Jungheinrich ECR 327, ECR 336 Operating Instructions Manual

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Operating instructions

50451814

ECR 327/336

10.05 -

03.07

Instrucciones de servicio

u E

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Foreword

Safe operation of the industrial truck requires specialist knowledge, which is acquired from this Operating Manual, from the training required by OSHA under 29 CFR

1910.178, and by training operators in factory installations and their functions. Safe operation of the industrial truck requires knowledge that can be acquired from this ORIGINAL OPERATING MANUAL. The information is set out concisely and in a clear format. The chapters are organized alphabetically, each starting at page 1. The page identifier consists of the chapter letter and page number. For example: Page B2 is the second page of Chapter B.

Various types of industrial trucks are described in this Operating Manual. When operating the truck and carrying out maintenance work, make certain you use the description corresponding to your vehicle type.

Safety instructions and important information, and their relative importance, are indicated by the following safety warning symbols and indicator words:

QwD This message indicates a hazardous situation that, if not avoided, will result

in death or serious injury. The instructions, safety precautions, actions, or procedures relating to this message must be observed to avoid the risk of death or serious injury.

QwW This message indicates a hazardous situation that, if not avoided, could

result in death or serious injury. The instructions, safety precautions, actions, or procedures relating to this message must be observed to avoid the potential risk of death or serious injury.

QwK This message indicates a situation that may lead to minor or moderate injury

if disregarded. The instructions, safety precautions, actions, or procedures relating to this message must be observed to avoid the risk of minor or moderate injury.

IMPORTANT This message appears if special precautionary measures are needed to

ensure that the correct action is taken or to prevent damage to or malfunction of the industrial truck or a component.

NOTICE This message appears if special information, instructions, or indications are

needed with regard to procedures, equipment, tools, pressures, loads, and other special data.

t Indicates component fitted as standard.

o Indicates optional extra.

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It is impossible for the manufacturer to foresee every possible operational circumstance that could involve a potential danger. For that reason, the warnings in this manual and on the equipment itself do not encompass all possible circumstances. If you use a tool, procedure, working method, or operating technique not expressly recommended by the manufacturer, you must make sure yourself that it does not present a safety risk to you or to anyone else. You must also ensure that the product will not be damaged or made unsafe through operation, lubrication, maintenance, or the chosen repair measures. The information, technical data, and illustrations contained in this document are based on the information available at the time of publication. Specifications, torques, pressures, measurements, settings, illustrations, and all other data are subject to change at any time. These changes relate to the performance of the product. Before executing a task, you should request the most up-to-date and comprehensive information from the manufacturer / dealer. You can also obtain additional copies of the manual from your dealer.

In the interests of technical advancement, the manufacturer reserves the right to make changes, while retaining the essential features of the type of vehicle described, without correcting this Operating Manual at the same time.

Jungheinrich Aktiengesellschaft

Am Stadtrand 35 22047 Hamburg - GERMANY

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

www.jungheinrich.com

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Table of contents

A Compliance with regulations -

Legislation and common sense

B Recognition and avoidance of risks

C Appropriate use

D Vehicle description

1 Description of use ............................................................................... D 1

2 Components ........................................................................................ D 2

3 Technical data ..................................................................................... D 3

3.1 Performance data ................................................................................ D 3

3.2 Dimensions ......................................................................................... D 4

3.3 Axle and drive wheel loads ................................................................. D 6

3.4 US standards ...................................................................................... D 15

3.5 Operating conditions ........................................................................... D 16

4 Position of signs and nameplates ...................................................... D 17

4.1 Nameplate, vehicle .............................................................................. D 18

4.2 Sign - Qmax (15) ................................................................................. D 19

4.3 Sign - Danger battery (16) ................................................................... D 19

4.4 Sign - Warning battery size (17) .......................................................... D 19

4.5 Sign - Warning stay clear (18) ............................................................. D 20

4.6 Sign - Warning jog button coast, left (20a) (o) ................................... D 20

4.7 Sign - Warning jog button coast, right (20b) (o) ................................. D 20

4.8 Sign - Warning stay clear stop truck (24) ............................................ D 21

4.9 Sign - Warning charger (25) ................................................................ D 21

4.10 Sign - Warning electrical device (27) .................................................. D 22

4.11 Sign - Warning coast system (28) (o) ................................................ D 22

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E Operation

1 Description of controls and indicators ................................................. E 1

2 Starting the vehicle .............................................................................. E 5

2.1 Preparing for operation ....................................................................... E 5

2.2 Driving, steering, braking .................................................................... E 6

2.3 Raising and lowering load units .......................................................... E 13

2.4 Switching off and securing the vehicle ................................................ E 14

2.5 Adjusting the fork height ...................................................................... E 14

3 Important general aspects affecting the safe use of the truck ............. E 15

3.1 Training, certification, and approval to use the truck ........................... E 15

3.2 Damage and repairs to the industrial truck ......................................... E 17

3.3 Aspects in relation to loading .............................................................. E 18

3.4 Operating environment ........................................................................ E 19

3.5 Safety devices and warning signs ....................................................... E 22

3.6 Lifting of people ................................................................................... E 23

4 Operating the industrial truck .............................................................. E 25

4.1 Safety regulations for industrial truck operators .................................. E 25

4.2 General operation of the truck ............................................................. E 25

4.3 Ensuring that the industrial truck is properly equipped ....................... E 28

4.4 Opening and closing railroad cars ....................................................... E 29

4.5 Safe loading and transportation .......................................................... E 30

4.6 Preventing overturning and tipping ..................................................... E 31

4.7 Supervising and securing the truck ..................................................... E 32

4.8 Lifting of people ................................................................................... E 32

5 Keypad (CANCODE) (o) .................................................................... E 34

5.1 Code lock ............................................................................................ E 34

5.2 Travel program .................................................................................... E 36

5.3 Parameters .......................................................................................... E 36

5.4 Parameter settings .............................................................................. E 37

5.5 Travel parameters ............................................................................... E 41

6 Information display (CANDIS) (o) ...................................................... E 42

6.1 Discharge monitor function ................................................................. E 43

6.2 Operating hours indicator .................................................................... E 43

6.3 Power-up test ...................................................................................... E 43

7 Discharge indicator (LEA) (t) ............................................................. E 44

8 Troubleshooting .................................................................................. E 45

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F Battery – Maintaining, recharging, replacing

1 Safety regulations for handling lead-acid batteries ............................. F 1

2 Battery type ......................................................................................... F 2

3 Uncovering the battery ........................................................................ F 3

4 Charging the battery ............................................................................ F 4

5 Removing and installing the battery .................................................... F 5

5.1 Removal, standard design .................................................................. F 5

5.2 Removal, "removal from side" (o) ...................................................... F 6

5.3 Installing the battery ............................................................................ F 6

G Industrial truck maintenance and troubleshooting

1 Operational safety and environmental protection ................................ G 1

2 Safety regulations for industrial truck maintenance ............................ G 1

3 Maintenance and inspection ............................................................... G 7

4 Maintenance checklist ........................................................................ G 8

5 Lubrication chart .................................................................................. G 10

5.1 Operating resources ............................................................................ G 11

6 Description of maintenance and servicing jobs ................................... G 12

6.1 Preparing the industrial truck for maintenance and servicing ............. G 12

6.2 Opening the front cover ....................................................................... G 13

6.3 Removing the motor cover .................................................................. G 13

6.4 Checking the hydraulic oil level ........................................................... G 14

6.5 Checking the electrical fuses .............................................................. G 15

6.6 Restarting the vehicle after cleaning or maintenance work G 16

7 Extended shutdown of the industrial truck .......................................... G 16

7.1 Measures required before shutdown ................................................... G 16

7.2 Measures required during the shutdown period .................................. G 17

7.3 Restarting the vehicle after shutdown ................................................. G 17

8 Safety inspections at regular intervals and after exceptional events .. G 18

H Transportation and commissioning

1 Securing the vehicle during transportation .......................................... H 1

2 Handling by crane ............................................................................... H 1

3 Commissioning .................................................................................... H 1

3.1 Adjusting the support roller forces before start-up .............................. H 2

4 Non-automotive movement of the vehicle ........................................... H 4

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A Compliance with regulations -

Legislation and common sense

In 1998, OSHA produced a report on its wide-ranging study into the use of powered industrial trucks in industry. This report was published in the US Federal Register/ vol. 63, no. 230. In this report OSHA sets out the many reasons why employers are required to train their employees in connection with the use of powered industrial trucks and why untrained personnel must be prohibited from using industrial trucks except in controlled operating conditions such as a training session. The report shows how extremely important a training program as required by the OSHA guidelines is for the safety of equipment and personnel in connection with the use of powered industrial trucks. 29 CFR part 1910.178. In simple terms, thorough training prior to the use of an industrial truck is extremely important and must take place before an industrial truck is used, since accidents leading to injury and death or property damage are almost always the consequence of disregarding the underlying risks held by the use of industrial trucks or of ignoring safety instructions and safety precautions designed to minimize or eliminate such risks. The OSHA training program specifically addresses these risks. The evidence contained in the OSHA report demonstrates that the statutory training requirements for operators and employers are based on experience and general judgment. Jungheinrich industrial trucks satisfy the requirements of 29 CFR 1910.178 and ASME B 56.1. Jungheinrich representatives are always on hand to provide advice on issues surrounding the loading, operation, use and maintenance of powered industrial trucks. According to the OSHA report, knowledge and skills to operate an industrial truck powered by an electric drive are not innate in human beings. Quite the contrary: This knowledge can only be acquired through theoretical and practical training. This means that having an industrial truck which complies with statutory regulations and standards, is only one half of the safety equation. It is the responsibility of you, the operator, and your employer to be aware of your responsibilities and of all national and regional regulations and laws governing training requirements and the safe use of powered industrial trucks, not only because the law requires it but because it is a matter of common sense.

Powered industrial trucks may only be operated by trained and tested persons.

Training programs must satisfy OSHA requirements and as a minimum address the topics mentioned here.

Employers and operators should pay especial attention to the section in ASME regulations B56.1 concerning the operator.

"Safe operation is the responsibility of the operator" ASME B56.1 – 2003, Part II Section 5.1.1.

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B Recognition and avoidance of risks

In its 1998 investigation into the use of powered industrial trucks, OSHA determined the ways in which accidents commonly occur and the causes of these accidents. OSHA concluded that considerable risks to operators themselves and to other people in their immediate vicinity can be put down to the inadequate or non-existent training of operating personnel. According to OSHA, incorrect and unsafe operation are the principal causes of accidents in connection with powered industrial trucks and the resulting injuries and fatalities. It is therefore no coincidence that in reviewing its own research, OSHA found that in almost all cases, accidents were attributable to situations or actions, which the operator, or the employer and the operator together, could have influenced or could have done better. This finding was confirmed by a simple check of the accident causes cited by OSHA. Of the 208 accidents investigated involving powered industrial trucks, 184 of which were fatal accidents or resulted in serious injuries, a full 50 percent of them were due to loading problems, including overloading, unstable loads, dropped loads or incorrect lifting of loads. 25 percent of the cases involved the tipping or overturning of the truck. A further 20 percent of the accidents were caused by the truck falling from a platform or a trailer or by persons falling from an elevated position in a truck. Although only 4% of the accidents were due to an absence of training and instruction, OSHA nevertheless noted that many accidents could also have been caused by inadequate training. For example, the overturning of a vehicle could just as easily be caused by poor or inadequate instruction of the operator with regard to the loading of the vehicle. Other less frequent accident causes, which could nevertheless still have been avoided by employers and operators, were excessive speeds and the use of inappropriate equipment.

The following measures are, therefore, of vital importance:

– Operators must be trained and aptitude-tested before working with a powered

industrial truck.

– Operators must be physically, mentally and emotionally capable of operating a

powered industrial truck.

– Operators must possess and apply all practical knowledge in relation to the safe

loading and correct operation of the vehicle. The capacity limits of the machine must be known and must never be exceeded.

– All circumstances which could cause the vehicle to tip or to overturn, must be

avoided. Attention must be paid in this regard to shifting centers of gravity, correct loading and the safe transport of loads, and to anticipatory driving, taking account of edges, bends, slopes, and other driving conditions.

– Without appropriate driver training and the correct type of truck, passengers should

never be carried nor people lifted under any circumstances. Furthermore, the correct procedure for this must be observed.

– Traffic rules must always be observed. Drivers must always be aware of the

position of colleagues and of other trucks and must pay attention to local conditions.

The manufacturer shall not be held liable for the consequences of the dismantling of the industrial truck or for modifications outside the manufacturer's control.

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The manufacturer's liability is limited to the configuration of the machine or plant described in the declaration of conformity. The manufacturer is absolved from all liability if modifications or additions are made or equipment from another manufacturer is used. In such a case the manufacturer's liability is transferred to the user/customer.

This Operating Manual shall cease to be valid if the machine is modified by a company outside our Group, even if original spare parts are used and our company logo can still be seen on the machine.

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C Appropriate use

NOTICE This Operating Manual contains all necessary information for the transport,

commissioning, normal use, maintenance, and servicing of the industrial truck it describes, in accordance with ASME B56.1-2003, UL 583, and ANSI Z535.4-2002. You should read these instructions carefully to ensure the safe and correct use of the industrial truck.

The industrial truck described in this Operating Manual is suitable for lifting and transporting loads. This vehicle must be used and maintained in accordance with the information set out in this Operating Manual. Any other usage constitutes improper use and may lead to damage or injury. In particular, overloading as a result of excessive weight or unbalanced loads must be avoided. The maximum permissible loading capacity is stated on the nameplate and on the load diagram sticker on the industrial truck. The industrial truck may not be used in areas where there is a risk of fire or explosion, or a corrosive or dusty atmosphere.

This Operating Manual must be kept available throughout the entire period of use of the vehicle.

Duties of the owner: Depending on the context cited in this Operating Manual, the user of a fork lift truck can refer to several people, including the owner of the truck, anyone who leases or borrows the truck, and the operator as defined in ASME B56.1-

2003. Generally speaking, the employer is the user, whereas his or her employee will

frequently perform the duties of the operator as described in the OSHA regulations. Every user must know and apply the applicable rules and regulations relating to the use and operation of the truck. The Operating Manual applies to all users and is aimed at the people who actually operate the truck. The operator and owner must ensure that the industrial truck is used correctly and only within its design limits, and that all health and safety risks to operators or third parties are avoided. The relevant accident prevention regulations and all relevant safety provisions, along with operating, servicing and maintenance instructions, must also be followed. The operator and owner must also ensure that anyone using the truck has read and understood this Operating Manual. The owner must ensure that all operators of the truck have read and understood this Operating Manual and that they have successfully completed all legally required training and aptitude testing before working with the truck.

Operators and users should understand that the vehicle operation changes if the functions of manually operated trucks are automated (for example, rail-mounted trucks or trucks with inductive guidance), resulting in changes to performance features and maintenance procedures and requiring additional safety precautions. If a manually operated industrial truck is adapted to include an automatic function, the implications of the automation on all other functions must be considered. Other functions may also need to be automated to some degree.

NOTICE Failure to comply with the content of this Operating Manual shall invalidate

the warranty. The same shall apply if the customer and/or third parties repair or modify the machine without the approval of our customer service department.

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Attachment of accessories: The attachment or installation of accessories, and modifications and/or additions to the hardware or software, which adversely affect or change the nominal power, the safe operation, the emergency devices or other functions of the industrial truck, are permissible only with the prior, express, written approval of the manufacturer. If such approval is granted, the nameplates, markings or warnings with regard to load capacity, operation, and maintenance must be altered accordingly. Local authority approval must be obtained if necessary. Local authority approval does not, however, release the owner from his or her duty to obtain approval from the manufacturer.

If the industrial truck is fitted with accessories, including fork extensions, the user must ensure that the truck is labeled to identify the accessories and that the approximate weight of the truck and the combined accessories is shown, together with the load capacity of the truck and accessories at maximum lift with a laterally centered load. If the modifications are associated with alterations and repairs to the basic functions, these changes must be made in accordance with the criteria and procedures set down by the manufacturer.

The basic functions comprise the following elements:

– Steering (guidance) – Travel speed – Controller and sensors – Lift and load influencing

Nameplate: We recommend that you copy the details from the nameplate onto the diagram below to ensure that this important data is available to the operator and that this Operating Manual is not accidentally used for another machine.

The operator is responsible for ensuring that all nameplates, warning signs and instruction signs are in place and are legible (see "Position of signs and nameplates" in Chapter D).

QwW The use of an industrial truck involves certain risks, which cannot be fully

excluded even with the use of electrical devices; these risks can, however, be minimized through intelligence, consideration, and common sense. It is, therefore, essential that operators are qualified, diligent, and physically and mentally fit, and have been thoroughly trained in the safe use of the machine and in materials handling techniques.

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General instructions for operators and owners

QwW The instructions set out below apply to all users, including managers,

supervisors, operators, carriers, and employees working in the vicinity of industrial trucks. The user is responsible for the safe use of this fork lift truck, and employers and operators must work closely together to ensure that the safety regulations applying to the use of the truck are observed and enforced.

1. This Operating Manual must be read before the industrial truck is used for the

first time and its content observed when using the truck.

2. The owner and operator must ensure that the industrial truck is used only for its

originally intended purpose. The owner and operator must NOT:

– Permit the industrial truck to be used for any other than its designated purpose – Disable the safety systems – Overload the industrial truck or use it if the arrangement of the load does not

match that shown in the load diagram

(see "Load capacity" in Chapter D) – Use the industrial truck as a crane – Lift or carry people – Lock a control in position – Ignore conventional practice in connection with the handling of loads – Carry loads over people's heads – Push or pull loads – Take part in games, such as races – Carry loads, which are not fully balanced

3. The owner and operator must check the load-bearing capacity of floors (to prevent damage), shelves, and in general all gangways in which the industrial truck may possibly be used.

4. Read the instructions on the signs attached to the industrial truck and ensure that they are always legible.

5. This Operating Manual must be made available to all operators.

6. Ensure that only trained, tested, and responsible people who are capable of operating the vehicle safely are allowed to operate the industrial truck.

7. Ensure that the industrial truck cannot be moved when it is not in use.

8. An industrial truck which is clearly not in good working order, must not be used.

9. The industrial truck must never be used to transport a load or to apply a force if the maximum permissible operating load would be exceeded as a consequence.

10. The industrial truck must only be used in the manner for which the truck was designed.

11. Read the safety instructions applicable for this industrial truck and comply with these instructions without exception.

12. The manufacturer accepts no liability for consequences arising from the dismantling of the industrial truck or from modifications outside the manufacturer's control.

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13. The manufacturer's liability is limited to the configuration of the machine described in the Declaration of Conformity. The manufacturer is absolved from all liability if modifications or additions are made or equipment from another supplier is used. In such a case the manufacturer's liability is transferred to the user.

14. This Operating Manual shall cease to be valid if the machine is modified by a company outside our Group, even if original spare parts are used and our company logo still appears on the machine.

15. Exceptional operating conditions require additional safety precautions and special operating instructions.

16. Supervision is essential to the safe use of powered industrial trucks.

17. The batteries must comply with the minimum and maximum weight range as specified on the nameplate.

18. Wheel chocks and wheel locks (where fitted) are only suitable for holding the industrial truck in the required position on a level surface.

QwW Extreme danger can arise from an overloaded truck, obstacles to free

passage of the load, impact with objects or pedestrians, poor maintenance, and the use of equipment for which the industrial truck was not designed or developed. Changes to the load, dimensions, coupling method, and/or position, and also to the surface of the ground or the battery weight, can have a negative impact on the load capacity and safe operation of the industrial truck. Only stable or securely-fastened loads may be transported.

The user is responsible for ensuring the load is stable and secure. This should be checked where necessary.

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D Vehicle description

1 Description of use

The vehicle is a three-wheel electric pedestrian pallet truck with operator stand-on platform. Additional support rollers improve its cornering stability. It is designed for use on level ground for the transport and picking of goods.

It can be used to pick up block pallets or stringer pallets that are beyond the range of barrows or trolleys.

Loads can be stacked and unstacked and transported over relatively long distances. The rated load capacity is stated on the nameplate or load plate (Qmax).

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2 Components

Item Designation Item Designation

1 t Tiller 8 t Forks 2 o Information display

(CANDIS)

9 t Battery connector/EMERGENCY

STOP 3 t Discharge indicator (EA) 10 t Battery 4 o Keypad

(CANCODE)

11 o

Leg cushion

5 o Access module ISM 12 t Support rollers 6 t Switch latch 13 t Drive wheel 7 o Safety guard 14 t Fixed operator stand-on platform

t = Fitted as standard o = Optional extra

1 2, 3 4,5 6 7

111312 1214

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3 Technical data

NOTICE The technical data specification complies with the German guidelines for

"Type sheets for industrial trucks".

Subject to technical modification.

3.1 Performance data

*)On the extended fork version, the load center is in the center of the forks.

Designation ECR 327 ECR 336

Q Rated load capacity 6000 (2700) 8000 (3600) lb (kg)

c Load center distance with

standard fork length *

)

23.6 (600) 23.6 (600) in (mm)

Travel speed with/without rated load

6.8/9.3 (11/15) 5.9/9.3 (9.5/15)

m/h (km/h)

Lift speed with/without rated load

(0.39/0.50) (0.37/0.50) cm/s

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3.2 Dimensions

(all dimensions in inches (mm))

Designation Standard

Overall length at front 42.2 (1073)

Lowered height of fork 3.3 (83)

Lift height 5.7 (145)

Vehicle width 35.8 (910)

Track width 13.0 / 17.8 (331 / 451)

Fork width Standard tip forks Extended tip forks

9.0 (229)

9.8 (249)

a Safe distance 7.9 (200)

Service weight: see nameplate, vehicle

ll1yW

Standard tip forks

35.7 (908) 78.0 (1980) 49.4 (1254) 65.6 (1667)

41.7 (1060) 83.9 (2132) 55.4 (1407) 71.7 (1820)

47.8 (1213) 90.0 (2285) 61.5 (1561) 77.7 (1974)

53.7 (1365) 95.9 (2437) 67.5 (1714) 83.7 (2127)

59.7 (1517) 101.9 (2589) 73.5 (1866) 89.7 (2279)

95.7 (2432) 138.0 (3504) 109.6 (2783) 125.8 (3196)

102.8 (2610) 145.0 (3682) 116.6 (2961) 132.8 (3374)

Extended tip forks

83.7 (2127) 125.9 (3199) 81.5 (2069) 97.7 (2482)

92.8 (2356) 135.0 (3428) 81.5 (2069) 97.7 (2482)

95.7 (2432) 138.0 (3504) 81.5 (2069) 97.7 (2482)

102.8 (2610) 145.0 (3682) 81.5 (2069) 97.7 (2482)

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1475 mm ( 58.1")

124 mm (4.9")

415 mm (16.3")

240 mm (9.4")

(L1)

 Standard Tip Forks x =185 mm (7.3")

 Extendet Tip Forks  Forks x =592 mm (23.3")  2133 mm (84") x =821 mm (32.5")  2362 mm (93") x =897 mm (35.3")  2438 mm (96") x =1075 mm (42.3")  2616 mm (103")

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3.3 Axle and drive wheel loads

Unladen vehicle, including 510 Ah battery

Drive wheel load

while moving

in fork direction

(level ground) in lb (kg)

1140 (517)

1232 (559)

1285 (583)

1032 (468)

1074 (487)

1276 (579)

1312 (595)

1376 (624)

1336 (606)

1321 (599)

1287 (584)

Drive wheel load

while moving

in drive direction

(level ground) in lb (kg)

1360 (617)

1453 (659)

1506 (683)

1274 (578)

1316 (597)

1519 (689)

1554 (705)

1596 (724)

1556 (706)

1541 (699)

1508 (684)

Load axle

in lb (kg)

637 (289)

584 (265)

573 (260)

569 (258)

567 (257)

606 (275)

619 (281)

686 (311)

756 (343)

783 (355)

840 (381)

Drive axle

in lb (kg)

1856 (842)

1949 (884)

2002 (908)

2046 (928)

2088 (947)

2291 (1039)

2326 (1055)

2092 (949)

2052 (931)

2037 (924)

2004 (909)

Vehicle weight

in lb (kg)

2493 (1131)

2533 (1149)

2575 (1168)

2615 (1186)

2654 (1204)

2897 (1314)

2945 (1336)

2778 (1260)

2809 (1274)

2820 (1279)

2844 (1290)

Forkoverhang

in inches (mm)

7.3 (185)

23.3 (592)

32.3 (821)

35.3 (897)

42.3 (1075)

Fork length

in inches (mm)

35.7 (908)

41.7 (1060)

47.8 (1213)

53.7 (1365)

59.7 (1517)

95.7 (2432)

102.8 (2610)

83.7 (2127)

92.8 (2356)

95.7 (2432)

102.8 (2610)

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Vehicle with 2700 kg load and 150 mm load carriage travel, including 510 Ah battery

Drive wheel load

while moving in

fork direction

(level ground)

in lb (kg)

2262 (1026)

1836 (833)

2412 (1094)

2299 (1043)

2482 (1126)

3201 (1452)

3300 (1497)

2363 (1072)

2002 (908)

1929 (875)

1898 (861)

Drive wheel load

while moving in

drive direction

(level ground)

in lb (kg)

2482 (1126)

2057 (933)

2632 (1194)

2542 (1153)

2725 (1236)

3444 (1562)

3543 (1607)

2584 (1172)

2222 (1008)

2149 (975)

2119 (961)

Load axle

in lb (kg)

5467 (2480)

5933 (2691)

5399 (2449)

5254 (2383)

5110 (2318)

4634 (2102)

4583 (2079)

5650 (2563)

6043 (2741)

6127 (2779)

6182 (2804)

Drive axle

in lb (kg)

2978 (1351)

2553 (1158)

3128 (1419)

3313 (1503)

3496 (1586)

4215 (1912)

4314 (1957)

3080 (1397)

2718 (1233)

2646 (1200)

2615 (1186)

Vehicle weight

in lb (kg)

8446 (3831)

8485 (3849)

8527 (3868)

8567 (3886)

8607 (3904)

8849 (4014)

8898 (4036)

8730 (3960)

8761 (3974)

8772 (3979)

8796 (3990)

Load center

(LC)

in inches (mm)

19.7 (500)

23.6 (600)

26.9 (683)

29.9 (759)

47.9 (1216)

51.4 (1305)

41.9 (1064)

46.4 (1178)

47.2 (1200)

Forkover-

hang

in inches

(mm)

7.3 (185)

23.3 (592)

32.3 (821)

35.3 (897)

42.3 (1075)

Fork length

in inches

(mm)

35.7 (908)

41.7 (1060)

47.8 (1213)

53.7 (1365)

59.7 (1517)

95.7 (2432)

102.8 (2610)

83.7 (2127)

92.8 (2356)

95.7 (2432)

102.8 (2610)

Page 23

0705.USA

D 8

Vehicle with 3600 kg load and 150 mm load carriage travel, including 510 Ah battery

Drive wheel load

while moving in

fork direction

(level ground)

in lb (kg)

2615 (1186)

2048 (929)

2795 (1268)

2736 (1241)

2965 (1345)

3851 (1747)

3968 (1800)

2701 (1225)

2229 (1011)

2138 (970)

2103 (954)

Drive wheel load

while moving in

drive direction

(level ground)

in lb (kg)

2835 (1286)

2269 (1029)

3016 (1386)

2978 (1351)

3208 (1455)

4094 (1857)

4211 (1910)

2921 (1325)

2449 (1111)

2359 (1070)

2324 (1054)

Load axle

in lb (kg)

7099 (3220)

7705 (3495)

7000 (3175)

6803 (3086)

6612 (2999)

5968 (2707)

5899 (2676)

7297 (3310)

7800 (3538)

7901 (3584)

7961 (3611)

Drive axle

in lb (kg)

3331 (1511)

2765 (1254)

3512 (1593)

3750 (1701)

3979 (1805)

4866 (2207)

4982 (2260)

3417 (1550)

2945 (1336)

2855 (1295)

2820 (1279)

Vehicle weight

in lb (kg)

10430 (4731)

10470 (4749)

10511 (4768)

10551 (4786)

10591 (4804)

10833 (4914)

10882 (4936)

10714 (4860)

10745 (4874)

10756 (4879)

10780 (4890)

Load center

(LC)

in inches (mm)

19.7 (500)

23.6 (600)

26.9 (683)

29.9 (759)

47.9 (1216)

51.4 (1305)

41.9 (1064)

46.4 (1178)

47.2 (1200)

Forkover-

hang

in inches

(mm)

7.3 (185)

23.3 (592)

32.3 (821)

35.3 (897)

42.3 (1075)

Fork length

in inches

(mm)

35.7 (908)

41.7 (1060)

47.8 (1213)

53.7 (1365)

59.7 (1517)

95.7 (2432)

102.8 (2610)

83.7 (2127)

92.8 (2356)

95.7 (2432)

102.8 (2610)

Page 24

D 9

0705.USA

Unladen vehicle, including 600 Ah battery

Drive wheel load

while moving

in fork direction

(level ground) in lb (kg)

1261 (572)

1358 (616)

1413 (641)

1162 (527)

1206 (547)

1415 (642)

1451 (658)

1510 (685)

1468 (666)

1455 (660)

1420 (644)

Drive wheel load

while moving

in drive direction

(level ground) in lb (kg)

1481 (672)

1578 (716)

1634 (741)

1404 (637)

1448 (657)

1658 (752)

1693 (768)

1731 (785)

1689 (766)

1675 (760)

1640 (744)

Load axle

in lb (kg)

668 (303)

611 (277)

597 (271)

591 (268)

586 (266)

619 (281)

633 (287)

703 (319)

776 (352)

800 (363)

860 (390)

Drive axle

in lb (kg)

1978 (897)

2075 (941)

2130 (966)

2176 (987)

2220 (1007)

2429 (1102)

2465 (1118)

2227 (1010)

2185 (991)

2172 (985)

2136 (969)

Vehicle weight

in lb (kg)

2646 (1200)

2685 (1218)

2727 (1237)

2767 (1255)

2806 (1273)

3049 (1383)

3097 (1405)

2930 (1329)

2961 (1343)

2972 (1348)

2996 (1359)

Forkoverhang

in inches (mm)

7.3 (185)

23.3 (592)

32.3 (821)

35.3 (897)

42.3 (1075)

Fork length

in inches (mm)

35.7 (908)

41.7 (1060)

47.8 (1213)

53.7 (1365)

59.7 (1517)

95.7 (2432)

102.8 (2610)

83.7 (2127)

92.8 (2356)

95.7 (2432)

102.8 (2610)

Page 25

0705.USA

D 10

Vehicle with 2700 kg load and 150 mm load carriage travel, including 600 Ah battery

Drive wheel load

while moving in

fork direction

(level ground)

in lb (kg)

2390 (1084)

1962 (890)

2540 (1152)

2429 (1102)

2615 (1186)

3340 (1515)

3439 (1560)

2496 (1132)

2136 (969)

2061 (935)

2030 (921)

Drive wheel load

while moving in

drive direction

(level ground)

in lb (kg)

2610 (1184)

2183 (990)

2760 (1252)

2672 (1212)

2857 (1296)

3582 (1625)

3682 (1670)

2716 (1232)

2357 (1069)

2282 (1035)

2251 (1021)

Load axle

in lb (kg)

5492 (2491)

5959 (2703)

5423 (2460)

5276 (2393)

5130 (2327)

4647 (2108)

4597 (2085)

5670 (2572)

6060 (2749)

6146 (2788)

6202 (2813)

Drive axle

in lb (kg)

3106 (1409)

2679 (1215)

3256 (1477)

3444 (1562)

3629 (1646)

4354 (1975)

4453 (2020)

3212 (1457)

2853 (1294)

2778 (1260)

2747 (1246)

Vehicle weight

in lb (kg)

8598 (3900)

8638 (3918)

8679 (3937)

8719 (3955)

8759 (3973)

9001 (4083)

9050 (4105)

8882 (4029)

8913 (4043)

8924 (4048)

8948 (4059)

Load center

(LC)

in inches (mm)

19.7 (500)

23.6 (600)

26.9 (683)

29.9 (759)

47.9 (1216)

51.4 (1305)

41.9 (1064)

46.4 (1178)

47.2 (1200)

Forkover-

hang

in inches

(mm)

7.3 (185)

23.3 (592)

32.3 (821)

35.3 (897)

42.3 (1075)

Fork length

in inches

(mm)

35.7 (908)

41.7 (1060)

47.8 (1213)

53.7 (1365)

59.7 (1517)

95.7 (2432)

102.8 (2610)

83.7 (2127)

92.8 (2356)

95.7 (2432)

102.8 (2610)

Page 26

D 11

0705.USA

Vehicle with 3600 kg load and 150 mm load carriage travel, including 600 Ah battery

Drive wheel load

while moving in

fork direction

(level ground)

in lb (kg)

2745 (1245)

2178 (988)

2930 (1329)

2864 (1299)

3097 (1405)

3990 (1810)

4109 (1864)

2833 (1285)

2366 (1073)

2269 (1029)

2238 (1015)

Drive wheel load

while moving in

drive direction

(level ground)

in lb (kg)

2965 (1345)

2399 (1088)

3150 (1429)

3106 (1409)

3340 (1515)

4233 (1920)

4352 (1974)

3053 (1385)

2586 (1173)

2489 (1129)

2458 (1115)

Load axle

in lb (kg)

7121 (3230)

7727 (3505)

7017 (3183)

6825 (3096)

6631 (3008)

5981 (2713)

5911 (2681)

7317 (3319)

7815 (3545)

7923 (3594)

7978 (3619)

Drive axle

in lb (kg)

3461 (1570)

2895 (1313)

3646 (1654)

3878 (1759)

4112 (1865)

5004 (2270)

5123 (2324)

3549 (1610)

3082 (1398)

2985 (1354)

2954 (1340)

Vehicle weight

in lb (kg)

10582 (4800)

10622 (4818)

10664 (4837)

10703 (4855)

10743 (4873)

10985 (4983)

11034 (5005)

10866 (4929)

10897 (4943)

10908 (4948)

10933 (4959)

Load center

(LC)

in inches (mm)

19.7 (500)

23.6 (600)

26.9 (683)

29.9 (759)

47.9 (1216)

51.4 (1305)

41.9 (1064)

46.4 (1178)

47.2 (1200)

Forkover-

hang

in inches

(mm)

7.3 (185)

23.3 (592)

32.3 (821)

35.3 (897)

42.3 (1075)

Fork length

in inches

(mm)

35.7 (908)

41.7 (1060)

47.8 (1213)

53.7 (1365)

59.7 (1517)

95.7 (2432)

102.8 (2610)

83.7 (2127)

92.8 (2356)

95.7 (2432)

102.8 (2610)

Page 27

0705.USA

D 12

Unladen vehicle, including 750 Ah battery

Drive wheel load

while moving

in fork direction

(level ground) in lb (kg)

1411 (640)

1526 (692)

1292 (586)

1345 (610)

1391 (631)

1314 (596)

1351 (613)

1404 (637)

1660 (753)

1647 (747)

1612 (731)

Drive wheel load

while moving

in drive direction

(level ground) in lb (kg)

1631 (740)

1746 (792)

1534 (696)

1587 (720)

1634 (741)

1590 (721)

1627 (738)

1647 (747)

1881 (853)

1867 (847)

1832 (831)

Load axle

in lb (kg)

769 (349)

694 (315)

672 (305)

659 (299)

653 (296)

666 (302)

675 (306)

763 (346)

836 (379)

860 (390)

919 (417)

Drive axle

in lb (kg)

2127 (965)

2242 (1017)

2306 (1046)

2359 (1070)

2405 (1091)

2637 (1196)

2674 (1213)

2418 (1097)

2377 (1078)

2363 (1072)

2328 (1056)

Vehicle weight

in lb (kg)

2897 (1314)

2937 (1332)

2978 (1351)

3018 (1369)

3058 (1387)

3300 (1497)

3349 (1519)

3181 (1443)

3212 (1457)

3223 (1462)

3247 (1473)

Forkoverhang

in inches (mm)

7.3 (185)

23.3 (592)

32.3 (821)

35.3 (897)

42.3 (1075)

Fork length

in inches (mm)

35.7 (908)

41.7 (1060)

47.8 (1213)

53.7 (1365)

59.7 (1517)

95.7 (2432)

102.8 (2610)

83.7 (2127)

92.8 (2356)

95.7 (2432)

102.8 (2610)

Page 28

D 13

0705.USA

Vehicle with 2700 kg load and 150 mm load carriage travel, including 750 Ah battery

Drive wheel load

while moving in

fork direction

(level ground)

in lb (kg)

2549 (1156)

2116 (960)

2412 (1094)

2608 (1183)

2795 (1268)

3236 (1468)

3338 (1514)

2385 (1082)

2321 (1053)

2251 (1021)

2218 (1006)

Drive wheel load

while moving in

drive direction

(level ground)

in lb (kg)

2769 (1256)

2337 (1060)

2654 (1204)

2851 (1293)

3038 (1378)

3512 (1593)

3613 (1639)

2628 (1192)

2542 (1153)

2471 (1121)

2438 (1106)

Load axle

in lb (kg)

5584 (2533)

6056 (2747)

5505 (2497)

5348 (2426)

5201 (2359)

4694 (2129)

4638 (2104)

5734 (2601)

6127 (2779)

6208 (2816)

6265 (2842)

Drive axle

in lb (kg)

3265 (1481)

2833 (1285)

3426 (1554)

3622 (1643)

3810 (1728)

4559 (2068)

4661 (2114)

3399 (1542)

3038 (1378)

2967 (1346)

2934 (1331)

Vehicle weight

in lb (kg)

8849 (4014)

8889 (4032)

8931 (4051)

8970 (4069)

9010 (4087)

9253 (4197)

9301 (4219)

9134 (4143)

9164 (4157)

9176 (4162)

9200 (4173)

Load center

(LC)

in inches (mm)

19.7 (500)

23.6 (600)

26.9 (683)

29.9 (759)

47.9 (1216)

51.4 (1305)

41.9 (1064)

46.4 (1178)

47.2 (1200)

Forkover-

hang

in inches

(mm)

7.3 (185)

23.3 (592)

32.3 (821)

35.3 (897)

42.3 (1075)

Fork length

in inches

(mm)

35.7 (908)

41.7 (1060)

47.8 (1213)

53.7 (1365)

59.7 (1517)

95.7 (2432)

102.8 (2610)

83.7 (2127)

92.8 (2356)

95.7 (2432)

102.8 (2610)

Page 29

0705.USA

D 14

Vehicle with 3600 kg load and 150 mm load carriage travel, including 750 Ah battery

Drive wheel load

while moving in

fork direction

(level ground)

in lb (kg)

2906 (1318)

2332 (1058)

2793 (1267)

3038 (1378)

3276 (1486)

3884 (1762)

4006 (1817)

2720 (1234)

2549 (1156)

2456 (1114)

2425 (1100)

Drive wheel load

while moving in

drive direction

(level ground)

in lb (kg)

3126 (1418)

2553 (1158)

3036 (1377)

3280 (1488)

3519 (1596)

4160 (1887)

4281 (1942)

2963 (1344)

2769 (1256)

2676 (1214)

2646 (1200)

Load axle

in lb (kg)

7211 (3271)

7824 (3549)

7108 (3224)

6903 (3131)

6704 (3041)

6030 (2735)

5957 (2702)

7383 (3349)

7884 (3576)

7987 (3623)

8042 (3648)

Drive axle

in lb (kg)

3622 (1643)

3049 (1383)

3807 (1727)

4052 (1838)

4290 (1946)

5207 (2362)

5328 (2417)

3735 (1694)

3265 (1481)

3172 (1439)

3142 (1425)

Vehicle weight

in lb (kg)

10833 (4914)

10873 (4932)

10915 (4951)

10955 (4969)

10994 (4987)

11237 (5097)

11285 (5119)

11118 (5043)

11149 (5057)

11160 (5062)

11184 (5073)

Load center

(LC)

in inches (mm)

19.7 (500)

23.6 (600)

26.9 (683)

29.9 (759)

47.9 (1216)

51.4 (1305)

41.9 (1064)

46.4 (1178)

47.2 (1200)

Forkover-

hang

in inches

(mm)

7.3 (185)

23.3 (592)

32.3 (821)

35.3 (897)

42.3 (1075)

Fork length

in inches

(mm)

35.7 (908)

41.7 (1060)

47.8 (1213)

53.7 (1365)

59.7 (1517)

95.7 (2432)

102.8 (2610)

83.7 (2127)

92.8 (2356)

95.7 (2432)

102.8 (2610)

Page 30

D 15

0705.USA

3.4 US standards

Continuous sound pressure level at ear level:

63 db(A)

determined by the ASME test procedure defined in ASME B56.11.5

NOTICE The continuous sound pressure level is a value determined in accordance

with the standard, taking into account the sound pressure level while driving, lifting and at idle. The sound pressure level is measured at ear level.

Vibrations: a

w,zS

= 3.08 ft/s2 (0.94 m/s2).

NOTICE The vibration acceleration acting on the body in the operating position is the

linearly integrated, weighted acceleration in the vertical direction. It is determined by driving over shock waves at a constant speed.

Electromagnetic compatibility (EMC)

The manufacturer confirms compliance with the limit values for electromagnetic interference and interference resistance and electrostatic discharge testing as set out in the table below:

Interference resistance

The following limit values apply for industrial trucks/transportation systems:

Environmental phenomenon Test value Unit

1.1 Frequency Electromagnetic field

Amplitude modulation

27-1000 *

10 80

MHz

V/m (unmodulated, rms)

% AM (1 kHz)

1.2 Frequency Electromagnetic field

Pulse modulation

900 ± 5

10 50

200

MHz

V/m (unmodulated, rms)

% operating cycle

Repetition frequency Hz

1.3 Electrostatic

discharge

4 contact

8 air

discharge

kV (discharge voltage)

* The frequency range has been expanded to include low-frequency

interference in the wiring.

Page 31

0705.USA

D 16

NOTICE Very strong electromagnetic fields can adversely affect the performance of

the industrial truck. In the same way, machinery that is highly sensitive to electromagnetic fields may also be adversely affected by the industrial truck. Be sure that emitted interference from the industrial truck cannot interfere with the operation of adjacent machinery.

NOTICE Electrical or electronic components and their configuration may not be

modified without the prior written approval of the manufacturer.

3.5 Operating conditions

Ambient temperature:

- during operation: 41°F (+5°C) through 104°F (+40°C) Ambient temperature measured over 24 hours: 77°F (25°C), max. Maximum indoor humidity 70%, without condensation

NOTICE Industrial trucks intended for use in environments with temperatures below

41°F (5°C) or in refrigerated warehouses with extreme temperature or humidity variations require special equipment and approval.

NOTICE If the vehicle is to be used for extended periods at temperatures below 32°F

(0°C), we recommend that you fill the hydraulic system with a low-viscosity oil in accordance with the manufacturer's instructions.

Page 32

D 17

0705.USA

4 Position of signs and nameplates

NOTICE The vehicle nameplate (23) can be accessed by opening the front cover (see

Chapter F).

Item Designation

15 Sign - Qmax 16 Danger battery 2x (1x opposite) 17 Warning battery size 2x (1x opposite) 18 Warning stay clear

19 Attachment point for handling by crane 20a Warning jog button coast, left (o) 20b Warning jog button coast, right (o)

21 Nameplate, battery

22 Attachment point for jack

23 Nameplate, vehicle

24 Warning stay clear stop truck

25 Warning charger

26 Vehicle serial number

27 Warning electrical device

28 Warning coast system (o)

20a 20b

opposite (not shown)

Page 33

0705.USA

D 18

4.1 Nameplate, vehicle

NOTICE In the event of queries about the vehicle or when ordering spare parts, please

quote the serial number (30).

Item Designation Item Designation

29 Model 37 Manufacturer

30 Serial no. 38 Battery code

31 Rated load capacity 39 Battery weight, min./max.

32 Battery voltage 40 Drive output

33 Empty weight without battery 41 Load center distance

34 Residual load capacity 42 Year of manufacture

35 Lift height, max. 43 Option

36 Manufacturer's logo

3933

4032

4131

4230

4329

Page 34

D 19

0705.USA

4.2 Sign - Qmax (15)

4.3 Sign - Danger battery (16)

4.4 Sign - Warning battery size (17)

Qmax

6000 lbs

Page 35

0705.USA

D 20

4.5 Sign - Warning stay clear (18)

4.6 Sign - Warning jog button coast, left (20a) (o)

4.7 Sign - Warning jog button coast, right (20b) (o)

Page 36

D 21

0705.USA

4.8 Sign - Warning stay clear stop truck (24)

4.9 Sign - Warning charger (25)

Page 37

0705.USA

D 22

4.10 Sign - Warning electrical device (27)

4.11 Sign - Warning coast system (28) (o)

Page 38

E 1

0705.USA

E Operation

1 Description of controls and indicators

Item Control or indicator

Function

1 Switch latch t Switches the control current on and off. Remove

the key to prevent the vehicle being switched on by

unauthorized persons. 2 Discharge indicator (EA) t Displays the battery capacity 3 Information display (CANDIS) o Operating hours indicator

Shows the residual battery capacity and the

number of operating hours already completed by

the vehicle 4 Keypad (CANCODE) o Code settings, access authorization

Travel program enabling 5 Access module ISM o Starts/switches off the vehicle.

Displays important information, prompts, shock

events, and error messages.

Sets date and time. 6 Tiller t Swiveling tiller; steering and braking 7 Jog button o Travel switch for travel in tiller direction. Coasting

at 5.6 km/h (3.5 mph). 8 Travel regulator t Controls the direction of travel and speed (see

Section 4.2). 9 "Down" rocker switch t Lowers the fork.

10 "Up" rocker switch t Raises the fork. 11 Anti-collision button t Safety function. Automatically moves the vehicle

for approximately 3 s in the direction of travel (R)

and then switches it off until the travel regulator is

moved briefly to neutral.

12 Warning signal button (horn) t Sounds the warning signal. 13 Tiller locking lever o Locks the tiller in the travel position. 14 Jog button o Travel switch for travel in tiller direction. Coasting

at 5.6 km/h (3.5 mph).

15 Brake button o Brakes the vehicle mechanically. 16 High-speed button t Moves the vehicle in ride-on mode at 15 km/h,

max. (9.3 mph) in the tiller direction or 9.0 km/h,

max. (5.6 mph) in the fork direction.

t = Fitted as standard o = Optional extra

Page 39

0705.USA

E 2

10 11 10

2, 3 4, 5 1

141315

14 15

Page 40

E 3

0705.USA

Item Control or indicator

Function

17 Coast LED o Flashes:

– when a jog button is pressed and the vehicle is

coasting. Lights up: – when the battery capacity is down between 30%

and 0% with a standard battery. – when the battery capacity is down between 40%

and 0% with a maintenance-free battery.

18 Jog button o Travel switch for travel in tiller direction. Coasting

at 5.6 km/h (3.5 mph).

19 Battery connector

(EMERGENCY STOP)

t The electric circuit is broken, all electrical functions

switch off and the vehicle brakes are automatically applied.

t = Fitted as standard o = Optional extra

Page 41

0705.USA

E 4

10 11 10

2, 3 4, 5 1

141315

14 15

Page 42

E 5

0705.USA

2 Starting the vehicle

QwW Before the vehicle can be started, operated or used to lift a load unit, the

driver must ensure that there is nobody in the danger zone.

Daily checks and actions before startup

– Visually inspect the entire vehicle (especially wheels and load-handling equipment)

for signs of damage. – Check for steering play. – Visually inspect the battery fixings and cable connections.

2.1 Preparing for operation

– Insert the key in the switch latch (1) and turn it clockwise to the "I" position.

Or:

– On vehicles without a switch latch, enter the enable code via the CANCODE (4, o).

On delivery, the CANCODE start PIN is factory set to 2580. Enter the code via the

keypad and press the Set button to confirm. – Check that the warning signal (horn) (12) is working correctly.

The vehicle is now ready for use. The discharge indicator (EA) (2) shows the charge level of the battery.

On vehicles with an information display (CANDIS) (3, o), the remaining battery capacity is displayed.

2, 312 12 4, 5

Page 43

0705.USA

E 6

2.2 Driving, steering, braking

QwW Extra care must be taken when driving and steering, especially outside the

perimeter of the vehicle. In ride-on mode, keep an adequate distance from the vehicle.

Emergency stop

– Pull out the battery connector (19).

All electrical functions are switched off. The magnetic brake is applied and brakes the vehicle with the highest brake step.

Driving

IMPORTANT Do not drive the vehicle unless all covers are closed and properly locked.

The main direction of travel is travel in the tiller direction (V). Extra care must be taken when traveling in the load direction (R).

NOTICE Travel in the load direction (R) should be limited to shunting and to picking up

and setting down loads.

– Prepare for operation (see Section 2.1). – Move the tiller (6) in the travel range "F". – Turn the travel regulator (8) in the desired direction of travel (forward (V) or

backward (R)).

The vehicle starts moving in the chosen direction. The speed of travel is controlled with the travel regulator (8). The maximum speed is 5.6 km/h (3.5 mph). If the highspeed button (16) is held down (t) in ride-on mode, the maximum speed of travel is 15 km/h (9.3 mph) in the tiller direction (V) and 9 km/h (5.6 mph) in the fork direction (R).

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Press the high-speed button and release (o, parameter setting): If the high-speed button (16) is pressed and released in ride-on mode, the maximum speed of travel is 15 km/h (9.3 mph) in the tiller direction (V) and 9 km/h (5.6 mph) in the fork direction (R). If the travel regulator (8) is reset and the speed of travel drops to 0, high-speed travel is deactivated. The maximum vehicle speed is then reset to 5.6 km/h (3.5 mph) and the high-speed button must be pressed again.

Maneuvering in tight spaces (t): If there is no room to move the tiller in the travel range "F" in order to start the vehicle (vehicle with tiller against obstacle), press the high-speed button (16) and move the travel regulator (8) at the same time. The vehicle starts to move at creep speed.

Steering

QwW In tight bends the driver is standing over the outer perimeter of the vehicle.

– Move the tiller (6) to the left or right.

Braking

QwW The vehicle's braking response largely depends on the travel surface

conditions. The driver should adapt his or her driving style accordingly.

The vehicle can be braked in three ways:

– With the service brake (brake for emergencies and hazardous situations) – With the plug brake – With the coasting brake

Braking with the service brake:

IMPORTANT Use this brake in an emergency or hazardous situation.

– Move the tiller (6) to one of the braking ranges (B).

The travel motor is braked with the motor brake. In borderline cases the magnetic brake is automatically applied. When the vehicle is stationary, the magnetic brake acts as a parking brake.

IMPORTANT If the tiller is released, it moves to the upper braking range (B).

Vehicle with locking tiller (13, o):

– Move the tiller to the lower or upper braking range B (the lock is released if the tiller

is moved toward the upper braking range B).

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Braking with the plug brake:

– Turn the travel regulator (8) in the opposite direction of travel until the vehicle is

stationary.

The vehicle is braked by reversal. When the vehicle is stationary, the magnetic brake is applied.

Braking with the coasting brake

– Release the travel regulator or move it to the 0 position. The vehicle is braked

regeneratively until it is stationary. When the vehicle is stationary, the magnetic

brake is applied.

NOTICE The braking force is adjustable (parameter setting)

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Traveling with the jog button (7, o / 14, o / 18 o)

QwW Extra care must be taken when driving and steering, especially outside the

perimeter of the vehicle. In ride-on mode, keep an adequate distance from the vehicle.

Vehicle tiller without locking lever with coasting brake (o)

– Move the tiller to the travel position (F). – Press the jog button (7, o).

The vehicle starts moving at 5.6 km/h (3.5 mph), max., in the direction of travel V (with button 14,

o only if the tiller is in the upright position).

– Release the jog button (7, o).

NOTICE The coasting brake is applied when you release the JOG button.

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Vehicle tiller with locking lever (13, o)

NOTICE In ride-on mode or order picking mode the tiller can be locked in the travel

position with the locking lever (13).

– Pull the tiller locking lever (13) up. – Move the tiller down until it locks. – When the tiller is locked, the vehicle is in coasting mode.

– Press the jog button (7, o / 14, o).

The vehicle starts moving in the direction of travel V at 5.6 km/h (3.5 mph), max.

– Release the jog button (7, o / 14, o).

The vehicle coasts for a predefined distance and is then braked automatically.

To brake the vehicle during coasting:

– Move the tiller to the lower or upper braking range B (the lock is released if the tiller

is moved toward the upper braking range B)

– Press the brake button (15, o)

NOTICE The LED (17) flashes when the vehicle is in coasting mode.

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Vehicle tiller without locking lever in coasting mode (o)

NOTICE To activate the coasting brake for the first time, move the tiller to the travel

position and press the JOG button.

– Press the jog button (7, o / 14, o / 18, o).

The vehicle starts moving at 5.6 km/h (3.5 mph), max., in the direction of travel V (with button 14, o only if the tiller is in the upright position).

– Release the jog button (7,

o / 14, o / 18, o).

The vehicle coasts for a predefined distance (configurable) and is then braked automatically.

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Once the JOG button has been pressed, coasting mode remains active for a predefined period. To activate coasting mode again, move the tiller to the travel position again and press the JOG button.

QwW If the tiller is released in the upper braking range B, the vehicle is not braked.

To brake the vehicle during coasting:

– Move the tiller to the lower braking range B

– Press the brake button (15, o)

– Turn the twist handle

– Press the anti-collision button.

NOTICE The LED (17) flashes when the vehicle is in coasting mode. Deactivated by

turning the twist handle (8) or when the predefined time is over.

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2.3 Raising and lowering load units

IMPORTANT Before lifting a load unit, the driver must be sure that it is palleted correctly

and does not exceed the permitted load capacity of the vehicle.

– Move the vehicle's fork arms as far as possible under the load unit. Long goods

must not be picked up transversely.

IMPORTANT The load unit must be picked up so that it does not project significantly

(< 2 inches (50 mm)) beyond the tips of the fork arms.

Raising and lowering

NOTICE The fork is raised or lowered at a predefined speed by pressing the "Up" or

"Down" buttons.

Raise

– Press the "Up" rocker switch (9). Hold down the rocker switch until the lift height is

reached.

Lower

– Press the "Down" rocker switch (8) to lower the fork.

9 8

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2.4 Switching off and securing the vehicle

When the vehicle is left, even for a short time, it must be switched off and secured.

QwW Do not park the vehicle on a slope.

– Lower the fork completely. – On vehicles with a locking tiller (13, o), push the tiller into the upper braking range

B (this releases the lock). – Turn the switch latch (1) to position "0" and remove the key.

2.5 Adjusting the fork height

IMPORTANT In the event of wear on the drive

wheel or support rollers, the fork base height or fork tip height must be adjusted. This is necessary to ensure that the fork can still be moved easily into and out of pallets.

The fork base height is adjusted with a bolt and counter nut located between the load frame and drive frame (20) on both sides.

The fork tip height is adjusted with the pull rod adjusting nuts (21).

IMPORTANT These adjustments may only be made by authorized and appropriately

trained employees.

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3 Important general aspects affecting the safe use of the truck

3.1 Training, certification, and approval to use the truck

Driver's permit: Powered industrial trucks may only be used by people who have

been trained to operate powered industrial trucks in accordance with 29 CFR

1910.178, who have demonstrated to the owner or his or her representative their competence to move and transport loads, and who have been expressly authorized by the owner or his or her representative to operate powered industrial trucks.

The operator must be sufficiently capable, both physically and mentally and in terms of eyesight and hearing, to operate the industrial truck safely.

Prohibition of unauthorized use: During his or her working hours, the operator is responsible for the industrial truck. He or she must prohibit unauthorized people from driving or operating the industrial truck.

Operator training: Employees who have not been trained to use a powered industrial truck may drive an industrial truck for training purposes only and only under the direct supervision of an instructor. This training should be carried out in an open area away from other industrial trucks, obstacles and pedestrians.

The operator training program should deal with the documented Operating Manual and the manufacturer's procedures, the employer's regulations for the site at which the trainee is to use the industrial truck, and the working conditions prevailing at this site, together with the special features of the industrial truck to be operated by the trainee. All new operators must complete the training program, regardless of their previous experience.

The training program provides for the following:

– The careful selection of operators, taking account of their physical suitability, their

personal approach to their work and their aptitude. – The significance of safety for operators, storage areas, sites, and for other

employees, including mention of all safety provisions and their meaning. – General principles of powered industrial trucks and components in terms of safety,

in other words loading, mechanical limitations, stability, braking power, etc. – Introduction to the equipment, the position and function of the controls, explanation

of the mode of operation when used correctly, and reference to problems when

used incorrectly. – Supervised practical exercises simulating the actual day-to-day tasks to be carried

out by the operator, including loading, etc. – Refresher courses as a condensed version of the main course, and periodic

assessment of the operator "in action".

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The principal duty of the operator is the safe operation of the powered industrial truck in accordance with the instructions covered in the training program.

Failure to observe the safety regulations when operating the industrial truck or improper use or maintenance of a powered industrial truck can have the following consequences:

– Death or serious injury to the operator or to other people; – Damage to the industrial truck or to other property.

The training program should focus on the safe and appropriate use of the industrial truck, with the goal of preventing injury to the operator or to other people and property damage. To this end the following topics should be covered:

1. General information about the industrial truck(s) to be operated by the trainee,

including: – Technical data on the powered industrial truck, including differences between

industrial trucks used in the area of work; – Differences in comparison to a car; – Meaning of the information on the nameplate, including rated load capacity,

warnings and instructions attached to the industrial truck; – Operating instructions and warnings set out in the Operating Manual for the

industrial truck, together with inspection and maintenance instructions to be

followed by the operator; – Type of drive motor and its features; – Type of steering; – Braking response and braking distance, laden and unladen; – Visibility to front and rear, laden and unladen; – Load capacity when handling loads, weight and load center distance; – Stability characteristics, laden and unladen, and with and without attachments; – Position of controls, function, operation, recognition of symbols; – Possible load-handling equipment, attachments; transport of loads; – Filling and charging the battery; – Safety devices and barriers for certain types of industrial truck; – Other features of a particular industrial truck;

2. The operating environment and its influence on the operation of the industrial truck, including:

– Floor surface and nature of the sub-floor, including temporary conditions; – Equipment for filling and charging the battery; – Use of "classified" industrial trucks in areas presenting a risk of fire or explosion

as defined in ANSI/NFPA 505.

– Narrow gangways, doors, overhead cables and pipe systems, and other

enclosed areas;

– Areas in which the industrial truck may possibly be operated alongside other

powered industrial trucks, vehicles or pedestrians; – Use and load capacity of elevators; – Other special operating conditions and hazards, which the operator could

encounter.

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3. Operating the powered industrial truck, including: – Systematic inspection before each shift and approved procedures for the

extended shutdown of an industrial truck requiring repair;

– Procedures for handling loads: raising, lowering, picking up, setting down,

swinging; – Traveling laden and unladen, negotiating bends; – Procedures for stopping and switching off; – Other special operating conditions for particular applications.

4. Rules for safe working and procedures including: – Provisions in this manual in the "Operating the industrial truck" section of this

chapter;

– Other rules, regulations or procedures laid down by the employer for the site at

which the powered industrial truck is used.

5. Practical exercises, including: – Where possible, exercises for operating powered industrial trucks should take

place in a separate area, which is physically separated from other workplaces and employees.

– The practical exercises should be carried out under the supervision of an

instructor;

– The practical exercises should include or simulate the actual undertaking of all

operational tasks, including transport, maneuvering, traveling, stopping, starting, and all other activities, under the conditions the operator will face during the actual operation of the truck.

6. Testing, follow-up training, and implementation – During the training program, the employer should assess the operator's skills

and knowledge in connection with the stipulated requirements by means of practical tests and oral and/or written tests. The employer should lay down appropriate criteria for passing or failing these tests. Employers may delegate these tests to other employees, but they are still responsible for the tests. Appropriate records must be kept.

– Operators should receive follow-up training in the event of the introduction of

new equipment, modification of existing equipment, changes in operating conditions, or unsatisfactory performance by an operator.

– The user is responsible for the safe use of the powered industrial truck in

accordance with the regulations set out in this manual.

NOTICE Information about operator training can be obtained from the manufacturers

of (powered) industrial trucks, from official bodies responsible for safety at work, from industrial truck operators' associations, and from safety consultants, for example.

3.2 Damage and repairs to the industrial truck

Damage and defects: If damage or defects are found on this industrial truck or

attachments, they must be reported immediately to the responsible person. Where the safe operation of the industrial truck cannot be guaranteed (due to worn wheels or defective brakes, for example), it must not be used again until it has been repaired in an appropriate manner.

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Repairs:The driver must not repair or modify the industrial truck unless he or she has received special training and has obtained express approval to do so. Under no circumstances must the driver change the setting of switches or safety systems or disable them.

3.3 Aspects in relation to loading

Sensors: If a load extends beyond the width and/or length of the industrial truck, the

owner should ask for sensors to be used in the direction of travel, which cover the maximum width and/or length of the industrial truck, to prevent the load from coming into contact with an obstacle.

Stability: Industrial trucks complying with the requirements set out in ASME B56.12003 are stable when used correctly. Any unstable state can be attributed to improper use, poor maintenance, travel ways and working areas.

The truck's stability can be adversely affected by the following factors, for example: ground conditions (such as ice, oil, or water), slopes, speed, load behavior (even when unladen, industrial trucks with attachments can behave like partly laden trucks), battery weight, dynamic and static forces, and the judgment of the operator.

Use batteries whose weight is within the minimum and maximum range as stated on the truck's nameplate (see "Nameplate, vehicle" in Chapter D).

The user is responsible for ensuring that the load is stable and secure. This should be checked where necessary.

The owner must take note of special operating conditions. The stability of an industrial truck as determined by intensive tests laid down in ASME B56.1-2003 in accordance with the manufacturer's requirements does not take account of situations where an industrial truck is operated on a slope or with a load that is far outside the center of gravity.

Some users may have established stability requirements for general applications which differ from the manufacturer's requirements in accordance with ASME B56.1-

2003. The user, in cooperation with the manufacturer, must, however, use the

regulations laid down in ASME B56.1-2003 Section 7.6 as a basis for his or her own more stringent requirements. Changes are permitted only with the manufacturer's prior, written approval of the proposed changes or additions.

Extending the safety guard: If the nature of the load presents a danger, the owner should fit a vertical extension to the truck's safety guard, manufactured in accordance with the manufacturer's requirements as set out in ASME B56.1-2003.

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3.4 Operating environment

Danger zone: The "danger zone" refers to the area in which people are put at risk by

the travel or lifting movements of the industrial truck or of its load-handling equipment (such as the forks or attachments, for example) or by the loads to be transported. It also includes the possible impact zone of falling loads or falling or lowering attachments.

QwW Unauthorized people must be asked to leave the danger zone. The driver

must indicate the possible development of a hazard situation for people by sounding a warning signal. The industrial truck must be stopped immediately if people do not leave the hazard zone, even though requested to do so.

The owner is responsible for classifying the atmosphere or hazard zones in accordance with ANSI/NFPA 505.

The industrial trucks used in hazard zones and the batteries used there must carry appropriate approval and satisfy the requirements of ANSI/NFPA 505.

Industrial trucks and their areas of use must be labeled in accordance with ANSI/ NFPA 505.

Braking distance: The braking distance of a powered industrial truck depends on many factors, including traffic in the form of other industrial trucks and pedestrians, the available space, the nature of the ground, and the stability of the load(s).

Particular care is required in situations where the environmental conditions have changed. Changes to the weather, the ground surface or the application can have a negative effect on the braking distance, so the maximum speed, the braking settings and/or the operation of the industrial truck must be adjusted accordingly.

Gangways and obstacles: Permanent gangways, travel ways or passages and floors must be marked appropriately in accordance with ANSI Z535.2.

Areas to which access by industrial trucks is not permitted must also be indicated and/ or marked.

In areas to which access is permitted, the area needed for the industrial truck and its load and the space required for turning and maneuvering must be clearly marked.

Automatic doors and blind corners must be fitted with appropriate acoustic and/or visual warning systems to indicate an approaching industrial truck or the operation of the door. Passive devices – such as mirrors – are also recommended.

A distance of at least 1.5 ft (450 mm) must be maintained between obstacles and freely moving industrial trucks (including load). All other areas with limited space must be closed to industrial trucks and be clearly identified by signs, markers, light signals, or other means.

– Automated industrial truck guidance systems must not pass through gangways

used frequently by pedestrians if the opening is not wide enough to allow people to stand outside the guide path. The opening and closing of non-motorized doors should be accompanied by a warning signal to warn people in the vicinity of the gangway to keep away.

– To avoid the risk that a fire door cannot be completely closed, the industrial truck

responds to an appropriate signal – from a limit switch and/or a heat sensor, for example – and stops ahead of the fire door.

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– The system must be designed and built in such a way that in the normal stopping

position an industrial truck or its load cannot prevent a fire door from being closed.

Parts of the load, machine, materials or structural equipment projecting permanently or temporarily into the normal working area must be appropriately protected and clearly marked.

Lighting of operating areas: The operating areas must be adequately lit in accordance with ANSI/IES RP7, see also 29 CFR 1910.178 (h) with regard to the installation of additional lamps for the direction indicator.

The owner is responsible for fitting an industrial truck with operating lights if working conditions require it.

Noise level: The use of powered industrial trucks can contributed to an elevated noise level in the work environment. Consideration must, therefore, be given to the noise pollution affecting employees in the work environment.

Loading ramps (loading aisles)1: The load capacity of portable and powered loading ramps must be clearly marked. The specified load capacity must not be exceeded.

The position of loading ramps must be fixed either by anchors or by devices to prevent the loading ramps from being moved.

The loading ramps must have handles or other effective devices allowing them to be handled safely. Where possible they should be fitted with fork loops or lifting eyes with which they can be carried by industrial trucks.

All types of loading ramps should have a non-slip surface to prevent employees or industrial trucks from slipping.

To prevent the loading ramps from wobbling or sliding, all types of loading ramp must be designed and maintained in such a way that one end is permanently attached to the loading ramp and the other to the transport vehicle.

All loading ramps and transition plates must be designed and maintained so that a smooth and horizontal transition is provided between the individual working areas.

1.The recommendations for loading ramps apply also to loading aisles.

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Freight trucks with/without trailers and rail cars: Industrial trucks must not be driven onto freight trucks, with or without trailers, or rail cars. In addition, rail cars or trailers must not be moved with a powered industrial truck.

Ground and ground surface: The areas in which the (manually operated high-lift) trucks are used must be smooth and horizontal and free from cracks, soil drainage, etc.

The ground must be maintained in an appropriate manner to keep it free from dirt and liquids which would adversely affect the safe operation of the truck.

Travel surface: The surface on which the industrial truck is used must be maintained in an appropriate manner to provide the expected traction for traveling, steering and braking under the prevailing environmental conditions.

The details given on the industrial truck nameplate are based on a horizontal, dry surface and a minimum coefficient of friction of the drive and braking wheel of 0.6. Other ground conditions may affect the safety of the industrial truck and require the nominal power of the truck to be adjusted accordingly.

Physical environment: The physical environment – including temperature, relative humidity, weather conditions, air quality (explosive, containing particles and/or gaseous components) – is also an aspect of the design criteria for an industrial truck. Changes to the environment should be checked accordingly to ensure that they have no adverse effects on the safety systems of the industrial truck.

Radiated emissions: Many devices radiate energy, such as electromagnetic, electrostatic or optical energy, which can adversely affect the operation of the vehicle system. Equally, the vehicle systems can also emit energy, which can have a negative effect on other systems and/or on personnel. The owner should contact the industrial truck manufacturer if there is reason to suspect that interference is occurring. The acceptable conditions for the industrial truck are laid down in an agreement between the owner and the industrial truck manufacturer.

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3.5 Safety devices and warning signs

Safety devices and warning signs: The safety devices, warning signs and warnings

described in this Operating Manual must be complied with at all times.

Warning systems: All industrial trucks must be fitted with a horn, whistle, bell or other acoustic systems, which can be actuated by the operator.

The owner must decide whether the operating conditions are such that the industrial truck should also be fitted with other acoustic or optical systems – such as work lighting or a flashing warning lamp – and is responsible for the use and maintenance of these systems.

The owner should determine the time interval(s) at which the warning systems should be actuated in conjunction with the manufacturer.

Where necessary, road signs, warning systems and other safety devices must be used to warn personnel and to protect them from contact with industrial trucks or the equipment used by industrial trucks. This includes equipment designed to interact with the vehicle system.

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3.6 Lifting of people

Lifting of people: The lifting or carrying of people, with the exception of the operator,

is prohibited without special training and working platforms. The following safety measures must be taken if a working platform is used to lift people with industrial trucks designed for the transport of goods:

– The working platform must comply with manufacturer requirements in accordance

with ASME B56.1-2003;

– Ensure that guards are provided for employees in the normal working position on

the platform to protect them against potentially dangerous moving parts of the industrial truck.

– Ensure that the necessary retaining systems – such as rails, chains, ropes, safety

belt(s) with chain links, or shock absorbers, etc., – are in place and are used correctly;

– Ensure that the laden or unladen lifting system can rise smoothly to the maximum

lift height and that all lift interruption systems – where fitted – are ready for use; – An overhead guard must be provided for the driver if operating conditions require it; – All safety belts, rails or shock absorbers that are permanently deformed or

otherwise damaged must be replaced.

If an industrial truck has a working platform (this excludes industrial trucks with a moving cab), the operator must comply with both the measures set out in ASME B56.1-2003 and the following safety precautions:

– Make sure that the platform meets the manufacturer's requirements in accordance

with ASME B56.1-2003; – Make sure that it is used only with an industrial truck satisfying the requirements of

ASME B56.10-1992 (for manually operated high-lift trucks); – Attach the platform fixing devices and secure the platform to the fork carrier or the

fork; – Fork carriers and/or forks used to lift people and to carry the platform must be

secured to prevent them from tipping; – The lift mast is in a vertical position – do not use it tilted to one side; – The platform must always be horizontal and centered and must not be tilted either

forward or backward during lifting; – The stacker must be positioned horizontally on a solid surface; – Move all travel regulators to neutral and apply the parking brake; – Before lifting people, mark out the area with traffic cones or other objects to indicate

high-level work. – People must be raised and lowered slowly and carefully and only when expressly

requested; – Avoid overhead obstacles and power cables; – Keep your hands and feet away from all controls not needed at present;

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– When there are people on the platform, move the truck and/or platform slowly and

execute small horizontal movements, only when expressly requested to do so; – Rotating systems on the industrial truck must be mechanically locked to prevent

any movement; – A trained operator must be present to control the industrial truck or must be

available to operate the controls. If the driver is not in the cab, he or she must

ensure that the parking brake has been applied; – The total weight of the platform, load and people must not exceed half the load

capacity for which the industrial truck used to lift the platform is designed; – The people must not leave the platform. The rails, planks, ladders, etc., on the

platform must not be used to extend the reach or height; – The people and objects/equipment on the platform must remain within the confines

of the available space; – There must be sufficient space for the people on the platform so that the people and

equipment can remain within the perimeter of the platform and do not have to stand

or sit on the equipment to be lifted; – The platform must be lowered to the ground if people wish to join or leave the

platform. Never try to join or leave the platform by climbing onto parts of the truck

or to join or leave the raised platform by climbing.

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4 Operating the industrial truck

4.1 Safety regulations for industrial truck operators

Areas of responsibility of the operator: This industrial truck can be dangerous if

used improperly.

The operator is responsible for safety in the workplace.

Operators are bound by the relevant safety regulations and provisions set out in this manual and all necessary operator training programs as stipulated by the employer or required by law.

Operators must adopt safe working practices and be aware of hazardous situations in order to safeguard both themselves and other employees and the truck and other goods.

Before starting to use the industrial truck, operators must familiarize themselves with all controls and indicators.

Manually controlled functions and movements of the industrial truck must only be performed at speeds at which the driver is sure of keeping control of the vehicle.

Before starting to use the industrial truck, the operator must have read and understood the Manufacturer's Operating Manual for the relevant truck and must comply with and implement the safety regulations described below.

Before starting to use the industrial truck, operators must familiarize themselves with unusual operating conditions for which additional safety precautions may need to be taken or special operating instructions followed.

4.2 General operation of the truck

The operator must carry out the following checks:

Before every shift and before starting up the industrial truck, its condition must be inspected; this applies in particular to the following components:

– Wheels and support wheels; – Warning and safety devices; – Protective devices; – Lighting; –Battery; – Controls; – Lifting systems; – Load-carrying attachments; – Chains; – Limit switches; – Brakes; – Ground lock(s) or wheel lock(s); – Anti-tilting mechanism; – Steering;

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If it is found that the industrial truck needs to be repaired and is, therefore, in an unsafe condition, or if it is likely that the safety of the truck can no longer be assured, the person authorized by the owner must be informed of the situation immediately and the truck must not be used again until it has been made safe for use.

If safety deficiencies on the industrial truck emerge during operation, the person authorized by the owner must be informed of the situation immediately and the truck must not be used again until it has been made safe for use.

Repairs and adjustments can be made if the appropriate permission has been granted.

If you have been asked to charge the battery(ies) on the industrial truck, check that the battery acid level is correct and that air can circulate freely through the ventilation openings in the battery compartment before connecting the charger to the power source.

Avoid naked flames when checking the electrolyte level in the batteries.

General: Before starting up the industrial truck, the operator must read "Starting the vehicle" in Chapter E.

The industrial truck and all its functions or attachments can only be started and used when the operator is in the driver's seat in the specific operating position.

Hands and feet must remain inside the area provided for the operator or inside the cab. No part of the body should be outside the driver's cab.

The wearing of safety shoes is recommended.

Keep all parts of the body away from the lifting system.

Keep all parts of the body away from the swivel system and from other attachments on the truck.

Familiarize yourself with the limits of the truck and when using the truck take care to avoid injuring people. The safety of pedestrians is always the highest priority.

– Never drive the truck up to a person who is standing in front of an object. – Before turning the truck round, make sure that nobody is standing in range of the

rear of the vehicle. – Pay particular attention to corridors, passageways or other areas where

pedestrians could cross the travel way of the industrial truck.

Nobody must ever stand or walk under the raised section of an industrial truck, regardless of whether the truck is laden or unladen.

Passengers must not be carried on a powered industrial truck unless a dedicated seat is provided by the manufacturer.

Do not allow people to ride on the fork carrier or forks.

When handling loads above the mast, sound decisions and maximum caution are critical.

In areas classed as potentially hazardous, only industrial trucks approved for these areas can be used.

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The truck must not be modified with additional equipment or in any other way.

Travel ways and working areas: Only travel ways and routes expressly cleared for industrial trucks may be used. Unauthorized third parties must keep away from the working area. The load must only be stored in the designated places.

Behavior when driving: The travel speed must always be adjusted to the prevailing conditions. The truck must be driven slowly on bends, when in and approaching narrow gangways, when passing through swing doors, and in blind positions. The driver must always keep a safe braking distance away from trucks traveling in front and must always have the truck under control. Abrupt stopping (except in an emergency), rapid turning, and overtaking in dangerous or blind positions are prohibited. Leaning out or reaching out of the working and operating area is prohibited.

You must observe all traffic regulations, including speed limits in force on the site. Under normal traffic conditions you must drive on the right. Always keep a safe distance from the truck in front, according to your speed. In addition, the driver must always be in control of the vehicle.

You should give way to pedestrians, emergency service vehicles – such as ambulances and fire department vehicles – and other (powered) industrial trucks.

You must not overtake other industrial trucks traveling in the same direction at junctions or in blind or dangerous areas.

Sound your horn and reduce speed or stop at gangways running perpendicular to your direction of travel and in blind places.

Cross railroad crossings at an acute angle if possible. Stop at a distance of at least 2 m/2.2 yards (6 ft) from the railroad tracks.

Always look in the direction in which you are traveling.

Ensure that you have an uninterrupted view of the travel way, pay attention to traffic and pedestrians, and keep a safe distance.

If the load restricts your view to the front, you should drive so that the load is facing the rear.

Control the speed of the vehicle so that you can stop safely at all times and in all conditions.

You should travel with the load-handling equipment or load held as low down as possible. Raise the load only for stacking. This does not apply to industrial trucks designed for traveling with raised loads or load-handling equipment.

Acceleration, stopping, turning and U-turns should be carried out slowly. The load must never slip and/or drop from the truck.

Never carry out reckless maneuvers or play games with the truck.

Be careful and reduce speed on slippery surfaces.

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Industrial trucks must not use elevators unless special approval has been granted. Do not exceed the load capacity of the elevator. Drive slowly into the center of the elevator as soon as the elevator is in a horizontal position. Move the controls into neutral, switch off the power supply and activate the ground or wheel locks (if fitted), as soon as the truck is in the elevator. All other people are recommended to leave the elevator before the truck is driven in or out.

Avoid driving over loose objects, dirt or damaged ground.

When turning the truck around, reduce your speed until it is safe for the operating environment and turn the steering mechanism gently with a circular movement. Even at very low speeds, the steering mechanism must be turned at a moderate and steady speed.

When driving an industrial truck onto or off of trailers not coupled to the truck, appropriate supports must be used to prevent the trailer from tipping backward or sideways.

Keep a safe distance from the edge of ramps, platforms, and other working areas. Rail cars must not be moved with a powered industrial truck.

Proceed with caution to avoid making contact with service installations below the ceiling – such as lighting, cabling, pipe systems, sprinkler systems, etc.

4.3 Ensuring that the industrial truck is properly equipped

All driver-operated industrial trucks must be fitted with an overhead guard to protect against falling objects unless all of the conditions below are met:

1. The movement of the vertical mast is limited to 1826 mm (72 inches) above

ground, maximum;

2. The industrial truck is operated in an area in which:

– The lower edge of a stacked load during stacking is no more than 1825 mm (72

inches) and the upper edge no more than 3050 mm (120 inches) above the ground;

– The loads are transported in the form of stable and preferably rigidly connected

elements or containers;

– Guards are in place to prevent objects from falling from adjacent high-bay

racks. An overhead guard was developed to protect the driver from falling objects; it does not, however, offer complete protection from all conceivable accidents. The operator should, therefore, not assume that these safety devices remove the need for sound judgment and caution when handling loads.

3. The industrial truck must be labeled for its area of use.

An extension to the safety guard must be fitted to protect operators from the load or from falling objects.

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4.4 Opening and closing railroad cars

An industrial truck must not be used to open or close the doors of railroad cars unless the truck is fitted with a special device for opening and closing railroad car doors and the operator has been trained to use this device.

When using a device to open or close railroad car doors, the truck must be moved parallel to the railroad car and the force exerted parallel to the movement of the door. When inserting the device to open and close railroad car doors, take care to prevent the strong forces from damaging the doors and/or truck. The entire procedure for opening the door must be visible to the operator. The industrial truck must always be positioned in such a way that the person on the load platform is protected when the locking pin in the door is removed. The operator must inform his or her supervisor or proceed in accordance with the instructions if an unusually strong force is required to open the door of a railroad car.

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4.5 Safe loading and transportation

Nature of the transported loads: Only adequately secured loads may be

transported (see "Load capacity" in Chapter D).

Stable or securely picked loads (see "Order picking and stacking" in Chapter E) must be transported in compliance with the load capacity of the industrial truck.

– Be extremely careful when transporting eccentric loads which cannot be centered. – Only transport loads whose weight does not exceed the load capacity of the

industrial truck. – The transportation of loads, which might exceed the load capacity, is prohibited. – Loads must only be transported with the load-handling equipment; loads or other

items must not be transported in the cab or in other areas of the truck unless the

owner has made specific and specially identified provisions to this end.

Check the nameplate on the industrial truck, which shows the load capacity of the truck and of the attachments, and always work within the stated load capacity range.

Take special care when positioning and transporting loads with the attachments. Unladen trucks with attachments must always be operated in the same way as partly laden trucks.

The entire load must be picked up by the load-handling equipment. The fork length must be at least two-thirds of the length of the load.

QwW The handling of loads suspended from a crane boom or other equipment can

induce dynamic forces, which may adversely affect the stability of the industrial truck and may not comply with the manufacturer's requirements in accordance with ASME B56.1-2003. Sudden acceleration, braking, and turning can cause the load to swing and be dangerous.

When handling suspended loads:

– The load capacity of industrial trucks designed for transporting suspended goods

as defined by the manufacturer must not be exceeded; – The load must be suspended vertically and must never be pulled in a horizontal

direction; – When transporting the load, the lower edge of the load and the lift mast must be

positioned as low as possible; – When the load is raised, the truck must be maneuvered slowly and carefully; the

operator must limit the vehicle to movements allowing the load to be lowered in the

transport position; – Where possible, use guide ropes to prevent the load from swinging.

Loading and unloading freight trucks and trailers: If a powered industrial truck is driven onto freight trucks or trailers, they must be immobilized with the parking brake and wheel chocks or other appropriate devices to prevent the freight truck or trailer from being moved accidentally.

Loading and unloading railroad cars: When loading and unloading railroad cars, appropriate precautions must be taken to prevent the car from being moved. Use wheel locks, parking brakes or other appropriate devices to prevent movement during loading and unloading.

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Transportation of liquids: When transporting liquids, the center of gravity can vary according to the movement of the industrial truck, and this can have a very adverse effect on the truck's stability. All necessary precautions must be taken when maneuvering; accelerating, braking and tight corners should be avoided where possible, as should any sudden movement.

Flattened wheels: If the industrial truck has been parked for a lengthy period of time, the wheel treads may become flattened. This does not adversely affect the safety or stability of the truck, however, since the flattening will disappear once the truck has been driven for a short distance.

4.6 Preventing overturning and tipping

Special safety precautions are required when operating an industrial truck (with counterweight) and central controls where the driver has a fixed driving position:

1. A laden or unladen truck can tip over if the driver does not brake to a safe speed

before a bend. The following signs indicate that a truck is approaching a bend too fast:

– Wheel slip; – Tilting to one side; – Lifting of one wheel; and – The need to hold onto the steering wheel harder to avoid sliding out of the seat.

1. The probability that the truck will overturn increases in the presence of one or

more of the following conditions:

– Overloaded truck; – Traveling with a raised load; – Sharp braking or acceleration on a bend; – Loading outside the center of gravity; – Traveling over uneven ground; – Traveling too fast.

2. The truck can also tip forward, and the probability of this increases in the

presence of one or more of the following conditions:

– Overloaded truck; – Traveling with a raised load; – Sharp braking when traveling in a straight line; – Sudden acceleration when reversing.

3. The driver should not leave the truck if it tips sideways or lengthways. The driver

should hold on tightly and lean in the opposite direction to the point of impact.

4. The driver should not leave the truck if it falls from a loading platform or ramp.

The driver should hold on tightly and lean in the opposite direction to the point of impact.

– The owner must take alternative and/or additional safety precautions and

define special working instructions if the surroundings present a serious danger or unusual operating conditions.

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An active driver protection system or similar system must be used if available. The driver protection system, which is intended to prevent injury to the driver's head and trunk, forces itself between the truck and the ground if the truck tips over. It cannot guarantee absolute protection against potential injury, however.

View when driving The driver must look in the direction of travel and must always have a clear view of the route traveled. When transporting loads that restrict the driver's view, the truck must be driven with the load at the end of the truck. If that is not possible, a second person must walk ahead to provide appropriate warning of any hazard.

Negotiating slopes and dips: Driving over sloping ground is only permitted if there are recognized tracks, if they are clean and non-slip and if the technical data for the truck allows it to travel safely over sloping ground. The load must be carried facing uphill. Turning around, traveling at an acute angle, and parking the vehicle are prohibited on sloping ground. Slopes must be traversed at low speed only and with the brake ready to be applied.

4.7 Supervising and securing the truck

A powered industrial truck is regarded as being supervised if the operator is inside a radius of 8 m/8.8 yards (25 ft), maximum, and keeps the truck in view.

A powered industrial truck is regarded as being unsupervised if the operator is outside a radius of 8 m/8.8 yards (25 ft) and keeps the truck in view, or if the operator leaves the vehicle and no longer has it in view.

Before leaving the driver's seat or operating position:

– Do not park the truck on a slope; – Bring the truck to a complete stop; – Move the direction of travel controls to neutral; – Lower the load-handling equipment completely unless it is carrying a raised

platform.

The following measures must be taken before the vehicle can be left unsupervised (see "Switching off and securing the vehicle" in Chapter E):

– Do not park the truck on a slope; – Bring the truck to a complete stop; – Lower the load-handling equipment completely; – Immobilize the wheels or activate the ground or wheel lock(s); – Turn the switch latch to position "0" and remove the safety key; – Press the main switch or the EMERGENCY STOP switch.

You must not block access to fire escape routes, staircases or fire systems.

4.8 Lifting of people

If an industrial truck is not fitted with controls that can be operated directly from the lifting device (as is the case with order pickers, for example), it should only be used for lifting people if it was designed by the manufacturer for that purpose and if the following rules are observed:

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– Check that it is designed for this type of operation; – All systems specified by the manufacturer for stabilizing and securing the position

of the truck must be in place and activated; – Be sure that the necessary retaining devices – such as railings, for example – are

in place and are used correctly; – Attach the platform fixing devices and secure the platform to the fork carrier or the

fork; – Ensure that the laden or unladen lifting system can rise smoothly to the maximum

lift height and that all lift interruption systems – where fitted – are ready for use; – The platform is horizontal and centered and cannot tip forward or backward while

being raised; – The industrial truck is in a stable, horizontal position; – Move all travel regulators to neutral and apply the parking brake; – Before lifting people, mark out the area with traffic cones or other objects to indicate

high-level work. – People must be raised and lowered slowly and carefully and only when expressly

requested; – Avoid overhead obstacles and power cables; – Keep your hands and feet away from all controls not needed at present; – If there are people on the platform, the truck and/or the platform may only be moved

slowly and only for minor changes to the horizontal position, and then only at the

express request of the people on the platform; – Rotating systems on the industrial truck must be mechanically locked to prevent

any movement; – If the operator is not in the operating position, he or she must ensure that the

parking brake has been applied; – The total weight of the platform, load and people must not exceed half the load

capacity for which the industrial truck used to lift the platform is designed; – The people must not leave the platform. The rails, planks, ladders, etc., on the

platform must not be used to extend the reach or height; – The people and objects/equipment on the platform must remain within the confines

of the available space; – The platform must be lowered to the ground if people wish to join or leave the

platform. Never try to join or leave the platform by climbing onto parts of the truck

or to join or leave the raised platform by climbing.

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5 Keypad (CANCODE) (o)

The keypad comprises 10 number keys, a set key, and a o key. The green LED in key 1 lights up when the travel program is active. The operating status is indicated by a red/green LED in the o key.

The keypad is used for the following functions:

– Code lock function (starting up the vehicle). – Setting travel and battery parameters, only in conjunction with the information

display (CANDIS (o)).

The o key has the highest priority and is used to reset the vehicle to its initial state from any other state, without changing the settings.

5.1 Code lock

The correct code must be entered before the vehicle can be used. A separate code can be assigned to every vehicle, every operator, or to a group of operators.

NOTICE When the vehicle is delivered, the operator code (factory setting 2-5-8-0) is

indicated on a sticker.

NOTICE When the vehicle is used for the first time, change the master and operator

codes (see Section 5.4)

1 2 3

4 5 6

7 8 9

Set

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First use

When the main switch and the switch latch (if applicable) are turned on, the LED (22) lights up red.

When the correct operating code (factory setting 2-5-8-0) is entered, the LED (22) lights up green.

If an incorrect code is entered, the LED (22) will flash red for two seconds. You will then need to re-enter the code.

NOTICE In user mode, the Set key (23) has no function.

Switching off

The vehicle is switched off by pressing the o key (27).

NOTICE The vehicle can be programmed to switch off after a predefined time. This

requires the corresponding code lock parameter to be set (see Section 5.4)

1 2 3

4 5 6

7 8 9

Set

2625

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5.2 Travel program

The vehicle comes with three travel programs. The active program is indicated by the green LED (24), keys 1, 2 and 3.

NOTICE The travel programs can be customized to the vehicle use.

5.3 Parameters

In programming mode the keypad can be used to set the code lock functions and to customize the travel programs. It can also be used to set battery parameters.

NOTICE On vehicles without an information display (CANDIS (o)), only the code lock

parameters can be set.

Parameter groups

The parameter number comprises three digits. The first digit indicates the parameter group as shown in Table 1. The second and third digits are numbered consecutively from 00 to 99.

No. Parameter group 0xx Code lock settings

(codes, travel program enables, automatic shutdown, etc.)

1xx Travel parameters for travel program 1

(acceleration, coasting brake, speed, etc.)

2xx Travel parameters for travel program 2

(acceleration, coasting brake, speed, etc.)

3xx Travel parameters for travel program 3

(acceleration, coasting brake, speed, etc.)

4xx Parameters not relating to the travel program

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5.4 Parameter settings

To change the vehicle settings you must enter the master code.

NOTICE The master code is factory set to 7-2-9-5.

NOTICE When the vehicle is used for the first time, change the master code (see

Section 5.1).

IMPORTANT Safety instructions for vehicles with information display (CANDIS (o))

– Parameter settings must be carried out with great care and only by people qualified

to do so. If in doubt, contact the manufacturer's service organization. – Each setting operation must be monitored on the LCD display of the information

display (CANDIS (o)). If in doubt, you can abort the setting process by pressing

the o key (27). – Since the driving behavior of the vehicle will change, you should carry out a test

drive in a designated working area after every parameter change.

To enter the master code:

– Press the o key – Enter the master code.

Code lock parameters

Setting process for vehicles with no information display (CANDIS (o)):

– Enter the three-digit parameter number

and press the Set key (23) to confirm. – Enter or change the setting as shown in

the parameter list and press the Set key

(23) to confirm.

If an illegal value is entered, the LED (22) in the o key (27) flashes red. Enter the parameter number again and then enter or change the setting.

Repeat the process to enter additional parameter settings. When you have finished, press the o key (27).

Information display

(CANDIS)

LED (27)

o key

LED (24)

Key 1

LED (25)

Key 2

LED (26)

Key 3

Operating hours are displayed

284.0

green

flashing

out out out

1 2 3

4 5 6

7 8 9

Set

2625

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Setting process for vehicles with and without an information display (CANDIS (o)):

– Enter the three-digit parameter number and press the Set key (22) to confirm. – The operating hours are still shown in the information display (CANDIS (o)). When

the display changes, you can end the setting process by pressing the o key (27)

and then start again. – Enter or change the setting as shown in the parameter list and press the Set key

(23) to confirm.

NOTICE If an illegal value is entered, the LED (22) in the o key (27) flashes red. Enter

the parameter number again and then enter or change the setting.

Repeat the process to enter additional parameter settings. When you have finished, press the o key (27).

The following parameters can be entered:

Code lock parameter list

No. Function Range

Setting value

Standard

Setting

value

Notes

Procedure

Code lock

000 Change master code

The length of the master code (4 to 6 digits) also determines the length of the operator code (4 to 6 digits). If operator codes have been programmed, only one new code of the same length can be entered. A change in the length of the code requires all operator codes to be deleted first.

0000 - 9999

00000 - 99999

000000 - 999999

7295 (LED 24 flashes)

Enter the

current code

Confirm (Set)

(LED 25 flashes)

Enter a

new code

Confirm (Set)

(LED 26 flashes)

Enter new code

again

Confirm (Set)

001 Add operator code (600,

max.)

0000 - 9999

00000 - 99999

000000 - 999999

2580 (LED 22 flashes)

Enter a

code

Confirm (Set)

(LED 23 flashes)

Enter the

code again

Confirm (Set)

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LEDs 24 to 26 are located in keys 1 to 3 (see Section 5.1).

No. Function Range

Setting value

Standard

Setting

value

Notes

Procedure

Code lock

002 Change operator code 0000 - 9999

00000 - 99999

000000 - 999999

(LED 24 flashes)

Enter the

current code

Confirm (Set)

(LED 25 flashes)

Enter a

new code

Confirm (Set)

(LED 26 flashes)

Enter the

code again

Confirm

003 Delete operator code 0000 - 9999

00000 - 99999

000000 - 999999

(LED 25 flashes)

Enter a

code

Confirm (Set)

(LED 26 flashes)

Enter the

code again

Confirm (Set)

004 Delete code buffer

(deletes all user codes)

3265 3265 = Delete

Other entry = Do not

delete

010 Timed automatic

shutdown

00 - 31 00 00 = No

shutdown

01 to 30 =

Shutdown time in

minutes

31 = Shutdown after

10 seconds

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*)only in conjunction with information display (CANDIS (o))

Keypad error messages

The following errors are indicated by the LED (22) flashing red:

– New master code same as operator code. – New operator code same as master code. – Operator code to be changed does not exist. – Operator code to be changed to an existing operator code. – Operator code to be deleted does not exist. – Code buffer is full.

No. Function Range

Setting value

Standard

Setting

value

Notes

Procedure

Code lock

021 Travel program 1 *

)

enable

0 or 1 1 0 = Travel program

not enabled

1 = Travel program

enabled

022 Travel program 2 *

)

enable

0 or 1 1 0 = Travel program

not enabled

1 = Travel program

enabled

023 Travel program 3 *

)

enable

0 or 1 1 0 = Travel program

not enabled

1 = Travel program

enabled

030 Shows number of

operator codes assigned*

)

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5.5 Travel parameters

NOTICE On vehicles without an information display (CANDIS (o)), travel parameters

can only be set by the manufacturer's service organization.

The example below shows how to change the acceleration parameter setting for travel program 1 (parameter 101).

Acceleration

– Enter the three-digit parameter number (101) and press the Set key (23) to confirm. – Check the LCD display on the information display (CANDIS (o)) (parameter

number and current parameter setting are displayed).

NOTICE If nothing is entered for around 5 seconds, the display switches back to the

operating hours display.

NOTICE If the parameter number displayed is not the one you require, you must wait

until the display changes back to the operating hours display.

– Enter or change the parameter value as shown in the parameter list. – Check the LCD display on the information display (CANDIS (o)) and press the

Set key (23) to confirm. – The LED (22) in the o key (27) lights up briefly and after about 2 seconds starts to

flash again.

NOTICE If an illegal value is entered, the LED (22) in the o key (27) flashes red. Enter

the parameter number again and then enter or change the setting.

To enter additional parameter settings, wait for the LED (22) in the o key (27) to start flashing and then repeat the process. When you have finished, press the o key (27).

Information display

(CANDIS)

LED (27)

o key

LED (24)

Key 1

LED (25)

Key 2

LED (26)

Key 3

Current setting is displayed

101 6

green

flashing

out out out

New setting is displayed

101 8

green

flashing

out out out

Parameter

number

Paramete

r setting

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6 Information display (CANDIS) (o)

The information display shows:

– Residual battery charge

(LED bar (29)), – Operating hours

(LCD display (30)).

Electronic component error messages and parameter changes are also displayed.

Charge level display

Depending on the type of battery used, there may also be switch-on limits for the additional displays "Warning" (28) and "Stop" (30).

Num-

ber of

bars

Charge level Wet battery Maintenance-free battery

LED (yellow)

Warning

LED (red)

Stop

LED (yellow)

Warning

LED (red)

Stop

10 90.1- 100% out out out out

9 80.1 - 90% out out out out 8 70.1 - 80% out out out out 7 60.1 - 70% out out out out 6 50.1 - 60% out out out out 5 40.1 - 50% out out on out 4 30.1 - 40% out out on on 3 20.1 - 30% on out on on 2 10.1 - 20% on on on on

Do not allow the charge level to drop below the 20% limit for wet batteries or the 40% limit for

maintenance-free batteries.

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6.1 Discharge monitor function

If the discharge monitor function is enabled, the lifting function is switched off when the battery reaches the discharge limit (Stop LED lights up). Traveling and lowering are still possible. The residual capacity limit is 20% for wet batteries and 40% for maintenance-free batteries. You should recharge the battery when the charge level drops below 30% for wet batteries and 50% for maintenance-free batteries (the yellow LED lights up as a warning).

6.2 Operating hours indicator

Indicator range between 0.0 and 99,999.0 hours. Travel and lifting movements are recorded. The display is backlit.

NOTICE With maintenance-free batteries, a "T" symbol appears in the operating hours

indicator (31).

Error messages

The operating hours indicator is also used to display errors. The error display is made up of two parts and alternates between "C" for component with a three-digit component number and "E" for error with a three-digit error number. If more than one error occurs at the same time, they are displayed one after the other. The error display remains until the error is rectified (always in the combination Cxxx/ Exxx). Error messages overwrite the operating hours indicator. Most errors cause an emergency stop to be triggered. The error display remains until the control current circuit is switched off (switch latch).

NOTICE Detailed descriptions of components and error codes can be obtained from

the manufacturer's service organization.

Display for parameter changes (travel programs)

The LCD display (31) and the keypad (CANCODE (o)) can be used to display the setting parameters. The first three digits of the display show the parameter number, the last three the parameter value.

NOTICE Settings for parameter group 0XX (code lock) are not displayed.

6.3 Power-up test

When the system is switched on, the following elements are displayed:

– the software version of the display unit (briefly) – the operating hours, – the discharge status.

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7 Discharge indicator (LEA) (t)

Once the vehicle has been enabled with the key switch or CANCODE, the battery charge level is displayed.

The colors of the LED (32) represent the following states:

NOTICE If the LED lights up red, load units can no longer be lifted. The "Lift" function

is not enabled again until the charge level of the connected battery reaches a minimum of 70%.

If the charge level status when the vehicle is switched on is at least 70% of the charge level of a fully charged battery, the display is reset to 100%. The display falls in 10% increments according to the charge level. The charge level display drops by a maximum of 10% in 3 minutes.

The charge level display cannot rise again while the truck continues to be operated.

The charge level display is reset to 100% when the battery type is set.

If the LED flashes red and the vehicle is not ready for use, contact the manufacturer's service organization. The red flashing light is a vehicle control fault code. The flashing sequence indicates the type of fault.

Error messages

Error messages (message number displayed as a flash code) are output via the LED of the connected information display. The tens position should be displayed at a frequency of 1 Hz and the units position at a frequency of 2 Hz. A 2 second pause should be inserted when switching between the units and the tens position.

LED color Value

green Residual capacity of standard battery 40 - 100%

Residual capacity of maintenance-free battery 60 - 100%

orange Residual capacity of standard battery 20 - 30%

Residual capacity of maintenance-free battery 40 - 50%

red Residual capacity of standard battery 0 - 30%

Residual capacity of maintenance-free battery 0 - 40%

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8 Troubleshooting

This section is designed to help users to identify and rectify simple faults or the consequences of operator errors themselves. When trying to locate faults, you should follow the sequence of actions shown in the table.

NOTICE If the "remedies" above did not help to rectify the fault, please contact the

manufacturer's service organization, since further fault correction can only be carried out by qualified service personnel.

Fault Possible cause Remedy

Vehicle will not move

– Battery connector not

plugged in

– Check battery connector and plug in if

necessary

– Battery holder not fitted

(o)

– Fit battery holder

– Switch latch in

position "0"

– Turn switch latch to position "I"

– Battery charge

too low

– Check battery charge, recharge

battery if necessary

– Faulty fuse – Check fuses

Load cannot be raised

– Vehicle not

ready for use

– Work through all the remedies listed

under "Vehicle will not move"

– Hydraulic oil level too

low

– Check hydraulic oil level

– Load too heavy – Check maximum load capacity

(see nameplate)

– Battery charge monitor

has switched off and indicates "STOP" (CANDIS, o)

– Charge battery

– LED on discharge

indicator lights up yellow (LEA, t)

– Charge battery

– Coast LED lights up

yellow

– Charge battery

– Faulty fuse – Check fuse 2F1

No display on battery discharge indicator

– Vehicle not

ready for use

– Check battery connector and plug in if

necessary

– Faulty fuse – Check fuse 6F1

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F Battery – Maintaining, recharging,

replacing

1 Safety regulations for handling lead-acid batteries

The industrial truck must be parked and in a safe condition before work is carried out on the batteries (see "Switching off and securing the vehicle" in Chapter E).

In order to avoid injury or damage, the equipment and procedures used to replace and charge the battery must comply with ANSI/NFPA 505.

The battery types and chargers (e.g., intermittent charging), which are supplied or stipulated by the industrial truck manufacturer but not referred to in ANSI/NFPA 505, should be maintained in accordance with the instructions from the truck manufacturer.

Maintenance personnel: Only trained and authorized personnel are permitted to charge, maintain and replace the batteries. The instructions in this manual together with the battery and charger manufacturer's instructions must be followed when carrying out the above procedures.

Fire prevention: Do not smoke and avoid naked flames when handling batteries. There must be no flammable substances or spark-generating materials within a radius of 78.7 inches (2 meters) of a vehicle parked for the purposes of battery charging. The area in which the battery is charged must be well-ventilated and have appropriate fire-protection equipment.

Battery maintenance: The cell screw caps on the battery must be kept dry and clean. Connections and cable lugs must be clean, lightly greased with pole grease, and adequately tightened. Batteries with bare connection terminals must be covered with a non-slip insulating mat.

QwW In order to prevent injury and/or damage, the manufacturer's procedures

must be followed when replacing the contacts in one of the battery terminals.

Battery disposal: The batteries must be disposed of in accordance with applicable national environment-protection regulations or waste-disposal regulations. The manufacturer's instructions for disposal should be observed.

IMPORTANT Before closing the battery cover, make sure that the battery cable cannot be

damaged.

QwW Batteries contain acid, which is toxic and corrosive. Protective clothing and

safety goggles must, therefore, be worn when working on the batteries. Avoid coming into contact with battery acid. If battery acid accidentally comes into contact with clothing, skin or eyes, wash the affected part of the body thoroughly with clean water. Seek medical attention if battery acid comes into contact with the skin or eyes. Battery acid spillages must be neutralized immediately.

IMPORTANT Only use batteries with a closed battery tray.

QwW The weight and dimensions of the battery have a considerable influence on

the operating safety of the industrial truck. The battery system must not be replaced without the prior written approval of the manufacturer.

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2Battery type

The table below shows the battery capacity and the combination fitted as standard:

The battery weights are stated on the battery nameplate.

QwW Use only batteries whose weight is within the minimum/maximum range

specified on the nameplate of the industrial truck.

QwW The use of a battery whose weight is outside the specified battery weight

range can adversely affect the braking action. Too light a battery can cause both the drive and brakes to fail (see Chapter H, Section 3.1).

Battery type Vehicle type

24 V 510 Ah 24 V 600 Ah 24 V 750 Ah

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3 Uncovering the battery

QwW Switch off and secure the vehicle (see Chapter E).

– Turn the switch latch (1) to the "OFF" position. – Lift the safety guard latch (4) and carefully fold down the safety guard (3, o).

QwK Hold onto the safety guard (3) as you fold it down.

– Lift up the battery cover (2).

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4 Charging the battery

– Switch off and secure the vehicle (see Chapter E).

QwW Always switch off the vehicle before plugging the battery connector into the

socket or unplugging it from the socket.

– Uncover the battery (see Section 3).

QwW The surfaces of the battery cells must be left uncovered during the charging

process to allow for adequate ventilation. Do not place any metallic objects on the battery. Before starting to charge the battery, inspect all cable joints and plug connections for visible damage. The safety instructions of the battery and charging station manufacturer must be followed.

– Pull out the battery connector (5). – Remove the insulating mat from the battery if present. – Connect the charging cable (6) to the battery connector (5) and switch on the

charging unit.

QwW Charge the battery in accordance with the instructions supplied by the battery

and charging station manufacturer.

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5 Removing and installing the battery

QwW The vehicle must be in a horizontal position (secured to prevent it rolling

away). To prevent short-circuits, cover batteries with exposed poles or connectors with a rubber mat. Position the battery connector or battery cable in such a way that it cannot catch on the vehicle when pulled out from the battery.

QwW If transporting the battery with a crane harness, check that it has an adequate

load capacity (see battery weight on the battery nameplate on the battery tray). The crane harness must exert a vertical pull to avoid crushing the battery tray. Attach the hooks to the sling eyes (7) on the battery in such a way that when the tension on the crane harness is released, they cannot fall onto the battery cells.

5.1 Removal, standard design

– Uncover the battery (see Section 3). – Pull out the battery connector and place it on the battery. – Close the battery cover. – Attach the crane harness to the sling eyes (7) and lift out the battery.

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5.2 Removal, "removal from side" (o)

NOTICE The battery can be removed from either side

– Uncover the battery (see Section 3). – Pull out the battery connector and place it on the battery. – Close the battery cover. – Pull out the battery holder (9). – Pull the battery (8) sideways onto the battery changing station.

QwW Follow the instructions in the Battery Changing Station Operating Manual.

5.3 Installing the battery

The battery is installed in the reverse sequence.

QwW After refitting the battery, inspect all cable joints and plug connections for

visible damage. On vehicles on which the battery is removed from the side, before restarting the vehicle check that:

– the battery holder (9) has been inserted correctly.

NOTICE If the battery holder is not inserted correctly, the travel function will not be

enabled (o).

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G Industrial truck maintenance and

troubleshooting

1 Operational safety and environmental protection

The checks and maintenance jobs set out in this chapter must be carried out at the intervals specified in the maintenance checklists.

QwW Operating an electric and manual industrial truck can be dangerous if

maintenance is neglected or if repairs, overhauls or settings are not carried out in accordance with the manufacturer's instructions.

QwW Any modification whatsoever to the industrial truck – and particularly to safety

devices – is prohibited. The operating speed of the industrial truck must not be changed under any circumstances.

IMPORTANT Only original spare parts are subject to our quality control. To ensure the safe

and reliable operation of the industrial truck, only spare parts from the manufacturer must be used. Used operating resources must be disposed of correctly in accordance with applicable environment protection regulations. Oil changes can be carried out by the manufacturer's customer service/oil service organization.

On completion of checks and maintenance jobs, the procedures listed in "Restarting the vehicle" must be carried out.

In unusual circumstances not described in this Operating Manual, please contact the industrial truck manufacturer.

2 Safety regulations for industrial truck maintenance

Servicing and maintenance personnel: Maintenance and repairs on all industrial

trucks and industrial truck systems may only be performed by qualified employees authorized by the manufacturer, and must be carried out in accordance with the procedures described in this chapter. Furthermore, maintenance and inspection must be carried out in accordance with the recommendations of the manufacturer and owner. The manufacturer's customer service organization has field engineers who have been specially trained for this work. We recommend, therefore, that you take out a maintenance agreement with the appropriate Customer Service Center.

The owner is responsible for ensuring that all procedures for the safe maintenance of the equipment are followed. Completed maintenance work should be recorded in an appropriate manner.

Lifting and jacking: In order to lift the industrial truck, slinging equipment should only be attached at the designated points. If the vehicle is jacked up, suitable means (wedges, wooden blocks) must be used to prevent it from slipping or tipping. Work under raised load-handling equipment is only permissible if the fork is immobilized and secured by a chain of appropriate strength.

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Cleaning: The industrial truck must not be cleaned with flammable liquids. Before cleaning the truck, all safety measures to prevent sparking (through short-circuits, for example) must be taken. On battery-powered industrial trucks, the battery connector must be pulled out. Electrical and electronic components must be cleaned with gentle suction or compressed air and a non-conducting, antistatic brush.

IMPORTANTIf the industrial truck is cleaned with a water jet or a high-pressure cleaner, all electrical and electronic components must be carefully covered first, since moisture can lead to malfunctions. Cleaning with a steam cleaner is prohibited.

On completion of cleaning, the procedures listed in "Restarting the vehicle" must be carried out.

Working on the electrical system: Only appropriately qualified employees are permitted to work on the truck's electrical system. Before working on the electrical system, all necessary measures must be taken to prevent electric shocks. On batterypowered industrial trucks, the power supply to the truck must also be disconnected by pulling out the battery connector.

Welding operations: Before starting welding operations, electrical and electronic components should be removed from the vehicle to prevent them from being damaged.

Setting values: In the event of repairs to or replacement of hydraulic/electrical/ electronic components, the vehicle-specific setting values must be retained.

Wheels: The quality of the wheels has a significant influence on the stability and driving behavior of the industrial truck. To ensure compliance with the specifications set out in the technical data sheet, only manufacturer's original parts should be used if the wheels fitted by the manufacturer have to be replaced. If the wheels are replaced, you must ensure that the truck's horizontal alignment is retained (wheels must always be replaced in pairs, in other words both left and right at the same time).

Lifting chains: Lifting chains (if fitted) must be inspected at regular intervals. Chains with torn, broken or missing link plates or protruding, twisted or pitted pins, or with severe corrosion must be replaced. If chains are fitted in pairs, both chains must be replaced. New chain anchor pins should be used if the chains are replaced. Lifting chains wear quickly if they are not lubricated sufficiently. The intervals specified in the maintenance checklist apply for normal use. More frequent lubrication is required under more extreme conditions (dust, temperature). The specified chain spray must be used in accordance with the instructions. Adequate lubrication cannot be achieved by the external application of grease.

Wire ropes: Wire ropes (if fitted) must be inspected at regular intervals. All ropes showing signs of a clear reduction in diameter, excessive wear on the outer wires, torn wires, damage or severe corrosion must be replaced.

Hydraulic hose lines: The hose lines must be replaced after a period of use of six years.

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Safety regulations for maintenance and inspection: The lifting of an industrial truck for repairs or inspection must be carried out in a reliable, safe and stable manner. The removal of components – such as the counterweights or supporting struts – shifts the center of gravity and can adversely affect the stability of the truck.

Before starting repairs and inspection: – Raise the drive wheels until they are no longer in contact with the ground, and

disconnect the battery. Immobilize the truck with wheel chocks or other devices; – Immobilize the load-handling equipment, the inner mast(s) or frame before starting

work on these components; – Disconnect the battery before starting work on the electrical system; – Plug the connector plug from the charging unit into the battery connector only, not

into the connector on the industrial truck.

Operation of the truck to test its performance must be carried out in a designated area, maintaining a safe distance.

1. Before starting up the industrial truck, the operator must read "Starting the

vehicle" in Chapter E.

2. The following measures must be taken before the vehicle can be left

unsupervised (see "Switching off and securing the vehicle" in Chapter E):

– Do not park the truck on a slope; – Bring the truck to a complete stop; – Lower the load-handling equipment completely; – Turn the switch latch to position "0" and remove the safety key; – Press the main switch or the EMERGENCY STOP switch.

Check that there is no fire hazard and ensure that there is fire-fighting equipment available in the working area. The use of a naked flame to check the fluid levels or to find possible fluid spillages, especially of battery acid, is prohibited.

Provide adequate ventilation in the working area and keep the workshop clean and dry.

Brakes, steering, control elements, warning systems, lighting, controls, lift interrupt systems, protective and safety devices, lifting systems, rotation axle stops, and frame components must be inspected carefully at regular intervals and maintained in a safe working condition.

Special industrial trucks or equipment designed and approved for use in danger zones require particular attention to ensure that the original and approved safe operating features are retained through maintenance.

All hydraulic systems must be inspected and serviced regularly. Hydraulic cylinders, valves, hoses, fittings, and all other hydraulic components must be inspected at regular intervals to ensure that no drift or leak has developed to a degree which could constitute a hazard.

The manufacturer's instruction signs, labels, and stickers containing information about load capacity, operation, and maintenance must be kept in a legible condition.

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Batteries, motors, regulators, limit switches, protective devices, electrical conductors, and connections must be inspected and serviced using generally recognized procedures. Particular attention should be paid to the condition of the electrical insulation.

In order to prevent injury and/or damage, the connection procedures specified by the battery manufacturer must be followed when replacing the contacts in one of the battery terminals.

Industrial trucks should be kept in a clean condition to minimize the risk of fire and to allow loose or defective parts to be identified quickly.

Modifications and/or additions to the industrial truck and/or to the hardware or software, which adversely affect the specified load capacity, the safe operation of the truck or the emergency controls or devices, should only be undertaken with the prior written approval of the manufacturer. If such modifications and/or additions are approved in writing by the manufacturer, all signs, markings or warnings in connection with load capacity, operation, and maintenance must be altered accordingly.

Ensure that all spare parts are mounted in the same way as the original components and that their quality and performance is at least equal to that of the original equipment. All parts must be fitted in accordance with the manufacturer's instructions.

Wheels, support wheels, ground or wheel locks, steering and control mechanisms, fastening and warning devices, lights, lift overload systems, protective and safety devices, lifting and lowering mechanisms, and frame crossbeams must be inspected carefully at regular intervals and maintained in a safe working condition.

When replacing the batteries on battery-powered industrial trucks, the weight of the replacement batteries must be within the minimum/maximum range specified on the manufacturer's nameplate.

Inspection and repair of the forks used on industrial trucks:

The forks that are used must be inspected at least every 12 months (in the case of a one-way swivel action) for damage or permanent deformation. If the vehicle is in heavy use, they should be inspected more frequently.

The load capacity of an individual fork arm: Where forks are used in pairs (standard configuration), the rated load capacity of the individual arms must be at least half the rated load capacity of the industrial truck as specified by the manufacturer, and the load center distance (nominal value) must be specified on the truck's nameplate.

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Inspection: The forks must be inspected carefully and at regular intervals by qualified personnel for signs of damage, cracks, permanent deformation, etc., which could adversely affect their safe use. All forks showing signs of such defects must be replaced or removed from service and may not be used again if they cannot be satisfactorily repaired by the fork manufacturer or by an appropriately qualified specialist.

1. Surface cracks: The forks and, in particular, the underside and the weld seams

with which all attachments are joined to the body of the fork, must be given a thorough visual inspection for cracks and – if necessary – subjected to nondestructive material testing to identify cracks. The inspection for cracks must include all special fixings between the body of the fork and the fork carrier, including all bolted-on systems and wrought fixings for suspended devices or undulating load suspension equipment. The forks must not be brought back into service if cracks are found.

2. Linearity of the fork blade and fork back: Check the linearity of the top of the fork

blade and the front of the fork back. If the deviation from the straight line is more than 0.5% of the length of the fork blade or the height of the fork back, the fork must not be brought back into service until it has been properly repaired.

3. Fork angle (between the top of the fork blade and fork back, facing the load): Any

fork with a deviation of more than 3 degrees from the original specification must not be brought back into service. After being removed from service, the fork must be realigned and then inspected again.

4. Difference in height between fork tips: They determine the difference in height

between a pair of forks mounted on the fork carrier. If the difference in height between the fork tips is more than 3% of the length of the fork blade, the forks must not be brought back into service until they have been properly repaired.

5. Position lock (if provided in original configuration): Check that the position lock is

in good repair and is operating correctly. If a fault is found, the fork must not be brought back into service until it has been properly repaired.

6. Wear:

– Fork blade and fork back: The fork blade and fork back – particularly in the area

of the fork stop – must be thoroughly inspected for wear. The fork must not be brought back into service if the thickness of the fork back is less than or equal to 90% of its original value.

– Positioning hooks (if provided in original configuration): The load-bearing

surface of the top hook and the retaining surfaces of both hooks must be inspected for wear, cracks and other local deformation. If deformation is found which leads to excessive play between the fork and the fork carrier, the fork must not be brought back into service until it has been properly repaired.

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7. Legibility of markings (where originally present): If the fork identification marking

is not clearly legible, it must be replaced in accordance with the instructions of the original supplier.

Repair and inspection:

– Repair: The decision as to whether a fork can be repaired and used again in future,

and the repair itself, is a matter for the fork manufacturer or for an appropriately

qualified specialist. The use of forging to repair surface cracks or wear is not

recommended. Following the completion of repairs requiring a realignment, the fork

must be heat-treated in the appropriate, specified manner. – Test loading: Following a repair – with the exception of repairs to or replacement of

the position locks and/or nameplate – a fork cannot be brought back into service

until it has successfully passed the tests specified by the manufacturer in

accordance with ASME B56.1-2003. The test load per fork must be the rated load

capacity specified on the industrial truck, however.

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3 Maintenance and inspection

A thorough and professional maintenance service is one of the most important requirements for the safe use of the industrial truck. Ignoring regular maintenance intervals can cause the truck to break down and presents a potential danger to personnel and equipment.

IMPORTANT The specified maintenance intervals assume single-shift operation and

normal working conditions. If the truck is used in very dusty environments or is exposed to extreme temperature variations in multi-shift operations, the maintenance intervals must be reduced accordingly.

The maintenance checklist below sets out the jobs to be done and the intervals at which they are required. The maintenance intervals are defined as follows:

W = Every 50 operating hours, or at least once a week A = Every 500 operating hours B = Every 1000 operating hours, at least once a year, however C = Every 2000 operating hours, at least once a year, however

NOTICE Jobs with maintenance interval W must be carried out by the owner/user.

In the run-in period - after approx. 100 service hours - or after repair work, the owner must check the wheel nuts/bolts and re-tighten if necessary.

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4 Maintenance checklist

Maintenance intervals Standard = t WA B C Refrigerated warehouse = k

Frame/ structure:

1.1 Check all load-bearing elements for damage t

1.2 Check bolted joints t

Drive: 2.1 Check gearbox for noises and leaks t

2.2 Check gearbox oil level t

Wheels: 3.1 Check for wear and damage, adjust fork base height and

fork tip height if necessary

3.2 Check bearings and mounting kt

Brake system:

5.1 Check function and settings kt

5.2 Check tiller spring for reset function, leaks and damage

5.3 Check wear on brake linings t

Hydraul. system:

6.1 Check function kt

6.2 Check joints and connections for leaks and damage

6.3 Check hydraulic cylinder for leaks, damage and mounting kt

6.4 Check oil level kt

6.5 Change hydraulic oil kt

6.6 Check function of pressure relief valves kt

Electrical system:

7.1 Check function t

7.2 Check cables for damage and for tight fit of connections t

7.3 Check fuses for correct value t

7.4 Check function of switches and switch cams and check for tight fit

7.5 Check contactors and relays, replace wear parts if necessary

7.6 Check function of warning devices and protective circuits

Electric motors:

8.1 Check wear on carbon brushes (lifting motor) t

8.2 Check motor mounting t

8.3 Vacuum out motor housing, check commutator for wear (lifting motor)

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Maintenance intervals Standard = t WA BC Refrigerated warehouse = k

Battery: 9.1 Check acid density, acid level and cell voltage t

9.2 Check connection terminals for tight fit, grease with pole grease

9.3 Clean battery jack connections, check for tight fit

9.4 Check battery cable for damage, replace if necessary t

Lifting equipment:

10.1 Check function, wear and settings t

10.2 Check fork arms and fork carrier for wear and damage

Lubrication service:

11.1 Lubricate vehicle as per lubrication chart t

General checks:

12.1 Check electrical system for short-circuits to frame t

12.2 Check travel speed and braking distance t

12.3 Check raising and lowering speed t

12.4 Check safety devices and cutouts t

Demonstration:

13.1 Test drive with rated load t

13.2 On completion of maintenance, demonstrate the vehicle in front of an authorized person

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5 Lubrication chart

NOTICE Raise or lower the fork to make the grease nipple more accessible.

g Sliding surfaces

s Grease nipple

Hydraulic oil filler neck

b Gearbox oil filler neck a Gearbox oil drain plug

Use in refrigerated warehouse

1) Mixing ratio for use in refrigerated warehouse 1 : 1

2,9 l / 0.76 gal

195 Nm / 143.82 lbf ft

A + C

0,7 l /

0.18 gal

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5.1 Operating resources

Handling of operating resources:

Operating resources must always be used properly and in accordance with the manufacturer's instructions.

QwW Improper handling can endanger health, life, and the environment. Operating

resources must only be stored in suitable containers. They may be flammable and must, therefore, not be brought into contact with hot components or naked flames.

Only clean containers should be used to fill operating resources. Different grades of operating resources should never be mixed. The only exception to this rule is if mixing is expressly stipulated in this Operating Manual.

Be careful not to spill liquids. Liquid spillages must be removed immediately using a suitable binder. The mixture of binder and operating resources must be disposed of in compliance with applicable regulations.

Code Order no. Amount

supplied

Designation Purpose

A 50 449 669 1.32 gal

(5.0 l)

H-LP 46, DIN 51524

Hydraulic system

B 29 200 680 1.32 gal

(5.0 l)

CLP 100, DIN 51517

Gearbox

C 29 200 810 1.32 gal

(5.0 l)

H-LP 10, DIN 51524

Hydraulic system

D 29 200 150 0.26 gal

(1.0 l)

Brake fluid Brake system

E 29 201 430 2.2 lbs

(1 kg)

Grease, DIN 51825 Lubrication service

F 50 430 702 2.2 lbs

(1 kg)

Low-temperature grease

Lubrication service

G 29 201 280 0.1 gal

(400 ml)

Chain spray Chains