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ESC 316/316z
Operating instructions G
ESC 316z
ESC 316
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11.1 4 E N
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11.1 4 E N
Foreword
Notes on the operating instructions
The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide
sufficient instruction for the safe operation of the industrial truck. The information is
provided clearly and concisely. The chapters are arranged by letter and the pages are
numbered continuously.
The operator manual details different industrial truck models. When operating and
servicing the industrial truck, make sure that the particular section applies to your
truck model.
Our trucks are subject to ongoing development. Jungheinrich reserves the right to
alter the design, equipment and technical features of the system. No guarantee of
particular features of the truck should therefore be assumed from the present
operating instructions.
Safety notices and text mark-ups
Safety instructions and important explanations are indicated by the following
graphics:
DANGER!
Indicates an extremely hazardous situation. Failure to comply with this instruction will
result in severe irreparable injury and even death.
WARNING!
Indicates an extremely hazardous situation. Failure to comply with this instruction
may result in severe irreparable injury and even death.
CAUTION!
Indicates a hazardous situation. Failure to comply with this instruction may result in
slight to medium injury.
NOTE
Indicates a material hazard. Failure to comply with this instruction may result in
material damage.
Z Used before notices and explanations.
t Indicates standard equipment
o Indicates optional equipment
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11.1 4 E N
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Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
Jungheinrich Aktiengesellschaft
Am Stadtrand 35
22047 Hamburg - Germany
Tel: +49 (0) 40/6948-0
www.jungheinrich.com
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11.1 4 E N
Table of contents
A Correct Use and Application ................................................... 9
1 General.................................................................................................... 9
2 Correct application................................................................................... 9
3 Approved application conditions.............................................................. 10
4 Proprietor responsibilities ........................................................................ 11
5 Adding attachments and/or optional equipment ...................................... 11
B Truck Description .................................................................... 13
1 Application ............................................................................................... 13
1.1 Truck models and rated capacity............................................................. 13
2 Travel direction definition......................................................................... 14
3 Assemblies and Functional Description................................................... 15
3.1 Assembly Overview ................................................................................. 15
3.2 Functional Description ............................................................................. 16
4 Technical Specifications .......................................................................... 18
4.1 Performance data .................................................................................... 18
4.2 Dimensions .............................................................................................. 19
4.3 Weights.................................................................................................... 22
4.4 Tyre type.................................................................................................. 22
4.5 Mast versions .......................................................................................... 23
4.6 EN norms................................................................................................. 24
4.7 Conditions of use ..................................................................................... 25
4.8 Electrical requirements ............................................................................ 25
5 Identification points and data plates ........................................................ 26
5.1 Data plate ................................................................................................ 27
5.2 Truck capacity plate................................................................................. 28
C Transport and Commissioning ................................................ 29
1 Lifting by crane ........................................................................................ 29
2 Transport ................................................................................................. 30
3 Using the Truck for the First Time ........................................................... 31
D Battery - Servicing, Recharging, Replacement ....................... 33
1 Safety Regulations Governing the Handling of Lead-Acid Batteries ....... 33
2 Battery types............................................................................................ 35
3 Exposing the battery................................................................................ 36
4 Charging the battery ................................................................................ 37
5 Battery removal and installation .............................................................. 39
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E Operation ................................................................................ 43
1 Safety Regulations for the Operation of the Forklift Truck....................... 43
2 Displays and Controls.............................................................................. 45
2.1 Battery discharge indicator ...................................................................... 48
2.2 Battery discharge monitor........................................................................ 49
3 Preparing the Truck for Operation ........................................................... 50
3.1 Checks and operations to be performed before starting daily operation . 50
3.2 Preparing the truck for operation ............................................................. 51
3.3 Checks and operations to be carried out when the truck is operational .. 52
3.4 Parking the truck securely ....................................................................... 53
3.5 Entry and exit........................................................................................... 55
3.6 Adjusting the floor plate height ................................................................ 56
3.7 Adjusting the driver’s seat ....................................................................... 57
4 Industrial Truck Operation ....................................................................... 58
4.1 Safety regulations for truck operation ...................................................... 58
4.2 Emergency Disconnect............................................................................ 61
4.3 Travel....................................................................................................... 63
4.4 Steering ................................................................................................... 65
4.5 Brakes ..................................................................................................... 66
4.6 Load handler raise/lower ......................................................................... 68
4.7 Lifting, transporting and depositing loads ................................................ 72
5 Troubleshooting....................................................................................... 75
5.1 Truck does not start ................................................................................. 76
5.2 Load cannot be lifted ............................................................................... 76
6 Operating the truck without its own drive system .................................... 77
7 Load handler emergency lowering .......................................................... 79
8 Optional equipment ................................................................................. 81
8.1 Display and control unit ........................................................................... 81
8.2 Setting the time........................................................................................ 82
8.3 Keypad (CanCode) (o) ........................................................................... 83
8.4 ISM access module (o)........................................................................... 101
F Industrial Truck Maintenance .................................................. 103
1 Operational Safety and Environmental Protection................................... 103
2 Maintenance Safety Regulations............................................................. 104
2.1 Working on the electrical system ............................................................. 105
2.2 Consumables and used parts .................................................................. 105
2.3 Wheels..................................................................................................... 105
2.4 Hydraulic system ..................................................................................... 106
2.5 Lift Chains................................................................................................ 107
3 Lubricants and Lubrication Schedule ...................................................... 108
3.1 Handling consumables safely .................................................................. 108
3.2 Lubrication Schedule ............................................................................... 110
3.3 Consumables........................................................................................... 111
4 Maintenance and repairs ......................................................................... 112
4.1 Preparing the truck for maintenance and repairs .................................... 112
4.2 Lifting and jacking up the truck safely...................................................... 112
4.3 Cleaning .................................................................................................. 113
4.4 Drive compartment cover disassembly/assembly ................................... 116
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4.5 Checking the hydraulic oil level ............................................................... 117
4.6 Tightening the wheel nuts........................................................................ 118
4.7 Checking electrical fuses ......................................................................... 119
4.8 Restoring the truck to service after maintenance and repairs ................. 120
5 Decommissioning the industrial truck ...................................................... 121
5.1 Prior to decommissioning ........................................................................ 121
5.2 During decommissioning ......................................................................... 121
5.3 Restoring the truck to service after decommissioning ............................. 122
6 Safety tests to be performed at intervals and after unusual incidents ..... 123
7 Final de-commissioning, disposal............................................................ 123
8 Human vibration measurement ............................................................... 123
9 Servicing and Inspection ......................................................................... 124
10 ESC 316 maintenance checklist.............................................................. 125
10.1 Operating company ................................................................................. 125
10.2 Customer service..................................................................................... 126
11 ESC 316z maintenance checklist ............................................................ 130
11.1 Operating company ................................................................................. 130
11.2 Customer service..................................................................................... 131
G Traction Battery Appendix....................................................... 135
1 Correct Use and Application.................................................................... 135
2 Data plate ................................................................................................ 135
3 Safety Instructions, Warning Indications and other Notes....................... 136
4 Lead acid batteries with armour plated cells and liquid electrolyte.......... 137
4.1 Description............................................................................................... 137
4.2 Operation ................................................................................................. 138
4.3 Servicing lead-acid batteries with armour plated cells............................. 141
5 PzV and PzV-BS lead-acid batteries with sealed armour plated cells..... 142
5.1 Description............................................................................................... 142
5.2 Operation ................................................................................................. 143
5.3 Servicing PzV and PzV-BS lead-acid batteries with sealed armour plated
cells ......................................................................................................... 146
6 Aquamatik water replenishment system.................................................. 147
6.1 Water replenishment system design ....................................................... 147
6.2 Functional Description ............................................................................. 148
6.3 Adding water............................................................................................ 148
6.4 Water pressure ........................................................................................ 148
6.5 Filling time ............................................................................................... 149
6.6 Water quality............................................................................................ 149
6.7 Battery tubing .......................................................................................... 149
6.8 Operating temperature ............................................................................ 149
6.9 Cleaning measures.................................................................................. 150
6.10 Service mobile vehicle ............................................................................. 150
7 Electrolyte circulation............................................................................... 151
7.1 Functional Description ............................................................................. 151
8 Cleaning batteries.................................................................................... 153
9 Storing the battery ................................................................................... 155
10 Troubleshooting....................................................................................... 155
11 Disposal................................................................................................... 155
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11.1 4 E N
A Correct Use and Application
1 General
The truck must be used, operated and serviced in accordance with the present
instructions. All other types of use are beyond its scope of application and may result
in damage to personnel, the industrial truck or property.
2 Correct application
NOTE
The maximum load and load distance are indicated on the capacity plate and must
not be exceeded.
The load must rest on the load handler or be lifted by an attachment approved by the
manufacturer.
The load must be fully raised,see "Lifting, transporting and depositing loads" on
page 72.
The following operations are in accordance with regulations and are permitted:
– Lifting and lowering loads.
– Transporting lowered loads.
The following operations are prohibited:
– Travelling with a raised load (>300 mm).
– Carrying and lifting passengers.
– Pushing or pulling loads.
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3 Approved application conditions
– Operation in industrial and commercial environments.
– Permissible temperature range 5°C to 40°C.
– Operation only on secure, level surfaces with sufficient capacity.
– Do not exceed the permissible surface and spot load limits on the travel routes.
– Operation only on routes that are visible and approved by the operating company.
– Negotiating inclines up to a maximum of 12 %.
– Do not travel across or at an angle on inclines. Travel with the load facing uphill.
– Operation in partially public traffic.
WARNING!
Use under extreme conditions
Using the truck under extreme conditions can result in malfunctions and accidents.
XSpecial equipment and authorisation are required if the truck is to be constantly
used in extreme conditions, especially in dusty or corrosive atmospheres.
XThe truck cannot be used in areas at risk of explosion.
XIn adverse weather conditions (thunder, lightning) the industrial truck must not be
operated outside or in endangered areas.
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11.1 4 E N
4 Proprietor responsibilities
For the purposes of the present operating instructions the “operating company” is
defined as any natural or legal person who either uses the industrial truck himself, or
on whose behalf it is used. In special cases (e.g. leasing or renting) the proprietor is
considered the person who, in accordance with existing contractual agreements
between the owner and user of the industrial truck, is charged with operational duties.
The proprietor must ensure that the industrial truck is used only for the purpose it is
intended for and that danger to life and limb of the user and third parties are excluded.
Furthermore, accident prevention regulations, safety regulations and operating,
servicing and repair guidelines must be followed. The operating company must
ensure that all users have read and understood these operating instructions.
NOTE
Failure to comply with the operating instructions invalidates the warranty. The same
applies if improper work is carried out on the truck by the customer or third parties
without the permission of the manufacturer.
5 Adding attachments and/or optional equipment
The mounting or installation of additional equipment which affects or enhances the
performance of the industrial truck requires the written permission of the
manufacturer. Local authority approval may also need to be obtained.
Local authority approval however does not constitute the manufacturer’s approval.
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11.1 4 E N
B Truck Description
1 Application
The ESC 316/316z is a four-wheel, electric side-seated pallet truck with a driver's
seat equipped with an electric steering wheel system.
The ESC 316/316z is designed to transport goods on level surfaces. The wheel arm
lift, also called initial lift (ESC 316z only), increases the ground clearance when
transporting loads on uneven ground. The truck can lift open bottom or diagonal
board pallets beyond the area of the load wheels as well as roll cages. Loads can be
stacked, unstacked and transported over long distances up to 5,25 m depending on
the mast type.
1.1 Truck models and rated capacity
The rated capacity depends on the model. The rated capacity can be derived from
the model name.
The rated capacity is not generally the same as the permissible capacity. The
capacity can be found on the capacity plate attached to the truck.
ESC316
ESC Model name
3Series
16 Rated capacity x 100 kg
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2 Travel direction definition
The following determinations have been made for travel direction specification:
Item Travel direction
1 Left
2 Drive direction
3 Load direction
4 Right
1
2
3
4
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11.1 4 E N
3 Assemblies and Functional Description
3.1 Assembly Overview
Item Description Item Description
5 t Discharge indicator 14 t Armrest
6 t Key switch 15 t Floor plate height adjuster
7 o Control / display unit 16 t Steering wheel
8 o CanCode code lock 17 t Battery
9 o ISM access module 18 t Load wheels
10 t Overhead guard 19 t Load handler
11 t Mast 20 t Deadman switch
12 t Multi-Pilot 21 t Seat cover
13 t Emergency Disconnect switch
t = Standard equipment o = Optional equipment
56 78 79
10
11
12
14
15
17
16
20
21
18
19
13
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3.2 Functional Description
Safety mechanisms
An enclosed, smooth truck geometry with rounded edges ensures safe handling of
the truck. The wheels are surrounded by a solid skirt.
Activating the Emergency Disconnect switch rapidly cuts out all electrical functions in
hazardous situations. The mast grille (o) protects the operator from moving mast
parts and the load. The overhead guard protects the operator from falling objects.
Emergency stop safety feature
The emergency stop is activated by the traction controller. Each time the truck is
switched on the system performs a self diagnosis. The steering controller sends a
system status signal which is monitored by the traction controller. If the signal fails to
appear or a fault is identified the truck automatically brakes to a halt. Control displays
on the control and display unit (o) indicate the emergency stop.
Deadman switch
The deadman switch ensures that the driver's feet do not extend outside the truck
during travel. The deadman switch in the foot compartment must be depressed to
enable the driver to operate the truck. Lifting and travel are inhibited if the operator
takes his foot off the deadman switch. Steering and braking remain enabled.
Operator position
The driver's seat and floor plate can be adjusted to suit different sized operators. All
travel and lift operations can be performed sensitively without having to reach. The
ergonomic steering wheel provides secure control of the truck.
Electrical system
The truck has electronic traction, lift and steering controllers. The operating voltage
of the truck's electrical system is 24 volts.
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11.1 4 E N
Drive system
A fixed AC three-phase motor actuates the drive wheel via a bevel spur gearbox. The
electronic traction controller ensures smooth drive-motor-speed control and hence
smooth starting, powerful acceleration and electrically controlled braking with energy
regeneration. The driver can choose from 3 travel programs depending on the load
and the environment: from high-performance to energy-saving.
Controls and displays
Ergonomic controls ensure fatigue-free operation for sensitive application of the
travel and hydraulic operations. The charge indicator shows the available battery
capacity. The control and display unit (o) shows the key operator information such
as battery capacity, service hours and event messages.
Steering
The operator steers with an ergonomically inclined steering wheel. The steering
motion is transmitted from the steering controller via a steer motor directly to the ring
gear of the pivoted drive system. The steering wheel has a steer angle of 180°.
Automatic travel speed reduction as a function of the steer angle (Curve Control o)
is optionally available.
Hydraulic system
Infinitely variable lifting and lowering operations are performed by moving the MultiPilot forward and back. When lifting is activated, the pump unit starts to operate,
supplying hydraulic oil from the oil reservoir to the lift cylinder.
If the truck is fitted with the "z" auxiliary lift, the wheel arms can be raised and lowered
via buttons. When the lift button is pressed the wheel arms are raised at an even
speed; when the lower button is pressed the wheel arms are lowered. When the
wheel arms are raised (initial lift) the lift height is restricted. When the lift height
exceeds 1800 mm the wheel arms lower automatically. The wheel arms can only be
lowered below this lift height.
Mast
The high strength steel sections are narrow, enabling excellent visibility of the load
handler. The lift rails and the load handler run on permanently-lubricated and hence
maintenance-free angled rollers.
3.2.1 Hourmeter
Z Prepare the truck for operation, see "Preparing the truck for operation" on page 51
or see "Keypad (CanCode) (o)" on page 83.
Service hours are counted while the truck is operational and the deadman button is
pressed.
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4 Technical Specifications
Z The technical specifications comply with the German "Industrial Truck Data Sheet"
Guidelines.
Technical modifications and additions reserved.
4.1 Performance data
ESC316 ESC316z
Q Rated capacity 1600 kg
Travel speed
with / without rated load
9.1/ 9.1 km/h
Lift speed
with / without rated load
0.13 / 0.24 0.14 / 0.23 m/s
Lower speed
with / without rated load
0.42 / 0.42 0.42 / 0.38 m/s
Max. gradeability
with / without rated load
7 / 12 %
Drive motor,
Output S2 60 min
2.8 kW
Lift motor,
Output S3 15%
3.0 (8 %) kW
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11.1 4 E N
4.2 Dimensions
b11
b5
b2
x
Wa
e
a/2
Ast
a/2
h13
h2
h3
h1
h4
l2
y
l1
l
c
m2
s
187
1278
h6
Q
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ESC316 ESC316z
c Load centre distance 600 mm
x
Load distance
lowered / raised
860 874 / 796 mm
y
Wheelbase
lowered / raised
1648 1692 / 1514 mm
h1 Mast height retracted 1995 mm
h2 Free lift 100 mm
h3 Lift 2800 mm
h4 Mast height extended 3422 mm
h5 Wheel arm lift (initial lift) - 125 mm
h6
Height above overhead
guard
2095 mm
h7 Seat height / standing height 950 mm
h13 Lowered height 90 mm
l1 Length 2125 2155 mm
l2 Headlength 975 1005 mm
b2 Overall width (drive) 930 mm
b5
Overall width of the load
handler
570
mm
s/e/l Load handler dimensions 60 / 185 / 1150 mm
b10 Track width, drive direction 645 mm
b11 Track width, load direction 385 mm
m1 Ground clearance, laden,
below mast
30 -
m2
Ground clearance, centre
wheelbase
30 25
mm
Ast
Working aisle width @
pallet 1000x1200 transv.
2310 / 2643 2383 / 2720 mm
Ast
Working aisle width @
pallet 800x1200 length
2360 / 2549 2433 / 2623 mm
Wa
Turning radius
lowered / raised
1863 1907 / 1830
mm
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11.1 4 E N
b11
b5
b2
x
Wa
e
a/2
Ast
a/2
h13
h2
h3
h1
h4
l2
y
l1
l
c
m2
s
187
1278
h6
Q
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4.3 Weights
4.4 Tyre type
ESC316 ESC316z
Net weight excl. battery 1366 1305 kg
Axle loading, laden
Drive direction / load direction
+ battery
1459 / 1228 1432 / 1857 kg
Axle loading, unladen
Drive direction / load direction
+ battery
1891 / 518 1190 / 495 kg
Battery weight 380 kg
ESC316 ESC316z
Tyres Vulkollan
Wheel size, drive direction 230 x 77 mm
Wheel size, load direction 85 x 85 mm
Caster wheel (twin roller) 140 x 54 mm
Wheels, no.
Drive direction
(x = driven)
2 + 1x
Wheels, no.
Load direction
4
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11.1 4 E N
4.5 Mast versions
*) With these masts the view of the load handler is restricted by the top cross member.
h1 h2 h3 h4 h6
ZT
1995 100 2800* 3372 2093 mm
2145 100 3100 3672 2243 mm
2345 100 3500 4072 2288 mm
2595 100 4000 4572 2288 mm
2695 100 4200 4772 2288 mm
ZZ
1945 1373 2800* 3372 2093 mm
2095 1523 3100 3672 2243 mm
2295 1723 3500 4072 2288 mm
2545 1973 4000 4572 2288 mm
2645 2073 4200 4772 2288 mm
DZ
1945 1376 4200* 4770 2093 mm
2295 1726 5250 5820 2288 mm
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4.6 EN norms
Noise emission level
– ESC 316/316z: 61 dB(A)
in accordance with 12053 as harmonised with ISO 4871.
Z The noise emission level is calculated in accordance with standard procedures and
takes into account the noise level when travelling, lifting and when idle. The noise
level is measured at the level of the driver's ear.
Vibration
– ESC 316/316z: 0,73 m/s²
in accordance with EN 13059
Z The vibration acceleration acting on the body in the operating position is, in
accordance with standard procedures, the linearly integrated, weighted
acceleration in the vertical direction. It is calculated when travelling over thresholds
at constant speed. These recordings were taken on a single occasion for the
industrial truck and must not be confused with the human vibrations of the "2002/
44/EC/Vibrations" operator directive. The manufacturer offers a special service to
measure these human vibrations, see "Human vibration measurement" on
page 123.
Electromagnetic compatibility (EMC)
The manufacturer confirms that the truck adheres to the limits for electromagnetic
emissions and resistance as well as the static electricity discharge test in accordance
with EN 12895 as well as the standardised instructions contained therein.
Z No changes to electric or electronic components or their arrangement may be
made without the written agreement of the manufacturer.
WARNING!
Medical equipment can be damaged by non-ionised radiation
Electrical equipment on the truck emitting non-ionised radiation (e.g. wireless data
transmission) can affect operators' medical equipment (pacemakers, hearing aids
etc.) and result in malfunctions. Consult with a doctor or the medical equipment
manufacturer to clarify whether it can be used near the industrial truck.
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11.1 4 E N
4.7 Conditions of use
Ambient temperature
– operating at 5°C to 40°C
Z Special equipment and authorisation are required if the truck is to be used
continually in conditions of extreme temperature or condensing air humidity
fluctuations.
4.8 Electrical requirements
The manufacturer certifies compliance with the requirements for the design and
manufacture of electrical equipment, according to EN 1175 "Industrial Truck Safety Electrical Requirements", provided the truck is used according to its purpose.
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5 Identification points and data plates
Item Description
22 Warning: “Do not step under the load handler”
23 Warning: "Do not reach through the mast"
24 Raise / lower wheel arms
25 Capacity plate
26 Multi-Pilot
27 Floor plate adjustment
28 Data plate
29 Test plaque
30 Attachment points for lifting by crane
31 Serial number
32 Model description
X.XXXX.XX.XX
22
23
24
25
26
27
28
30 31
29
32
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11.1 4 E N
5.1 Data plate
Z For queries regarding the truck or ordering spare parts always quote the truck serial
number (34).
33 34 3635 37
44
40
43
42
41
3938
Item Description Item Description
33 Type 39 Year of manufacture
34 Serial number 40 Load centre (mm)
35 Rated capacity (kg) 41 Output
36 Battery voltage (V) 42 Min./max. battery weight (kg)
37 Net weight w.o. battery (kg) 43 Manufacturer
38 Option 44 Manufacturer’s logo
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5.2 Truck capacity plate
The rating plate (45) indicates the maximum capacity Q (in kg) for a given load centre
C (in mm) and corresponding lift height H (in mm) for the truck with a horizontal load.
Example of how to calculate the maximum capacity:
With a load centre distance C of 600 mm and a maximum lift height H of 3600 mm.
the max. capacity Q is 1105 kg.
600
X.XXXX.XX.XX
11053600
45
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11.1 4 E N
C Transport and Commissioning
1 Lifting by crane
WARNING!
Incorrect lifting by crane can result in accidents
Improper use or use of unsuitable lifting gear and can cause the truck to fall when
being lifted by crane.
Prevent the truck from hitting other objects during lifting, and avoid uncontrolled
movements. If necessary, secure the truck with guide ropes.
XThe truck should only be loaded by personnel trained in the use of lifting slings and
tools.
XWear personal protective equipment (e. g. safety shoes, safety helmet, hi-vis
jacket, protective gloves, etc.) when loading by crane.
XDo not stand under suspended loads.
XDo not enter or stand in a hazardous area.
XAlways use lifting gear with sufficient capacity (for truck weight see truck rating
plate).
XAlways attach the crane lifting gear to the prescribed strap points and prevent them
from slipping.
XUse the lifting slings only in the prescribed loading direction.
XCrane slings should be fastened in such a way that they do not come into contact
with any attachments when lifting.
Lifting the truck by crane
Requirements
– Park the truck securely, see "Parking the
truck securely" on page 53.
– Remove any mast guards.
Tools and Material Required
– Lifting gear
– Crane lifting gear
Procedure
• Secure the lifting slings to the strap
points (30).
The truck can now be lifted by crane.
30
30
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30
2 Transport
WARNING!
Accidental movement during transport
Improper fastening of the truck and mast during transport can result in serious
accidents.
XLoading must only be performed by specialist personnel trained for this purpose.
The specialist personnel must be instructed in securing loads on road vehicles and
handling load securing devices. In each case correct measurements must be taken
and appropriate safety measures applied.
XThe truck must be securely fastened when transported on a lorry or a trailer.
XThe lorry or trailer must have fastening rings.
XUse wedges to prevent the truck from moving.
XUse only fastening belts with sufficient strength.
XUse non-slip materials to securing the load aids (pallet, wedges, ...) e. g. non-slip
mats.
Securing the industrial truck for transport
Requirements
– Load the truck.
– Park the truck securely, see "Parking the truck securely" on page 53.
Tools and Material Required
– Lashing straps
Procedure
• Attach the lashing straps (46) to the industrial truck and the transport vehicle and
tension sufficiently.
The truck can now be transported.
4646
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11.1 4 E N
3 Using the Truck for the First Time
WARNING!
The use of unsuitable energy sources can be hazardous
Rectified AC current will damage the assemblies (controllers, sensors, motors etc.)
of the electronic system.
Unsuitable cable connections (too long, insufficient wire cross-section) to the battery
(tow cables) can overheat, setting the truck and battery on fire.
XThe truck must only be operated with battery current.
XCable connections to the battery (tow leads) must be less than 6 m long and have
a minimum cross-section of 50 mm².
NOTE
Do not lift loads if the truck is operated via a tow lead with an external battery.
NOTE
Cold store trucks
XTrucks designed for use in cold stores have a cold store hydraulic oil and a
protective frame instead of a mast guard on the mast.
XIf a truck with cold store oil is used outside the cold store, the lowering speeds may
increase.
Procedure
• Check the equipment is complete.
• If necessary, install the battery, see "Battery removal and installation" on page 39.
Do not damage the battery cable.
• Charge the battery, see "Charging the battery" on page 37.
Z The truck settings must match the battery model (if the customer is charging the
battery).
• Check the hydraulic oil level and top up if necessary (see "Checking the hydraulic
oil level" on page 117).
• Start up the truck (see "Preparing the truck for operation" on page 51).
Truck is operational.
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11.1 4 E N
32
Wheel flattening
If the truck has been parked for a long period, the wheel surfaces may tend to flatten.
This flattening has a negative effect on the safety and stability of the truck. Once the
truck has covered a certain distance, the flattening will disappear.
Page 34
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11.1 4 E N
D Battery - Servicing, Recharging,
Replacement
1 Safety Regulations Governing the Handling of Lead-Acid
Batteries
Maintenance personnel
Batteries may only be charged, serviced or replaced by trained personnel. This
operator manual and the manufacturer’s instructions concerning batteries and
charging stations must be observed when carrying out the work.
Fire Protection
Do not smoke and avoid naked flames when handling batteries. Wherever an
industrial truck is parked for charging there must be no inflammable material or
consumables capable of creating sparks within a minimum distance of 2 m from the
truck. The room must be ventilated. Fire protection equipment must be available.
CAUTION!
The use of unsuitable fire protection equipment can result in scalding
Extinguishing fires with water can cause a reaction with the battery acid. This can
result in scalding from the acid.
XUse powder extinguishers.
XNever extinguish a burning battery with water.
Battery maintenance
The battery cell covers must be kept dry and clean. The terminals and cable shoes
must be clean, secure and have a light coating of dielectric grease.
CAUTION!
Short circuits can cause fires
Damaged cables can cause a short circuit, setting the truck and the battery on fire.
XBefore closing the battery cover make sure that the battery cables cannot be
damaged.
Battery disposal
Batteries may only be disposed of in accordance with national environmental
protection regulations or disposal laws. The manufacturer’s disposal instructions
must be followed.
Page 35
11.1 4 E N
34
WARNING!
Batteries can be hazardous
Batteries contain an acid solution which is poisonous and corrosive. Avoid contact
with battery acid at all times.
XDispose of used battery acid in accordance with regulations.
XAlways wear protective clothing and goggles when working with batteries.
XDo not let battery acid come into contact with skin, clothing or eyes. If necessary,
rinse with plenty of clean water.
XIn the event of physical damage (e.g. skin or eye contact with battery acid) call for
a doctor immediately.
XSpilled battery acid should be neutralised immediately with plenty of water.
XOnly batteries with a sealed battery container may be used.
XFollow national guidelines and legislation.
WARNING!
Unsuitable batteries that have not been approved by Jungheinrich for the truck
can be hazardous
The design, weight and dimensions of the battery have a considerable effect on the
operational safety of the truck, in particular its stability and capacity. The use of
unsuitable batteries that have not been approved by Jungheinrich for the truck can
lead to a deterioration of the braking system during energy recovery operations and
also cause considerable damage to the electrical control system. The use of batteries
that have not been approved by Jungheinrich can therefore affect the health and
safety of personnel.
XOnly Jungheinrich-approved batteries may be used on the truck.
XBattery equipment may only be replaced with the agreement of Jungheinrich.
XWhen replacing/installing the battery make sure the battery is securely located in
the battery compartment of the truck.
XDo not use batteries that have not been approved by the manufacturer.
Park the truck securely before carrying out any work on the batteries (see "Parking
the truck securely" on page 53).
Page 36
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11.1 4 E N
2 Battery types
Depending on the model, the truck will be supplied with different battery types. The
following table shows which combinations are included as standard:
The battery weights can be taken from the battery data plate. Batteries with non
insulated terminals must be covered with a non slip insulating mat.
Battery type Capacity Weight
24 volt battery
796 x 210 x 782 mm (LXWXH)
3 PzS 465 Ah 380 kg
Page 37
11.1 4 E N
36
3 Exposing the battery
CAUTION!
Trapping hazard
XMake sure there is nothing between the battery cover and the truck when you fit the
battery cover.
WARNING!
An unsecured truck can cause accidents
Parking the truck on an incline or with a raised load handler is dangerous and is
strictly prohibited.
XPark the truck on a level surface. In special cases the truck may need to be secured
with wedges.
XFully lower the load handler.
XSelect a place to park where no other people are at risk of injury from the lowered
load handler.
XIf the brakes are not working, place wedges underneath the wheels of the truck to
prevent it from moving.
Requirements
– Park the truck on a horizontal surface.
– Park the truck securely, see "Parking
the truck securely" on page 53.
Procedure
• Fold up the arm rest (14).
The battery connector (48) and battery
retainer (47) can be accessed
48
47
14
Page 38
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11.1 4 E N
4 Charging the battery
WARNING!
The gases produced during charging can cause explosions
The battery produces a mixture of nitrogen and hydrogen (electrolytic gas) during
charging. Gassing is a chemical process. This gas mixture is highly explosive and
must not be ignited.
XSwitch the charging station and truck off first before connecting/disconnecting the
charging cable of the battery charging station to/from the battery connector.
XThe charger must be adapted to the battery in terms of voltage and charge
capacity.
XBefore charging, check all cables and plug connections for visible signs of damage.
XVentilate the room in which the truck is being charged.
XThe battery cover must be open and the battery cell surfaces must be exposed
during charging to ensure adequate ventilation.
XDo not smoke and avoid naked flames when handling batteries.
XWherever an industrial truck is parked for charging there shall be no inflammable
material or lubricants capable of creating sparks within 2 m around the truck.
XFire protection equipment must be on hand.
XDo not lay any metallic objects on battery.
XIt is essential to follow the safety regulations of the battery and charger station
manufacturers.
Page 39
11.1 4 E N
38
Charging the battery
Requirements
– Expose the battery, see "Exposing the
battery" on page 36.
– Correct charging program set on
charger.
Procedure
• Remove the battery connector (48)
from the truck plug (49).
• Remove any insulating mats from the
battery.
• Connect the battery connector (48) to
the charging cable (50) of the
stationary charger.
• Start charging in accordance with the charger operating instructions.
• Switch on the charger / charging begins automatically.
The battery is now charged.
Completing battery charging, restoring the truck to operation
NOTE
If charging has been interrupted, the full battery capacity will not be available.
Requirements
– The battery is fully charged.
Procedure
• Complete charging in accordance with the charger operating instructions.
• Disconnect the battery connector (48) from the charging cable (50) of the stationary
charger.
• Attach the battery connector (48) to the industrial truck.
The truck is now ready for operation.
48
50
49
Page 40
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11.1 4 E N
5 Battery removal and installation
WARNING!
Accident risk during battery removal and installation
Due to the battery weight and acid there is a risk of trapping or scalding when the
battery is removed and installed.
XNote the "Safety regulations for handling acid batteries" section in this chapter.
XWear safety shoes when removing and installing the battery.
XUse only batteries with insulated cells and terminal connectors.
XPark the truck on a level surface to prevent the battery from sliding out.
XMake sure the crane slings have sufficient capacity to replace the battery.
XUse only approved battery replacement devices (battery roller stand, replacement
trolley etc.).
XMake sure the battery is securely located in the truck's battery compartment.
CAUTION!
Unsecured battery
An unsecured battery can result in trapping and injury
XWear safety shoes when removing and installing the battery.
XDo not reach between the battery and the chassis.
CAUTION!
Battery stop
Removing the battery stop can result in trapping and injury. The battery must only be
removed from the right-hand side of the truck. The battery stop on the left-hand side
serves to prevent the battery from sliding out.
XThe battery stop on the left-hand side of the truck must not be removed.
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40
Removing the battery
Requirements
– Park the truck on a horizontal surface.
– Park the truck securely, see "Parking the truck securely" on page 53.
– Expose the battery, see "Exposing the battery" on page 36.
Tools and Material Required
– Battery replacement trolley (o)
Procedure
• Remove the battery connector (48) from the truck.
• Place the battery connector on the battery.
• Turn the battery lock (52) over and pull it up.
• Flip the battery retainer (47) over.
• Pull the battery (51) off the truck.
Z Observe the battery replacement trolley operating instructions.
The battery has now been removed.
51
52
47
48
Page 42
41
11.1 4 E N
Battery installation
Requirements
– Park the truck securely, see "Parking the truck securely" on page 53.
Tools and Material Required
– Battery replacement trolley (o)
Procedure
• Insert the battery (51) in the truck.
Z Place the battery cable on the tray so that it cannot be severed when the battery is
inserted.
• Push the battery (51) into the battery compartment.
• Flip the battery retainer (47) back.
• Insert the battery lock (52) in the truck chassis and flip it over.
• Attach the battery connector (48) to the truck connector.
Z Observe the battery replacement trolley operating instructions.
The battery is now installed.
51
52
47
48
Page 43
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42
Checking the battery acid level
Requirements
– Park the truck securely, see "Parking the truck securely" on page 53.
– Expose the battery, see "Exposing the battery" on page 36.
Procedure
• Remove the battery connector (48) from the truck.
• Place the battery connector on the battery.
• Flip the battery retainer (47) over so that the wider side is over the battery.
• Flip the battery lock (52) over and pull it up.
• Keep pulling the battery (51) out of the truck until the battery is resting against the
battery retainer.
• Check the battery acid level.
All indicators should show sufficient acid level, if necessary add battery water, see
"Traction Battery Appendix" on page 135.
• Push the battery (51) into the truck
• Flip the battery retainer (47) back.
• Insert the battery lock (52) in the truck chassis and flip it over.
The acid level has now been checked.
51
52
47
48
Page 44
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11.1 4 E N
E Operation
1 Safety Regulations for the Operation of the
Forklift Truck
Driver authorisation
The truck may only be used by suitably trained personnel, who have demonstrated to
the proprietor or his representative that they can drive and handle loads and have
been authorised to operate the truck by the proprietor or his representative.
Operator’s rights, responsibilities and rules of conduct
The driver must be informed of his duties and responsibilities and be instructed in the
operation of the truck and shall be familiar with the operating instructions. Safety
shoes must be worn on pedestrian-operated trucks.
Unauthorised use of truck
The operator is responsible for the truck during the time it is in use. The operator must
prevent unauthorised persons from driving or operating the truck. Do not carry
passengers or lift other people.
Damage and faults
The supervisor must be informed immediately of any damage or faults to the truck or
attachment. Trucks which are unsafe for operation (e.g. wheel or brake problems)
must not be used until they have been rectified.
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44
Repairs
The operator must not carry out any repairs or alterations to the truck without
authorisation and the necessary training to do so. The operator must never disable or
adjust safety mechanisms or switches.
Hazardous area
WARNING!
Risk of accidents/injury in the hazardous area of the truck
A hazardous area is defined as the area in which people are at risk due to travel or
lifting operations of the truck, its load handler or the load. This also includes the area
within reach of falling loads or lowering/falling operating equipment.
XInstruct unauthorised persons to leave the hazardous area.
XIn case of danger to third parties, give a warning signal in good time.
XIf unauthorised persons are still within the hazardous area, stop the truck
immediately.
WARNING!
Falling objects can cause accidents
Falling objects can injure the operator while the truck is being operated.
XThe operator must remain within the protected area of the overhead guard while
the truck is being operated.
Safety devices, warning signs and warning instructions
Safety devices, warning signs (see "Identification points and data plates" on page 26)
and warning instructions in the present operating instructions must be strictly
observed.
Page 46
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11.1 4 E N
2 Displays and Controls
712535455 6 56 13
16
15
57
58
59
20
Page 47
11.1 4 E N
46
Item Control / Display Function
5 Battery Discharge
Indicator
t Shows the battery charge status
6 Key switch and key t – Activates the truck by applying the
control voltage
– Removing the key prevents the truck
from being switched on by unauthorised
personnel
CanCode code lock o Replaces the key switch
– Entering the correct code activates the
truck
– Travel program selection
– Code setting
ISM access module o Replaces the key switch
– Activates the truck via a card /
transponder
– Displays readiness for operation
– Operational data logging
– Data exchange with card / transponder
7 Display and control unit o Displays key travel and lift parameters,
warnings, notification of incorrect operation
and service displays, replaces the
discharge indicator
12 Multi-Pilot t Controls:
– Travel in drive direction / load direction
– Load handler lift / lower
13 Emergency Disconnect
switch
t Disconnects the battery supply
– All electric functions are cut out and the
industrial truck decelerates
15 Floor plate height
adjuster
t Button for releasing and adjusting the floor
plate height
16 Steering wheel t Steers the truck
20 Deadman switch t Deadman switch pressed:
– Travel and lifting enabled.
Deadman switch not pressed:
– Travel and lifting are deactivated.
– The truck brakes to a halt.
53 “Warning” button t Warning button
54 "Wheel arm lift" button o Button for lifting the wheel arms
55 "Wheel arm lower" button o Button for lowering the wheel arms
56 “Seat heater” switch o – Switches the seat heating on and off
– Displays the seat heating when switched
on
57 Seat adjustment lever t Adjusts the driver's seat horizontally
58 Seat cushioning
adjusting wheel
t Sets the ideal seat cushioning for the
driver's weight
Page 48
47
11.1 4 E N
59 Backrest adjustment
lever
t Adjusts the backrest tilt
Item Control / Display Function
712535455 6 56 13
16
15
57
58
59
20
Page 49
11.1 4 E N
48
2.1 Battery discharge indicator
When the truck has been released via the key
switch, CanCode or ISM, the battery charge status
is displayed. The LED colours (60) represent the
following conditions:
Z If the LED is red, the load can no longer be lifted. Lifting is only enabled when the
battery connected is at least 70% charged.
If the LED flashes red and the truck is not ready for operation, inform the
manufacturer's service department. Red flashing is a truck controller code. The
flashing sequence indicates the type of fault.
LED colour Charge status
Green 40–100%
Orange 30–40%
Green/orange
flashes at 1 Hz
20–30%
Red 0–20%
60
Page 50
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11.1 4 E N
2.2 Battery discharge monitor
Z The standard setting for the battery discharge indicator / discharge monitor is
based on standard batteries. When using maintenance-free or special batteries,
the display and cut-out points of the battery discharge monitor must be set by
manufacturer's service department. If this adjustment is not made, the battery may
become damaged due to deep discharge.
NOTE
Full discharge can damage the battery
Self-discharge can cause the battery to fully discharge. Full discharge shortens the
useful life of the battery.
XCharge the battery at least every 2 months.
Z Charge the battery see "Charging the battery" on page 37.
If the residual capacity falls below the required level, lifting is inhibited. An alternating
display (60) appears. Lifting is only released when the battery connected is at least
70% charged.
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50
3 Preparing the Truck for Operation
3.1 Checks and operations to be performed before starting daily
operation
WARNING!
Risk of accident due to damage to or other defects in the truck and optional
features
If damage or other truck or attachment (optional equipment) defects are discovered
during the following checks, the truck must be taken out of service until it has been
repaired.
XReport any defects immediately to your supervisor.
XMark defective truck and take out of service.
XDo not return the industrial truck to service until you have identified and rectified the
fault.
Inspection before daily operation
Procedure
• Check the whole of the outside of the truck for signs of damage and leaks.
Damaged hoses must be replaced immediately.
• Check the battery attachment and wire connections for damage and make sure
they are secure.
• Check the battery connectors are secure.
• Check the overhead guard for damage.
• Check the load handler for visible signs of damage such as cracks, bent or severely
worn forks.
• Check the drive wheel and load wheels for damage.
• Check that the lift chains are evenly tensioned and damage-free.
• Check that the markings and labels are present, clean and legible, see
"Identification points and data plates" on page 26.
• Make sure the drive panels and covers are secure and check for damage.
Page 52
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11.1 4 E N
3.2 Preparing the truck for operation
Switching on the truck
Requirements
– For checks and operations to be performed before starting daily operation, see
"Checks and operations to be performed before starting daily operation" on
page 50.
Procedure
• Enter the operator position, see "Entry and exit" on page 55.
• Pull the Emergency Disconnect switch (13) to unlock it.
• Switch on the truck, to do this
• Insert the key in the key switch (6) and turn it as far to the right as it will go.
• Enter the code in the code lock (8) (o).
• Hold the card or transponder in front of the ISM access module and depending
on the setting press the green button on the ISM access module (o).
The truck is ready for operation.
6,8 13
20
Page 53
11.1 4 E N
52
3.3 Checks and operations to be carried out when the truck is
operational
WARNING!
Risk of accident due to damage to or other defects in the truck and optional
features
If damage or other truck or attachment (optional equipment) defects are discovered
during the following checks, the truck must be taken out of service until it has been
repaired.
XReport any defects immediately to your supervisor.
XMark defective truck and take out of service.
XDo not return the industrial truck to service until you have identified and rectified the
fault.
Procedure
• Test warning indicators and safety devices:
• Test the Emergency Disconnect function by pressing the Emergency Disconnect
switch. The main circuit is disconnected and no truck operations can be
performed. Now pull the Emergency Disconnect switch to unlock it.
• Test the horn by pressing the "warning signal" button.
• Test the effectiveness of the brakes, see "Brakes" on page 66.
• Test the steering, see "Steering" on page 65.
• Test the hydraulic system, see "Load handler raise/lower" on page 68.
• Test travel operations, see "Travel" on page 63.
• Test the controls and displays and check for damage, see "Displays and Controls"
on page 45.
• Check the controls are automatically restored to the neutral position after being
applied.
Page 54
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11.1 4 E N
3.4 Parking the truck securely
WARNING!
An unsecured truck can cause accidents
Parking the truck on an incline, without the brakes applied or with a raised load or load
handler is dangerous and is strictly prohibited.
XPark the truck on a level surface. In special cases the truck may need to be secured
with wedges.
XFully lower the load handler.
XSelect a place to park where no other people are at risk of injury from the lowered
load handler.
XIf the brakes are not working, place wedges underneath the wheels of the truck to
prevent it from moving.
Page 55
11.1 4 E N
54
Parking the truck securely
Procedure
• Park the truck on a level surface.
• Fully lower the load handler (61):
• Apply the “wheel arm lower” button (55) .
• Press the Multi-Pilot (12) in the arrow direction.
• Set the drive wheel to “Straight ahead”.
• Switch off the truck, to do this:
• Turn the key in the key switch (6) anti-clockwise as far as it will go. Remove the
key from the key switch (6).
• For CanCode (8), press the O key (o).
• Press the red key on the ISM access module (o).
• Press the Emergency Disconnect switch (13).
The truck is parked.
55 6,81312
61
Page 56
55
11.1 4 E N
3.5 Entry and exit
Requirements
– Load handler fully lowered.
Procedure
Z Always enter and exit the truck facing the load direction.
• To enter and exit, hold onto the handle (62).
• Enter or leave the truck.
CAUTION!
No more than one person may operate the truck at a time.
62
Page 57
11.1 4 E N
56
3.6 Adjusting the floor plate height
Procedure
• Sit down on the driver’s seat.
• Press and hold down on the floor plate height adjustment button (15).
The floor plate can now be adjusted.
• Set the floor plate (63) to the correct height by standing on it / discharging it.
• Release the floor plate height adjustment button (15).
The floor plate is now adjusted and locked at the required height
63 15
Page 58
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11.1 4 E N
3.7 Adjusting the driver’s seat
CAUTION!
An unsecured driver's seat can cause injury
An unsecured driver's seat can slide out of its guide during travel, resulting in
accidents.
XThe driver's seat must be locked in position.
XDo not adjust the driver’s seat while travelling.
Adjusting the driver’s seat
Procedure
• Sit down on the driver’s seat.
• Loosen the seat lock (57) and push it forward or backward to the desired position.
• Lock the seat in position again.
• Undo the backrest lock (59) and bring the backrest into its required position.
• Lock the backrest in position again.
• Set the seat cushioning to the required level by turning the adjusting wheel (58).
The driver's seat is now set in the correct position for the controls.
58
57
59
Page 59
11.1 4 E N
58
4 Industrial Truck Operation
4.1 Safety regulations for truck operation
Travel routes and work areas
Only use lanes and routes specifically designated for truck traffic. Unauthorised third
parties must stay away from work areas. Loads must only be stored in places
specially designated for this purpose.
The truck must only be operated in work areas with sufficient lighting to avoid danger
to personnel and materials. Additional equipment is necessary to operate the truck in
areas of insufficient lighting.
DANGER!
Do not exceed the permissible surface and point loading on the travel lanes.
At blind spots get a second person to assist.
The driver must ensure that the loading dock /dock leveller cannot be removed or
come loose during loading/unloading.
Travel conduct
The operator must adapt the travel speed to local conditions. The truck must be
driven at slow speed when negotiating bends or narrow passageways, when passing
through swing doors and at blind spots. The operator must always observe an
adequate braking distance between the forklift truck and the vehicle in front and must
be in control of the truck at all times. Abrupt stopping (except in emergencies), rapid
U turns and overtaking at dangerous or blind spots are not permitted. Do not lean out
or reach beyond the working and operating area.
Page 60
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11.1 4 E N
Travel visibility
The operator must look in the direction of travel and must always have a clear view
of the route ahead. If the truck is carrying loads that affect visibility, the truck must
travel against the load direction. If this is not possible, a second person must walk
alongside the truck as a lookout to observe the travel route while maintaining eye
contact with the operator. Proceed only at walking pace and with particular care. Stop
the truck as soon as you lose eye contact.
DANGER!
Tipovers can result in fatal accidents
If the truck is in danger of tipping over, incorrect operator action can result in serious
injury and death.
XDo not jump off the truck if it tips over.
XIf the truck tips over on the right side of the load direction, hold onto the option bar
with both hands.
XIf the truck tips over on the left side in the load direction, hold onto the steering
wheel or the display panel with both hands.
XNever hold onto the side where the truck is about to tip over.
XTilt your body in the opposite direction of fall.
Negotiating slopes and inclines
Negotiating slopes and inclines up to 12 % is only permitted when they are
recognised lanes. The slopes and inclines must be clean, have a non-slip surface,
and negotiating them safely must be within the technical specifications of the truck.
The truck must always be driven with the load facing uphill. The industrial truck must
not be turned, operated at an angle or parked on inclines or slopes. Inclines must only
be negotiated at slow speed, with the driver ready to brake at any moment.
Page 61
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60
Negotiating lifts, loading ramps and docks
Lifts may only be negotiated if they have sufficient capacity, are suitable for driving on
and authorised for truck traffic by the owner. The driver must satisfy himself of the
above before entering these areas. The truck must enter lifts with the load in front and
must take up a position which does not allow it to come into contact with the walls of
the lift shaft. Persons riding in the lift with the forklift truck must only enter the lift after
the truck has come to a rest and must leave the lift before the truck. The driver must
ensure that the loading ramp / dock cannot move or come loose during loading /
unloading.
Type of loads to be carried
The operator must make sure that the load is in a satisfactory condition. Loads must
always be positioned safely and carefully. Use suitable precautions to prevent parts
of the load from tipping or falling down. Prevent liquid loads from sloshing out.
WARNING!
Electromagnetic influence can result in accidents
Strong magnets can cause electronic components such as Hall sensors to become
damaged, resulting in accidents.
XDo not use magnets in the operating area of the truck. Exceptions to this rule are
commercial, weak clamping magnets for attaching notices.
Page 62
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11.1 4 E N
4.2 Emergency Disconnect
CAUTION!
Applying maximum braking can result in accidents
Applying the Emergency Disconnect switch during travel will cause the truck to
decelerate to a halt at maximum force. This may cause the load to slide off the load
handler. There is a higher risk of accidents and injury.
XDo not use the Emergency Disconnect switch as a service brake.
XUse the Emergency Disconnect switch during travel only in emergencies.
CAUTION!
Faulty or non-accessible Emergency Disconnect switches can cause accidents
A faulty or non-accessible Emergency Disconnect switch can cause accidents. In
dangerous situations the operator cannot bring the truck to a halt in time by applying
the Emergency Disconnect switch.
XThe operation of the Emergency Disconnect switch must not be affected by any
objects placed in its way.
XReport any defects on the Emergency Disconnect switch immediately to your
supervisor.
XMark defective truck and take out of service.
XDo not return the industrial truck to service until you have identified and rectified the
fault.
Page 63
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62
Press the Emergency Disconnect switch
Procedure
• Press the Emergency Disconnect (13).
All electrical functions are deactivated. The truck brakes to a halt.
Z Press the Emergency Disconnect switch on in emergencies.
Releasing the Emergency Disconnect switch
Procedure
• Pull the Emergency Disconnect switch (13) to unlock it.
All electrical functions are enabled and the truck is operational again (provided the
truck was operational before the Emergency Disconnect was pressed).
Z Trucks with CanCode and ISM access module remain switched off.
6,8
13
20
12
32
7
Page 64
63
11.1 4 E N
4.3 Travel
WARNING!
Collision hazard when operating the truck
Collisions with personnel and equipment can result if the truck is operated with open
panels.
XDo not operate the truck unless the panels and covers are closed and properly
locked.
Requirements
– Start up the truck, see "Preparing the truck for operation" on page 51.
Procedure
• Press the deadman switch (20).
• Set the Multi-Pilot (12) to the required travel direction.
• Move the Multi-Pilot (12) in the load direction (3):
Travel in the load direction.
• Move the Multi-Pilot (12) in the drive direction (2):
Travel in the drive direction.
• Control the travel speed by moving the Multi-Pilot (12):
• The further the Multi-Pilot (12) is moved, the greater the travel speed.
Z When the Multi-Pilot (12) is released, it automatically returns to the neutral position
and the truck brakes.
The brakes are released and the truck moves in the selected direction.
Z The travel direction is indicated on the display (7) (o).
Page 65
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64
4.3.1 Changing direction during travel
CAUTION!
Danger when changing direction during travel
Changing direction during travel causes the truck to decelerate rapidly. When the
truck changes direction, it can start travelling at high speed in the opposite direction
unless the Multi-Pilot is released in time.
XAfter setting off in the opposite direction, apply the Multi-Pilot gently or not at all.
XDo not perform any sudden steering operations.
XAlways face the direction of travel.
XMaintain an adequate overview of the route you are travelling.
Changing direction during travel
Procedure
• Set the Multi-Pilot (12) to the opposite direction while travelling.
The truck decelerates until it starts to travel in the opposite direction.
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11.1 4 E N
4.4 Steering
Requirements
– Start up the truck, see "Preparing the truck for operation" on page 51.
Procedure
• Turn the steering wheel (16) to the left or right.
Z The wheel position is indicated on the display (7) (o).
The truck is steered in the required direction.
1216 7
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11.1 4 E N
66
4.5 Brakes
WARNING!
Accident risk while braking
The truck’s braking response depends largely on the floor condition and the type of
surface. The truck’s braking distance increases when the ground is wet or dirty.
XThe operator must be aware of floor conditions and take them into account when
braking.
XBrake with care to prevent the load from slipping.
The truck can brake in two ways:
– With the service brake (deadman switch)
– By regenerative braking (coasting brake).
CAUTION!
XUse the service brake in emergencies.
Braking with the service brake
Procedure
• During travel, take your foot off the deadman switch (20).
The truck decelerates regeneratively at the maximum rate until it comes to a halt. The
parking brake then applies.
Regenerative braking
Procedure
• While travelling, release the Multi-Pilot (12).
The Multi-Pilot reverts to the neutral position. The truck brakes regeneratively to a
halt. The parking brake then applies.
Z The brake force can be set by the manufacturer’s customer service department.
Page 68
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11.1 4 E N
4.5.1 Deadman button
The deadman switch (20) must be pressed to lift, lower or travel.
If the deadman switch is released during travel, the truck decelerates at the maximum
rate until it stops.
If the deadman switch is released during lifting or lowering, the respective function
cuts out immediately.
20
12
Page 69
11.1 4 E N
68
4.6 Load handler raise/lower
WARNING!
Accident risk when lifting and lowering
Other people can be injured in the truck's hazardous area.
The hazardous area is defined as the area in which people are at risk from the
movement of the truck including the load handler, etc. This also includes areas which
can be reached by falling loads, operating equipment, etc.
Apart from the driver (in the normal operating position) there should be no other
people in the truck's hazardous area.
XInstruct other people to move out of the hazardous area of the truck. Stop working
with the truck if people do not leave the hazardous area.
XIf people do not leave the hazardous area despite the warning, prevent the truck
from being used by unauthorised people.
XOnly carry loads that have been secured and positioned in accordance with
regulations. Use suitable precautions to prevent parts of the load from tipping or
falling down.
XNever exceed the maximum loads specified on the capacity plate.
XDo not stand on the load handler.
XDo not lift other people on the load handler.
XNever reach or climb into moving truck parts.
XDo not climb onto parts of the building or other trucks.
Page 70
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11.1 4 E N
4.6.1 Raising the load handler
Requirements
– Prepare the truck for operation, see "Preparing the truck for operation" on page 51.
– Deadman switch pressed, see page 67.
Procedure
• Pull the Multi-Pilot (12) in the arrow
direction until you reach the required
lift height.
Z The lift and lower speeds can be
infinitely controlled by moving the
Multi-Pilot.
Short movement = slow lift / lower
Large movement = fast lift / lower
The load handler is raised.
4.6.2 Lowering the load handler
Requirements
– Prepare the truck for operation, see "Preparing the truck for operation" on page 51.
– Deadman switch pressed, see page 67.
Procedure
• Push the Multi-Pilot (12) in the arrow
direction until you reach the required
lift height.
Z The lift and lower speeds can be
infinitely controlled by moving the
Multi-Pilot.
Short movement = slow lift / lower
Large movement = fast lift / lower
The load handler is lowered.
12
12
Page 71
11.1 4 E N
70
4.6.3 Raising the wheel arms
Z Wheel arm lift, also known as initial lift (ESC 316z only), increases the ground
clearance when transporting goods on uneven surfaces.
Requirements
– Prepare the truck for operation, see
"Preparing the truck for operation" on
page 51.
– Deadman switch pressed, see
page 67.
Procedure
• Press the "wheel arm lift" button (54)
on the Multi-Pilot.
Z Press down on the button until the
wheel arms have reached their
maximum height.
The wheel arms are raised.
1254 55
Page 72
71
11.1 4 E N
4.6.4 Lowering the wheel arms
Requirements
– Prepare the truck for operation, see "Preparing the truck for operation" on page 51.
– Deadman switch pressed, see page 67.
Procedure
• Press the "wheel arm lower" button (55) on the Multi-Pilot.
Z Press down on the button until the wheel arms are fully lowered.
The wheel arms are lowered.
Safety height on the ESC 316z
Z To ensure the operational stability of the truck the wheel arms must first be lowered
beyond a load handler lift height of approx. 1.80 m before you can continue lifting.
Beyond this height, wheel arm lift is inhibited.
Page 73
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72
4.7 Lifting, transporting and depositing loads
WARNING!
Unsecured and incorrectly positioned loads can cause accidents.
Before lifting a load unit, the driver must make sure that it has been correctly
palletised and does not exceed the truck’s capacity.
XInstruct other people to move out of the hazardous area of the truck. Stop working
with the truck if people do not leave the hazardous area.
XOnly carry loads that have been correctly secured and positioned. Use suitable
precautions to prevent parts of the load from tipping over or falling off the truck.
XDamaged loads must not be transported.
XNever exceed the maximum loads specified on the load diagram.
XNever stand underneath a raised load handler.
XDo not stand on the load handler.
XDo not lift other people on the load handler.
XInsert the load handler as far as possible underneath the load.
Page 74
73
11.1 4 E N
4.7.1 Raising a load
Requirements
– Load correctly palletised.
– Load weight matches the truck's
capacity.
– Load handler evenly loaded for heavy
loads.
Procedure
• Drive the truck carefully up to the
pallet.
• Drive the load handler slowly into the
pallet until the pallet is against the back
of the load handler (see graphic to the
right).
Z The load must not extend by more than
50 mm beyond the load handler tips.
• Raise the load handler until the desired height is reached, (see page 69).
The load is being raised.
NOTE
Risk of material damage to the hydraulic unit
When the mechanical stops of the load handler have been reached, release the "raise
load handler" button. Otherwise the hydraulic unit may suffer material damage.
Page 75
11.1 4 E N
74
4.7.2 Transporting loads
Requirements
– Load raised correctly.
– Mast lowered for transport (approx. 150
- 200 mm above the ground).
– Good ground conditions.
Procedure
• Accelerate and decelerate with care.
• Adapt your travel speed to the conditions
of the route and the load you are
transporting.
• Travel at a constant speed.
• Be prepared to brake at all times.
• Brake gently in normal circumstances.
• Only stop abruptly in hazardous situations.
• Watch out for other traffic at crossings and passageways.
• Always travel with a lookout at blind spots.
• Do not travel across or at an angle on inclines. Do not turn on slopes and inclines,
and always drive with the load facing uphill (see graphic).
4.7.3 Depositing a load
CAUTION!
Loads must not be set down on transport or escape routes, in front of safety
installations or factory equipment that must be accessible at all times.
Requirements
– Storage location suitable for storing the load.
Procedure
• Drive the truck carefully up to the storage location.
• Lowers the load handler.
Z To avoid damaging the load and the load handler, avoid setting the load down
abruptly.
• Lower the load handler so that it is clear of the load (see page 69).
• Carefully drive the load handler out from beneath the pallet.
The load is deposited.
Page 76
75
11.1 4 E N
5 Troubleshooting
This chapter enables the operator to localize and rectify basic faults or the results of
incorrect operation himself. When trying to locate a fault, proceed in the order shown
in the remedy table.
Z If, after carrying out the following remedial action, the truck cannot be restored to
operation or if a fault in the electronics system is displayed with a corresponding
error code, contact the manufacturer’s service department.
Troubleshooting must only be performed by the manufacturer’s customer service
department. The manufacturer has a service department specially trained for these
tasks.
In order for customer services to react quickly and specifically to the fault, the
following information is essential:
- Truck serial number
- Event message from the display unit (if applicable)
- Error description
- Current location of truck.
Page 77
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76
5.1 Truck does not start
5.2 Load cannot be lifted
Possible Cause Remedy
Battery connector not inserted Check the battery connector
and insert if necessary
Emergency Disconnect switch pressed Release the Emergency Disconnect
switch, see page 61
Key switch set to O Set the key switch to “I”
Deadman switch not pressed Press deadman switch
Battery charge too low Check battery charge,
Charge battery if necessary, see page 37
Faulty fuse Check fuses see page 119
Incorrect ISM access module transponder
used
Use correct transponder
Incorrect CANCode PIN entered Enter correct PIN, see page 85
Possible Cause Remedy
Truck not operational Carry out all measures listed under “Truck
does not start”
Hydraulic oil level too low Check the hydraulic oil level see page 117
Battery discharge monitor has switched
off
Charge the battery, see page 37
Faulty fuse Check fuses see page 119
Excessive load Note maximum capacity, see data plate
Switch in mast implausible
(event message E-2124 appears in the
display and control unit (o)
– Lowering and travelling possible up to
1.5 km/h
– Park the truck securely, see page 53.
– Contact the manufacturer's customer
service department.
Ramp lift activated, wheel arms raised When ramp lift is activated the load can
only be raised up to 1800 mm. Lower the
wheel arms, see page 71.
Page 78
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11.1 4 E N
6 Operating the truck without its own drive system
WARNING!
Accidental truck movement
When the brakes are de-activated the
truck must be parked on a level surface,
since the brakes are no longer effective.
XDo not release the brake on slopes or
inclines.
XDo not park the truck with the brake
released.
XApply the brake again when you reach
your destination.
Releasing the brake
Tools and Material Required
– Two M5x45 screws
– Spanner wrench
Procedure
• Switch off the truck, to do this:
• Turn the key in the key switch (6) anticlockwise as far as it will go. Remove the
key from the key switch (6).
• For CanCode (8)(o) press the O key.
• Press the red button on the ISM access
module(o).
• Press the Emergency Disconnect switch (13).
• Disconnect the battery.
• Use wedges to prevent the truck from moving.
• Remove the drive compartment cover, see "Drive compartment cover disassembly/
assembly" on page 116.
• Insert two M5x45 screws (64) as far as the stop and lift up the anchor plate.
The brake is now released. The truck can be moved.
6,8 13
64
Page 79
11.1 4 E N
78
Activating the brake
Procedure
• Use wedges to prevent the truck from moving.
• Unscrew the two M5x45 screws (64) again.
CAUTION!
Open covers can cause injury and accidents
XThe covers (battery cover, side panels, drive compartment cover etc.) must be
closed during operation.
• Fit the drive compartment cover, see "Drive compartment cover disassembly/
assembly" on page 116.
The brakes are now applied again. The brake is now be applied without current.
WARNING!
Only return the truck to service when you have identified and rectified the fault.
Page 80
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11.1 4 E N
7 Load handler emergency lowering
WARNING!
Lowering the load handler can result in injuries
The hazardous area is defined as the area in which people are at risk from the mast,
the load handler or the load. This also includes areas which can be reached by falling
loads or lowering operating equipment.
XInstruct other people to move out of the hazardous area of the truck during
emergency lowering.
XDo not stand underneath a raised load handler.
XIf the load handler is lowered with the emergency lowering device below it, the
operator must be in a safe area to avoid any danger.
XDo not activate emergency lowering of the load handler when the load handler is in
the rack.
XReport any defects immediately to your supervisor.
XMark defective truck and take out of service.
XDo not return the industrial truck to service until you have identified and rectified the
fault.
Page 81
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80
Load handler emergency lowering
Requirements
– Load handler is not in the rack.
– 3 mm diameter pin, tool etc.
Procedure
• Fully lower the floor plate (63), see
"Adjusting the floor plate height" on
page 56.
• Remove the screws (65) from the
seat cover (66).
• Remove the seat cover (66).
• Using a suitable object push in and
hold down on the emergency
lowering valve (67).
The load handler is lowered.
65
66
63
67
Page 82
81
11.1 4 E N
8 Optional equipment
8.1 Display and control unit
Item Description
68 STOP
69 Parking brake applied
70 WARNING
71 Displays the current steer angle (drive wheel direction)
72 Steer mode, displays possible travel directions
73 Time display (hours: minutes)
60 Battery charge status
74 Discharge indicator
75 Set travel speed for current profile (max = 5 bars)
76 Slow travel activated (reduced travel speed)
77 Profile number (travel profile 1, 2 or 3)
78 Deadman button not pressed
79 Information display
80 Service mode active (icon illuminated),
service interval expired (symbol flashes)
81 Overtemperature
82 Slow travel button, when illuminated the 76 icon illuminates
83 Parking brake button (void)
84 Shift key, to set the time
85 Profile key, selects the travel profile
73
82 84 858381
80
78
76
68 69 70 71 72 60 74
75
77
79
Page 83
11.1 4 E N
82
8.2 Setting the time
Setting the time (73)
Procedure
• Press the Shift key (84) for 8 secs. until the "Set Clock Time" menu is displayed.
• Set the time with the Up (82) and Down (86) keys.
• Confirm with the Shift key (84).
• Set the minutes with the Up (82) and Down (86) keys.
• Confirm with the Shift (84) or profile (85) keys to return to normal operating mode.
The time is now set.
858482 86
Page 84
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11.1 4 E N
8.3 Keypad (CanCode) (o)
8.3.1 Code lock
The code lock allows a user or group of users to assign an individual user code.
Travel programs can also be assigned to the individual user codes. The user code is
configured with a master code and is described in the following sections in this
chapter.
When you have entered the valid user code the truck will be operational. The truck
will be able to perform travel, steering and hydraulic operations.
When you have entered the valid master code the truck will be switched on. Travel
operations are inhibited. The truck will be able to perform steering and hydraulic
operations. The code lock is in programming mode. When you enter one of the
following parameters the settings in the code lock can be changed.
Newly supplied trucks have the code indicated on a sticker. When using the truck for
the first time change the master and user codes and remove the sticker.
– User code factory setting: 2-5-8-0
– Master code factory setting: 7-2-9-5
Z When allocating the codes, ensure the rider trucks are given a different code than
pedestrian trucks.
Parameter Description
0-0-0
– Change master code
(see "Changing the master code" on page 86)
0-0-1
– Add user codes
(see "Add operator code" on page 88)
0-0-2
– Change a user code
(see "Change operator code" on page 90)
0-0-3
– Delete a user code
(see "Delete individual user codes" on page 92)
0-0-4
– Delete all user codes
(see "Delete all user codes," on page 94)
0-1-0
– Switch on the truck automatically
(see "Setting the automatic truck cutout (timeframe)" on
page 96)
0-2-4
– Assign travel programs to the user codes
(see "Assigning the travel program" on page 98)
o
Page 85
11.1 4 E N
84
The keypad consists of 10 digit keys, a Set key (90)
and a o key (92)
Digit keys
The digit keys are used to enter the user or master
code and select the travel program.
The green LEDs of the digit keys 1, 2 and 3 (87, 88,
89) show the travel program setting.
o
key
Pressing the o key switches the truck off and sets it
to "non operational" status.
The o key indicates the follow operating conditions via a red / green LED (91):
– Code lock function (commissioning the truck).
– Error display configuring the user code.
– Adjusting the travel program depending on the setting and truck.
– Setting and changing parameters.
SET key
When you change the parameters the SET key (90) acts as a confirmation key.
1 2 3
4 5 6
7 8 9
0
Set
90
87 88 89
9291
o
Page 86
85
11.1 4 E N
8.3.2 Preparing the truck for operation with the keypad (CanCode)
Preparing the truck for operation by entering a valid operator code
Procedure
• Pull the Emergency Disconnect to unlock it, see "Emergency Disconnect" on
page 61.
The LED (91) lights up red.
• Enter the operator code with the digit keys.
When you have entered a valid operator code the LED (91) lights up green, the
travel program selected is indicated by the corresponding LEDs (87,88,89) and the
truck is switched on.
Z If the LED (91) flashes red this means the wrong code has been entered. Enter the
code again.
The Set key (90) has no function in operating mode.
8.3.3 Switching off the truck with the keypad (CanCode)
Switching off the truck
Procedure
• Press the O key (92).
The truck is switched off and the LED (91) is lit red.
Z The truck can cut out automatically after a specified time. If no travel, steering or
hydraulic operations are performed within a set time, the truck switches off
automatically. When you enter a valid code again the truck will be operational. The
code lock parameter responsible for automatic cutout must be set, see "Setting the
automatic truck cutout (timeframe)" on page 96.
Page 87
11.1 4 E N
86
8.3.4 Changing the master code
Z To change the length of the master code you must follow the procedure in "Choose
length of the new master code (4-6 digit) and add user codes", see "Choose length
of the new master code (4-6 digit) and add user codes" on page 95. If there are still
user codes stored in the code lock, the master code to be changed must be the
same length as the saved user codes.
Requirements
– To prepare the truck for operation, see "Preparing
the truck for operation with the keypad (CanCode)"
on page 85.
Procedure
• Press the O key (92).
• Enter the valid master code with the digit keys.
When you enter the valid master code the LED
(91) flashes green.
• Enter the parameters 0-0-0 with the digit keys.
• Confirm with the SET key (90).
The LEDs (87,91) flash green.
• Enter the valid master code again with the digit keys.
• Confirm with the SET key (90).
The LEDs (88,91) flash green.
• Enter the valid master code with the digit keys.
Z The new master code must be different from existing user codes.
• Confirm with the SET key (90).
The LEDs (89,91) flash green.
• Enter the new master code again with the digit keys.
• Confirm with the SET key (90).
Wait until the LED (91) flashes green. The setting is saved.
• Press the O key (92).
The truck is switched off and the LED (91) is lit red.
• Check the new master code:
• Switch on the truck with the new master code, see "Preparing the truck for
operation with the keypad (CanCode)" on page 85
When you enter the valid master code the LED (91) flashes green.
• Press the O key (92).
The truck is switched off and the LED (91) is lit red.
1 2 3
4 5 6
7 8 9
0
Set
90
87 88 89
9291
Page 88
87
11.1 4 E N
Error displays changing the master code
For the following events the LED (91) flashes red:
Cause Remedy
– New master code is already
occupied by a user code
– Switch off the truck, see "Switching off the truck
with the keypad (CanCode)" on page 85.
– Choose a different master code, see "Changing
the master code" on page 86.
– Change the user code so that the required
master code can be used, see "Change
operator code" on page 90.
– Delete the user code so that the required
master code can be used, see "Delete
individual user codes" on page 92.
– The master codes to be
changed do not match
– Switch off the truck, see "Switching off the truck
with the keypad (CanCode)" on page 85.
– Enter the master code again, see "Changing the
master code" on page 86.
– The master code entered is
not the same length as the
user code
– Switch off the truck, see "Switching off the truck
with the keypad (CanCode)" on page 85.
– Repeat the entry, making sure that the length of
the master code matches that of the user code.
Page 89
11.1 4 E N
88
8.3.5 Add operator code
Requirements
– To prepare the truck for operation, see "Preparing
the truck for operation with the keypad (CanCode)"
on page 85.
Procedure
• Press the O key (92).
• Enter the valid master code with the digit keys.
When you enter the valid master code the LED (91)
flashes green.
• Enter the parameters 0-0-1 with the digit keys.
• Confirm with the SET key (90).
The LEDs (88,91) flash green.
• Enter the new user code with the digit keys.
Z The length (4-6 digit) of the new user code must be the same as that of the
previously entered master code. The new user code must also be different from the
existing master code.
• Confirm with the SET key (90).
The LEDs (89,91) flash green.
• Enter the new user code again with the digit keys.
• Confirm with the SET key (90).
Wait until the LED (91) flashes green. The setting is saved.
• Press the O key (92).
The truck is switched off and the LED (91) is lit red.
• Check the new user code:
• Switch on the truck with the new user code, see "Preparing the truck for
operation with the keypad (CanCode)" on page 85
After entering the valid user code the LED (91) lights up green, the travel
program setting is shown by the illumination of the corresponding LEDs
(87,88,89) and the truck is switched on.
• Press the O key (92).
The truck is switched off and the LED (91) is lit red.
1 2 3
4 5 6
7 8 9
0
Set
90
87 88 89
9291
Page 90
89
11.1 4 E N
Error displays adding a user code
For the following events the LED (91) flashes red:
Cause Remedy
– The user code entered is not
the same length as the
master code
– Switch off the truck, see "Switching off the truck
with the keypad (CanCode)" on page 85.
– Repeat the entry, making sure that the master
code is the same length as the user code.
– New user code is already
occupied by a master code
– Switch off the truck, see "Switching off the truck
with the keypad (CanCode)" on page 85.
– Choose a different user code, see "Add
operator code" on page 88.
– The newly entered user
codes do not match
– Switch off the truck, see "Switching off the truck
with the keypad (CanCode)" on page 85.
– Add the user code again, see "Add operator
code" on page 88.
– Code log full. – Switch off the truck, see "Switching off the truck
with the keypad (CanCode)" on page 85.
– Delete individual user codes, see "Delete
individual user codes" on page 92.
– Delete all user codes, see "Delete all user
codes," on page 94.
Page 91
11.1 4 E N
90
8.3.6 Change operator code
Requirements
– To prepare the truck for operation, see "Preparing
the truck for operation with the keypad (CanCode)"
on page 85.
Procedure
• Press the O key (92).
• Enter the valid master code with the digit keys.
When you enter the valid master code the LED (91)
flashes green.
• Enter the parameters 0-0-2 with the digit keys.
• Confirm with the SET key (90).
The LEDs (87,91) flash green.
• Enter the user code to be changed with the digit keys.
• Confirm with the SET key (90).
The LEDs (88,91) flash green.
• Enter the new user code with the digit keys.
Z The length (4-6 digit) of the new user code must be the same as that of the
previously entered master code. The new user code must also be different from the
existing master code.
• Confirm with the SET key (90).
The LEDs (89,91) flash green.
• Enter the new user code again with the digit keys.
• Confirm with the SET key (90).
Wait until the LED (91) flashes green. The setting is saved.
• Press the O key (92).
The truck is switched off and the LED (91) is lit red.
• Check the new user code:
• Switch on the truck with the new user code, see "Preparing the truck for
operation with the keypad (CanCode)" on page 85
After entering the valid user code the LED (91) lights up green, the travel
program setting is shown by the illumination of the corresponding LEDs
(87,88,89) and the truck is switched on.
• Press the O key (92).
The truck is switched off and the LED (91) is lit red.
1 2 3
4 5 6
7 8 9
0
Set
90
87 88 89
9291
Page 92
91
11.1 4 E N
Error displays changing a user code
For the following events the LED (91) flashes red:
Cause Remedy
– The user code entered is not
the same length as the
master code
– Switch off the truck, see "Switching off the truck
with the keypad (CanCode)" on page 85.
– Repeat the entry, making sure that the master
code is the same length as the user code.
– Operator code to be
changed does not exist.
– Switch off the truck, see "Switching off the truck
with the keypad (CanCode)" on page 85.
– Check the user code entered.
– The user codes to be
changed do not match
– Switch off the truck, see "Switching off the truck
with the keypad (CanCode)" on page 85.
– Change the user code again, see "Change
operator code" on page 90.
– Tried to change the operator
code to another user code
that already exists.
– Switch off the truck, see "Switching off the truck
with the keypad (CanCode)" on page 85.
– Choose a different user code, see "Change
operator code" on page 90.
Page 93
11.1 4 E N
92
8.3.7 Delete individual user codes
Requirements
– To prepare the truck for operation, see "Preparing
the truck for operation with the keypad (CanCode)"
on page 85.
Procedure
• Press the O key (92).
• Enter the valid master code with the digit keys.
When you enter the valid master code the LED
(91) flashes green.
• Enter the parameters 0-0-3 with the digit keys.
• Confirm with the SET key (90).
The LEDs (88,91) flash green.
• Enter the user code to be deleted with the digit keys.
• Confirm with the SET key (90).
The LEDs (89,91) flash green.
• Enter the user code to be deleted again with the digit keys.
• Confirm with the SET key (90).
Wait until the LED (91) flashes green. The user code is now deleted.
• Press the O key (92).
The truck is switched off and the LED (91) is lit red.
• Check that the user code has been deleted:
• Switch the truck on with the user code to be deleted, see "Preparing the truck for
operation with the keypad (CanCode)" on page 85
After entering the user code the LED (91) flashes red and the truck remains
switched off.
• Press the O key (92).
The truck remains switched off and the LED (91) is lit red.
1 2 3
4 5 6
7 8 9
0
Set
90
87 88 89
9291
Page 94
93
11.1 4 E N
Error displays deleting individual user codes
For the following events the LED (91) flashes red:
Cause Remedy
– The user code entered is not
the same length as the
master code
– Switch off the truck, see "Switching off the truck
with the keypad (CanCode)" on page 85.
– Repeat the entry, making sure that the master
code is the same length as the user code.
– Tried to delete an operator
code that does not exist.
– Switch off the truck, see "Switching off the truck
with the keypad (CanCode)" on page 85.
– Check the user code entered.
– The user codes to be
changed do not match
– Switch off the truck, see "Switching off the truck
with the keypad (CanCode)" on page 85.
– Delete the user code again, see "Delete
individual user codes" on page 92.
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94
8.3.8 Delete all user codes,
Requirements
– To prepare the truck for operation, see "Preparing
the truck for operation with the keypad
(CanCode)" on page 85.
Procedure
• Press the O key (92).
• Enter the valid master code with the digit keys.
When you enter the valid master code the LED
(91) flashes green.
• Enter the parameters 0-0-4 with the digit keys.
• Confirm with the SET key (90).
The LEDs (89,91) flash green.
• Enter the code 3-2-6-5 with the digit keys.
• Confirm with the SET key (90).
Wait until the LED (91) flashes green. All user codes are deleted.
• Press the O key (92).
The truck is switched off and the LED (91) is lit red.
• Check that the user codes have been deleted:
• Switch on the truck with a previous user code, see "Preparing the truck for
operation with the keypad (CanCode)" on page 85.
After entering the user code the LED (91) flashes red and the truck remains
switched off.
• Press the O key (92).
The truck remains switched off and the LED (91) is lit red.
1 2 3
4 5 6
7 8 9
0
Set
90
87 88 89
9291
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11.1 4 E N
8.3.9 Choose length of the new master code (4-6 digit) and add user codes
Z The master code is factory set to a four-digit entry: If necessary, the four-digit
master code can be changed to a five or six-digit entry. Before the master code
length can be changed, all user codes must be deleted. The length of the user code
(4-6 digit) is always determined by the length of the master code.
Requirements
– To prepare the truck for operation, see
"Preparing the truck for operation with the keypad
(CanCode)" on page 85.
Procedure
• Delete all user codes, see "Delete all user
codes," on page 94.
• Enter the new master code (4-6 digit), see
"Changing the master code" on page 86.
• Add user codes again, see "Add operator code"
on page 88.
The length of the new master code is now changed and user codes have been added.
1 2 3
4 5 6
7 8 9
0
Set
90
87 88 89
9291
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96
8.3.10 Setting the automatic truck cutout (timeframe)
Requirements
– To prepare the truck for operation, see "Preparing
the truck for operation with the keypad (CanCode)"
on page 85.
Procedure
• Press the O key (92).
• Enter the valid master code with the digit keys.
When you enter the correct master code the LED
(91) flashes green.
• Enter the 0-1-0 parameter with the digit keys.
• Confirm with the SET key (90).
Wait until the LED (91) flashes green.
• Set the truck automatic cutout (time period) with the digit keys:
• 00:
Automatic truck cutout is deactivated.
• 01 - 30:
Set time period (in minutes) after which the truck automatically cuts out
(minimum cutout time is 1 minute,
maximum cutout time is 30 minutes).
• 31:
After 10 seconds the truck cuts out automatically.
• Confirm with the SET key (90).
Wait until the LED (91) flashes green. The setting is saved.
• Press the O key (92).
The truck is switched off and the LED (91) lights up red.
• Checking the truck's automatic cutout:
• Switch on the truck with a valid operator code, see "Preparing the truck for
operation with the keypad (CanCode)" on page 85.
When you have entered a valid operator code the LED (91) lights up green, the
travel program selected is indicated by the corresponding LEDs (87,88,89) and
the truck is switched on.
• Do not perform any travel, steering or hydraulic operations with the truck.
• Wait until the truck automatically cuts out at the end of the time period.
The truck is switched off and the LED (91) lights up red.
1 2 3
4 5 6
7 8 9
0
Set
90
87 88 89
9291
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11.1 4 E N
Error displays setting the automatic cutout period of the truck
For the following events the LED (91) flashes red:
Cause Remedy
– Cutout time entered is out of
range
– Switch off the truck, see "Switching off the truck
with the keypad (CanCode)" on page 85.
– Enter the time again while making sure it is
within range.
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8.3.11 Assigning the travel program
The travel programs are fixed to the user code and can be released or blocked with
a configuration code. The configuration code can also be used to assign a starting
travel program to each user code.
Z The starting travel program is the travel program that is activated when the truck is
switched on and is displayed by the (87,88,89) LEDs.
LED (87) lit = travel program 1 activated
LED (88) lit = travel program 2 activated
LED (89) lit = travel program 3 activated
The configuration code is four-digit and is comprised as follows:
– 1st digit: Specifies the authorisation for travel program 1:
– 2nd digit: Specifies the authorisation for travel program 2:
– 3rd digit: Specifies the authorisation for travel program 3:
– 4. digit: Specifying the starting travel program
When you add or change a user code all travel programs are enabled, the starting
travel program is travel program 2.
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11.1 4 E N
Specifying a configuration code:
Z The default setting for the travel program configuration code is:
1-1-1-2.
Meaning:
Travel programs 1, 2 and 3 are enabled.
When the truck has been switched on with the selected user code, travel program
2 is activated
Setting Description
1st digit
0
– Travel program 1 is blocked for the user code
selected
1
– Travel program 1 is enabled for the user code
selected
2nd digit
0
– Travel program 2 is blocked for the user code
selected
1
– Travel program 2 is enabled for the user code
selected
3rd digit
0
– Travel program 3 is blocked for the user code
selected
1
– Travel program 3 is enabled for the user code
selected
4th digit
0
– When the truck has been switched on with the
selected user code, no travel program is activated
1
– When the truck has been switched on with the
selected user code, travel program 1 is activated
2
– When the truck has been switched on with the
selected user code, travel program 2 is activated
3
– When the truck has been switched on with the
selected user code, travel program 3 is activated
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