg

– Move lever (9) again in the direction ofthe arrow until the correspondingweight mark on scale (18) is reached.Then finally return lever.

– Sit on the driver’s seat

F From the driver’s seat do not reach outto the side wall / roof of cab.

Adjust ing the backrest

– Lift up locking lever (10) and adjust the tilt of the backrest (19).– Release locking lever, the backrest is set

Adjusting the sitting position:

– Pull up the locking lever to locate the driver’s seat (8) in the direction of the arrowand push the seat forwards or backwards to the desired position.

– Re-engage locking lever (8).

F The driver’s seat must be securely located in the desired position. The position of thedriver’s seat must not be altered when driving.

Z The seat adjustment refers to series standard design. For other designs refer to themanufacturer’s adjustment instructions.When adjusting ensure that all controls are within reach

10

18 98

19

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3 Starting the Truck

F Before the truck is started, operated or a load unit raised, the driver must ensure thatthere is no one standing in the danger area.

Daily tests and procedures before commencing work

– The entire truck (particularly wheels and lifting devices) to be inspected fordamage.

– Check whether the load chains are evenly tensioned– Visibly check battery and cable connections

Adjusting the driver’s seat

Z To achieve optimal seat cushioning the driver’s seat must be adjusted according tothe driver’s weight. The driver’s seat must not be occupied when being adjusted driver’s weight.

To adjust the driver's weight :

– Pull the lever (9) in the direction of thearrow and return.

Z The previous weight setting is reset tothe minimum valueSetting range of seat suspension from50 kg to 130 kg

– Move lever (9) again in the direction ofthe arrow until the correspondingweight mark on scale (18) is reached.Then finally return lever.

– Sit on the driver’s seat

F From the driver’s seat do not reach outto the side wall / roof of cab.

Adjust ing the backrest

– Lift up locking lever (10) and adjust the tilt of the backrest (19).– Release locking lever, the backrest is set

Adjusting the sitting position:

– Pull up the locking lever to locate the driver’s seat (8) in the direction of the arrowand push the seat forwards or backwards to the desired position.

– Re-engage locking lever (8).

F The driver’s seat must be securely located in the desired position. The position of thedriver’s seat must not be altered when driving.

Z The seat adjustment refers to series standard design. For other designs refer to themanufacturer’s adjustment instructions.When adjusting ensure that all controls are within reach

10

18 98

19

E 7

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.GBAdjusting the steering column

– Slacken the steering column stop (16)and set the steering head (20) to therequired position horizontally andvertically.

Re-tighten the steering column stop.

Adjusting the arm rest

– Lift the arm rest (7) lock and set thearm rest (21) to the desired position(longitudinally).

– Release the arm rest lock (7)

1620

7 21

E 7

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Adjusting the steering column

– Slacken the steering column stop (16)and set the steering head (20) to therequired position horizontally andvertically.

Re-tighten the steering column stop.

Adjusting the arm rest

– Lift the arm rest (7) lock and set thearm rest (21) to the desired position(longitudinally).

– Release the arm rest lock (7)

1620

7 21

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3.1 How to use the safety belt (o)

F Before starting the forklift read theseinstructions carefully.

– Put on the belt before starting thetruck.

– Change the belt height settingaccording to body size.

F The belt will protect against seriousinjury.

– A frozen belt lock or reel must beallowed to thaw out and dry.

M The hot air temperature must not exceed+60 °C.

F Do not alter the belt setting.

– Safety belt and seat hood to bechecked for damage following anaccident and replaced if necessary.

– Damaged or unusable belts to bereplaced only by contracted dealers orbranches.

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

24

22 23

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3.1 How to use the safety belt (o)

F Before starting the forklift read theseinstructions carefully.

– Put on the belt before starting thetruck.

– Change the belt height settingaccording to body size.

F The belt will protect against seriousinjury.

– A frozen belt lock or reel must beallowed to thaw out and dry.

M The hot air temperature must not exceed+60 °C.

F Do not alter the belt setting.

– Safety belt and seat hood to bechecked for damage following anaccident and replaced if necessary.

– Damaged or unusable belts to bereplaced only by contracted dealers orbranches.

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

24

22 23

E 9

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.GBHow to proceed in unusual situations (o)

M If there is a danger of a tipover, proceed as follows:

– Press the upper body against the back of seat.

– Grip the steering wheel with both hands and fix your feet firmlyon the floor.

– Lean your body out against the direction of fall.

Safety belt user instructions (o)

Before starting the forklift pull the belt from the reel, pull tightly across the body andengage in the lock (22).

F The belt must not be twisted when fastened.

When operating the forklift (driving, lifting, lowering etc.) alwayssit with your back against the backrest.

The automatic lock on the belt reel allows for sufficientmovement in the seat.

F If you sit on the front edge of the seat too long, the extended beltoffers less protection.

Z Belt only to be used to secure one person.

– After use press the red switch and manually feed the locktongue (23) back to the reel.

Procedure for starting the forklift on an incline (o)

The automatic lock prevents the belt from coming loose when the truck is on a strongincline. The belt can no longer be pulled from the reel.

Z Carefully drive the truck out from the inclined position and apply the belt.

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How to proceed in unusual situations (o)

M If there is a danger of a tipover, proceed as follows:

– Press the upper body against the back of seat.

– Grip the steering wheel with both hands and fix your feet firmlyon the floor.

– Lean your body out against the direction of fall.

Safety belt user instructions (o)

Before starting the forklift pull the belt from the reel, pull tightly across the body andengage in the lock (22).

F The belt must not be twisted when fastened.

When operating the forklift (driving, lifting, lowering etc.) alwayssit with your back against the backrest.

The automatic lock on the belt reel allows for sufficientmovement in the seat.

F If you sit on the front edge of the seat too long, the extended beltoffers less protection.

Z Belt only to be used to secure one person.

– After use press the red switch and manually feed the locktongue (23) back to the reel.

Procedure for starting the forklift on an incline (o)

The automatic lock prevents the belt from coming loose when the truck is on a strongincline. The belt can no longer be pulled from the reel.

Z Carefully drive the truck out from the inclined position and apply the belt.

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3.2 Preparation for Use

Pull out the main switch (2)

Insert the key in the key switch and turnto the right to position "I" or:

– for trucks without a key switch enterthe free switch codevia CANCODE (1a), or.via the on board computer.

With CANCODE (o), the start PIN2580 is inserted via the control panel(1a) and confirmed by the set key.

– For the on board computer (17a)(o), enter the start PIN 14016 andconfirm with OK.

– Check the horn operation.

The truck is now ready for use. The battery charge monitor shows the battery capacityavailable.

– Check the brake and handbrake operation(see Section 4.2).

– On starting the dead man pedal must be activated.

1 2 3

4 5 6

7 8 9

0Set

2117

21a17

BITTE PINCODE EINGEBEN

OK0

CE

8TUV7

PQRS

9WXYZ

5JKL4

GHI

6MNO

2ABC1

3DEF

2117a

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E 10

3.2 Preparation for Use

Pull out the main switch (2)

Insert the key in the key switch and turnto the right to position "I" or:

– for trucks without a key switch enterthe free switch codevia CANCODE (1a), or.via the on board computer.

With CANCODE (o), the start PIN2580 is inserted via the control panel(1a) and confirmed by the set key.

– For the on board computer (17a)(o), enter the start PIN 14016 andconfirm with OK.

– Check the horn operation.

The truck is now ready for use. The battery charge monitor shows the battery capacityavailable.

– Check the brake and handbrake operation(see Section 4.2).

– On starting the dead man pedal must be activated.

1 2 3

4 5 6

7 8 9

0Set

2117

21a17

BITTE PINCODE EINGEBEN

OK0

CE

8TUV7

PQRS

9WXYZ

5JKL4

GHI

6MNO

2ABC1

3DEF

2117a

E 11

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3.3 Emergency Stop Device

Z The truck is equipped with an emergency stop device. After switching on the mainswitch (2) and the ignition switch (1) or entering the Pin code there is an automaticsafety prompt.

Emergency Stop Display

If a fault is detected on the steering or brake systems, a display will appear on thedriver display panel (t) (17) or on the board computer (o) (17a) (see Section 6.2).

Emergency Stop Activation

If a fault occurs in the steering system during travel which impairs the safety of theoperator there will be a controlled braking of the truck until it comes to rest.

Emergency Stop Re-Set.

– Turn the main switch and key switch off and on again.

Z If the emergency stop display appears on the driver display (t) or on the on-boardcomputer (o) even after repeatedly pressing the emergency stop reset button,contact the manufacturer’s service department to have the fault rectified.

M If, after the emergency stop has been triggered, the truck is in a dangerous area oraisle it can be operated via the emergency mechanical steering system(see Section 5).

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3.3 Emergency Stop Device

Z The truck is equipped with an emergency stop device. After switching on the mainswitch (2) and the ignition switch (1) or entering the Pin code there is an automaticsafety prompt.

Emergency Stop Display

If a fault is detected on the steering or brake systems, a display will appear on thedriver display panel (t) (17) or on the board computer (o) (17a) (see Section 6.2).

Emergency Stop Activation

If a fault occurs in the steering system during travel which impairs the safety of theoperator there will be a controlled braking of the truck until it comes to rest.

Emergency Stop Re-Set.

– Turn the main switch and key switch off and on again.

Z If the emergency stop display appears on the driver display (t) or on the on-boardcomputer (o) even after repeatedly pressing the emergency stop reset button,contact the manufacturer’s service department to have the fault rectified.

M If, after the emergency stop has been triggered, the truck is in a dangerous area oraisle it can be operated via the emergency mechanical steering system(see Section 5).

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4 Operating the Forklift Truck

4.1 Safety Rules when Driving

Routes and Work Areas: The truck may only be driven on routes specificallydesignated for traffic. Unauthorised persons must not enter the working area. Loadsmust only be deposited at the designated places

Travel Procedure: The driver must adjust the speed of the truck to suit localconditions. He must drive slowly into curves and also when approaching and drivingin narrow gangways, when traveling through swing doors and approaching blindareas. He must always keep a safe braking distance to the truck ahead and keep thetruck under control. Sudden stopping (except in case of danger) fast turning,overtaking at dangerous or blind spots is not permitted. It is not permitted to lean orreach out of the working and operating area.

Visibility when Driving: The driver must look in the direction in which he is travellingand shall always maintain a clear view of the road ahead. If a load is beingtransported which impairs his view then the load must be carried on the trailing endof the truck. If this is not possible, a guard shall be posted who shall walk ahead ofthe truck.

Negotiating Inclines or Dips: Negotiating inclines or dips is only permitted if suchroads are clean and have a non-slip surface and providing such journeys are safelyundertaken in accordance with the technical specifications for that truck. During suchoperations the load shall always be carried on the incline side of the truck. Turning,traversing and parking of the forklift is not allowed on inclines or dips. Driving downhillmay only be permitted with reduced speed and where the brake can be appliedinstantly.

Elevators and Docks: Elevators or docks may only be entered if they are sufficientlyrobust to carry the load, are suitable for traffic and are authorised by the owner foroperation. This must be checked before traffic is allowed onto them. The forklift mustbe driven into the elevator with the load leading and be positioned such that the truckdoes not come into contact with the shaft sidings.Persons riding in the elevator may only enter when the truck is secure and mustvacate the lift before the truck.

Composition of the transported load: Loads may only be transported whose safetyhas been ensured in accordance with safety regulations. Never transport loads whichhave been stacked higher than top of the fork carriage or the load guard.

Towing Trailers: The maximum trailing load for a forklift truck towing unbraked orbraked trailers shall not be exceeded. The trailer load must be secured in accordancewith regulations and must not exceed the dimensions permitted for that roadway.After coupling and before starting the driver shall ensure that the trailer couplingcannot become detached. Forklift trucks towing a load must be driven so that thetrailing truck is safe and can be stopped under any conditions.

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4 Operating the Forklift Truck

4.1 Safety Rules when Driving

Routes and Work Areas: The truck may only be driven on routes specificallydesignated for traffic. Unauthorised persons must not enter the working area. Loadsmust only be deposited at the designated places

Travel Procedure: The driver must adjust the speed of the truck to suit localconditions. He must drive slowly into curves and also when approaching and drivingin narrow gangways, when traveling through swing doors and approaching blindareas. He must always keep a safe braking distance to the truck ahead and keep thetruck under control. Sudden stopping (except in case of danger) fast turning,overtaking at dangerous or blind spots is not permitted. It is not permitted to lean orreach out of the working and operating area.

Visibility when Driving: The driver must look in the direction in which he is travellingand shall always maintain a clear view of the road ahead. If a load is beingtransported which impairs his view then the load must be carried on the trailing endof the truck. If this is not possible, a guard shall be posted who shall walk ahead ofthe truck.

Negotiating Inclines or Dips: Negotiating inclines or dips is only permitted if suchroads are clean and have a non-slip surface and providing such journeys are safelyundertaken in accordance with the technical specifications for that truck. During suchoperations the load shall always be carried on the incline side of the truck. Turning,traversing and parking of the forklift is not allowed on inclines or dips. Driving downhillmay only be permitted with reduced speed and where the brake can be appliedinstantly.

Elevators and Docks: Elevators or docks may only be entered if they are sufficientlyrobust to carry the load, are suitable for traffic and are authorised by the owner foroperation. This must be checked before traffic is allowed onto them. The forklift mustbe driven into the elevator with the load leading and be positioned such that the truckdoes not come into contact with the shaft sidings.Persons riding in the elevator may only enter when the truck is secure and mustvacate the lift before the truck.

Composition of the transported load: Loads may only be transported whose safetyhas been ensured in accordance with safety regulations. Never transport loads whichhave been stacked higher than top of the fork carriage or the load guard.

Towing Trailers: The maximum trailing load for a forklift truck towing unbraked orbraked trailers shall not be exceeded. The trailer load must be secured in accordancewith regulations and must not exceed the dimensions permitted for that roadway.After coupling and before starting the driver shall ensure that the trailer couplingcannot become detached. Forklift trucks towing a load must be driven so that thetrailing truck is safe and can be stopped under any conditions.

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4.2 Driving, Steering, Braking

Emergency Stop

– Press down the main switch (2).

All electrical functions are switched off. The function of the main switch must not beimpaired by any external objects.

Driving

F Only drive the truck with closed and properly locked hoods.The main travel direction is the drive direction (V). Pay extra attention when travellingin the load direction (R).

Z Travelling in the load direction should only be undertaken whilst manoeuvering andpicking up or depositing a load.

– Prepare truck for use (see Section 32).– Release parking brake via brake switch (25).

Z When the truck is ready for use no travel direction is selected. The truck can only bedriven after the required direction has been selected.

– When the truck is ready for use press the travel direction switch (26) in the directionof the arrow to select required direction (R). Continually pressing the directionswitch will change the direction.

– Press the dead man pedal (13) and the accelerator (11).The truck will start in the desired direction.

F The dead man pedal ensures that the driver’s feet do not extend outside the truck.When operated all electrical functions are cut out except the steering, the driverdisplay panel and the horn. The truck rolls to a stop in accordance with the "RolloutBrake" parameter.

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

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4.2 Driving, Steering, Braking

Emergency Stop

– Press down the main switch (2).

All electrical functions are switched off. The function of the main switch must not beimpaired by any external objects.

Driving

F Only drive the truck with closed and properly locked hoods.The main travel direction is the drive direction (V). Pay extra attention when travellingin the load direction (R).

Z Travelling in the load direction should only be undertaken whilst manoeuvering andpicking up or depositing a load.

– Prepare truck for use (see Section 32).– Release parking brake via brake switch (25).

Z When the truck is ready for use no travel direction is selected. The truck can only bedriven after the required direction has been selected.

– When the truck is ready for use press the travel direction switch (26) in the directionof the arrow to select required direction (R). Continually pressing the directionswitch will change the direction.

– Press the dead man pedal (13) and the accelerator (11).The truck will start in the desired direction.

F The dead man pedal ensures that the driver’s feet do not extend outside the truck.When operated all electrical functions are cut out except the steering, the driverdisplay panel and the horn. The truck rolls to a stop in accordance with the "RolloutBrake" parameter.

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

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Steering

Reverse Steering (t)

When travelling forward travel (drive direction) steer left into a left hand bend and rightinto a right hand bend. The position of the drive wheel will be shown on the driverdisplay panel or the on board computer.

Synchronous Steering (o)

– When travelling forward travel (drivedirection) steer to the left for a righthand bend and steer to the right for aleft hand bend. The position of thedrive wheel will be shown on the driverdisplay panel or the on boardcomputer.

Braking

Z The braking pattern of the truck depends essentially upon the ground conditions. Thedriver must take this into account when driving the truck.

The truck can be braked in three ways:

– with the reversing brake– with the rollout brake– with the service brake

F If the truck is operated by several drivers (e.g. multi-shift working) attention must bepaid to the individual parameter settings for different braking and driving patterns.When the truck is started up again check how the truck reacts!

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Steering

Reverse Steering (t)

When travelling forward travel (drive direction) steer left into a left hand bend and rightinto a right hand bend. The position of the drive wheel will be shown on the driverdisplay panel or the on board computer.

Synchronous Steering (o)

– When travelling forward travel (drivedirection) steer to the left for a righthand bend and steer to the right for aleft hand bend. The position of thedrive wheel will be shown on the driverdisplay panel or the on boardcomputer.

Braking

Z The braking pattern of the truck depends essentially upon the ground conditions. Thedriver must take this into account when driving the truck.

The truck can be braked in three ways:

– with the reversing brake– with the rollout brake– with the service brake

F If the truck is operated by several drivers (e.g. multi-shift working) attention must bepaid to the individual parameter settings for different braking and driving patterns.When the truck is started up again check how the truck reacts!

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– Press the direction switch (26) during travel. The direction of travel will be reversedand the brakes applied bythe traction current controller until the truck travels in theopposite direction.

Z This type of operation reduces energy consumption. There will be a regeneration ofenergy, governed by the traction current controller. The driver display panel or the onboard computer will indicate energy recovery.

Braking with the Rollout Brake:

– Release accelerator during travel; thebrake will be applied by the tractioncurrent controller according to theposition of the accelerator.

Braking with the Service Brake:

– Press the brake pedal (12).

The vehicle will be braked by the reversecurrent in the traction motor and wherenecessary by the electric load wheelbrakes.

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Braking with the Reversing Brake:

– Press the direction switch (26) during travel. The direction of travel will be reversedand the brakes applied bythe traction current controller until the truck travels in theopposite direction.

Z This type of operation reduces energy consumption. There will be a regeneration ofenergy, governed by the traction current controller. The driver display panel or the onboard computer will indicate energy recovery.

Braking with the Rollout Brake:

– Release accelerator during travel; thebrake will be applied by the tractioncurrent controller according to theposition of the accelerator.

Braking with the Service Brake:

– Press the brake pedal (12).

The vehicle will be braked by the reversecurrent in the traction motor and wherenecessary by the electric load wheelbrakes.

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4.3 Fork Adjustment

F In order to securely position a load theforks should be set as far as possibleapart from each other and centrallyaligned with the truck. The load centre ofgravity must lie between the forks.

– Tilt the locating lever (27) up.– Push the forks (28) to the correct

position on the fork carriage.– Tilt the locating lever down until the

locating pin engages in a slot.

4.4 Picking Up and Depositing a Load

M Before a load is lifted the driver mustensure that it is arranged on the pallet inaccordance with regulations and thetruck capacity is not exceeded.

– Position the forks as far as possibleunderneath the load.

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4.3 Fork Adjustment

F In order to securely position a load theforks should be set as far as possibleapart from each other and centrallyaligned with the truck. The load centre ofgravity must lie between the forks.

– Tilt the locating lever (27) up.– Push the forks (28) to the correct

position on the fork carriage.– Tilt the locating lever down until the

locating pin engages in a slot.

4.4 Picking Up and Depositing a Load

M Before a load is lifted the driver mustensure that it is arranged on the pallet inaccordance with regulations and thetruck capacity is not exceeded.

– Position the forks as far as possibleunderneath the load.

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F Do not allow anybody to standunderneath a load that is being raised.

– Pull Multi-Pilot (3) in direction (H).

Z The angle of the control leverdetermines the lift speed.

– Operate the Multi-Pilot until thedesired height is reached.

Z When the end stop is reached (there willbe a noise from the pressure relief valve)return the control lever immediately tothe start position.

Lowering

– Press Multi-Pilot (3) in direction (S).

Z The angle of the Multi-Pilot determines the lowering speed.

M Avoid dropping the load unit heavily in order to protect the load and the rack surface.

4.5 Emergency Lowering

F Do not allow anyone in the danger area when performing emergency lowering.

If the hoist frame does not lower due to a fault in the lift controller the emergencylowering valve (30) located on the back of the mast holder must be applied.

F Only operate the emergency loweringvalve when you are standing next to thetruck!Never reach through the hoist frame!Do not walk underneath the load!

– Turn off the main switch and the keyswitch

– Withdraw battery connector.– Press the red valve head downwards

using a suitable extension and hold inthis position. Lower the hoist frameand load pickup device slowly.

F Only operate the truck when the fault has been rectified.

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Lifting

F Do not allow anybody to standunderneath a load that is being raised.

– Pull Multi-Pilot (3) in direction (H).

Z The angle of the control leverdetermines the lift speed.

– Operate the Multi-Pilot until thedesired height is reached.

Z When the end stop is reached (there willbe a noise from the pressure relief valve)return the control lever immediately tothe start position.

Lowering

– Press Multi-Pilot (3) in direction (S).

Z The angle of the Multi-Pilot determines the lowering speed.

M Avoid dropping the load unit heavily in order to protect the load and the rack surface.

4.5 Emergency Lowering

F Do not allow anyone in the danger area when performing emergency lowering.

If the hoist frame does not lower due to a fault in the lift controller the emergencylowering valve (30) located on the back of the mast holder must be applied.

F Only operate the emergency loweringvalve when you are standing next to thetruck!Never reach through the hoist frame!Do not walk underneath the load!


– Withdraw battery connector.– Press the red valve head downwards

using a suitable extension and hold inthis position. Lower the hoist frameand load pickup device slowly.

F Only operate the truck when the fault has been rectified.

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Mast Holder Reach

F Do not reach between the mast and thebattery cover.

– Tilt the Multi-Pilot (3) in direction (T) toextend the mast holder and indirection (U) to retract it.

Z The angle of the Multi-Pilot determinesthe reach speed.

o Mast Reach Damping

Hydraulic damping of the mast holderreach is automatically activated abovethe free lift.

t Mast Tilt/ o Fork Tilt

– For forward tilt press rocker (V), rockerswitch (31).

– For reverse tilt press rocker (R).

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Mast Holder Reach

F Do not reach between the mast and thebattery cover.

– Tilt the Multi-Pilot (3) in direction (T) toextend the mast holder and indirection (U) to retract it.

Z The angle of the Multi-Pilot determinesthe reach speed.

o Mast Reach Damping

Hydraulic damping of the mast holderreach is automatically activated abovethe free lift.

t Mast Tilt/ o Fork Tilt

– For forward tilt press rocker (V), rockerswitch (31).

– For reverse tilt press rocker (R).

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– Set forks to the horizontal position:Press rocker switch (31), rocker (V) or(R).

– Approach the load unit– Extend the mast holder. Tilt Multi-Pilot

(3) in direction (T).– Lift fork prongs to correct level: Pull

Multi-Pilot (3) in direction (H).– Position forks under the load– Lift load freely: Pull Multi-Pilot (3) in

direction (H).– To retract mast holder: Tilt Multi-Pilot

in direction (U).

F Only transport the truck with or without a load when the mast holder is retracted, thelifting frame tilted back and the load pickup device lowered.

– Lower load unit in the transport position: Press Multi-Pilot (3) in direction (S).– Tilt the load unit back: Press rocker switch (31), rocker (R).– Transport load unit.– Position the load horizontally: Press rocker switch (31), rocker (V).– Set the load to correct height: Pull Multi-Pilot (3) in direction (H) and if necessary tilt

the Multi-Pilot in direction (T) to extend the mast holder.– To lower the load: Press Multi-Pilot (3) in direction (S).– To retract the mast holder: Tilt Multi-Pilot (3) in direction (U).

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Placing, Lifting and TransportingLoad Units

– Set forks to the horizontal position:Press rocker switch (31), rocker (V) or(R).

– Approach the load unit– Extend the mast holder. Tilt Multi-Pilot

(3) in direction (T).– Lift fork prongs to correct level: Pull

Multi-Pilot (3) in direction (H).– Position forks under the load– Lift load freely: Pull Multi-Pilot (3) in

direction (H).– To retract mast holder: Tilt Multi-Pilot

in direction (U).

F Only transport the truck with or without a load when the mast holder is retracted, thelifting frame tilted back and the load pickup device lowered.

– Lower load unit in the transport position: Press Multi-Pilot (3) in direction (S).– Tilt the load unit back: Press rocker switch (31), rocker (R).– Transport load unit.– Position the load horizontally: Press rocker switch (31), rocker (V).– Set the load to correct height: Pull Multi-Pilot (3) in direction (H) and if necessary tilt

the Multi-Pilot in direction (T) to extend the mast holder.– To lower the load: Press Multi-Pilot (3) in direction (S).– To retract the mast holder: Tilt Multi-Pilot (3) in direction (U).

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4.6 Operating Attachments

Integrated Sideshift

Z The directions left and right refer to theload when viewed from the operator’sseat

Moving the sideshift to the left (fromdriver’s view):

– Set key (32) to direction (X1)

Moving the sideshift to the right (fromdriver’s view):

– Set key (32) to direction (Y1).

F When extended be aware of reducedcapacity. (See Chapter B).

o Hydraulic attachments

The control lever (33) has functions (X2)and (Y2) to operate a hydraulic attachment (HF5).(Refer to manufacturer’s Operator Manual)

F Note capacity of the attachment.

4.7 Parking the truck safely

If it is necessary to leave the truck ensure that it is parked safely even if it is left foronly a short period.

F Do not park the truck on a slope! The load pickup device must always be fullylowered.

– Activate the parking brake by pressingthe brake switch (34).

– Lower the load pickup device fully andset it horizontally.

– Completely retract the mast holder– Set the main switch (2) “OFF”.– Turn key switch (1) to the "0" position

and remove the key.

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4.6 Operating Attachments

Integrated Sideshift

Z The directions left and right refer to theload when viewed from the operator’sseat

Moving the sideshift to the left (fromdriver’s view):

– Set key (32) to direction (X1)

Moving the sideshift to the right (fromdriver’s view):

– Set key (32) to direction (Y1).

F When extended be aware of reducedcapacity. (See Chapter B).

o Hydraulic attachments

The control lever (33) has functions (X2)and (Y2) to operate a hydraulic attachment (HF5).(Refer to manufacturer’s Operator Manual)

F Note capacity of the attachment.

4.7 Parking the truck safely

If it is necessary to leave the truck ensure that it is parked safely even if it is left foronly a short period.

F Do not park the truck on a slope! The load pickup device must always be fullylowered.

– Activate the parking brake by pressingthe brake switch (34).

– Lower the load pickup device fully andset it horizontally.

– Completely retract the mast holder– Set the main switch (2) “OFF”.– Turn key switch (1) to the "0" position

and remove the key.

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5 Mechanical Back Up Steering (Emergency Steering Operation)

The mechanical back-up steering system is used to recover the truck in the event ofan electrical failure.

F It must only be implemented by trained maintenance personnel who have beentrained to operate the truck.


– Ensure that the truck cannot roll away.– Push the seat from the guide towards

the steering wheel.– Disconnect fan connection– Remove the cover above the seat by

removing three fixing screws.– Release the magnetic brake

(see Chapter C).– Remove the protective cover from the

centre bolt.– Before recovering the truck the drive

wheel can be turned to the requiredposition via the centre bolt of thesteering motor by using a crankhandle.

– Assemble the crank handle (35) as indicated in the tool set table.– Fit handle to steering drive and turn the drive wheel to the desired steering position.

o Crank Handle Tool Set (35)

Item. Part Order No. Description1 1 95 600 230 Box spanner 8 mm 1/2 " DIN 31202 1 95 608 130 Crank3 1 27 636 010 Cardan joint

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5 Mechanical Back Up Steering (Emergency Steering Operation)

The mechanical back-up steering system is used to recover the truck in the event ofan electrical failure.

F It must only be implemented by trained maintenance personnel who have beentrained to operate the truck.


– Ensure that the truck cannot roll away.– Push the seat from the guide towards

the steering wheel.– Disconnect fan connection– Remove the cover above the seat by

removing three fixing screws.– Release the magnetic brake

(see Chapter C).– Remove the protective cover from the

centre bolt.– Before recovering the truck the drive

wheel can be turned to the requiredposition via the centre bolt of thesteering motor by using a crankhandle.

– Assemble the crank handle (35) as indicated in the tool set table.– Fit handle to steering drive and turn the drive wheel to the desired steering position.

o Crank Handle Tool Set (35)

Item. Part Order No. Description1 1 95 600 230 Box spanner 8 mm 1/2 " DIN 31202 1 95 608 130 Crank3 1 27 636 010 Cardan joint

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F When steering in the standing position the drive wheel tyre is under tension. Acorrecting moment can be created by releasing the Allen screw.

M When the truck has reached a safe position return the brake system to operationalcondition! The truck must not be parked with the brakes released.

– Remove the Allen screw from the engine.– Replace the protective cover.– Remove the locking bolts for the magnetic brake and screw into the drive plate.– Assemble seat hood (3) (3 fixing screws)– Re-connect the fan– Push driver’s seat along the guide and position it.

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F When steering in the standing position the drive wheel tyre is under tension. Acorrecting moment can be created by releasing the Allen screw.

M When the truck has reached a safe position return the brake system to operationalcondition! The truck must not be parked with the brakes released.

– Remove the Allen screw from the engine.– Replace the protective cover.– Remove the locking bolts for the magnetic brake and screw into the drive plate.– Assemble seat hood (3) (3 fixing screws)– Re-connect the fan– Push driver’s seat along the guide and position it.

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6 Display Items


The driver display unit is the user interface to the truck. It is both a display andoperating unit for the operator and service engineers.

Press the 4 short stroke keys (55, 56, 57, 58) to operate the driver display and thetruck. The LEDs of the 11 lights (35 – 44, 59, 60) can indicate three conditions: active,flashing or off.

All displays are shown in plain text or as symbols. The significance of the individualsymbols is explained in Section 6.2.

The contrasting display provides information on the direction of travel, the selectedsteering angle, the battery charge condition and other selected truck parameters.

Setting the Clock:

– Press the shift key for 3 secs.

The display (48) above the battery shows the actual time. It switches between actualtime and time remaining.

– Press the shift key for 8 secs. until menu "Set Clock Time" is displayed.– Set the hours using the "Up" (58) and "Down" (57) keys.– Confirm with the shift key.– Set the minutes using the "Up" (58) and the "Down" (57) keys.– Press the shift key or the profile key to return to normal operating mode.

Z Either the 24 hour or the 12 hour system can be used to set the time.

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6 Display Items


The driver display unit is the user interface to the truck. It is both a display andoperating unit for the operator and service engineers.

Press the 4 short stroke keys (55, 56, 57, 58) to operate the driver display and thetruck. The LEDs of the 11 lights (35 – 44, 59, 60) can indicate three conditions: active,flashing or off.

All displays are shown in plain text or as symbols. The significance of the individualsymbols is explained in Section 6.2.

The contrasting display provides information on the direction of travel, the selectedsteering angle, the battery charge condition and other selected truck parameters.

Setting the Clock:

– Press the shift key for 3 secs.

The display (48) above the battery shows the actual time. It switches between actualtime and time remaining.

– Press the shift key for 8 secs. until menu "Set Clock Time" is displayed.– Set the hours using the "Up" (58) and "Down" (57) keys.– Confirm with the shift key.– Set the minutes using the "Up" (58) and the "Down" (57) keys.– Press the shift key or the profile key to return to normal operating mode.

Z Either the 24 hour or the 12 hour system can be used to set the time.

43 49 50

59 58 57 56 5560

44 45 46 47 4842

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Item. Description36 Warning, warning triangle (red graphic symbol),37 Battery is unlocked (red graphic symbol),38 Overtemperature (red graphic symbol)39 Dead man pedal not activated (yellow graphic sysmbol)40 Lift limit reached (yellow graphic symbol)41 Forks in horizontal position (green graphic symbol),42 Slow travel (green graphic symbol),43 Sideshift in central position (green graphic symbol)44 Service mode active (yellow graphic symbol),

Service interval expired (graphic symbol flashes)45 Steering angle in 30° increments as arrow46 Steering mode 180 or 360° by display of 2 or 4 circular segments.47 Remaing time display with in-built battery in the form of hours: minutes48 Time in form of hours: minutes49 Battery discharge status in 10% bars (0 – 100%) and energy recovery (t)

display50 Discharge Display51 Set speed (drive direction) of current profile.

(bars 1 to 5).52 Set speed (lifting) of current profile

(bars 1 to 5).53 Profile number (drive / lift profile 1, 2 or 3)54 Warning and error messages as text (14 segment display) and data

registration.55 Profile switch to select drive and lift mode56 shift key (to alternate between display and access to service mode)57 Brake switch to apply / release handbrake58 Slow drive switch to throttle travel speed59 Fault, STOP sign (red graphic symbol),60 Parking brake applied (red graphic symbol

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Item. Description36 Warning, warning triangle (red graphic symbol),37 Battery is unlocked (red graphic symbol),38 Overtemperature (red graphic symbol)39 Dead man pedal not activated (yellow graphic sysmbol)40 Lift limit reached (yellow graphic symbol)41 Forks in horizontal position (green graphic symbol),42 Slow travel (green graphic symbol),43 Sideshift in central position (green graphic symbol)44 Service mode active (yellow graphic symbol),

Service interval expired (graphic symbol flashes)45 Steering angle in 30° increments as arrow46 Steering mode 180 or 360° by display of 2 or 4 circular segments.47 Remaing time display with in-built battery in the form of hours: minutes48 Time in form of hours: minutes49 Battery discharge status in 10% bars (0 – 100%) and energy recovery (t)

display50 Discharge Display51 Set speed (drive direction) of current profile.

(bars 1 to 5).52 Set speed (lifting) of current profile

(bars 1 to 5).53 Profile number (drive / lift profile 1, 2 or 3)54 Warning and error messages as text (14 segment display) and data

registration.55 Profile switch to select drive and lift mode56 shift key (to alternate between display and access to service mode)57 Brake switch to apply / release handbrake58 Slow drive switch to throttle travel speed59 Fault, STOP sign (red graphic symbol),60 Parking brake applied (red graphic symbol

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– regulate travel speed (slow travel switch),– apply or release the handbrake (brake switch),– change display to service mode (shift key) and – select between travel and lift mode.

The display shows:

– Steering angle in 30° increments (as arrow)– Steering mode of 180° or 360° (2 or 4 segments are shown,)– Drive or lift profile (as 1, 2 or 3),– The set speed (drive direction) of current profile (bars 1 to 5 ),– The set speed (lift) of the current profile (bars 1 to 5,– The discharge status of the battery in 10% increments ( 0 – 100%),– Battery discharge warning (flashing battery symbol and buzzing tone),– Operating hours : complete hours)– Time (hours: minutes),– Lift height in mm (5 digit),– Maximum lift height in mm (5 digit),– Load weight in kg (4 digit)– The time remaining for built in battery (hours: minutes),– Warning and fault messages as text (14 segment display),– Service mode parameters– Service mode diagnostics.

The coloured lights indicate

– Forks in horizontal position (green graphic symbol),– Sideshift in central position (green graphic symbol),– Lift limit reached (yellow graphic symbol),– Slow travel (green graphic symbol),– Dead man pedal not activated (yellow graphic symbol),– Service mode active (yellow graphic symbol),– Service interval expired (yellow graphic symbol spanner flashes),– Overtemperature (red graphic symbol),– Battery unlocked (red graphic symbol),– Parking brake applied (red graphic symbol),– Warning, warning triangle (red graphic symbol),– Fault, STOP sign (red graphic symbol).

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The four short stroke keys are used to:

– regulate travel speed (slow travel switch),– apply or release the handbrake (brake switch),– change display to service mode (shift key) and – select between travel and lift mode.

The display shows:

– Steering angle in 30° increments (as arrow)– Steering mode of 180° or 360° (2 or 4 segments are shown,)– Drive or lift profile (as 1, 2 or 3),– The set speed (drive direction) of current profile (bars 1 to 5 ),– The set speed (lift) of the current profile (bars 1 to 5,– The discharge status of the battery in 10% increments ( 0 – 100%),– Battery discharge warning (flashing battery symbol and buzzing tone),– Operating hours : complete hours)– Time (hours: minutes),– Lift height in mm (5 digit),– Maximum lift height in mm (5 digit),– Load weight in kg (4 digit)– The time remaining for built in battery (hours: minutes),– Warning and fault messages as text (14 segment display),– Service mode parameters– Service mode diagnostics.

The coloured lights indicate

– Forks in horizontal position (green graphic symbol),– Sideshift in central position (green graphic symbol),– Lift limit reached (yellow graphic symbol),– Slow travel (green graphic symbol),– Dead man pedal not activated (yellow graphic symbol),– Service mode active (yellow graphic symbol),– Service interval expired (yellow graphic symbol spanner flashes),– Overtemperature (red graphic symbol),– Battery unlocked (red graphic symbol),– Parking brake applied (red graphic symbol),– Warning, warning triangle (red graphic symbol),– Fault, STOP sign (red graphic symbol).

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6.2 Driver display lights

SYMBOLForks in horizontal position (green graphic symbol),

SYMBOLSideshift central position (green graphic symbol),

SYMBOLLift limit reached (yellow graphic symbol),

SYMBOLSlow travel (green graphic symbol),

SYMBOLDead man pedal not activated (yellow graphic symbol),

SYMBOLService mode active (yellow graphic symbol),

SYMBOLOvertemperature (red graphic symbol),

SYMBOLBattery unlocked (red graphic symbol),

SYMBOLParking brake applied (red graphic symbol),

SYMBOLWarning, warning triangle (red graphic symbol),

SYMBOLFault, STOP sign (red graphic symbol),

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6.2 Driver display lights

SYMBOLForks in horizontal position (green graphic symbol),

SYMBOLSideshift central position (green graphic symbol),

SYMBOLLift limit reached (yellow graphic symbol),

SYMBOLSlow travel (green graphic symbol),

SYMBOLDead man pedal not activated (yellow graphic symbol),

SYMBOLService mode active (yellow graphic symbol),

SYMBOLOvertemperature (red graphic symbol),

SYMBOLBattery unlocked (red graphic symbol),

SYMBOLParking brake applied (red graphic symbol),

SYMBOLWarning, warning triangle (red graphic symbol),

SYMBOLFault, STOP sign (red graphic symbol),

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Driver display warning messages

Travel speed throttled (slow travel switch),

Hand brake applied or released (brake switch),

Change of display to service mode (shift key)

Selection of travel and lift modes

43 49 50

59 58 57 56 5560

44 45 46 47 4842

4151

54�

52

53

40

39

38

37

36

E 27

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Driver Display Keys

Driver display warning messages

Travel speed throttled (slow travel switch),

Hand brake applied or released (brake switch),

Change of display to service mode (shift key)

Selection of travel and lift modes

43 49 50

59 58 57 56 5560

44 45 46 47 4842

4151

54�

52

53

40

39

38

37

36

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Display Further Action Meaning

LED 39 on Seat switch not closed

INFO 02 LED 36 on No travel direction pre-selected.

LED 49 flashing Battery drained main lift cut out

LED 39 on Safety switch not activated

INFO 07 LED 44 flashing At least one control not in the reset position at start

INFO 09 LED 42 on Creep travel applied, or pre-set by locks

INFO 10 LED 38 on Traction motor overtemperature

INFO 11 LED 38 on Lift motor overtemperature

INFO 12 LED 38 on Steering motor overtemperature

LED 40 on Lift limit reached

LED 40 flashing Safety height not reached

INFO 25 LED 38 flashing Traction controller overtemperature

INFO 26 LED 38 flashing Lift controller overtemperature

INFO 27 LED 38 flashing Steering controller overtemperature

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Display Further Action Meaning

LED 39 on Seat switch not closed

INFO 02 LED 36 on No travel direction pre-selected.

LED 49 flashing Battery drained main lift cut out

LED 39 on Safety switch not activated

INFO 07 LED 44 flashing At least one control not in the reset position at start

INFO 09 LED 42 on Creep travel applied, or pre-set by locks

INFO 10 LED 38 on Traction motor overtemperature

INFO 11 LED 38 on Lift motor overtemperature

INFO 12 LED 38 on Steering motor overtemperature

LED 40 on Lift limit reached

LED 40 flashing Safety height not reached

INFO 25 LED 38 flashing Traction controller overtemperature

INFO 26 LED 38 flashing Lift controller overtemperature

INFO 27 LED 38 flashing Steering controller overtemperature

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The on board computer represents the operator’s interface to the truck. It acts as adisplay and control unit for the operator as well service engineers. By pressingdifferent keys (softkeys (64)) a range of menus (65) can be selected. Menu (66)shows three conditions: Active, inactive and not available for selection (greybackground).

All displays are shown as plain text or in symbol form for easy identification. Thesignificance of the individual symbols is explained in Section 6.4.

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

Item. Description61 Operating Hours62 Battery Charge as %63 "T" for full discharge protection on maintenance free batteries.64 Softkeys65 Menus

OK0CE

8TUV

7PQRS

9WXYZ

5JKL

4GHI

6MNO

2ABC

1 3DEF

0009 h 08:45

km/h

50 % T

0

63 6462

61

65 65

E 29

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The on board computer represents the operator’s interface to the truck. It acts as adisplay and control unit for the operator as well service engineers. By pressingdifferent keys (softkeys (64)) a range of menus (65) can be selected. Menu (66)shows three conditions: Active, inactive and not available for selection (greybackground).

All displays are shown as plain text or in symbol form for easy identification. Thesignificance of the individual symbols is explained in Section 6.4.

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

Item. Description61 Operating Hours62 Battery Charge as %63 "T" for full discharge protection on maintenance free batteries.64 Softkeys65 Menus

OK0CE

8TUV

7PQRS

9WXYZ

5JKL

4GHI

6MNO

2ABC

1 3DEF

0009 h 08:45

km/h

50 % T

0

63 6462

61

65 65

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6.4 Display Symbol for On Board Computer

ESCAPEGoes to a higher level

TRAVEL PROFILE 1Creep travel

TRAVEL PROFILE 2Normal travelAcceleration, speed etc. Can be adjusted to the driver’s requirements.TRAVEL PROFILE 3Fast travel

LIFT MENUParameters/Diagnosis/ Error logbook

SERVICE MENU / PARAMETER MENU

DATA FUNCTION MENU

SCROLL UPScroll up

SCROLL DOWNScroll down

PAGE UPPage up

PAGE DOWNPage down

BATTERY CHARGE STATUSReady for operation

BATTERY CHARGE STATUSReady for operation, warning status

BATTERY CHARGE STATUSReady for operation, warning status criticalLifting is inhibited

STOP

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6.4 Display Symbol for On Board Computer

ESCAPEGoes to a higher level

TRAVEL PROFILE 1Creep travel

TRAVEL PROFILE 2Normal travelAcceleration, speed etc. Can be adjusted to the driver’s requirements.TRAVEL PROFILE 3Fast travel

LIFT MENUParameters/Diagnosis/ Error logbook

SERVICE MENU / PARAMETER MENU

DATA FUNCTION MENU

SCROLL UPScroll up

SCROLL DOWNScroll down

PAGE UPPage up

PAGE DOWNPage down

BATTERY CHARGE STATUSReady for operation

BATTERY CHARGE STATUSReady for operation, warning status

BATTERY CHARGE STATUSReady for operation, warning status criticalLifting is inhibited

STOP

E 31

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TIME

OPERATING HOURS DISPLAY

PARAMETER SELECTIONParameters: acceleration, rollout brake, reverse brake, travel direction speed and fork direction speed.

PARAMETER SELECTIONLift speed parameters

STEERING ANGLE DISPLAY 360°


TABULATORTo next input field

WARNING SYMBOLBattery not interlocked!

WARNING SYMBOLParking brake applied

SYMBOLSideshift in central position

CREEP

PIN INPUTInputted PIN / Variable of current field / Variable PIN input

08:45

0009 h

km/h0

km/h0

P

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Display Symbols

TIME

OPERATING HOURS DISPLAY

PARAMETER SELECTIONParameters: acceleration, rollout brake, reverse brake, travel direction speed and fork direction speed.

PARAMETER SELECTIONLift speed parameters



TABULATORTo next input field

WARNING SYMBOLBattery not interlocked!

WARNING SYMBOLParking brake applied

SYMBOLSideshift in central position

CREEP

PIN INPUTInputted PIN / Variable of current field / Variable PIN input

08:45

0009 h

km/h0

km/h0

P

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7 Operator Keypad (CANCODE) (o)

The keypad consists of 10 digit keys, one set keyand one extra key o�

The o key indicates the operational status via ared/ green LED.

It has the following functions:

– Code key function (starting the truck).

7.1 Code Key

After entering the correct code the truck is ready for use. It is possible to allocate anindividual code to each truck, driver or group of drivers.

Z When delivered from the factory the operational codes are shown on the driverdisplay unit and CANCODE (o) (factory setting 2-5-8-0) or for the on board computer(o) (factory setting ( 1-4-0-3-7) on a sticker.

M When using the truck for the first time change the mast and operator code!

1 2 3

4 5 6

7 8 9

0Set

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7 Operator Keypad (CANCODE) (o)

The keypad consists of 10 digit keys, one set keyand one extra key o�

The o key indicates the operational status via ared/ green LED.

It has the following functions:

– Code key function (starting the truck).

7.1 Code Key

After entering the correct code the truck is ready for use. It is possible to allocate anindividual code to each truck, driver or group of drivers.

Z When delivered from the factory the operational codes are shown on the driverdisplay unit and CANCODE (o) (factory setting 2-5-8-0) or for the on board computer(o) (factory setting ( 1-4-0-3-7) on a sticker.

M When using the truck for the first time change the mast and operator code!

1 2 3

4 5 6

7 8 9

0Set

E 33

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After switching on the main switch and if necessary the key switch LED (66) showsred.

On entering the correct operating code LED (65) shows green.

If the wrong code is entered LED (65) flashes red for two seconds. Then the correctcode can be entered.

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

Switching off

The truck can be switched off by pressingthe o switch (70)

Z The truck can be switched off automaticallyafter a pre-set time. To do this theappropriate code keyparameters must beentered.(see Section 6.3).

7.2 Parameters

The code key functions can be adjusted inthe programming mode via the keypad.

Parameter Groups

The parameter number consists of three digits. The first digit refers to the parametergroup as in Table 1. The second and third digits are progressively numbered from 00to 99.

No. Parameter Group0xx Code Key Setting

(Codes, travel program release, automatic cut out, etc.)

1 2 3

4 5 6

7 8 9

0Set

67

66

65

70

6968

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Starting

After switching on the main switch and if necessary the key switch LED (66) showsred.

On entering the correct operating code LED (65) shows green.

If the wrong code is entered LED (65) flashes red for two seconds. Then the correctcode can be entered.

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

Switching off

The truck can be switched off by pressingthe o switch (70)

Z The truck can be switched off automaticallyafter a pre-set time. To do this theappropriate code keyparameters must beentered.(see Section 6.3).

7.2 Parameters

The code key functions can be adjusted inthe programming mode via the keypad.

Parameter Groups

The parameter number consists of three digits. The first digit refers to the parametergroup as in Table 1. The second and third digits are progressively numbered from 00to 99.

No. Parameter Group0xx Code Key Setting

(Codes, travel program release, automatic cut out, etc.)

1 2 3

4 5 6

7 8 9

0Set

67

66

65

70

6968

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7.3 Parameter Settings

The master code must be entered to change the truck setting.

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

M Change the master code when starting the truck for the first time (see Section 7.1).

Entering the master code:

– Press the o key– Enter the master code

Code Key Parameters

Setting procedure for truck:

– Enter the three digit parameter number, confirm with the Set key (66).– Enter the set value according to parameter list or change and confirm with Set key

(66).

Z If an unauthorised number is entered the LED (65) of the o switch (70) will flash red.When the parameter number is entered again the set value can be entered orchanged.

Repeat the procedure to enter additional parameters. When input is complete pressthe o key (70).

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7.3 Parameter Settings

The master code must be entered to change the truck setting.

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

M Change the master code when starting the truck for the first time (see Section 7.1).

Entering the master code:

– Press the o key– Enter the master code

Code Key Parameters

Setting procedure for truck:

– Enter the three digit parameter number, confirm with the Set key (66).– Enter the set value according to parameter list or change and confirm with Set key

(66).

Z If an unauthorised number is entered the LED (65) of the o switch (70) will flash red.When the parameter number is entered again the set value can be entered orchanged.

Repeat the procedure to enter additional parameters. When input is complete pressthe o key (70).

E 35

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.GBThe following parameters may be entered.

Code Key Parameter List

No. Function Setting Range StandardSetting

CommentsWorkflow

Code Key000 Changes the Master Code

The length (4-6 digits) of the master code also pre-determines the length of the operator code. (4-6 digits). As long as operator codes are programmed only a code of the same length can be entered. If the code length is changed then all operator codes should be deleted beforehand.

0000 - 9999or

00000 - 99999or

000000 - 999999

7295 (LED 67 flashes)Input of

current code

confirm (Set)

(LED 68 flashes)Input of

new code

confirm (Set)

(LED 69 flashes)Repeat new code

confirm (Set)001 Add operator code (max.

600)0000 - 9999

or00000 - 99999

or000000 - 999999

2580 (LED 68 flashes)Input ofCode

confirm (Set)

(LED 69 flashes)Repeat Input of

Code

confirm (Set)

E 35

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The following parameters may be entered.

Code Key Parameter List


CommentsWorkflow

Code Key000 Changes the Master Code

The length (4-6 digits) of the master code also pre-determines the length of the operator code. (4-6 digits). As long as operator codes are programmed only a code of the same length can be entered. If the code length is changed then all operator codes should be deleted beforehand.

0000 - 9999or

00000 - 99999or

000000 - 999999

7295 (LED 67 flashes)Input of

current code

confirm (Set)


new code

confirm (Set)

(LED 69 flashes)Repeat new code

confirm (Set)001 Add operator code (max.

600)0000 - 9999

or00000 - 99999

or000000 - 999999

2580 (LED 68 flashes)Input ofCode

confirm (Set)


Code

confirm (Set)

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LEDs 67-69 are located in key fields 1-3 (see Section 7)


CommentsWorkflow

Code Key002 Change operator code 0000 - 9999

or00000 - 99999

or000000 - 999999


current code

confirm (Set)


new code

confirm (Set)


Code

confirm003 Delete operator code 0000 - 9999

or00000 - 99999

or000000 - 999999

(LED 68 flashes)Input ofCode

confirm (Set)


Code

confirm (Set)004 Delete code memory

(Deletes all user codes )3265 3265 = delete

other inputs= do not delete

010 Automatic time cutout 00 - 31 00 00 = noSwitch off

01 to 30 =Switch off time in

Minutes

31 = Switch off after 10 seconds

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LEDs 67-69 are located in key fields 1-3 (see Section 7)


CommentsWorkflow

Code Key002 Change operator code 0000 - 9999

or00000 - 99999

or000000 - 999999


current code

confirm (Set)


new code

confirm (Set)


Code

confirm003 Delete operator code 0000 - 9999

or00000 - 99999

or000000 - 999999

(LED 68 flashes)Input ofCode

confirm (Set)


Code

confirm (Set)004 Delete code memory

(Deletes all user codes )3265 3265 = delete

other inputs= do not delete

010 Automatic time cutout 00 - 31 00 00 = noSwitch off

01 to 30 =Switch off time in

Minutes

31 = Switch off after 10 seconds

E 37

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The following faults are shown by the LED (65) flashing red:

– New master code is already the operator code– New operator code is already the master code– There is no operator code to be altered.– Operator code to be changed to another operating code which already exists.– No operator code to delete.– Code memory full

8 Changing Truck Parameters

F Changing the truck parameters affects the travel pattern of the truck. This must betaken into account when starting the truck again. Parameters may only be changed when truck is standing and no lifting operations arein progress.

With the driver display (t) or the on board computer (o) it is also possible to changecertain truck parameters and hence the truck behaviour (acceleration, rollout brake,reverse brake, drive direction travel speed, fork direction travel speed and lift speed).

t Trucks with driver display and ignition switch

On trucks with an ignition switch use the grey service key in order to access the traveland lift parameters.

o Trucks with driver display and CANCODE or on board computer

Z Before entering the SERVICE MENU / PARAMETER MENU you will be asked foryour PIN. Trucks with CANCODE (o) are factory set with PIN 2580 or if they have anon board computer (o) PIN 14037.

To switch the truck on enter the allocated PIN. You will then not be requested toproduce the PIN before entering the SERVICE MENU / PARAMETER MENU. Theparameter settings are saved in the PIN memory.It is possible to have 15 individually programmable parameter settings (truck orprogramme change). In order to select other programme settings the truck must belogged off and on logged on again or switched on and off. Enter next PIN.

M Changes to the service mode may only be undertaken by the manufacturer’sauthorised service engineers!

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Keypad Fault Messages

The following faults are shown by the LED (65) flashing red:

– New master code is already the operator code– New operator code is already the master code– There is no operator code to be altered.– Operator code to be changed to another operating code which already exists.– No operator code to delete.– Code memory full

8 Changing Truck Parameters

F Changing the truck parameters affects the travel pattern of the truck. This must betaken into account when starting the truck again. Parameters may only be changed when truck is standing and no lifting operations arein progress.

With the driver display (t) or the on board computer (o) it is also possible to changecertain truck parameters and hence the truck behaviour (acceleration, rollout brake,reverse brake, drive direction travel speed, fork direction travel speed and lift speed).

t Trucks with driver display and ignition switch

On trucks with an ignition switch use the grey service key in order to access the traveland lift parameters.

o Trucks with driver display and CANCODE or on board computer

Z Before entering the SERVICE MENU / PARAMETER MENU you will be asked foryour PIN. Trucks with CANCODE (o) are factory set with PIN 2580 or if they have anon board computer (o) PIN 14037.

To switch the truck on enter the allocated PIN. You will then not be requested toproduce the PIN before entering the SERVICE MENU / PARAMETER MENU. Theparameter settings are saved in the PIN memory.It is possible to have 15 individually programmable parameter settings (truck orprogramme change). In order to select other programme settings the truck must belogged off and on logged on again or switched on and off. Enter next PIN.

M Changes to the service mode may only be undertaken by the manufacturer’sauthorised service engineers!

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9 Troubleshooting

All faults or consequences of incorrect operation are shown on the driver display unit.Follow the instructions shown on the display.

It may be necessary to start again. Turn the main switch off and on again.

If the truck will not start consider the following:

Z If the fault persists, after having carried out the instructions shown on the driverdisplay panel and in the troubleshooting section, inform the manufacturer’s servicedepartment. The fault can only be rectified by trained and qualified service engineers.

Fault Possible Causes ActionTruck cannot be switched on

Battery connector not inserted / battery cable detached

Check battery connector, insert if necessary / test cable

Main switch pressed Latch main switchKey switch in position "0" Set key switch to "I" positionFaulty fuse. Check fuses .

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9 Troubleshooting

All faults or consequences of incorrect operation are shown on the driver display unit.Follow the instructions shown on the display.

It may be necessary to start again. Turn the main switch off and on again.

If the truck will not start consider the following:

Z If the fault persists, after having carried out the instructions shown on the driverdisplay panel and in the troubleshooting section, inform the manufacturer’s servicedepartment. The fault can only be rectified by trained and qualified service engineers.

Fault Possible Causes ActionTruck cannot be switched on

Battery connector not inserted / battery cable detached

Check battery connector, insert if necessary / test cable

Main switch pressed Latch main switchKey switch in position "0" Set key switch to "I" positionFaulty fuse. Check fuses .

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10 Auxiliary Electrical System

10.1 Headlights

Z The headlight is equipped with a 360° swivel link.

10.2 Beacon

Item. Description71 o Searchlight72 o Searchlight73 o Headlight switch ON / OFF for (Item 71)74 o Headlight switch ON / OFF for (Item 72)

Item. Description75 o Beacon76 o Beacon switch ON/OFF

7473

71 72

7675

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10 Auxiliary Electrical System

10.1 Headlights

Z The headlight is equipped with a 360° swivel link.

10.2 Beacon

Item. Description71 o Searchlight72 o Searchlight73 o Headlight switch ON / OFF for (Item 71)74 o Headlight switch ON / OFF for (Item 72)

Item. Description75 o Beacon76 o Beacon switch ON/OFF

7473

71 72

7675

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10.3 Bridging Switch (ESA / electrical lift limit switch )

o Bridging switch ESA 1

ESA stands for End-Schalter-Anlage / 1 (Lift Switching System)

The function of the ESA 1 is to prevent damage to the truck and/or the load by theoutriggers due to incorrect operation.ESA 1 can only be supplied for trucks with an integrated sideshift. The function canbe described as follows:

– Functions are only released when the mast is extended or the fork carriage is abovethe outriggers.

– In the outrigger height range (i.e. below a lift height of 500 – 600 mm) sideshift andother hydraulic functions except lift and tilt (forward / reverse) are inhibited if themast is not extended.

Automatic centring release allows

– mast reach automatically to be released in the outrigger range when the sideshiftis in the central position

– lowering to the ground when the sideshift is central– other hydraulic functions however remain interrupted– the central position on the driver display to be indicated via a control display (77)

Item. Description15 o Bridging switch77 o Sideshift in central position symbol display

15 77

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10.3 Bridging Switch (ESA / electrical lift limit switch )



The function of the ESA 1 is to prevent damage to the truck and/or the load by theoutriggers due to incorrect operation.ESA 1 can only be supplied for trucks with an integrated sideshift. The function canbe described as follows:

– Functions are only released when the mast is extended or the fork carriage is abovethe outriggers.

– In the outrigger height range (i.e. below a lift height of 500 – 600 mm) sideshift andother hydraulic functions except lift and tilt (forward / reverse) are inhibited if themast is not extended.

Automatic centring release allows

– mast reach automatically to be released in the outrigger range when the sideshiftis in the central position

– lowering to the ground when the sideshift is central– other hydraulic functions however remain interrupted– the central position on the driver display to be indicated via a control display (77)

Item. Description15 o Bridging switch77 o Sideshift in central position symbol display

15 77

E 41

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The function of the lift cut out mechanism is to prevent damage to the truck and/or theload by the outriggers due to incorrect operation.

This also applies to trucks with equipment such as:

– various attachments such as e.g. tine adjustment devices, bale tongs– Hoist frames with integrated sideshift– Particularly sensitive loads

Functions are only released when the mast is extended or the fork carriage is abovethe outriggers.

In the outrigger height range (i.e. below a lift height of 500 – 600 mm) sideshift andother hydraulic functions except lift and tilt (forward / reverse) are inhibited if the mastis not extended.

On the ETM/V 214/216 the facility to lower the load in this range is cut out.

Bridging switch

The bridging switch (15) is locateed above the steering head and releases allfunctions when activated.

10.4 Seat Heater

Item. Description78 o Seat Heater Switch79 o Seat Heater Indicator

79 78

E 41

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The function of the lift cut out mechanism is to prevent damage to the truck and/or theload by the outriggers due to incorrect operation.

This also applies to trucks with equipment such as:

– various attachments such as e.g. tine adjustment devices, bale tongs– Hoist frames with integrated sideshift– Particularly sensitive loads

Functions are only released when the mast is extended or the fork carriage is abovethe outriggers.

In the outrigger height range (i.e. below a lift height of 500 – 600 mm) sideshift andother hydraulic functions except lift and tilt (forward / reverse) are inhibited if the mastis not extended.

On the ETM/V 214/216 the facility to lower the load in this range is cut out.

Bridging switch

The bridging switch (15) is locateed above the steering head and releases allfunctions when activated.

10.4 Seat Heater

Item. Description78 o Seat Heater Switch79 o Seat Heater Indicator

79 78

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F 1

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1 Operational Safety and Environmental Protection

Test and maintenance work must be carried out within the intervals specified in themaintenance check list.

F Any changes to the materials handling truck are forbidden especially where theyaffect safety mechanisms. On no account must the operating speed of the truck bealtered.

M Our quality control only recognises original spare parts. To ensure safe and reliableoperation only use the manufacturer’s spare parts. Old parts and used fluids must bedesposed of in accordance with current environmental protection legislation. Themanufacturer’s lubrication service is available to carry out oil changes.

Following testing and maintenance work procedures must be carried out as containedin "Starting the Truck again” (see Chapter F).

2 Safety Regulations for Mantenance

Maintenance Staff: The repair and maintenance of materials handling equipmentmust only be carried out by engineers trained by the manufacturer. Themanufacturer’s service department provides service engineers especially trained tocarry out such tasks. We recommend the conclusion of a maintenance contract witha manufacturer’s service centre.

Lifting and Jacking: To lift the truck, sling chains etc. must only be attached todesignated lifting points. When jacking up the truck suitable devices must be usedsuch as wedges or wooden blocks to prevent the truck from rolling away or tippingover. Work may only be carried out beneath a suspended load providing the liftingchains are of adequate strength.

Cleaning: Do not use flammable liquids to clean the truck. Before commencingcleaning it is necessary to take all safety measures into account to prevent emissionof sparks (e.g short circuits). On battery operated trucks the battery plug must beremoved. Electric and electronic assemblies should be cleaned using light suction orcompressed air and a non-conductive, anti-static brush.

M If the truck is cleaned using a water jet or a high pressure cleaner all electrical andelectronic assemblies must be carefully covered since moisture can cause equipmentmalfunctioning.Steam jet cleaning is not permitted.

After cleaning, carry out the tasks described in the section entitled "Returning toService".

F 1

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1 Operational Safety and Environmental Protection

Test and maintenance work must be carried out within the intervals specified in themaintenance check list.

F Any changes to the materials handling truck are forbidden especially where theyaffect safety mechanisms. On no account must the operating speed of the truck bealtered.

M Our quality control only recognises original spare parts. To ensure safe and reliableoperation only use the manufacturer’s spare parts. Old parts and used fluids must bedesposed of in accordance with current environmental protection legislation. Themanufacturer’s lubrication service is available to carry out oil changes.

Following testing and maintenance work procedures must be carried out as containedin "Starting the Truck again” (see Chapter F).

2 Safety Regulations for Mantenance

Maintenance Staff: The repair and maintenance of materials handling equipmentmust only be carried out by engineers trained by the manufacturer. Themanufacturer’s service department provides service engineers especially trained tocarry out such tasks. We recommend the conclusion of a maintenance contract witha manufacturer’s service centre.

Lifting and Jacking: To lift the truck, sling chains etc. must only be attached todesignated lifting points. When jacking up the truck suitable devices must be usedsuch as wedges or wooden blocks to prevent the truck from rolling away or tippingover. Work may only be carried out beneath a suspended load providing the liftingchains are of adequate strength.

Cleaning: Do not use flammable liquids to clean the truck. Before commencingcleaning it is necessary to take all safety measures into account to prevent emissionof sparks (e.g short circuits). On battery operated trucks the battery plug must beremoved. Electric and electronic assemblies should be cleaned using light suction orcompressed air and a non-conductive, anti-static brush.

M If the truck is cleaned using a water jet or a high pressure cleaner all electrical andelectronic assemblies must be carefully covered since moisture can cause equipmentmalfunctioning.Steam jet cleaning is not permitted.

After cleaning, carry out the tasks described in the section entitled "Returning toService".

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Working on Electrical Equipment: Any work on electrical equipment should only beundertaken by qualified electricians. Before starting work they must take allprecautions necessary to prevent electrical accidents. Battery operated trucks shouldbe made safe by removing the battery and thereby isolating the power.

Welding: In order to avoid damage to electrical and electronic components thesemust be removed from the truck before any welding work is carried out.

Settings: When repairs are being made or changes made to hydraulic, electric orelectronic components the truck settings must be taken into consideration.

Tyres: The quality of the tyres affects the safety and driving pattern of the truck.When replacing tyres fitted at the factory, only use the manufacturer’s original spareparts, otherwise the data plate details cannot be complied with. When changingwheels and tyres care should be taken to ensure that the truck does not slew (e.g.when wheel is changed there is no simultaneous left and right movement).

Lifting Chains: Non-lubricated chains will wear rapidly. Lubrication intervals shownin the check list refer to normal use. Abnormal conditions such as dust and hightemperature may require more frequent lubrication. Prescribed chain sprays must beused in accordance with instructions. The external application of grease will notprovide the necesary level of lubrication.

Hydraulic Hoses: All hydraulic hoses must be replaced after six years of use. If anyhydraulic components are changed the hoses in that particular hydraulic system mustalso be changed.

Hydraulic Equipment: The mast reach damping cylinder (option) must not beopened!

F The damping cylinder contains high tensioned springs. When opened up there couldbe serious danger if the springs are not handled correctly.

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Working on Electrical Equipment: Any work on electrical equipment should only beundertaken by qualified electricians. Before starting work they must take allprecautions necessary to prevent electrical accidents. Battery operated trucks shouldbe made safe by removing the battery and thereby isolating the power.

Welding: In order to avoid damage to electrical and electronic components thesemust be removed from the truck before any welding work is carried out.

Settings: When repairs are being made or changes made to hydraulic, electric orelectronic components the truck settings must be taken into consideration.

Tyres: The quality of the tyres affects the safety and driving pattern of the truck.When replacing tyres fitted at the factory, only use the manufacturer’s original spareparts, otherwise the data plate details cannot be complied with. When changingwheels and tyres care should be taken to ensure that the truck does not slew (e.g.when wheel is changed there is no simultaneous left and right movement).

Lifting Chains: Non-lubricated chains will wear rapidly. Lubrication intervals shownin the check list refer to normal use. Abnormal conditions such as dust and hightemperature may require more frequent lubrication. Prescribed chain sprays must beused in accordance with instructions. The external application of grease will notprovide the necesary level of lubrication.

Hydraulic Hoses: All hydraulic hoses must be replaced after six years of use. If anyhydraulic components are changed the hoses in that particular hydraulic system mustalso be changed.

Hydraulic Equipment: The mast reach damping cylinder (option) must not beopened!

F The damping cylinder contains high tensioned springs. When opened up there couldbe serious danger if the springs are not handled correctly.

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3 Maintenance and Inspection

Thorough and correct maintenance is an important pre-requisite for safe operation ofthe truck. If regular maintenance is neglected truck breakdowns can occur which inturn could endanger life and limb and lead to operational failure.

M Maintenance intervals are based on single shifts, working under normal conditions.For more arduous conditions such as a dusty environment, extreme temperatures ormulti-shift working patterns, maintenance intervals should be reduced accordingly.

The following maintenance checklist gives the duties and intervals in which theyshould be carried out. Maintenance intervals are defined as:

W1 = Every 50 Operating hours, however at least once a weekM3 = Every 500 Operating hours, however at least every 3 monthsM6 = Every 1000 Operating hours, however at least every 6 monthsM12 = Every 2000 Operating hours, however at least every 12 months

Z Maintenance intervals W1 to be carried out by the operator

During the running in period additional tasks must also be carried out:

After the first 100 operating hours:

– Wheel nuts to be checked for tightness, tighten if necessary.– Check tightness of bolts in drivers cab and hood, tighten if necessary.– Check hydraulic hoses for leaks, tighten if necessary– Change the hydraulic filter cartridge– Tighten battery post screws and check condition of cell connector.– Inspect all electrical and mechanical components.– Check that the lifting chains are evenly tensioned (for aux. lift and duplex mast).– Check the gearbox for leaks.– Check that bolts are tight and mechanical locks are secure.– Check mast slide pieces, adjust if required.

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3 Maintenance and Inspection

Thorough and correct maintenance is an important pre-requisite for safe operation ofthe truck. If regular maintenance is neglected truck breakdowns can occur which inturn could endanger life and limb and lead to operational failure.

M Maintenance intervals are based on single shifts, working under normal conditions.For more arduous conditions such as a dusty environment, extreme temperatures ormulti-shift working patterns, maintenance intervals should be reduced accordingly.

The following maintenance checklist gives the duties and intervals in which theyshould be carried out. Maintenance intervals are defined as:

W1 = Every 50 Operating hours, however at least once a weekM3 = Every 500 Operating hours, however at least every 3 monthsM6 = Every 1000 Operating hours, however at least every 6 monthsM12 = Every 2000 Operating hours, however at least every 12 months

Z Maintenance intervals W1 to be carried out by the operator

During the running in period additional tasks must also be carried out:

After the first 100 operating hours:

– Wheel nuts to be checked for tightness, tighten if necessary.– Check tightness of bolts in drivers cab and hood, tighten if necessary.– Check hydraulic hoses for leaks, tighten if necessary– Change the hydraulic filter cartridge– Tighten battery post screws and check condition of cell connector.– Inspect all electrical and mechanical components.– Check that the lifting chains are evenly tensioned (for aux. lift and duplex mast).– Check the gearbox for leaks.– Check that bolts are tight and mechanical locks are secure.– Check mast slide pieces, adjust if required.

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4 Maintenance Check List ETM/V 214/216

M a)When changing load wheel check the brake lining wear of the load wheel brake andif necessary replace the multi plates.

Maintenance IntervalStandard = t W M M MFreezer = k 1 3 6 12

Frame/Assembly:

1.1 Check all load bearing items for damage. t1.2 Check screw connections t1.3 Check overhead guard for damage and attachment k t1.4 Check fixing screws in driver’s cab. k t

Drive: 2.1 Examine the gearbox for noise and leakage. t2.2 Check drive plate and bolts for tightness t2.3 Check gearbox oil level t2.4 Check pedal mechanism t2.5 Change gearbox oil k t

Wheels: 3.1 Check for wear and damage. t3.2 Check suspension and attachment k t

Steering: 4.1 Check steering gear for wear and lubricate. k t4.2 Check mechanical parts of steering head t4.3 Check steering operation t

Brake System

5.1 Check brake lining wear except load wheel brake. a) t5.2 Check operation and settings k t5.3 Check brake mechanism k t5.4 Check brake hoses for insulation and physical damage. t5.5 Check and adjust where necessary the emergency stop

mechanism magnetic liftt

Hydraulic.System

6.1 Check operation t6.2 Check unions and connections for leaks and

damaget

6.3 Check the hydraulic cylinder for leaks, damage and attachment.

k t

6.4 Check oil level k t6.5 Change hydraulic oil, filter cartridge and fan filter k t6.6 Check operation of hose guides for and check for

damage.k t

6.7 Check pressure limiting valve operation k t6.8 Check emergency drop valve operation t6.9 Remove gauze filter from control valve and rinse. t

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4 Maintenance Check List ETM/V 214/216

M a)When changing load wheel check the brake lining wear of the load wheel brake andif necessary replace the multi plates.

Maintenance IntervalStandard = t W M M MFreezer = k 1 3 6 12

Frame/Assembly:

1.1 Check all load bearing items for damage. t1.2 Check screw connections t1.3 Check overhead guard for damage and attachment k t1.4 Check fixing screws in driver’s cab. k t

Drive: 2.1 Examine the gearbox for noise and leakage. t2.2 Check drive plate and bolts for tightness t2.3 Check gearbox oil level t2.4 Check pedal mechanism t2.5 Change gearbox oil k t

Wheels: 3.1 Check for wear and damage. t3.2 Check suspension and attachment k t

Steering: 4.1 Check steering gear for wear and lubricate. k t4.2 Check mechanical parts of steering head t4.3 Check steering operation t

Brake System

5.1 Check brake lining wear except load wheel brake. a) t5.2 Check operation and settings k t5.3 Check brake mechanism k t5.4 Check brake hoses for insulation and physical damage. t5.5 Check and adjust where necessary the emergency stop

mechanism magnetic liftt

Hydraulic.System

6.1 Check operation t6.2 Check unions and connections for leaks and

damaget

6.3 Check the hydraulic cylinder for leaks, damage and attachment.

k t

6.4 Check oil level k t6.5 Change hydraulic oil, filter cartridge and fan filter k t6.6 Check operation of hose guides for and check for

damage.k t

6.7 Check pressure limiting valve operation k t6.8 Check emergency drop valve operation t6.9 Remove gauze filter from control valve and rinse. t

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Z Maintenance intervals apply to normal conditions. For extreme conditions reduceintervals accordingly.

Maintenance IntervalStandard = t W M M MCold Storage

= k 1 3 6 12

Electrical.System:

7.1 Check operation t7.2 Check cable for connections and damage. t7.3 Check that fuses are of the correct rating t7.4 Check operation and safety of switch t7.5 Check operation of warning devices and safety switches k t7.6 Check switch contacts for wear, replace worn parts where

necessary.t

7.7 Check electronic components for attachment and cleanliness.

t

Electric Motors:

8.1 Check motor attachment. t

Battery: 9.1 Check battery cable for damage, change if required. t9.2 Check battery trolley lock, setting and operation. t9.3 Check acid density, acid level and cell voltage k t9.4 Check that terminals are secure, lubricate with dielectric

greasek t

9.5 Clean battery plug and make sure it is secure. k tHoist Frame:

10.1 Check hoist frame attachment. t10.2 Check lift chain and guides for wear, adjust and grease. k t10.3 Check tilt cylinder bearing and make sure it is secure t10.4 Check tilt angle of hoist frame t10.5 Carry out visual check of rollers, slide pieces and stops. k t10.6 Check hoist frame t10.7 Check reach mechanism for wear and damage. Adjust

lateral play if necessary. Adjust rollers and grease runners.

t

10.8 Check fork arms and fork carriage for wear k tAttach-ments

11.1 Check operation k t11.2 Check attachment to truck and load bearing items k t11.3 Check position of bearings, guides and stops for wear and

damage and grease.t

General Measure-ments:

12.1 Check earth connections of electrical system. t12.2 Check travel speed and braking distance t12.3 Check lift and lowering speeds t12.4 Check safety mechanisms and cutouts t

Lubrication: 13.1 Lubricate truck in accordance with lubricating schedule. k tDemonstration:

14.1 Test drive with rated load t14.2 Following successful maintenance present the truck to a

company official.k t

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Z Maintenance intervals apply to normal conditions. For extreme conditions reduceintervals accordingly.

Maintenance IntervalStandard = t W M M MCold Storage

= k 1 3 6 12

Electrical.System:

7.1 Check operation t7.2 Check cable for connections and damage. t7.3 Check that fuses are of the correct rating t7.4 Check operation and safety of switch t7.5 Check operation of warning devices and safety switches k t7.6 Check switch contacts for wear, replace worn parts where

necessary.t

7.7 Check electronic components for attachment and cleanliness.

t

Electric Motors:

8.1 Check motor attachment. t

Battery: 9.1 Check battery cable for damage, change if required. t9.2 Check battery trolley lock, setting and operation. t9.3 Check acid density, acid level and cell voltage k t9.4 Check that terminals are secure, lubricate with dielectric

greasek t

9.5 Clean battery plug and make sure it is secure. k tHoist Frame:

10.1 Check hoist frame attachment. t10.2 Check lift chain and guides for wear, adjust and grease. k t10.3 Check tilt cylinder bearing and make sure it is secure t10.4 Check tilt angle of hoist frame t10.5 Carry out visual check of rollers, slide pieces and stops. k t10.6 Check hoist frame t10.7 Check reach mechanism for wear and damage. Adjust

lateral play if necessary. Adjust rollers and grease runners.

t

10.8 Check fork arms and fork carriage for wear k tAttach-ments

11.1 Check operation k t11.2 Check attachment to truck and load bearing items k t11.3 Check position of bearings, guides and stops for wear and

damage and grease.t

General Measure-ments:

12.1 Check earth connections of electrical system. t12.2 Check travel speed and braking distance t12.3 Check lift and lowering speeds t12.4 Check safety mechanisms and cutouts t

Lubrication: 13.1 Lubricate truck in accordance with lubricating schedule. k tDemonstration:

14.1 Test drive with rated load t14.2 Following successful maintenance present the truck to a

company official.k t

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5 Lubrication Schedule ETM/V 214/216

A

G

EF

EF

J

Min. = 13lMax.= 30l

BB+C 1)

3,9 l

E F

195 ±10 Nm

75 ±5 Nm

367 ±10 Nm

2)

g Contact Surfacess Grease Nipples

Hydraulic Oil filler neckc Hydraulic Bleed Screwb Transmission Oil drain pluga Drain Plug for Gearbox Oil

Freezer application

1) Mix ratio for freezer trucks 1:12) For lubricant volumes see "Checking Hydraulic Oil Level"

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5 Lubrication Schedule ETM/V 214/216

A

G

EF

EF

J

Min. = 13lMax.= 30l

BB+C 1)

3,9 l

E F

195 ±10 Nm

75 ±5 Nm

367 ±10 Nm

2)

g Contact Surfacess Grease Nipples

Hydraulic Oil filler neckc Hydraulic Bleed Screwb Transmission Oil drain pluga Drain Plug for Gearbox Oil

Freezer application

1) Mix ratio for freezer trucks 1:12) For lubricant volumes see "Checking Hydraulic Oil Level"

F 7

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5.1 Operating Fluids

Handling Operating Fluids: Operating fluids must always be handled correctly andin accordance with the manufacturer’s regulations.

F Incorrect handling endangers health, life and the environment. Operating fluids mayonly be stored in regulation containers. They may be inflammable therefore theyshould not come into contact with hot components or flames.

When topping up operating fluids only use clean containers. Do not mix differentgrade fluids. This regulation may only be disregarded if a mixture is specificallyprescribed in this instruction.

Do not spill fluids. Spilled fluids must be removed immediately with a suitable bondingagent and the resultant mix must be disposed of in accordance with disposalregulations.

Grease Guidelines

5.2 Tank Capacity ETM/V 214/216

Code Order No. Volume Description Application forA 29 200 670 5.0 1 H-LP 46,

DIN 51524Hydraulic Equipment

B 29 200 680 5.0 1 CLP 100,DIN 51517

Gearbox

C 29 200 810 5.0 1 H-LP 10,DIN 51524

Gearbox ,Hydraulic Equipment

E 29 201 430 1.0 kg Grease, DIN 51825 Lubrication F 29 200 100 1.0 kg Grease, TTF52 LubricationG 29 201 280 0.51 kg Chain Spray ChainsJ 29 202 020 5 1 AeroShell Fluid 4 Hydraulic System

Code Type of Saponification

Drop Point ° C

Walk penetration at 25 °C

NLG1-Class Operating temperature °C

E Lithium 185 265 - 295 2 -35 / +120F -- -- 310 - 340 1 -52 / +100

Litre Lift Height (h3)ZT DZ

approx. - up to 10250approx. - up to 9620approx. - up to 9020approx. - up to 7400approx. - up to 6200approx. up to 4200 up to 4700approx. - -

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5.1 Operating Fluids

Handling Operating Fluids: Operating fluids must always be handled correctly andin accordance with the manufacturer’s regulations.

F Incorrect handling endangers health, life and the environment. Operating fluids mayonly be stored in regulation containers. They may be inflammable therefore theyshould not come into contact with hot components or flames.

When topping up operating fluids only use clean containers. Do not mix differentgrade fluids. This regulation may only be disregarded if a mixture is specificallyprescribed in this instruction.

Do not spill fluids. Spilled fluids must be removed immediately with a suitable bondingagent and the resultant mix must be disposed of in accordance with disposalregulations.

Grease Guidelines

5.2 Tank Capacity ETM/V 214/216

Code Order No. Volume Description Application forA 29 200 670 5.0 1 H-LP 46,

DIN 51524Hydraulic Equipment

B 29 200 680 5.0 1 CLP 100,DIN 51517

Gearbox

C 29 200 810 5.0 1 H-LP 10,DIN 51524

Gearbox ,Hydraulic Equipment

E 29 201 430 1.0 kg Grease, DIN 51825 Lubrication F 29 200 100 1.0 kg Grease, TTF52 LubricationG 29 201 280 0.51 kg Chain Spray ChainsJ 29 202 020 5 1 AeroShell Fluid 4 Hydraulic System

Code Type of Saponification

Drop Point ° C

Walk penetration at 25 °C

NLG1-Class Operating temperature °C

E Lithium 185 265 - 295 2 -35 / +120F -- -- 310 - 340 1 -52 / +100

Litre Lift Height (h3)ZT DZ

approx. - up to 10250approx. - up to 9620approx. - up to 9020approx. - up to 7400approx. - up to 6200approx. up to 4200 up to 4700approx. - -

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6 Maintenance

6.1 Prepare truck for maintenance and repairs

All necessary safety measures must be implemented to avoid accidents during repairand maintenance work. Park truck safely (see Chapter E).

– Remove battery plug (1).– This ensures that the truck cannot be accidentally put into operation.

F When working under raised forks or a raised truck ensure that the truck cannot lower,tip over or slide. When lifting the truck, follow the regulations specified in "Transportand Commissioning".When work is carried out on the safety brake, ensure that the truck cannot roll away.

6.2 Safety Belt Maintenance (o)

Each day, before using the truck the driver shall check the condition and function ofthe safety belt. Only regular checking ensures that faults are avoided.

– Remove the belt completely and check for fraying.– Check the belt lock and make sure the belt enters the reel mechanism correctly.

o Test the automatic interlock:

– Park truck in horizontal condition.– Pull heavily on the belt.

M The interlock should prevent the belt from coming out.

F Do not operate the machine with a defective safety belt. Replace the beltimmediately!

1

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6 Maintenance

6.1 Prepare truck for maintenance and repairs

All necessary safety measures must be implemented to avoid accidents during repairand maintenance work. Park truck safely (see Chapter E).

– Remove battery plug (1).– This ensures that the truck cannot be accidentally put into operation.

F When working under raised forks or a raised truck ensure that the truck cannot lower,tip over or slide. When lifting the truck, follow the regulations specified in "Transportand Commissioning".When work is carried out on the safety brake, ensure that the truck cannot roll away.

6.2 Safety Belt Maintenance (o)

Each day, before using the truck the driver shall check the condition and function ofthe safety belt. Only regular checking ensures that faults are avoided.

– Remove the belt completely and check for fraying.– Check the belt lock and make sure the belt enters the reel mechanism correctly.

o Test the automatic interlock:

– Park truck in horizontal condition.– Pull heavily on the belt.

M The interlock should prevent the belt from coming out.

F Do not operate the machine with a defective safety belt. Replace the beltimmediately!

1

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6.3 Removing the seat hood

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

Z Expose drive unit and hydraulic equipment for maintenance.

6.4 Checking the hydraulic oil level

– Prepare truck for maintenance andrepair work(see Section 6.1 and 6.3).

– Check oil level in hydraulic tank.

Z The oil level can be read from thehydraulic tank with the load pickupdevice fully lowered.

– If necessary top up the oil at the fillerneck (6) using oil of the right grade (forhydraulic oil specification, see Section5.1).

– Replace hood and secure with clampscrews (4).

– Connect fan.– Push seat into position and engage

locking lever (2).

3

5

42

6

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6.3 Removing the seat hood

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

Z Expose drive unit and hydraulic equipment for maintenance.

6.4 Checking the hydraulic oil level

– Prepare truck for maintenance andrepair work(see Section 6.1 and 6.3).

– Check oil level in hydraulic tank.

Z The oil level can be read from thehydraulic tank with the load pickupdevice fully lowered.

– If necessary top up the oil at the fillerneck (6) using oil of the right grade (forhydraulic oil specification, see Section5.1).

– Replace hood and secure with clampscrews (4).

– Connect fan.– Push seat into position and engage

locking lever (2).

3

5

42

6

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6.5 Opening the fuse cover

– Exerting a little force, withdraw hoodand set to one side.

Z The fuses are located under the hood.

6.6 Removing the cover from theinstrument panel

– Slacken the screws in the safetyscreen. Push the steering wheeltowards the seat (furthest position).

Z Remove hood (7). The main fuses arelocated under the hood (7).

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6.5 Opening the fuse cover

– Exerting a little force, withdraw hoodand set to one side.

Z The fuses are located under the hood.

6.6 Removing the cover from theinstrument panel

– Slacken the screws in the safetyscreen. Push the steering wheeltowards the seat (furthest position).

Z Remove hood (7). The main fuses arelocated under the hood (7).

7

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6.7 Checking the electrical fuses.

– Prepare truck for maintenance and repairs(see Section 6.5 and 6.6).

– Ensure all the fuses are of the correct rating (see table) and replace if necessary.

Item Description Rating / Type8 4F11 Driver Display / On Board Computer Fuse 5 A9 F17 Radio fuse 5 A10 1 F 4 Steering Electronics / Travel Control Fuse 5 A11 2 F 10 Hydraulics Fuse 5 A12 9 F 2 Fan / Seat Fuse 10 A13 5 F 7 Options Fuse 10 A14 1 F 14 Brake Fuse 10 A15 2 F 18 MFC Aux. / Aux. Hydraulics Control Fuse 10 A16 F8 Main Fuse 355 A17 2F1 Pump Motor Fuse 250 A18 1F1 Traction Motor Fuse 250 A19 F1 General Control Fuse 30 A20 F13 Valves Brakes Fuse 30 A21 3F1 Steering Fuse 30 A

16

17

1820 21

19

89101112131415

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6.7 Checking the electrical fuses.

– Prepare truck for maintenance and repairs(see Section 6.5 and 6.6).

– Ensure all the fuses are of the correct rating (see table) and replace if necessary.

Item Description Rating / Type8 4F11 Driver Display / On Board Computer Fuse 5 A9 F17 Radio fuse 5 A10 1 F 4 Steering Electronics / Travel Control Fuse 5 A11 2 F 10 Hydraulics Fuse 5 A12 9 F 2 Fan / Seat Fuse 10 A13 5 F 7 Options Fuse 10 A14 1 F 14 Brake Fuse 10 A15 2 F 18 MFC Aux. / Aux. Hydraulics Control Fuse 10 A16 F8 Main Fuse 355 A17 2F1 Pump Motor Fuse 250 A18 1F1 Traction Motor Fuse 250 A19 F1 General Control Fuse 30 A20 F13 Valves Brakes Fuse 30 A21 3F1 Steering Fuse 30 A

16

17

1820 21

19

89101112131415

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6.8 Starting the Truck Again

After cleaning and maintenance work, start up the truck again provided the followingactivities have been carried out:

– Test horn.– Test main switch.– Test brakes.– Lubricate truck as per Lubrication Schedule.

7 Putting the Truck Out of Service

If, for operational reasons, the truck is out of service for longer than two months itmust be parked in a frost free, dry area and measures before, during and afterdecommissioning must be carried out as described.

M During this period the truck should be chocked up so that all the wheels are clear ofthe ground. This ensures that wheels and bearings cannot be damaged.

If the machine is inoperative for longer than 6 months preparatory measures must bediscussed with the manufacturer’s service department.

7.1 Measures to be taking before putting the truck out of service

– Thoroughly clean the truck.– Check brakes.– Check hydraulic oil level, top up where necessary (see Chapter F).– Apply a thin layer of oil or grease to each mechanical part not coated with paint.– Lubricate truck as per Lubrication Schedule (see Chapter F).– Charge up the battery (see Chapter D).– Disconnect the battery, clean and grease the terminals with dielectric grease.

Z Also note all information provided by the battery manufacturer.

– Spray all open electrical contacts with contact spray.

7.2 When the truck is de-commissioned

Every 2 Months:

– Charge up the battery (see Chapter D).

M Battery Operated Materials Handling Equipment:The battery should be charged up regularly since when the battery automaticallydischarges the charge becones so low that sulphation occurs which destroys thebattery.

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6.8 Starting the Truck Again

After cleaning and maintenance work, start up the truck again provided the followingactivities have been carried out:

– Test horn.– Test main switch.– Test brakes.– Lubricate truck as per Lubrication Schedule.

7 Putting the Truck Out of Service

If, for operational reasons, the truck is out of service for longer than two months itmust be parked in a frost free, dry area and measures before, during and afterdecommissioning must be carried out as described.

M During this period the truck should be chocked up so that all the wheels are clear ofthe ground. This ensures that wheels and bearings cannot be damaged.

If the machine is inoperative for longer than 6 months preparatory measures must bediscussed with the manufacturer’s service department.

7.1 Measures to be taking before putting the truck out of service

– Thoroughly clean the truck.– Check brakes.– Check hydraulic oil level, top up where necessary (see Chapter F).– Apply a thin layer of oil or grease to each mechanical part not coated with paint.– Lubricate truck as per Lubrication Schedule (see Chapter F).– Charge up the battery (see Chapter D).– Disconnect the battery, clean and grease the terminals with dielectric grease.

Z Also note all information provided by the battery manufacturer.

– Spray all open electrical contacts with contact spray.

7.2 When the truck is de-commissioned

Every 2 Months:

– Charge up the battery (see Chapter D).

M Battery Operated Materials Handling Equipment:The battery should be charged up regularly since when the battery automaticallydischarges the charge becones so low that sulphation occurs which destroys thebattery.

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7.3 Starting the truck again after de-commissioning

– Thoroughly clean the truck.– Lubricate truck as per Lubrication Schedule (see Chapter F).– Clean battery, grease terminal scews with dielectric grease and connect battery.– Charge up the battery (see Chapter D).– Check gearbox oil for condensation and change if necessary.– Check hydraulic oil for condensation and change if necessary.– Operating Materials Handling Equipment (see Chapter E)

Z Battery Operated Materials Handling Equipment:If you experience with electrical switches spray contacts with contact spray andremove any possible layers of oxide from the operating elements by activating thecontrols several times.

F Immediately after commissioning carry out several brake tests.

8 Safety test after periodic intervals and after special occurences.(D: UVV-Test BGV D27)

The truck must be examined by a suitably trained engineer annually or after specialoccurences. This person shall issue his report and assessment from a safetyperspective and shall have sufficient knowledge and experience to be able to assessthe condition of materials handling equipment and also the effectiveness of the safetymechanisms in accordance with engineering principles and guidelines relating to thetesting of materials handling equipment.

A complete test must be carried out on the truck with regard to safety. The truck mustalso be thoroughly examined for damage which may have been caused by incorrectoperation. A test report shall be submitted. The results of the test must be kept untilthe date of the test after next.

The operator must rectify any defects immediately.

Z For testing the manufacturer can provide appropriately trained personnel to carry outspecial safety checks. After successful checks have been carried out a test noticeshall be attached to the truck indicating the month and year when the next test is due.

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7.3 Starting the truck again after de-commissioning

– Thoroughly clean the truck.– Lubricate truck as per Lubrication Schedule (see Chapter F).– Clean battery, grease terminal scews with dielectric grease and connect battery.– Charge up the battery (see Chapter D).– Check gearbox oil for condensation and change if necessary.– Check hydraulic oil for condensation and change if necessary.– Operating Materials Handling Equipment (see Chapter E)

Z Battery Operated Materials Handling Equipment:If you experience with electrical switches spray contacts with contact spray andremove any possible layers of oxide from the operating elements by activating thecontrols several times.

F Immediately after commissioning carry out several brake tests.

8 Safety test after periodic intervals and after special occurences.(D: UVV-Test BGV D27)

The truck must be examined by a suitably trained engineer annually or after specialoccurences. This person shall issue his report and assessment from a safetyperspective and shall have sufficient knowledge and experience to be able to assessthe condition of materials handling equipment and also the effectiveness of the safetymechanisms in accordance with engineering principles and guidelines relating to thetesting of materials handling equipment.

A complete test must be carried out on the truck with regard to safety. The truck mustalso be thoroughly examined for damage which may have been caused by incorrectoperation. A test report shall be submitted. The results of the test must be kept untilthe date of the test after next.

The operator must rectify any defects immediately.

Z For testing the manufacturer can provide appropriately trained personnel to carry outspecial safety checks. After successful checks have been carried out a test noticeshall be attached to the truck indicating the month and year when the next test is due.

1003

.GB

F 14

1003

.GB

F 14

Documents

V 4467 JAG GB - Jungheinrich · 2018. 4. 27. · Jungheinrich reserves the right to alter the design, equipment and technical features of the truck. ... 3.3 Standard Hoist Frames