ETM/V 110/112/114/116
04.99-
Operating instructions
50047421
10.05
G
1
0903.GB
Important notes on transporting and mounting load lifting devices
to reach trucks
Transport
Depending on the overall height of the lifting mast and the local conditions transport
can be performed in three different ways
– Standing, with the lifting mast mounted (for trucks with low overall height)
– Standing, with martially mounted lifting mast tilted towards the overhead guard (for
trucks with medium overall height). Hydraulic line for the lifting function is interrupted.
– Standing, with the lifting mast dismounted (for trucks with large overall height)
Safety Instructions for Assembly and Commissioning
f
The assembly of the truck on site, commissioning the truck and instructing the driver
must be carried out by personnel trained and authorised by the manufacturer
Connect the hydraulic lines to the basic machine / mast interface and commission the
truck only after having installed the mast as per the instructions.
1
0903.GB
Important notes on transporting and mounting load lifting devices
to reach trucks
Transport
Depending on the overall height of the lifting mast and the local conditions transport
can be performed in three different ways
– Standing, with the lifting mast mounted (for trucks with low overall height)
– Standing, with martially mounted lifting mast tilted towards the overhead guard (for
trucks with medium overall height). Hydraulic line for the lifting function is interrup-
ted.
– Standing, with the lifting mast dismounted (for trucks with large overall height)
Safety Instructions for Assembly and Commissioning
f
The assembly of the truck on site, commissioning the truck and instructing the driver
must be carried out by personnel trained and authorised by the manufacturer
Connect the hydraulic lines to the basic machine / mast interface and commission the
truck only after having installed the mast as per the instructions.
0903.GB 20903.GB
2
0108.GB
Foreword
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. Each chapter
starts with page 1. The page identification consists of a chapter letter and a page
number.
For example: Page B 2 is the second page in chapter B.
The operating instructions detail different truck models. When operating and servicing
the truck, make sure that the instructions apply to your truck model.
Safety instructions and important explanations are indicated by the following
graphics:
f
Used before safety instructions which must be observed to avoid danger to
personnel.
m
Used before notices which must be observed to avoid material damage.
A
Used before notices and explanations.
t Used to indicate standard equipment.
o Used to indicate optional equipment.
Our trucks are subject to ongoing development. Jungheinrich reserves the right to
alter the design, equipment and technical features of the truck. No guarantee of
particular features of the truck should therefore be inferred from the present operating
instructions.
Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
Jungheinrich Aktiengesellschaft
Am Stadtrand 35
22047 Hamburg - GERMANY
Telephone: +49 (0) 40/6948-0
www.jungheinrich.com
0108.GB
Foreword
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. Each chapter
starts with page 1. The page identification consists of a chapter letter and a page
number.
For example: Page B 2 is the second page in chapter B.
The operating instructions detail different truck models. When operating and servicing
the truck, make sure that the instructions apply to your truck model.
Safety instructions and important explanations are indicated by the following
graphics:
f
Used before safety instructions which must be observed to avoid danger to
personnel.
m
Used before notices which must be observed to avoid material damage.
A
Used before notices and explanations.
t Used to indicate standard equipment.
o Used to indicate optional equipment.
Our trucks are subject to ongoing development. Jungheinrich reserves the right to
alter the design, equipment and technical features of the truck. No guarantee of
particular features of the truck should therefore be inferred from the present operating
instructions.
Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
Jungheinrich Aktiengesellschaft
Am Stadtrand 35
22047 Hamburg - GERMANY
Telephone: +49 (0) 40/6948-0
www.jungheinrich.com
0108.GB
0108.GB
I 1
0903.GB
Table of contents
A Correct use and application of the truck
B Description of the truck
1 Application ........................................................................................ B 1
2 Assembly description and functional description ............................ B 2
2.1 Truck ................................................................................................ B 3
2.2 Load lifting system ........................................................................... B 5
3 Technical data - Standard version ................................................... B 6
3.1 Output data for standard truck versions ........................................... B 6
3.2 Standard hoist frame versions ......................................................... B 6
3.3 Dimensions ...................................................................................... B 7
3.4 EN standards ................................................................................... B 8
3.5 Operation conditions ........................................................................ B 8
4 Location of instruction labels and identification plates .................... B 9
4.1 Truck identification plate) ............................................................... B 10
4.2 Load diagram / capacity / load centre / lifting height ...................... B 10
4.3 Load diagram, capacity / load centre / fork .................................... B 11
4.4 Load diagram, capacity / lateral traversing device ......................... B 11
4.5 Pick-up points for lifting jack ........................................................... B 11
C Transportation and commissioning
1 Loading and unloading of trucks by crane ....................................... C 1
2 Commissioning ................................................................................. C 1
3 Moving a defective truck .................................................................. C 2
D Battery - servicing, recharging, replacement
1 Safety regulations governing the handling of lead-acid batteries ..... D 1
2 Battery type ...................................................................................... D 1
3 Exposing the battery ........................................................................ D 2
3.1 Bypassing the drive current interruption ........................................... D 3
3.2 Battery trolley emergency unlocking system .................................... D 3
4 Charging the battery ......................................................................... D 3
5 Removing and installing the battery ................................................. D 4
6 Battery discharge indicator,
battery discharge monitor and hour meter ....................................... D 5
I 1
0903.GB
Table of contents
A Correct use and application of the truck
B Description of the truck
1 Application ........................................................................................ B 1
2 Assembly description and functional description ............................ B 2
2.1 Truck ................................................................................................ B 3
2.2 Load lifting system ........................................................................... B 5
3 Technical data - Standard version ................................................... B 6
3.1 Output data for standard truck versions ........................................... B 6
3.2 Standard hoist frame versions ......................................................... B 6
3.3 Dimensions ...................................................................................... B 7
3.4 EN standards ................................................................................... B 8
3.5 Operation conditions ........................................................................ B 8
4 Location of instruction labels and identification plates .................... B 9
4.1 Truck identification plate) ............................................................... B 10
4.2 Load diagram / capacity / load centre / lifting height ...................... B 10
4.3 Load diagram, capacity / load centre / fork .................................... B 11
4.4 Load diagram, capacity / lateral traversing device ......................... B 11
4.5 Pick-up points for lifting jack ........................................................... B 11
C Transportation and commissioning
1 Loading and unloading of trucks by crane ....................................... C 1
2 Commissioning ................................................................................. C 1
3 Moving a defective truck .................................................................. C 2
D Battery - servicing, recharging, replacement
1 Safety regulations governing the handling of lead-acid batteries ..... D 1
2 Battery type ...................................................................................... D 1
3 Exposing the battery ........................................................................ D 2
3.1 Bypassing the drive current interruption ........................................... D 3
3.2 Battery trolley emergency unlocking system .................................... D 3
4 Charging the battery ......................................................................... D 3
5 Removing and installing the battery ................................................. D 4
6 Battery discharge indicator,
battery discharge monitor and hour meter ....................................... D 5
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E Operation
1 Safety regulations governing the operation of the truck ................... E 1
2 Description of the operating controls and indicators ........................ E 2
3 Start-up of truck ................................................................................ E 6
3.1 How to use the safety belt o ............................................................ E 7
4 Truck operation ................................................................................ E 9
4.1 Safety regulations applicable when operating the truck ................... E 9
4.2 Driving, steering, braking ............................................................... E 10
4.3 Adjusting the fork tines ................................................................... E 12
4.4 Picking up and setting down loads ................................................. E 12
4.5 Picking up, lifting and transporting of loads .................................... E 14
4.6 Operating an attachment ................................................................ E 15
4.7 Rendering vehicle safe when parking ............................................ E 15
5 Information and service display (LISA) .......................................... E 16
5.1 LED warning lamps ........................................................................ E 17
5.2 Key assignment .............................................................................. E 17
5.3 Displays .......................................................................................... E 18
5.4 Changing truck parameters ............................................................ E 19
6 Fault locating operations ................................................................ E 20
7 Auxiliary electrical systems ............................................................ E 21
7.1 Seat heating ................................................................................... E 21
7.2 Floodlight ....................................................................................... E 21
7.3 360° warning light .......................................................................... E 22
7.4 Flash lamp ...................................................................................... E 22
7.5 DC/DC transformer on/off switch ................................................... E 22
7.6 Override switch ESA ...................................................................... E 23
7.7 LED Lateral traversing device in centre position ............................ E 23
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E Operation
1 Safety regulations governing the operation of the truck ................... E 1
2 Description of the operating controls and indicators ........................ E 2
3 Start-up of truck ................................................................................ E 6
3.1 How to use the safety belt o ............................................................ E 7
4 Truck operation ................................................................................ E 9
4.1 Safety regulations applicable when operating the truck ................... E 9
4.2 Driving, steering, braking ............................................................... E 10
4.3 Adjusting the fork tines ................................................................... E 12
4.4 Picking up and setting down loads ................................................. E 12
4.5 Picking up, lifting and transporting of loads .................................... E 14
4.6 Operating an attachment ................................................................ E 15
4.7 Rendering vehicle safe when parking ............................................ E 15
5 Information and service display (LISA) .......................................... E 16
5.1 LED warning lamps ........................................................................ E 17
5.2 Key assignment .............................................................................. E 17
5.3 Displays .......................................................................................... E 18
5.4 Changing truck parameters ............................................................ E 19
6 Fault locating operations ................................................................ E 20
7 Auxiliary electrical systems ............................................................ E 21
7.1 Seat heating ................................................................................... E 21
7.2 Floodlight ....................................................................................... E 21
7.3 360° warning light .......................................................................... E 22
7.4 Flash lamp ...................................................................................... E 22
7.5 DC/DC transformer on/off switch ................................................... E 22
7.6 Override switch ESA ...................................................................... E 23
7.7 LED Lateral traversing device in centre position ............................ E 23
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F Maintenance of the fork-lift truck
1 Operational safety and environmental protection ..............................F 1
2 Safety regulations applicable to truck maintenance ..........................F 1
3 Servicing and inspection ...................................................................F 3
4 Maintenance Check .........................................................................F 4
5 Lubrication Schedule .........................................................................F 6
5.1 Fuels, coolants and lubricants ...........................................................F 7
5.2 Reservoir filling level ETM/V 110, 112, 114 ......................................F 7
6 Instructions for the servicing operations ............................................F 8
6.1 Preparing the truck for the performance of servicing and
maintenance operations ....................................................................F 8
6.2 Opening the hood ..............................................................................F 8
6.3 Opening the battery doors and the seat hood ...................................F 9
6.4 Checking the hydraulic oil level .........................................................F 9
6.5 Checking the brake fluid level .........................................................F 10
6.6 Safety belt maintenance o .............................................................F 10
6.7 Checking the electric fuses .............................................................F 11
6.8 Recommissioning the truck .............................................................F 12
7 Decommissioning the truck .............................................................F 12
7.1 Operations to be performed prior to decommissioning ...................F 12
7.2 Measures to be taken during decommissioning ..............................F 12
7.3 Recommissioning the truck .............................................................F 13
8 Safety checks to be performed at regular intervals and following
any untoward incidents (D: Accident prevention check
according to BGV D27) ....................................................................F 13
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F Maintenance of the fork-lift truck
1 Operational safety and environmental protection ..............................F 1
2 Safety regulations applicable to truck maintenance ..........................F 1
3 Servicing and inspection ...................................................................F 3
4 Maintenance Check .........................................................................F 4
5 Lubrication Schedule .........................................................................F 6
5.1 Fuels, coolants and lubricants ...........................................................F 7
5.2 Reservoir filling level ETM/V 110, 112, 114 ......................................F 7
6 Instructions for the servicing operations ............................................F 8
6.1 Preparing the truck for the performance of servicing and
maintenance operations ....................................................................F 8
6.2 Opening the hood ..............................................................................F 8
6.3 Opening the battery doors and the seat hood ...................................F 9
6.4 Checking the hydraulic oil level .........................................................F 9
6.5 Checking the brake fluid level .........................................................F 10
6.6 Safety belt maintenance o .............................................................F 10
6.7 Checking the electric fuses .............................................................F 11
6.8 Recommissioning the truck .............................................................F 12
7 Decommissioning the truck .............................................................F 12
7.1 Operations to be performed prior to decommissioning ...................F 12
7.2 Measures to be taken during decommissioning ..............................F 12
7.3 Recommissioning the truck .............................................................F 13
8 Safety checks to be performed at regular intervals and following
any untoward incidents (D: Accident prevention check
according to BGV D27) ....................................................................F 13
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A 1
0600.GB
A Correct use and application of the truck
A
The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are
included in the scope of delivery for this truck. The guidelines are part of these operating instructions and must always be heeded. National regulations are fully applicable.
The fork lift truck described in these operating instructions is a truck that is suitable
for lifting and transporting loads.
It must be used, operated and maintained according to the information in these operating instructions. Any other uses are outside the design envelope and can lead to
injury to persons or damage to equipment and property. Above all, overloading
caused by excessively heavy or unbalanced loads must be avoided. The max. admissible load to be picked up is indicated on the identification plate or load diagram label
shown on the truck. The fork lift truck must not be operated in spaces subject to fire
or explosion hazards, or in spaces where corrosive or very dusty atmospheres prevail.
Duties of the user: A “user” within the meaning of these operating instructions is defined as any natural or legal person who either uses the fork lift truck himself, or on
whose behalf it is used. In special cases (e.g. leasing or renting), the user is considered the person, who, in accordance with existing contractual agreements between the
owner and the user of the fork lift truck, is charged with the observance of the operating duties.
The user must ensure that the truck is not abused and only used within its design limits and that all danger to life and limb of the operator, or third parties, is avoided. In
addition to this, it must be ensured that the relevant accident prevention regulations
and other safety-related provisions, as well as the operating, servicing and maintenance guidelines, are observed. The user must also ensure that all persons operating
the truck have read and understood these operating instructions.
m
If these operating instructions are not observed the warranty becomes void. The
same applies if improper works are carried out at the device by the customer and/or
third parties without permission of our Customer Service.
Mounting of attachments: The mounting or installation of any attachments which
will interfere with, or supplement, the functions of the truck is permitted only after written approval by the manufacturer has been obtained. If necessary, the approval of
local authorities has to be obtained.
Any approval obtained from local authorities does not, however, make the approval
by the manufacturer unnecessary.
A 1
0600.GB
A Correct use and application of the truck
A
The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are
included in the scope of delivery for this truck. The guidelines are part of these ope-
rating instructions and must always be heeded. National regulations are fully applica-
ble.
The fork lift truck described in these operating instructions is a truck that is suitable
for lifting and transporting loads.
It must be used, operated and maintained according to the information in these ope-
rating instructions. Any other uses are outside the design envelope and can lead to
injury to persons or damage to equipment and property. Above all, overloading
caused by excessively heavy or unbalanced loads must be avoided. The max. admis-
sible load to be picked up is indicated on the identification plate or load diagram label
shown on the truck. The fork lift truck must not be operated in spaces subject to fire
or explosion hazards, or in spaces where corrosive or very dusty atmospheres pre-
vail.
Duties of the user: A “user” within the meaning of these operating instructions is de-
fined as any natural or legal person who either uses the fork lift truck himself, or on
whose behalf it is used. In special cases (e.g. leasing or renting), the user is conside-
red the person, who, in accordance with existing contractual agreements between the
owner and the user of the fork lift truck, is charged with the observance of the opera-
ting duties.
The user must ensure that the truck is not abused and only used within its design li-
mits and that all danger to life and limb of the operator, or third parties, is avoided. In
addition to this, it must be ensured that the relevant accident prevention regulations
and other safety-related provisions, as well as the operating, servicing and mainte-
nance guidelines, are observed. The user must also ensure that all persons operating
the truck have read and understood these operating instructions.
m
If these operating instructions are not observed the warranty becomes void. The
same applies if improper works are carried out at the device by the customer and/or
third parties without permission of our Customer Service.
Mounting of attachments: The mounting or installation of any attachments which
will interfere with, or supplement, the functions of the truck is permitted only after writ-
ten approval by the manufacturer has been obtained. If necessary, the approval of
local authorities has to be obtained.
Any approval obtained from local authorities does not, however, make the approval
by the manufacturer unnecessary.
0600.GB
A 2
0600.GB
A 2
B 1
0903.GB
B Description of the truck
1 Application
The ETM/V 110-116 is an electrically driven three-wheel truck incorporating a traversing mast and a lateral seat. It is intended for the lifting and transportation of goods
on level ground. It can pick up pallets of open ground support, pallets provided with
lateral boards arranged outside or inside the range of the load-bearing wheels, or trolleys. Loads can be stacked in and out and transported across greater distances.
Its capacity is shown on the identification label.
Type Capacity Load centre distance
ETM/V 110 1000 kg 600 mm
ETM/V 112 1200 kg 600 mm
ETM/V 114 1400 kg 600 mm
ETV 116 1600 kg 600 mm
B 1
0903.GB
B Description of the truck
1 Application
The ETM/V 110-116 is an electrically driven three-wheel truck incorporating a traver-
sing mast and a lateral seat. It is intended for the lifting and transportation of goods
on level ground. It can pick up pallets of open ground support, pallets provided with
lateral boards arranged outside or inside the range of the load-bearing wheels, or trol-
leys. Loads can be stacked in and out and transported across greater distances.
Its capacity is shown on the identification label.
Type Capacity Load centre distance
ETM/V 110 1000 kg 600 mm
ETM/V 112 1200 kg 600 mm
ETM/V 114 1400 kg 600 mm
ETV 116 1600 kg 600 mm
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B 2
2 Assembly description and functional description
Item Designation Item Designation
1
t
Clear-view lifting mast 10
t
Drive wheel
2
t
Overhead guard 11
t
Foot switch
3
t
Free-lift cylinder 12
t
Battery trolley unlocking system
4
o
Auxiliary hydraulics (ZH2) 13
t
Parking brake
5
t
Control lever „Mast tilting“ 14
t
Key switch
6
t
Control lever „Traversing of
Mast“
15
t
Master switch (emergency stop)
7
t
Solo-pilot 16
t
Information and
service display (LISA)
8
t
Load-bearing wheels 17
o
Safety belt
9
t
Wheel arm
t
= Standard equipment
o
= Optional equipment
0903.GB
B 2
2 Assembly description and functional description
Item Designation Item Designation
1
t
Clear-view lifting mast 10
t
Drive wheel
2
t
Overhead guard 11
t
Foot switch
3
t
Free-lift cylinder 12
t
Battery trolley unlocking system
4
o
Auxiliary hydraulics (ZH2) 13
t
Parking brake
5
t
Control lever „Mast tilting“ 14
t
Key switch
6
t
Control lever „Traversing of
Mast“
15
t
Master switch (emergency stop)
7
t
Solo-pilot 16
t
Information and
service display (LISA)
8
t
Load-bearing wheels 17
o
Safety belt
9
t
Wheel arm
t
= Standard equipment
o
= Optional equipment
B 3
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2.1 Truck
Safety installations: The enclosed truck contour featuring rounded edges ensures
safe handling of the ETM/V 110-116 truck. The driver is protected by the overhead
guard (2). The drive wheel (10) and the load-bearing wheels (8) are enclosed by a
sturdy collision guard.
The master switch (15) ensures instant cut-out of all electrical functions in an emergency. Six red LED warning lights in the information and service display (16) indicate
the following states:
– Direction of motion Forward (V), „Drive direction“
– Parking brake applied
– Direction of motion Backward (R), „Load direction“
– Lack of brake liquid
– Center position of lateral traversing device (option)
– Battery locking
In case of malfunctions within the hydraulic system, line break safety devices limit the
speed at which the load is lowered.
Indicating instruments: Information and service display (LISA) (16) with large indications in LCD-technology. Hour meter and battery discharge indicator with lifting movement cut-out function.
Drive system: The complete drive unit is screwed into the vehicle chassis. A stationary shunt motor with an output of 5.4 kW drives the drive wheel (10) via a spur wheel
gear. The electronic drive current control system provides variable speed to the drive
motor, thus allowing smooth starting without jerks, vigorous accelerating and electronically controlled regenerative braking.
The rate of energy regeneration can be set with the LISA system.
Brake system: Two independent brake systems act on the drive wheel. The service
brake is designed as a hydraulic drum brake with asbestos-free brake linings and is
applied by means of the foot pedal. The parking brake (12) acts mechanically as an
electromagnetic brake on the drum brake by pulling a rope.
The brake fluid level is monitored by the LISA system. A warning light shows when
the parking brake is applied.
Steering system: Chain-operated steering using a steering gear and, as standard,
hydraulic steering. The pivoted drive unit can be swivelled by 90° to both sides. The
steering head can be adjusted hrizontally.
Driver position: The driver’s place is ergonomically designed and equipped with a
large foot space. In order to obtain an ergonomic seating position, the driver can adjust the driver’s seat and the steering column.
Accelerator and brake pedals are arranged as found in normal vehicles.
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2.1 Truck
Safety installations: The enclosed truck contour featuring rounded edges ensures
safe handling of the ETM/V 110-116 truck. The driver is protected by the overhead
guard (2). The drive wheel (10) and the load-bearing wheels (8) are enclosed by a
sturdy collision guard.
The master switch (15) ensures instant cut-out of all electrical functions in an emer-
gency. Six red LED warning lights in the information and service display (16) indicate
the following states:
– Direction of motion Forward (V), „Drive direction“
– Parking brake applied
– Direction of motion Backward (R), „Load direction“
– Lack of brake liquid
– Center position of lateral traversing device (option)
– Battery locking
In case of malfunctions within the hydraulic system, line break safety devices limit the
speed at which the load is lowered.
Indicating instruments: Information and service display (LISA) (16) with large indi-
cations in LCD-technology. Hour meter and battery discharge indicator with lifting mo-
vement cut-out function.
Drive system: The complete drive unit is screwed into the vehicle chassis. A statio-
nary shunt motor with an output of 5.4 kW drives the drive wheel (10) via a spur wheel
gear. The electronic drive current control system provides variable speed to the drive
motor, thus allowing smooth starting without jerks, vigorous accelerating and electro-
nically controlled regenerative braking.
The rate of energy regeneration can be set with the LISA system.
Brake system: Two independent brake systems act on the drive wheel. The service
brake is designed as a hydraulic drum brake with asbestos-free brake linings and is
applied by means of the foot pedal. The parking brake (12) acts mechanically as an
electromagnetic brake on the drum brake by pulling a rope.
The brake fluid level is monitored by the LISA system. A warning light shows when
the parking brake is applied.
Steering system: Chain-operated steering using a steering gear and, as standard,
hydraulic steering. The pivoted drive unit can be swivelled by 90° to both sides. The
steering head can be adjusted hrizontally.
Driver position: The driver’s place is ergonomically designed and equipped with a
large foot space. In order to obtain an ergonomic seating position, the driver can ad-
just the driver’s seat and the steering column.
Accelerator and brake pedals are arranged as found in normal vehicles.
0903.GB
B 4
Item Designation Item Designation
1
t
Clear-view lifting mast 10
t
Drive wheel
2
t
Overhead guard 11
t
Foot switch
3
t
Free-lift cylinder 12
t
Battery trolley unlocking system
4
o
Auxiliary hydraulics (ZH2) 13
t
Parking brake
5
t
Control lever „Mast tilting“ 14
t
Key switch
6
t
Control lever „Traversing of
Mast“
15
t
Master switch (emergency stop)
7
t
Solo-pilot stick 16
t
Information and
service display (LISA)
8
t
Load-bearing wheels 17
o
Safety belt
9
t
Wheel arm
t
= Standard equipment
o
= Optional equipment
0903.GB
B 4
Item Designation Item Designation
1
t
Clear-view lifting mast 10
t
Drive wheel
2
t
Overhead guard 11
t
Foot switch
3
t
Free-lift cylinder 12
t
Battery trolley unlocking system
4
o
Auxiliary hydraulics (ZH2) 13
t
Parking brake
5
t
Control lever „Mast tilting“ 14
t
Key switch
6
t
Control lever „Traversing of
Mast“
15
t
Master switch (emergency stop)
7
t
Solo-pilot stick 16
t
Information and
service display (LISA)
8
t
Load-bearing wheels 17
o
Safety belt
9
t
Wheel arm
t
= Standard equipment
o
= Optional equipment
B 5
0903.GB
Operating controls and indicators: The operating controls and indicators are clearly laid out and arranged at the driver position.
Control lever (5) is used to operate the “Mast tilting” function, control lever (6) to operate the “Forward/backward traversing of mast” function. The solo-pilot stick (7) is
used to operate the “Lifting/lowering” function, to select the direction of travel, to move
the lateral traversing device to the left or right in lateral traversing device operation
(auxiliary hydraulics ZH1) and to actuate the horn.
As an option, an auxiliary hydraulic system (ZH2) can be operated via control lever
(4).
Hydraulic system: Pump unit with an externally ventilated series-wound motor and
a noiseless precision jetting pump. The system is controlled using the individual levers (5-7) and the optional auxiliary hydraulics (4).
Electric system: 48 V two-wire system.
As a standard feature, the truck is equipped with an electronic drive and lifting control
system. The electronic drive control system variably controls the travelling speed and
allows counter-current braking when switching the direction of travel.
The information and service display (LISA) (16) allows a adjustment of the driving and
lifting parameters according to the current requirements. Warning indications, operating error indications and service functions are also shown on the LISA.
For possible drive batteries, see chapter D.
2.2 Load lifting system
Mast holder: The mast holder is borne by supporting rollers. The protracting and re-
tracting movements are carried out directly by a simply telescoping traversing cylinder. The guide rails for the mast holder are screwed onto the wheel arms (9).
Hoist frame: The trucks are equipped with tiltable, telescoping free-vision hoist frames (1) supported by the mast holder. Adjustable lateral rollers and guide pieces absorb the lateral pressure acting on the fork carrier when transporting unbalanced
loads. The mounting of the fork to the fork carrier permits adjustments to be made to
the tines. In the case of the double-lift triplex mast (DZ), the initial lifting sequence of
the load carriage (free lift), which does not change the total height, is effected by a
short free-lift cylinder (3) arranged off-centre. In the case of the telescopic mast (ZT),
the free-lift sequence is limited to 100 mm due to the construction of the truck.
Attachments: Mechanical and hydraulic attachments are available as optional
equipment.
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0903.GB
Operating controls and indicators: The operating controls and indicators are clear-
ly laid out and arranged at the driver position.
Control lever (5) is used to operate the “Mast tilting” function, control lever (6) to ope-
rate the “Forward/backward traversing of mast” function. The solo-pilot stick (7) is
used to operate the “Lifting/lowering” function, to select the direction of travel, to move
the lateral traversing device to the left or right in lateral traversing device operation
(auxiliary hydraulics ZH1) and to actuate the horn.
As an option, an auxiliary hydraulic system (ZH2) can be operated via control lever
(4).
Hydraulic system: Pump unit with an externally ventilated series-wound motor and
a noiseless precision jetting pump. The system is controlled using the individual le-
vers (5-7) and the optional auxiliary hydraulics (4).
Electric system: 48 V two-wire system.
As a standard feature, the truck is equipped with an electronic drive and lifting control
system. The electronic drive control system variably controls the travelling speed and
allows counter-current braking when switching the direction of travel.
The information and service display (LISA) (16) allows a adjustment of the driving and
lifting parameters according to the current requirements. Warning indications, opera-
ting error indications and service functions are also shown on the LISA.
For possible drive batteries, see chapter D.
2.2 Load lifting system
Mast holder: The mast holder is borne by supporting rollers. The protracting and re-
tracting movements are carried out directly by a simply telescoping traversing cylin-
der. The guide rails for the mast holder are screwed onto the wheel arms (9).
Hoist frame: The trucks are equipped with tiltable, telescoping free-vision hoist fra-
mes (1) supported by the mast holder. Adjustable lateral rollers and guide pieces ab-
sorb the lateral pressure acting on the fork carrier when transporting unbalanced
loads. The mounting of the fork to the fork carrier permits adjustments to be made to
the tines. In the case of the double-lift triplex mast (DZ), the initial lifting sequence of
the load carriage (free lift), which does not change the total height, is effected by a
short free-lift cylinder (3) arranged off-centre. In the case of the telescopic mast (ZT),
the free-lift sequence is limited to 100 mm due to the construction of the truck.
Attachments: Mechanical and hydraulic attachments are available as optional
equipment.
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3 Technical data - Standard version
A
Technical data to VDI 2198.
Technical data are subject to alteration and extension in scope.
3.1 Output data for standard truck versions
3.2 Standard hoist frame versions
*) ETM/V 110/112
Designation ETM/V 110 ETM/V 112 ETM/V 114 ETV 116
Q Capacity
(at C = 600 mm)
1000 1200 1400 1600 Kg
C Load centre di-
stance
600 600 600 600 mm
Travelling speed
with / without load
9,4 / 9,9 9,3 / 9,9 9,2 / 9,8 10,3 / 10,6 km/h
Lifting speed
with / without load
0,35 / 0,55 0,34 / 0,55 0,31 / 0,45 0,33 / 0,54 m/s
Lowering speed
with / without load
0,50 0,50 0,50 0,50 m/s
±15%
Traversing speed
with / without load
0,2 0,2 0,2 0,2 m/s
Climbing ability
with / without load
7 / 10 7 / 10 7 / 10 7 / 10 %
Max. climbing ability (max. 5 min)
with / without load
10 / 15 10 / 15 10 / 15 10 / 15 %
Designation Telescopic mast
(ZT)
Double lift triplex
mast (ZZ)*
Double lift
triplex mast (DZ)
h
1
Total height 1950 - 3050 1950 - 2400 1950 - 2900 mm
h
2
Free lift 100 1315 - 1765 1315 - 2256 mm
h
3
Lift 2890 - 5290 2890 - 3790 4250 - 7100 mm
h
4
Max. height 3460 - 5860 3460 - 4360 4894 - 7744 mm
h
2
s
h
2
l
4
l
7
l
1
h
1
h
6
h
3
h
4
Q
c
0903.GB
B 6
3 Technical data - Standard version
A
Technical data to VDI 2198.
Technical data are subject to alteration and extension in scope.
3.1 Output data for standard truck versions
3.2 Standard hoist frame versions
*) ETM/V 110/112
Designation ETM/V 110 ETM/V 112 ETM/V 114 ETV 116
Q Capacity
(at C = 600 mm)
1000 1200 1400 1600 Kg
C Load centre di-
stance
600 600 600 600 mm
Travelling speed
with / without load
9,4 / 9,9 9,3 / 9,9 9,2 / 9,8 10,3 / 10,6 km/h
Lifting speed
with / without load
0,35 / 0,55 0,34 / 0,55 0,31 / 0,45 0,33 / 0,54 m/s
Lowering speed
with / without load
0,50 0,50 0,50 0,50 m/s
±15%
Traversing speed
with / without load
0,2 0,2 0,2 0,2 m/s
Climbing ability
with / without load
7 / 10 7 / 10 7 / 10 7 / 10 %
Max. climbing abili-
ty (max. 5 min)
with / without load
10 / 15 10 / 15 10 / 15 10 / 15 %
Designation Telescopic mast
(ZT)
Double lift triplex
mast (ZZ)*
Double lift
triplex mast (DZ)
h
1
Total height 1950 - 3050 1950 - 2400 1950 - 2900 mm
h
2
Free lift 100 1315 - 1765 1315 - 2256 mm
h
3
Lift 2890 - 5290 2890 - 3790 4250 - 7100 mm
h
4
Max. height 3460 - 5860 3460 - 4360 4894 - 7744 mm
h
2
s
h
2
l
4
l
7
l
1
h
1
h
6
h
3
h
4
Q
c
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3.3 Dimensions
a) with fork length 800 mm; 330 Ah ±0 mm; 420 Ah battery: +84 mm;
560 Ah battery: +174 mm
b) with fork length 800 mm; 560 Ah battery: +90 mm
c) with fork length 800 mm; 560 Ah battery: +90 mm / 700 Ah battery: +180 mm
d) 420 Ah battery: -84 mm; 560 Ah battery: -174 mm
e) 420 Ah battery: ±0 mm; 560 Ah battery: -90 mm
f) with 280 Ah battery
g) with 420 Ah battery
Designation ETM/V 110
(ZT/DZ/ZZ)
ETM/V112
(ZT/DZ)
ETM/V114
(ZT/DZ)
ETV116
(ZT/DZ)
s Height of lowered
fork
40 40 40 40 mm
h
6
Height above overhead guard
2075 2075 2075 2190 mm
l
1
Total length 1870 a) 1954 b) 1957/1985 b)1967/1995 c)mm
l
4
Traversing distance
602 d) 618 e) 624/602 e) 666/644 e) mm
l
7
Length across
wheel arms
1625 1725 1725 1812 mm
b
1
Total width 1120/1238 1120/1238 1120/1238 - /1238 mm
b
2
Total width ETM/V 1106 1106 1106 1186 mm
W
a
Turning radius 1538 1636 1636 1690 mm
Ast Working aisle
width 800 x 1200
pallets, lengthwise
2508/2606 f) 2590/2690 g) 2592/2614 g)2756/2775 g)mm
Ast Working aisle
width1000 x 1200
pallets, crosswise
2308/2566 f) 2390/2653 g) 2392/2414 g)2716/2731 g)mm
Dead weight : Refer to truck identification plate
Ast
b
1
b
2
Wa
B 7
0903.GB
3.3 Dimensions
a) with fork length 800 mm; 330 Ah ±0 mm; 420 Ah battery: +84 mm;
560 Ah battery: +174 mm
b) with fork length 800 mm; 560 Ah battery: +90 mm
c) with fork length 800 mm; 560 Ah battery: +90 mm / 700 Ah battery: +180 mm
d) 420 Ah battery: -84 mm; 560 Ah battery: -174 mm
e) 420 Ah battery: ±0 mm; 560 Ah battery: -90 mm
f) with 280 Ah battery
g) with 420 Ah battery
Designation ETM/V 110
(ZT/DZ/ZZ)
ETM/V112
(ZT/DZ)
ETM/V114
(ZT/DZ)
ETV116
(ZT/DZ)
s Height of lowered
fork
40 40 40 40 mm
h
6
Height above over-
head guard
2075 2075 2075 2190 mm
l
1
Total length 1870 a) 1954 b) 1957/1985 b)1967/1995 c)mm
l
4
Traversing di-
stance
602 d) 618 e) 624/602 e) 666/644 e) mm
l
7
Length across
wheel arms
1625 1725 1725 1812 mm
b
1
Total width 1120/1238 1120/1238 1120/1238 - /1238 mm
b
2
Total width ETM/V 1106 1106 1106 1186 mm
W
a
Turning radius 1538 1636 1636 1690 mm
Ast Working aisle
width 800 x 1200
pallets, lengthwise
2508/2606 f) 2590/2690 g) 2592/2614 g)2756/2775 g)mm
Ast Working aisle
width1000 x 1200
pallets, crosswise
2308/2566 f) 2390/2653 g) 2392/2414 g)2716/2731 g)mm
Dead weight : Refer to truck identification plate
Ast
b
1
b
2
Wa
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B 8
3.4 EN standards
Continuous sound level: 67dB(A)
according to EN 12053 as stipulated in
ISO 4871.
A
The continues sound level is an average value determined according to the standard’s guidelines and takes into consideration the sound level when driving, lifting
and in idle mode. The sound level is measured at the driver’s ear.
Vibration: 0,30 m/s
2
according to document N47E of CEN/TC 150/WG8.
A
The vibration acceleration applied to the operator’s body is measured according the
standard’s guidelines as a linearly integrated, weighted acceleration in vertical direction. The acceleration is measured when driving across bumps at steady speed.
Electromagnetic compatibility (EMC)
The following limit values are observed according to
the product standards “Electromagnetic Compatibility
of Industrial Trucks (9/95)“:
- interference emission (EN 50081-1)
- interference immunity (EN 50082-2)
- electrostatic discharge (EN 61000-4-2).
A
Electrical or electronic components and their arrangement may only be modified after
written approval by the manufacturer has been obtained.
3.5 Operation conditions
Environmental temperature
in operation: –25°C to 40°C
A
If the truck is operated continuously below 0°C, it is recommended to fill the hydraulic
system with frost resisting oil as approved by the manufacturer.
For applications in cold stores resp. in areas with extreme temperature or humidity
changes the truck has to be specially equipped and approved.
0903.GB
B 8
3.4 EN standards
Continuous sound level: 67dB(A)
according to EN 12053 as stipulated in
ISO 4871.
A
The continues sound level is an average value determined according to the stan-
dard’s guidelines and takes into consideration the sound level when driving, lifting
and in idle mode. The sound level is measured at the driver’s ear.
Vibration: 0,30 m/s
2
according to document N47E of CEN/TC 150/WG8.
A
The vibration acceleration applied to the operator’s body is measured according the
standard’s guidelines as a linearly integrated, weighted acceleration in vertical direc-
tion. The acceleration is measured when driving across bumps at steady speed.
Electromagnetic compatibility (EMC)
The following limit values are observed according to
the product standards “Electromagnetic Compatibility
of Industrial Trucks (9/95)“:
- interference emission (EN 50081-1)
- interference immunity (EN 50082-2)
- electrostatic discharge (EN 61000-4-2).
A
Electrical or electronic components and their arrangement may only be modified after
written approval by the manufacturer has been obtained.
3.5 Operation conditions
Environmental temperature
in operation: –25°C to 40°C
A
If the truck is operated continuously below 0°C, it is recommended to fill the hydraulic
system with frost resisting oil as approved by the manufacturer.
For applications in cold stores resp. in areas with extreme temperature or humidity
changes the truck has to be specially equipped and approved.
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4 Location of instruction labels and identification plates
Item Designation
18 Drive direction when locking the steering wheel (option)
19 Load diagram, capacity / lateral traversing device
20 Load diagram, capacity / load centre / fork
21 Load diagram, capacity / load centre / lifting height
21.1 Sign: Put on safety belt
22 Prohibitive sign “Do not reach through the hoist frame”
23 Prohibitive sign “Keep away from under the load lifting device”
24 Pick-up points for crane transportation
25 Warning sign "Low voltage electronics"
26 Truck identification plate
27 Plaque confirming accident prevention checks (only D)
28 Pick-up points for lifting jack
B 9
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4 Location of instruction labels and identification plates
Item Designation
18 Drive direction when locking the steering wheel (option)
19 Load diagram, capacity / lateral traversing device
20 Load diagram, capacity / load centre / fork
21 Load diagram, capacity / load centre / lifting height
21.1 Sign: Put on safety belt
22 Prohibitive sign “Do not reach through the hoist frame”
23 Prohibitive sign “Keep away from under the load lifting device”
24 Pick-up points for crane transportation
25 Warning sign "Low voltage electronics"
26 Truck identification plate
27 Plaque confirming accident prevention checks (only D)
28 Pick-up points for lifting jack
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B 10
4.1 Truck identification plate)
A
In event of queries relating to the truck or spare part orders, please state the serial
no. (30) of the truck.
4.2 Load diagram / capacity / load centre / lifting height
The load diagram (21) shows the capacity of the truck in Q kg with the hoist frame in
vertical position. The diagram indicates the maximum capacity at a standard load
centre* C (in mm) and at the desired lifting height H (in mm) in the form of a table.
*) Apart from the height of the load, the standard load centre also includes the width
of the load.
Example showing the determination of the max. capacity:
At a load centre C of 600 mm and a max. lifting height H of 3600 mm, the max. capacity Qkg is 1105 kg.
Item Designation Item Designation
29 Type 35 Manufacturer
30 Serial No. 36 Min./max. battery weight in kg
31 Rated capacity in kg 37 Drive power in kW
32 Battery: Voltage V 38 Load centre distance in mm
33 Empty weight without battery in kg 39 Year of manufacture
34 Manufacturer logo 40 Option
35
34
3633
3732
3831
3930
4029
0903.GB
B 10
4.1 Truck identification plate)
A
In event of queries relating to the truck or spare part orders, please state the serial
no. (30) of the truck.
4.2 Load diagram / capacity / load centre / lifting height
The load diagram (21) shows the capacity of the truck in Q kg with the hoist frame in
vertical position. The diagram indicates the maximum capacity at a standard load
centre* C (in mm) and at the desired lifting height H (in mm) in the form of a table.
*) Apart from the height of the load, the standard load centre also includes the width
of the load.
Example showing the determination of the max. capacity:
At a load centre C of 600 mm and a max. lifting height H of 3600 mm, the max. capa-
city Qkg is 1105 kg.
Item Designation Item Designation
29 Type 35 Manufacturer
30 Serial No. 36 Min./max. battery weight in kg
31 Rated capacity in kg 37 Drive power in kW
32 Battery: Voltage V 38 Load centre distance in mm
33 Empty weight without battery in kg 39 Year of manufacture
34 Manufacturer logo 40 Option
35
34
3633
3732
3831
3930
4029
B 11
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4.3 Load diagram, capacity / load centre / fork
The load diagram (20) shows the capacity Q of the fork in kg. A diagram shows
the max. capacity at different load
centres (C in mm).
4.4 Load diagram, capacity / lateral traversing device
The load diagram (19) shows the reduced capacity Q in kg with the lateral traversing device extended.
4.5 Pick-up points for lifting jack
For lifting and jacking up the truck (28).
(Refer to chapter F)
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4.3 Load diagram, capacity / load centre / fork
The load diagram (20) shows the capa-
city Q of the fork in kg. A diagram shows
the max. capacity at different load
centres (C in mm).
4.4 Load diagram, capacity / lateral tra-
versing device
The load diagram (19) shows the redu-
ced capacity Q in kg with the lateral tra-
versing device extended.
4.5 Pick-up points for lifting jack
For lifting and jacking up the truck (28).
(Refer to chapter F)
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B 12
C 1
0601.GB
C Transportation and commissioning
1 Loading and unloading of trucks by crane
f
Ensure that the lifting gear is of adequate capacity (Transportation weight = net
weight + battery weight; see truck identification plate)
– To load the truck with lifting gear, lay the loop of the rope around the strut of the
overhead guard (1). Two lifting points (2) are provided on the wheel arms.
– Park the truck and render it safe (refer to chapter E).
– Use chocks to prevent the truck from moving!
m
The lilting gear must be secured to the lifting points in such a way that it does not
come into contact with any attachments when the truck is lifted.
2 Commissioning
m
The truck must only be operated on battery current. Rectified alternate current will damage the electronics. Cables connected to the battery (towing cable) must be less
than 6 meters in length.
To prepare the truck for work following delivery or transportation, the following operations must be performed:
– Check that the equipment is complete.
– If necessary, install the battery. Do not damage the battery cable.
(Refer to chapter D)
– Charge the battery. (Refer to chapter D)
– Commission the truck as prescribed. (Refer to chapter E)
1
2
C 1
0601.GB
C Transportation and commissioning
1 Loading and unloading of trucks by crane
f
Ensure that the lifting gear is of adequate capacity (Transportation weight = net
weight + battery weight; see truck identification plate)
– To load the truck with lifting gear, lay the loop of the rope around the strut of the
overhead guard (1). Two lifting points (2) are provided on the wheel arms.
– Park the truck and render it safe (refer to chapter E).
– Use chocks to prevent the truck from moving!
m
The lilting gear must be secured to the lifting points in such a way that it does not
come into contact with any attachments when the truck is lifted.
2 Commissioning
m
The truck must only be operated on battery current. Rectified alternate current will da-
mage the electronics. Cables connected to the battery (towing cable) must be less
than 6 meters in length.
To prepare the truck for work following delivery or transportation, the following ope-
rations must be performed:
– Check that the equipment is complete.
– If necessary, install the battery. Do not damage the battery cable.
(Refer to chapter D)
– Charge the battery. (Refer to chapter D)
– Commission the truck as prescribed. (Refer to chapter E)
1
2
0601.GB
C 2
3 Moving a defective truck
– Secure the towing device to the recovery vehicle and to the truck to be towed away.
– Disconnect the battery connector
– Release the parking brake.
f
The towed truck must be steered by a person seated on the truck seat. Tow the truck
at a walking pace.
A
As the power steering is not operative, the truck can only be steered with increased
effort.
0601.GB
C 2
3 Moving a defective truck
– Secure the towing device to the recovery vehicle and to the truck to be towed away.
– Disconnect the battery connector
– Release the parking brake.
f
The towed truck must be steered by a person seated on the truck seat. Tow the truck
at a walking pace.
A
As the power steering is not operative, the truck can only be steered with increased
effort.
D 1
0601.GB
D Battery - servicing, recharging,
replacement
1 Safety regulations governing the handling of lead-acid batteries
The truck must be parked and rendered safe, before any operations on batteries are
to be undertaken (refer to Chapter E).
Servicing staff: Recharging, servicing and replacing of batteries must only be performed by qualified personnel. The instructions contained in this operating manual,
and the instructions as prepared by the battery supplier and as available at the battery
recharging station must be observed, when performing the above operations.
Fire protection measures: Smoking and naked flames are not permitted when
handling batteries. No inflammable substances or spark-generating materials must
be present or stored within a distance of 2 meters of the truck parked for battery recharging. The location must be well ventilated and fire fighting equipment must be
kept ready.
Servicing of batteries: The battery cell screw caps must be kept dry and clean. Terminals and cable shoes must be clean, lightly greased with pole grease and must be
securely tightened.
Disposal of the battery: Batteries must only be disposed of as stipulated in the national environmental protection regulations or waste disposal provisions. The manufacturer’s specifications for the disposal must be heeded.
m
Before closing the battery hood, make sure that the battery cable cannot be damaged.
f
Batteries contain dissolved acid, which is toxic and caustic. For this reason protective
clothing and goggles must be worn whenever work is undertaken on batteries. Avoid
physical contact with battery acid. If clothing, skin or eyes have accidentally come into
contact with battery acid, liberally flush the affected parts with clean water. Consult a
doctor, when skin or eyes have come into contact with battery acid. Spilled battery
acid must be immediately neutralized.
2Battery type
The batteries are designed in accordance with IEC 254 / EN 60254.
Depending on use, the ETM/V 110-116 can be equipped with different types of batteries:
1
) Only for ETM/V 110
2
) Only for ETV 116
Capacity Standard Performance-
Enhanced
48 V - 2PzS - Battery 220 Ah
1
) 220L 240HX
48 V - 2PzS - Battery 280 Ah
1
) 280L 300HX
48 V - 3PzS - Battery 330 Ah 330L 360HX
48 V - 3PzS - Battery 420 Ah 420L 450HX
48 V - 4PzS - Battery 560 Ah 560L 600HX
48 V - 5PzS - Battery 700 Ah
2
) 700L 750HX
D 1
0601.GB
D Battery - servicing, recharging,
replacement
1 Safety regulations governing the handling of lead-acid batteries
The truck must be parked and rendered safe, before any operations on batteries are
to be undertaken (refer to Chapter E).
Servicing staff: Recharging, servicing and replacing of batteries must only be per-
formed by qualified personnel. The instructions contained in this operating manual,
and the instructions as prepared by the battery supplier and as available at the battery
recharging station must be observed, when performing the above operations.
Fire protection measures: Smoking and naked flames are not permitted when
handling batteries. No inflammable substances or spark-generating materials must
be present or stored within a distance of 2 meters of the truck parked for battery re-
charging. The location must be well ventilated and fire fighting equipment must be
kept ready.
Servicing of batteries: The battery cell screw caps must be kept dry and clean. Ter-
minals and cable shoes must be clean, lightly greased with pole grease and must be
securely tightened.
Disposal of the battery: Batteries must only be disposed of as stipulated in the na-
tional environmental protection regulations or waste disposal provisions. The manu-
facturer’s specifications for the disposal must be heeded.
m
Before closing the battery hood, make sure that the battery cable cannot be dama-
ged.
f
Batteries contain dissolved acid, which is toxic and caustic. For this reason protective
clothing and goggles must be worn whenever work is undertaken on batteries. Avoid
physical contact with battery acid. If clothing, skin or eyes have accidentally come into
contact with battery acid, liberally flush the affected parts with clean water. Consult a
doctor, when skin or eyes have come into contact with battery acid. Spilled battery
acid must be immediately neutralized.
2Battery type
The batteries are designed in accordance with IEC 254 / EN 60254.
Depending on use, the ETM/V 110-116 can be equipped with different types of bat-
teries:
1
) Only for ETM/V 110
2
) Only for ETV 116
Capacity Standard Performance-
Enhanced
48 V - 2PzS - Battery 220 Ah
1
) 220L 240HX
48 V - 2PzS - Battery 280 Ah
1
) 280L 300HX
48 V - 3PzS - Battery 330 Ah 330L 360HX
48 V - 3PzS - Battery 420 Ah 420L 450HX
48 V - 4PzS - Battery 560 Ah 560L 600HX
48 V - 5PzS - Battery 700 Ah
2
) 700L 750HX
0601.GB
D 2
The battery weights can be seen on the battery identification plate.
Depending on the type of battery used, it is also possible to use models with enhanced performance or maintenance-free batteries.
f
When replacing or installing batteries, ensure that the battery is correctly secured in
the battery compartment of the truck. Battery weight and battery dimensions have a
considerable effect on the stability of the truck. Battery type changes are therefore
permitted only after obtaining approval from the manufacturer.
3 Exposing the battery
– Sit on the driver´s seat
– Render the truck ready for operation (refer to chapter E, section 3).
– Tilt the control lever (1) in direction of arrow (U), drive mast holder to its limit stop
position towards the battery and release control lever (1) (mast is in final position).
– Tilt the control lever (1) once again in direction of arrow (U) and go on driving mast
holder to its limit stop position towards the battery (preparation of battery unlok-
king).
– Actuate the battery trolley unlocking system (4). The LED (2) lights up.
– Tilt the control lever (1) in the T direction and push the mast holder with the coupled
battery trolley forward until the battery is exposed for servicing.
– Switch off the master switch and the key switch.
f
Connecting and disconnecting of battery connector and socket is permitted only with
the master switch and battery charger switched off.
– Withdraw the battery connector (5) from the socket.
– Remove any insulating matting from the batteries.
A
The safety switch of the battery unlocking system interrupts the driving function as
long as the battery trolley is unlocked and the LED (2) is lit. Before commissioning the
truck again, the battery trolley must be returned to the original position to uncouple
the battery trolley and the mast holder. The LED (2) must have gone out.
1
2
5
4
3
0601.GB
D 2
The battery weights can be seen on the battery identification plate.
Depending on the type of battery used, it is also possible to use models with enhan-
ced performance or maintenance-free batteries.
f
When replacing or installing batteries, ensure that the battery is correctly secured in
the battery compartment of the truck. Battery weight and battery dimensions have a
considerable effect on the stability of the truck. Battery type changes are therefore
permitted only after obtaining approval from the manufacturer.
3 Exposing the battery
– Sit on the driver´s seat
– Render the truck ready for operation (refer to chapter E, section 3).
– Tilt the control lever (1) in direction of arrow (U), drive mast holder to its limit stop
position towards the battery and release control lever (1) (mast is in final position).
– Tilt the control lever (1) once again in direction of arrow (U) and go on driving mast
holder to its limit stop position towards the battery (preparation of battery unlok-
king).
– Actuate the battery trolley unlocking system (4). The LED (2) lights up.
– Tilt the control lever (1) in the T direction and push the mast holder with the coupled
battery trolley forward until the battery is exposed for servicing.
– Switch off the master switch and the key switch.
f
Connecting and disconnecting of battery connector and socket is permitted only with
the master switch and battery charger switched off.
– Withdraw the battery connector (5) from the socket.
– Remove any insulating matting from the batteries.
A
The safety switch of the battery unlocking system interrupts the driving function as
long as the battery trolley is unlocked and the LED (2) is lit. Before commissioning the
truck again, the battery trolley must be returned to the original position to uncouple
the battery trolley and the mast holder. The LED (2) must have gone out.
1
2
5
4
3
D 3
0601.GB
3.1 Bypassing the drive current interruption
– Switch on the switch “Cut-back speed” (3).
f
If the battery is protruding, the truck may only be driven at cut-back speed in the battery charging station!
3.2 Battery trolley emergency unlocking system
– Render the truck ready for operation
(refer to chapter E).
– Tilt control lever (1) in direction of ar-
row (U), drive mast holder to its limit
stop position towards the battery and
release control lever (1).
– Tilt control lever (1) once again in di-
rection of arrow (U) and go on driving
mast holder to its limit stop position to-
wards the battery.
– Switch off the master switch and the
key switch.
– Open seat hood(see chapter F)
– Loosen screws (6) of the battery lok-
king system and pull out locking system (7).
– Close seat hood.
– Connect master switch and key switch.
– Tilt the control lever (1) in the T direction and push the mast holder with the coupled
battery trolley forward until the battery is exposed for servicing.
– LED (2) lights up.
– Disconnect main switch and key switch.
A
Eliminate the malfunction of the battery unlocking system before mounting the battery
locking system.
A
The safety switch of the battery unlocking system interrupts the driving function as
long as the battery trolley is unlocked and the LED (2) is lit. Before commissioning the
truck again, the battery trolley must be returned to the original position to uncouple
the battery trolley and the mast holder. The LED (2) must have gone out.
4 Charging the battery
– Expose the battery (refer to section 3).
f
During the recharging operation the tops of the battery cells must be exposed to ensure adequate ventilation. No metal objects must be placed on the battery. Prior to
starting the recharging operation, check all cable connections and plugged connections for visible damage.
– Remove any insulating mats from the battery.
– Connect the charging cable of the battery charger to the battery connector (5).
– Recharge the battery observing the instructions provided by the battery supplier
and by the battery charger supplier.
f
All safety instructions as provided by the battery supplier and battery charger supplier
must be strictly observed.
6
7
D 3
0601.GB
3.1 Bypassing the drive current interruption
– Switch on the switch “Cut-back speed” (3).
f
If the battery is protruding, the truck may only be driven at cut-back speed in the bat-
tery charging station!
3.2 Battery trolley emergency unlocking system
– Render the truck ready for operation
(refer to chapter E).
– Tilt control lever (1) in direction of ar-
row (U), drive mast holder to its limit
stop position towards the battery and
release control lever (1).
– Tilt control lever (1) once again in di-
rection of arrow (U) and go on driving
mast holder to its limit stop position to-
wards the battery.
– Switch off the master switch and the
key switch.
– Open seat hood(see chapter F)
– Loosen screws (6) of the battery lok-
king system and pull out locking system (7).
– Close seat hood.
– Connect master switch and key switch.
– Tilt the control lever (1) in the T direction and push the mast holder with the coupled
battery trolley forward until the battery is exposed for servicing.
– LED (2) lights up.
– Disconnect main switch and key switch.
A
Eliminate the malfunction of the battery unlocking system before mounting the battery
locking system.
A
The safety switch of the battery unlocking system interrupts the driving function as
long as the battery trolley is unlocked and the LED (2) is lit. Before commissioning the
truck again, the battery trolley must be returned to the original position to uncouple
the battery trolley and the mast holder. The LED (2) must have gone out.
4 Charging the battery
– Expose the battery (refer to section 3).
f
During the recharging operation the tops of the battery cells must be exposed to en-
sure adequate ventilation. No metal objects must be placed on the battery. Prior to
starting the recharging operation, check all cable connections and plugged connec-
tions for visible damage.
– Remove any insulating mats from the battery.
– Connect the charging cable of the battery charger to the battery connector (5).
– Recharge the battery observing the instructions provided by the battery supplier
and by the battery charger supplier.
f
All safety instructions as provided by the battery supplier and battery charger supplier
must be strictly observed.
6
7
0601.GB
D 4
5 Removing and installing the battery
– Expose the battery (refer to chapter D, section 3).
f
Batteries with open poles, or open cell bridges, must be covered with a rubber mat to
prevent short-circuiting. When using a crane in battery replacing operations, ensure
that the crane is of adequate capacity (refer to the battery weight indicated on the battery identification plate located at the battery trough). The battery must be lifted vertically to prevent crushing of the battery trough. Lifting hooks must be applied in such
a way that, with the lifting gear slack, they will not drop on to the battery cells.
Removing and installing the battery using lifting gear
– Secure the lifting gear to the battery trough (8).
– Loosen counternut (10) and screw (11) at the red battery lock (9).
– Pull out the red battery lock (9).
– With the lifting gear attached, lift out the battery and move it to one side.
Installation is in the reverse order of operations.
Removing and installing the battery using a battery trolley
f
The truck must stand horizontally so that the battery does not automatically roll out
when the battery safety device is removed.
– Use the service key to open the side door (12).
(only required for battery capacity 560 Ah for ETM/V 110).
– Loosen counternut (10) and screw (11) at the red battery lock (9).
– Pull out the red battery lock (9).
– Pull the battery laterally onto the battery transport trolley.
Installation is in the reverse order of operations.
f
When replacing batteries, ensure that a battery of the same type is fitted. Upon completion of the battery refitting operations, check all cable connections and plugged
connections for any visible damage. Covers and side doors must be safely locked.
10
11
9
8
12
0601.GB
D 4
5 Removing and installing the battery
– Expose the battery (refer to chapter D, section 3).
f
Batteries with open poles, or open cell bridges, must be covered with a rubber mat to
prevent short-circuiting. When using a crane in battery replacing operations, ensure
that the crane is of adequate capacity (refer to the battery weight indicated on the bat-
tery identification plate located at the battery trough). The battery must be lifted verti-
cally to prevent crushing of the battery trough. Lifting hooks must be applied in such
a way that, with the lifting gear slack, they will not drop on to the battery cells.
Removing and installing the battery using lifting gear
– Secure the lifting gear to the battery trough (8).
– Loosen counternut (10) and screw (11) at the red battery lock (9).
– Pull out the red battery lock (9).
– With the lifting gear attached, lift out the battery and move it to one side.
Installation is in the reverse order of operations.
Removing and installing the battery using a battery trolley
f
The truck must stand horizontally so that the battery does not automatically roll out
when the battery safety device is removed.
– Use the service key to open the side door (12).
(only required for battery capacity 560 Ah for ETM/V 110).
– Loosen counternut (10) and screw (11) at the red battery lock (9).
– Pull out the red battery lock (9).
– Pull the battery laterally onto the battery transport trolley.
Installation is in the reverse order of operations.
f
When replacing batteries, ensure that a battery of the same type is fitted. Upon com-
pletion of the battery refitting operations, check all cable connections and plugged
connections for any visible damage. Covers and side doors must be safely locked.
10
11
9
8
12
D 5
0601.GB
6 Battery discharge indicator, battery discharge monitor and hour meter
Battery discharge indicator: The charging state of the battery (13) is indicated in
10% steps in the LISA display.
m
The standard setting of the battery discharge indicator / discharge monitor is
made using standard batteries..
When using maintenance-free batteries,
the indication has to be adjusted in a
way that the symbol (T) (14) comes up
behind the percent indication. When this
setting is not performed, the battery
might suffer damage caused by exhaustive discharge.
Setting of the instrument should be performed by service staff from the manufacturer of the truck.
In case of a rest capacity of the battery of
20% for standard batteries or
40% for maintenance-free batteries, a
battery charge is necessary.
Battery discharge monitor: In case of undershooting the rest capacity the lifting
function is disconnected. LISA indicates a corresponding message.
A
Lifting will only become possible again, after the battery has been recharged to at
least 70 per cent.
Hour meter: The service hours (15) are indicated besides the charging state of the
battery. The hour meter indicates the overall time of the driving and the lifting movements.
BAT T T:0 0%4471h
13 14 15
D 5
0601.GB
6 Battery discharge indicator, battery discharge monitor and hour meter
Battery discharge indicator: The charging state of the battery (13) is indicated in
10% steps in the LISA display.
m
The standard setting of the battery di-
scharge indicator / discharge monitor is
made using standard batteries..
When using maintenance-free batteries,
the indication has to be adjusted in a
way that the symbol (T) (14) comes up
behind the percent indication. When this
setting is not performed, the battery
might suffer damage caused by exhau-
stive discharge.
Setting of the instrument should be per-
formed by service staff from the manu-
facturer of the truck.
In case of a rest capacity of the battery of
20% for standard batteries or
40% for maintenance-free batteries, a
battery charge is necessary.
Battery discharge monitor: In case of undershooting the rest capacity the lifting
function is disconnected. LISA indicates a corresponding message.
A
Lifting will only become possible again, after the battery has been recharged to at
least 70 per cent.
Hour meter: The service hours (15) are indicated besides the charging state of the
battery. The hour meter indicates the overall time of the driving and the lifting move-
ments.
BAT T T:0 0%4471h
13 14 15
0601.GB
D 6
0601.GB
D 6
E 1
1005.GB
E Operation
1 Safety regulations governing the operation of the truck
Driving permission: The truck must only be operated by persons who have been
trained in the operation of trucks, who have demonstrated to the user or his representative their capability of moving and handling loads, and who have expressly been
charged by the user or his representative with the operation of the truck.
Rights, duties and conduct of the driver: The driver must be: informed of his rights
and duties; trained in the operation of the fork-lift truck; and familiar with the contents
of these operating instructions. All necessary rights must be granted to him. If the
fork-lift truck can be used in the pedestrian-controlled mode, the driver must wear
safety boots when operating the truck.
Prohibition of unauthorized use: The driver is responsible for his truck during working time. He must forbid unauthorized persons to drive or operate the truck. The
transport or lifting of persons is forbidden.
Damage and defects: Damage or defects noted on the truck or on the attachments
must immediately be brought to the notice of the person in charge. Trucks that cannot
be safely operated (e.g. due to worn tyres or defective brakes) must not be used until
they have been properly repaired.
Repairs: Without specific training and express authorization the driver is not allowed
to perform any repairs or modifications on the truck. Under no circumstances must
the driver change the setting of switches or safety installations, or render them ineffective.
Danger area: As danger area is considered the area within which persons are endangered by the travelling or lifting movements of the truck or its load lifting devices (e.g.
fork or attachments), or by the loads being transported. This includes also the area
within reach of dropping loads or dropping truck attachments.
f
Unauthorized persons must be asked to leave the danger area. The driver must give
a warning signal, whenever a situation presenting danger to persons might develop.
The truck must immediately be brought to a standstill, if persons, although asked, do
not leave the danger area.
Safety devices and warning labels: The safety devices, warning labels and warning
notes described in the present operating instructions must always be heeded.
E 1
1005.GB
E Operation
1 Safety regulations governing the operation of the truck
Driving permission: The truck must only be operated by persons who have been
trained in the operation of trucks, who have demonstrated to the user or his represen-
tative their capability of moving and handling loads, and who have expressly been
charged by the user or his representative with the operation of the truck.
Rights, duties and conduct of the driver: The driver must be: informed of his rights
and duties; trained in the operation of the fork-lift truck; and familiar with the contents
of these operating instructions. All necessary rights must be granted to him. If the
fork-lift truck can be used in the pedestrian-controlled mode, the driver must wear
safety boots when operating the truck.
Prohibition of unauthorized use: The driver is responsible for his truck during wor-
king time. He must forbid unauthorized persons to drive or operate the truck. The
transport or lifting of persons is forbidden.
Damage and defects: Damage or defects noted on the truck or on the attachments
must immediately be brought to the notice of the person in charge. Trucks that cannot
be safely operated (e.g. due to worn tyres or defective brakes) must not be used until
they have been properly repaired.
Repairs: Without specific training and express authorization the driver is not allowed
to perform any repairs or modifications on the truck. Under no circumstances must
the driver change the setting of switches or safety installations, or render them inef-
fective.
Danger area: As danger area is considered the area within which persons are endan-
gered by the travelling or lifting movements of the truck or its load lifting devices (e.g.
fork or attachments), or by the loads being transported. This includes also the area
within reach of dropping loads or dropping truck attachments.
f
Unauthorized persons must be asked to leave the danger area. The driver must give
a warning signal, whenever a situation presenting danger to persons might develop.
The truck must immediately be brought to a standstill, if persons, although asked, do
not leave the danger area.
Safety devices and warning labels: The safety devices, warning labels and warning
notes described in the present operating instructions must always be heeded.
1005.GB
E 2
2 Description of the operating controls and indicators
Item Operating
control /indicator
Function
1 Control lever
„Inclining of mast“
t
Operates the following function:
– Tilting the hoist frame forward / backward
2 Control lever
„Inclining of fork“
t
Operates the following function:
– Pushing forward / retracting the mast holder
3 Solo-pilot
t
Operates the following functions:
– Forward / reverse drive direction
– Lifting / lowering the load lifting device
– Moving the lateral traversing device to the left /
right
– Horn key
4 Accelerator
t
Stepless control of the truck travelling speed.
5 Brake pedal
t
Braking of the truck.
6 Foot key
t
– not pressed:
The driving and lifting functions, as well as the
auxiliary functions, are locked. The lowering
function remains functional. The truck rolls to a
stop.
– pressed:
The driving and lifting functions, as well as the
auxiliary functions, are released.
7 Driver seat lock
t
Horizontal adjustment of the driver seat.
8 Driver seat weight
adjustment
t
Setting of driver weight for optimum seat damping.
9 Backrest adjustment
t
Adjustment of the driver seat backrest.
10 Steering column adju-
sting mechanism
t
The steering column is adjusted to the required distance and locked in that position.
11 Parking brake
t
Prevents the truck from moving when parked.
12 Battery trolley unlok-
king system
t
Unlocks the battery trolley.
13 Key switch with key t For connection and disconnection of the battery
voltage to the truck.
– Red key (No. 702):
for the user
– Grey key (No. 738):
for service and workshop
14 Switch -
cut-back speed
t
Switches cut-back speed on and off.
t = Standard equipment o = Optional equipment
1005.GB
E 2
2 Description of the operating controls and indicators
Item Operating
control /indicator
Function
1 Control lever
„Inclining of mast“
t
Operates the following function:
– Tilting the hoist frame forward / backward
2 Control lever
„Inclining of fork“
t
Operates the following function:
– Pushing forward / retracting the mast holder
3 Solo-pilot
t
Operates the following functions:
– Forward / reverse drive direction
– Lifting / lowering the load lifting device
– Moving the lateral traversing device to the left /
right
– Horn key
4 Accelerator
t
Stepless control of the truck travelling speed.
5 Brake pedal
t
Braking of the truck.
6 Foot key
t
– not pressed:
The driving and lifting functions, as well as the
auxiliary functions, are locked. The lowering
function remains functional. The truck rolls to a
stop.
– pressed:
The driving and lifting functions, as well as the
auxiliary functions, are released.
7 Driver seat lock
t
Horizontal adjustment of the driver seat.
8 Driver seat weight
adjustment
t
Setting of driver weight for optimum seat damping.
9 Backrest adjustment
t
Adjustment of the driver seat backrest.
10 Steering column adju-
sting mechanism
t
The steering column is adjusted to the required di-
stance and locked in that position.
11 Parking brake
t
Prevents the truck from moving when parked.
12 Battery trolley unlok-
king system
t
Unlocks the battery trolley.
13 Key switch with key t For connection and disconnection of the battery
voltage to the truck.
– Red key (No. 702):
for the user
– Grey key (No. 738):
for service and workshop
14 Switch -
cut-back speed
t
Switches cut-back speed on and off.
t = Standard equipment o = Optional equipment
E 3
1005.GB
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4
8
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13
14
15
16
17
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2
3
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14
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16
17
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1
2
3
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10
1005.GB
E 4
Item Operating
control /indicator
Function
15 Master switch
(emergency stop)
t
The circuit is interrupted, all electrical functions are
switched off and automatic braking of the truck is
triggered.
16 Information and ser-
vice display (LISA)
t
Display of essential driving parameters, lifting parameters, warning signals, operating error indications
and service indications
17 Control lever ZH 2
o
Controls the second auxiliary hydraulic system.
t = Standard equipment o = Optional equipment
1005.GB
E 4
Item Operating
control /indicator
Function
15 Master switch
(emergency stop)
t
The circuit is interrupted, all electrical functions are
switched off and automatic braking of the truck is
triggered.
16 Information and ser-
vice display (LISA)
t
Display of essential driving parameters, lifting para-
meters, warning signals, operating error indications
and service indications
17 Control lever ZH 2
o
Controls the second auxiliary hydraulic system.
t = Standard equipment o = Optional equipment
E 5
1005.GB
6
5
4
8
12
13
14
15
16
17
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1
2
3
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1005.GB
E 6
3 Start-up of truck
f
The driver must make sure that nobody is within the danger area of the truck, before
the truck is switched on or operated, or before a load is lifted.
Checks and operations to be performed before starting daily work
– Perform a visual check of the entire truck (especially wheels and load lifting equip-
ment) for visible damage.
– Check the load chains for uniform tension.
– Visually check the security of the battery and the cable connections.
Adjusting the driver seat
A
To ensure optimum shock absorption, the driver seat must be adjusted to the weight
of the driver.
The driver seat must not be occupied while being adjusted to the driver weight.
Setting the driver weight:
– Pull the lever (8) in the direction indi-
cated by the arrow and release it
again.
A
The previously set driver weight is reset
to the minimum value. Setting range for
the shock absorption: 50 kg to 130 kg.
– Pull the lever (8) again in the direction
indicated indicated by the arrow until
reaching the appropriate weight mark
on the scale (18). Then release the le-
ver again.
– Sit down on the driver seat.
f
Do not reach between the seat and the
chassis wall/overhead guard.
Adjusting the backrest:
– Pull the locking lever (9) upward and adjust the inclination of the backrest (19).
– Release the locking lever again, the backrest is locked in position.
Adjusting the seat position:
– Pull the locking lever (7) of the driver seat locking system outward and move the
driver seat forward or backward to a comfortable position.
– Let the locking lever (7) engage again.
f
The driver seat locking system must be properly engaged in the set position. The position of the seat must not be changed while driving!
A
The driver seat adjusting mechanism shown relates to the standard version. For all
different designs the adjusting instructions as supplied by the manufacturer apply.
When performing the seat adjustments, ensure that all operating controls are within
easy reach.
9
18 8
7
19
1005.GB
E 6
3 Start-up of truck
f
The driver must make sure that nobody is within the danger area of the truck, before
the truck is switched on or operated, or before a load is lifted.
Checks and operations to be performed before starting daily work
– Perform a visual check of the entire truck (especially wheels and load lifting equip-
ment) for visible damage.
– Check the load chains for uniform tension.
– Visually check the security of the battery and the cable connections.
Adjusting the driver seat
A
To ensure optimum shock absorption, the driver seat must be adjusted to the weight
of the driver.
The driver seat must not be occupied while being adjusted to the driver weight.
Setting the driver weight:
– Pull the lever (8) in the direction indi-
cated by the arrow and release it
again.
A
The previously set driver weight is reset
to the minimum value. Setting range for
the shock absorption: 50 kg to 130 kg.
– Pull the lever (8) again in the direction
indicated indicated by the arrow until
reaching the appropriate weight mark
on the scale (18). Then release the le-
ver again.
– Sit down on the driver seat.
f
Do not reach between the seat and the
chassis wall/overhead guard.
Adjusting the backrest:
– Pull the locking lever (9) upward and adjust the inclination of the backrest (19).
– Release the locking lever again, the backrest is locked in position.
Adjusting the seat position:
– Pull the locking lever (7) of the driver seat locking system outward and move the
driver seat forward or backward to a comfortable position.
– Let the locking lever (7) engage again.
f
The driver seat locking system must be properly engaged in the set position. The po-
sition of the seat must not be changed while driving!
A
The driver seat adjusting mechanism shown relates to the standard version. For all
different designs the adjusting instructions as supplied by the manufacturer apply.
When performing the seat adjustments, ensure that all operating controls are within
easy reach.
9
18 8
7
19
E 7
1005.GB
Adjusting the steering column
– Release the steering column locking
mechanism (10) and adjust the incli-
nation and the height of the steering
column (20) as required.
– Tighten steering column locking me-
chanism.
Switching on the truck
– Pull up the master switch (15).
– Insert the key in the key switch (13)
and turn clockwise against the stop to
position "I".
– Check the horn for proper function.
– Check the brake pedal and the parking
brake for correct functioning
(refer to chapter E, section 4.2).
The truck is now ready for operation. The battery discharge monitor shows the current battery capacity.
3.1 How to use the safety belt o
f
Read this section completely before
starting up the floor conveyor.
– Fasten the belt before performing any
movement of the floor conveyor.
– Adjust the belt height setting (49) ac-
cording to your size.
f
The belt protects you against severe injuries.
– If the belt buckle (47) or the belt reel-
up device is frozen in, let it thaw and
dry.
m
The temperature of the warm air-stream
must not exceed +60°C.
f
Do not modify the safety belt.
– After an accident has occurred, check
the safety belt and the seating cover
for damages. Exchange them, if requi-
red.
– Damaged or not fully functioning safe-
ty belts may only be exchanged by
contract dealers or branches.
– Only original spare parts may be used for upgrading or repairs.
15
20
13
10
49
47 48
E 7
1005.GB
Adjusting the steering column
– Release the steering column locking
mechanism (10) and adjust the incli-
nation and the height of the steering
column (20) as required.
– Tighten steering column locking me-
chanism.
Switching on the truck
– Pull up the master switch (15).
– Insert the key in the key switch (13)
and turn clockwise against the stop to
position "I".
– Check the horn for proper function.
– Check the brake pedal and the parking
brake for correct functioning
(refer to chapter E, section 4.2).
The truck is now ready for operation. The battery discharge monitor shows the cur-
rent battery capacity.
3.1 How to use the safety belt o
f
Read this section completely before
starting up the floor conveyor.
– Fasten the belt before performing any
movement of the floor conveyor.
– Adjust the belt height setting (49) ac-
cording to your size.
f
The belt protects you against severe in-
juries.
– If the belt buckle (47) or the belt reel-
up device is frozen in, let it thaw and
dry.
m
The temperature of the warm air-stream
must not exceed +60°C.
f
Do not modify the safety belt.
– After an accident has occurred, check
the safety belt and the seating cover
for damages. Exchange them, if requi-
red.
– Damaged or not fully functioning safe-
ty belts may only be exchanged by
contract dealers or branches.
– Only original spare parts may be used for upgrading or repairs.
15
20
13
10
49
47 48
1005.GB
E 8
o Behaviour in unusual situations
m
Proceed as follows, if there is danger of the floor conveyor tipping over.
– Press the upper part of your body against the the backrest.
– Keep both hands at the steering wheel and use your feed for
additional support.
– Bend your body against the falling direction.
o Operating instruction of the safety belt
Before starting up the floor conveyor, pull the belt continuously
out of the reel-up device and let it catch in with the belt fitting
tight to your body.
f
The belt must not be twisted when being fastened.
When operating the floor conveyor (e.g. driving, lifting, lowering,
etc.) always try to sit with your back having contact with the
backrest.
The locking mechanism of the reel-up device permits enough
freedom of motion when sitting.
f
If you are sitting on the front edge of the seat, protecton will decrease due to the belt band being too loose.
A
Use the belt only for protecting one person.
– After using the belt, press the red button and direct the belt
locking tongue back to the reel-up device with your hand.
o Behaviour for starting up the floor conveyor on steep slopes
The locking mechanism blocks the belt drawing mechanism if the floor conveyor is
parked on a steep slope. The belt can no longer be pulled out of the reel-up device.
A
Drive the floor conveyor carefully out of its slope position and fasten the belt.
1005.GB
E 8
o Behaviour in unusual situations
m
Proceed as follows, if there is danger of the floor conveyor tipping over.
– Press the upper part of your body against the the backrest.
– Keep both hands at the steering wheel and use your feed for
additional support.
– Bend your body against the falling direction.
o Operating instruction of the safety belt
Before starting up the floor conveyor, pull the belt continuously
out of the reel-up device and let it catch in with the belt fitting
tight to your body.
f
The belt must not be twisted when being fastened.
When operating the floor conveyor (e.g. driving, lifting, lowering,
etc.) always try to sit with your back having contact with the
backrest.
The locking mechanism of the reel-up device permits enough
freedom of motion when sitting.
f
If you are sitting on the front edge of the seat, protecton will de-
crease due to the belt band being too loose.
A
Use the belt only for protecting one person.
– After using the belt, press the red button and direct the belt
locking tongue back to the reel-up device with your hand.
o Behaviour for starting up the floor conveyor on steep slopes
The locking mechanism blocks the belt drawing mechanism if the floor conveyor is
parked on a steep slope. The belt can no longer be pulled out of the reel-up device.
A
Drive the floor conveyor carefully out of its slope position and fasten the belt.
E 9
1005.GB
4 Truck operation
4.1 Safety regulations applicable when operating the truck
Driving lanes and work areas: Only such lanes and routes that are specially alloca-
ted for truck traffic must be used. Unauthorized persons must stay away from work
areas. Loads must only be stored at places specially provided for this purpose.
Driving conduct: The travelling speed must be adapted to the prevailing local conditions. The truck must be driven at slow speed when negotiating bends or narrow
passages, when passing through swing doors and at blind spots. The driver must always observe an adequate braking distance between his truck and the vehicle in front
and he must be in control of his truck at all times. Sudden stopping (except in emergencies), rapid U-turns and overtaking at dangerous or blind spots is not permitted. It
is forbidden to lean out of or reach beyond the working and operating area.
Visibility: The driver must look in the direction of travel and must always have a clear
view of the route ahead. When loads blocking the view are carried, the ETM/V 10-12
must be driven with the load at the rear. If this is not possible, a second person must
walk in front of the truck to give suitable warnings.
Negotiating slopes and inclines: Negotiating of slopes and inclines is permitted only, when they are recognized lanes, when they are clean and non-slipping, and when
the technical specification of the truck permits safe driving on such slopes or inclines.
Loads must always be carried at that end of the truck facing uphill. U-turns, cutting
obliquely over slopes or inclines and parking of the truck on slopes or inclines is not
permitted. Inclines must only be negotiated at slow speed with the driver ready to brake at any moment.
Use of lifts and driving on loading platforms: Lifts and loading platforms must only
be used, if they are of adequate load bearing capacity, if suitable for driving on, and
if authorized by the user of the truck for truck traffic. The truck driver has to satisfy
himself accordingly before driving into lifts or on to loading platforms. 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 together with
the truck must only enter the lift after the truck has come safely to a standstill, and
must leave the lift before the truck.
Nature of the loads carried: Only loads that have been safely and correctly secured
must be carried. Never transport loads stacked higher than the top of the fork carriage, or stacked higher than the guard grille.
E 9
1005.GB
4 Truck operation
4.1 Safety regulations applicable when operating the truck
Driving lanes and work areas: Only such lanes and routes that are specially alloca-
ted for truck traffic must be used. Unauthorized persons must stay away from work
areas. Loads must only be stored at places specially provided for this purpose.
Driving conduct: The travelling speed must be adapted to the prevailing local con-
ditions. The truck must be driven at slow speed when negotiating bends or narrow
passages, when passing through swing doors and at blind spots. The driver must al-
ways observe an adequate braking distance between his truck and the vehicle in front
and he must be in control of his truck at all times. Sudden stopping (except in emer-
gencies), rapid U-turns and overtaking at dangerous or blind spots is not permitted. It
is forbidden to lean out of or reach beyond the working and operating area.
Visibility: The driver must look in the direction of travel and must always have a clear
view of the route ahead. When loads blocking the view are carried, the ETM/V 10-12
must be driven with the load at the rear. If this is not possible, a second person must
walk in front of the truck to give suitable warnings.
Negotiating slopes and inclines: Negotiating of slopes and inclines is permitted on-
ly, when they are recognized lanes, when they are clean and non-slipping, and when
the technical specification of the truck permits safe driving on such slopes or inclines.
Loads must always be carried at that end of the truck facing uphill. U-turns, cutting
obliquely over slopes or inclines and parking of the truck on slopes or inclines is not
permitted. Inclines must only be negotiated at slow speed with the driver ready to bra-
ke at any moment.
Use of lifts and driving on loading platforms: Lifts and loading platforms must only
be used, if they are of adequate load bearing capacity, if suitable for driving on, and
if authorized by the user of the truck for truck traffic. The truck driver has to satisfy
himself accordingly before driving into lifts or on to loading platforms. 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 together with
the truck must only enter the lift after the truck has come safely to a standstill, and
must leave the lift before the truck.
Nature of the loads carried: Only loads that have been safely and correctly secured
must be carried. Never transport loads stacked higher than the top of the fork carria-
ge, or stacked higher than the guard grille.
1005.GB
E 10
4.2 Driving, steering, braking
Emergency cut-out
– Depress the master switch (15).
This will switch off all electric functions.
Functioning of the switch must not be affected by object placed on it.
Driving
f
Do not drive the truck unless the hoods
are closed and locked in the stipulated
manner.
The main direction of travel is in the direction of the drive (V). Be especially careful when driving in the direction of the
load (R).
A
The truck should only be driven in the direction of the load (R) for positioning purposes and for picking up or depositing loads.
– Render truck ready for operation (refer to section 3).
– Release the parking brake (11).
– Set the travel direction switch (21) to the desired travelling direction (V) or (R).
– Press the accelerator pedal (4) and the foot key (6).
The truck will now move in the selected direction.
f
The foot key (6) prevents the operator's foot from protuding beyond the truck's contour while driving.
If it is not pressed, all electrical func-tions except for the steering, the information and
service display (LISA), the horn and the battery discharge indicator are deactivated.
The truck rolls to a stop.
The lowering function remains functional.
A
The travelling speed is controlled by means of the accelerator (4).
Steering
When the steering wheel is actuated, the steering booster is automatically switched
on and the position of the drive wheel is set accordingly.
t Contradirectional steering (standard version)
When travelling forward (travel direction switch (21) set to V = drive direction), turning
the steering wheel to the left results in a left turn and turning the wheel to the right in
a right turn.
The position of the drive wheel is shown on the LISA display.
o Synchronized steering
When travelling forward (travel direction switch (21) set to V = drive direction), turning
the steering wheel to the left results in a right turn and turning the wheel to the right
to a left turn.
The position of the drive wheel is shown on the LISA display.
R
V
15
21
11
4
5
6
1005.GB
E 10
4.2 Driving, steering, braking
Emergency cut-out
– Depress the master switch (15).
This will switch off all electric functions.
Functioning of the switch must not be af-
fected by object placed on it.
Driving
f
Do not drive the truck unless the hoods
are closed and locked in the stipulated
manner.
The main direction of travel is in the di-
rection of the drive (V). Be especially ca-
reful when driving in the direction of the
load (R).
A
The truck should only be driven in the direction of the load (R) for positioning purpo-
ses and for picking up or depositing loads.
– Render truck ready for operation (refer to section 3).
– Release the parking brake (11).
– Set the travel direction switch (21) to the desired travelling direction (V) or (R).
– Press the accelerator pedal (4) and the foot key (6).
The truck will now move in the selected direction.
f
The foot key (6) prevents the operator's foot from protuding beyond the truck's con-
tour while driving.
If it is not pressed, all electrical func-tions except for the steering, the information and
service display (LISA), the horn and the battery discharge indicator are deactivated.
The truck rolls to a stop.
The lowering function remains functional.
A
The travelling speed is controlled by means of the accelerator (4).
Steering
When the steering wheel is actuated, the steering booster is automatically switched
on and the position of the drive wheel is set accordingly.
t Contradirectional steering (standard version)
When travelling forward (travel direction switch (21) set to V = drive direction), turning
the steering wheel to the left results in a left turn and turning the wheel to the right in
a right turn.
The position of the drive wheel is shown on the LISA display.
o Synchronized steering
When travelling forward (travel direction switch (21) set to V = drive direction), turning
the steering wheel to the left results in a right turn and turning the wheel to the right
to a left turn.
The position of the drive wheel is shown on the LISA display.
R
V
15
21
11
4
5
6
E 11
1005.GB
Braking
A
The braking behaviour of the truck strongly depends on the state of the floor. This
must be taken into account by the driver for his driving behaviour.
The truck can be braked in three ways:
– by counter-current braking,
– by coasting, or by
– using the service brake.
f
If the truck is operated by several drivers
(for instance in multi-shift operations),
the braking and travelling behaviour of
the truck must be checked, when the parameters are individually set. Check the
truck reactions when taking over the
truck.
Counter-current braking:
– Change over the travelling direction
switch (21) during travel to the opposi-
te driving direction. The truck is then
braked by the drive current control system until movement in the opposite direction
commences.
A
This mode of braking reduces energy consumption, as it involves energy recovery via
the drive current control system.
Braking by coasting:
– Slowly release the accelerator pedal while driving. The truck is braked by the drive
current control according to the position of the accelerator pedal.
Braking using the service brake:
– Depress the brake pedal (5).
A
The truck is braked hydraulically by means of a drum brake (respectively additional
load wheel brakes for ETV 116).
21
4
5
E 11
1005.GB
Braking
A
The braking behaviour of the truck strongly depends on the state of the floor. This
must be taken into account by the driver for his driving behaviour.
The truck can be braked in three ways:
– by counter-current braking,
– by coasting, or by
– using the service brake.
f
If the truck is operated by several drivers
(for instance in multi-shift operations),
the braking and travelling behaviour of
the truck must be checked, when the pa-
rameters are individually set. Check the
truck reactions when taking over the
truck.
Counter-current braking:
– Change over the travelling direction
switch (21) during travel to the opposi-
te driving direction. The truck is then
braked by the drive current control system until movement in the opposite direction
commences.
A
This mode of braking reduces energy consumption, as it involves energy recovery via
the drive current control system.
Braking by coasting:
– Slowly release the accelerator pedal while driving. The truck is braked by the drive
current control according to the position of the accelerator pedal.
Braking using the service brake:
– Depress the brake pedal (5).
A
The truck is braked hydraulically by means of a drum brake (respectively additional
load wheel brakes for ETV 116).
21
4
5
1005.GB
E 12
4.3 Adjusting the fork tines
f
To ensure safe picking up of loads, the tines should be apart as far as possible
and set centrally to the truck. The load
centre must be located centrally between the fork tines.
– Swivel the locking lever (22) upwards.
– Push the fork tines (23) along the fork
carrier (24) to the required position.
– Swivel the locking lever downwards
and deplace the fork until it engages a
groove.
4.4 Picking up and setting down loads
m
Before picking up a load, the driver has
to check that the load rests properly on
its pallet and that it does not exceed the
capacity of his truck.
– Pass the fork tines as far as possible
under the load.
Lifting
f
Persons must not be allowed to stand
under raised forks.
Pull the solo-pilot (3) in the H direction.
A
The inclination angle of the control lever
controls the lifting speed.
– Do not release the solo-pilot until the
desired lifting height has been rea-
ched.
A
If the fork moves against the end stop
(audible noise emitted by the pressure limiting valve), the multi-pilot stick must
immediately be returned to its neutral position.
Lowering
– Push the solo-pilot (3) in the S direction.
A
The inclination angle of the solo-pilot controls the lowering speed.
m
Avoid impacting of the load to prevent damage to the load and to the racking.
23
22
24
H
S
3
1005.GB
E 12
4.3 Adjusting the fork tines
f
To ensure safe picking up of loads, the ti-
nes should be apart as far as possible
and set centrally to the truck. The load
centre must be located centrally bet-
ween the fork tines.
– Swivel the locking lever (22) upwards.
– Push the fork tines (23) along the fork
carrier (24) to the required position.
– Swivel the locking lever downwards
and deplace the fork until it engages a
groove.
4.4 Picking up and setting down loads
m
Before picking up a load, the driver has
to check that the load rests properly on
its pallet and that it does not exceed the
capacity of his truck.
– Pass the fork tines as far as possible
under the load.
Lifting
f
Persons must not be allowed to stand
under raised forks.
Pull the solo-pilot (3) in the H direction.
A
The inclination angle of the control lever
controls the lifting speed.
– Do not release the solo-pilot until the
desired lifting height has been rea-
ched.
A
If the fork moves against the end stop
(audible noise emitted by the pressure li-
miting valve), the multi-pilot stick must
immediately be returned to its neutral po-
sition.
Lowering
– Push the solo-pilot (3) in the S direction.
A
The inclination angle of the solo-pilot controls the lowering speed.
m
Avoid impacting of the load to prevent damage to the load and to the racking.
23
22
24
H
S
3
E 13
1005.GB
f
The fork must be free before they can be lowered from the rack.
Do not start before the fork is completely lowered.
Pushing the mast holder forward
f
Do not reach between the mast and the
battery hood.
– Tilt the control lever (2) in the T direc-
tion to push the mast holder forward
and in the U direction to retract it.
A
The inclination angle of the control lever
controls the traversing speed.
f
Transport runs with or without load must
only be performed with the mast holder
retracted, the hoist frame tilted backwards and the load lifting device lowered.
Mast tilting
– Move control lever (1) in direction (V)
for front inclining and in direction (R)
for back inclining.
U
T
2
R
V
1
E 13
1005.GB
f
The fork must be free before they can be lowered from the rack.
Do not start before the fork is completely lowered.
Pushing the mast holder forward
f
Do not reach between the mast and the
battery hood.
– Tilt the control lever (2) in the T direc-
tion to push the mast holder forward
and in the U direction to retract it.
A
The inclination angle of the control lever
controls the traversing speed.
f
Transport runs with or without load must
only be performed with the mast holder
retracted, the hoist frame tilted back-
wards and the load lifting device lowe-
red.
Mast tilting
– Move control lever (1) in direction (V)
for front inclining and in direction (R)
for back inclining.
U
T
2
R
V
1
1005.GB
E 14
4.5 Picking up, lifting and transporting of loads
– Tilt the control lever (2) in the V or the R direction to bring the fork tines into a hori-
zontal position.
– Move the truck up to the load.
– Tilt the control lever (2) in the T direction to push the mast holder forward.
– Pull the solo-pilot (3) in the H direction to lift the fork tines to the appropriate height.
– Move the fork tines under the load.
– Pull the solo-pilot (3) in the H direction to lift the load clear.
– Tilt the control lever (2) in the U direction to retract the mast holder.
f
Transport runs with or without load must only be performed with the mast holder retracted, the hoist frame tilted backwards and the load lifting device lowered.
– Press the solo-pilot (3) in the S dir. to lower the load to the transport position.
– Pull the control lever (2) in the R direction to tilt the load backward.
– Transport the load to the required location.
– Press the control lever (2) in the V direction to bring the load into the horizontal po-
sition.
– Bring load to the desired height: Pull the solo-pilot (3) the H direction, if necessary,
tilt the control lever (2) the T direction in order to extraxt the mast holder.
– Press the solo-pilot (3) in the S direction to set down the load.
– Pull the control lever (3) in the U direction to retract the mast holder.
1005.GB
E 14
4.5 Picking up, lifting and transporting of loads
– Tilt the control lever (2) in the V or the R direction to bring the fork tines into a hori-
zontal position.
– Move the truck up to the load.
– Tilt the control lever (2) in the T direction to push the mast holder forward.
– Pull the solo-pilot (3) in the H direction to lift the fork tines to the appropriate height.
– Move the fork tines under the load.
– Pull the solo-pilot (3) in the H direction to lift the load clear.
– Tilt the control lever (2) in the U direction to retract the mast holder.
f
Transport runs with or without load must only be performed with the mast holder re-
tracted, the hoist frame tilted backwards and the load lifting device lowered.
– Press the solo-pilot (3) in the S dir. to lower the load to the transport position.
– Pull the control lever (2) in the R direction to tilt the load backward.
– Transport the load to the required location.
– Press the control lever (2) in the V direction to bring the load into the horizontal po-
sition.
– Bring load to the desired height: Pull the solo-pilot (3) the H direction, if necessary,
tilt the control lever (2) the T direction in order to extraxt the mast holder.
– Press the solo-pilot (3) in the S direction to set down the load.
– Pull the control lever (3) in the U direction to retract the mast holder.
E 15
1005.GB
4.6 Operating an attachment
o Integrated lateral traversing device
A
The directions “to the left” and “to the
right” refer to the load lifting device as
seen from the operator’s position.
Moving the lateral traversing device to
the left:
– Press the switch (21) in the X1 direc-
tion.
Moving the lateral traversing device to
the right:
– Press the switch (21) in the Y1 direc-
tion.
f
Reduced capacity must be taken into account when traversing of load is required
(refer to chapter B, section 4.4).
o Hydraulic attachments
The control lever (17) controlling the functions (X2) and (Y2) is provided for the operation of a hydraulic attachment. (Refer to the operating instructions provided by the
manufacturer).
f
Check the capacity of the respective attachment.
f
Observe load chart for the truck with attachment and the truck and attachment operator manuals.
– The attachment must only be operated by trained and authorised personnel.
– Any operation that could affect safety must be prohibited.
– The attachment must only be operated when fully functional.
– Check the attachment for visible signs of damage at least once a shift.
– Report any signs of damage immediately.
21
17
Y1
Y2
X1
X2
E 15
1005.GB
4.6 Operating an attachment
o Integrated lateral traversing device
A
The directions “to the left” and “to the
right” refer to the load lifting device as
seen from the operator’s position.
Moving the lateral traversing device to
the left:
– Press the switch (21) in the X1 direc-
tion.
Moving the lateral traversing device to
the right:
– Press the switch (21) in the Y1 direc-
tion.
f
Reduced capacity must be taken into ac-
count when traversing of load is required
(refer to chapter B, section 4.4).
o Hydraulic attachments
The control lever (17) controlling the functions (X2) and (Y2) is provided for the ope-
ration of a hydraulic attachment. (Refer to the operating instructions provided by the
manufacturer).
f
Check the capacity of the respective attachment.
f
Observe load chart for the truck with attachment and the truck and attachment ope-
rator manuals.
– The attachment must only be operated by trained and authorised personnel.
– Any operation that could affect safety must be prohibited.
– The attachment must only be operated when fully functional.
– Check the attachment for visible signs of damage at least once a shift.
– Report any signs of damage immediately.
21
17
Y1
Y2
X1
X2
1005.GB
E 16
4.7 Rendering vehicle safe when parking
When the vehicle is parked and left unattended, it has to be rendered safe, even if it
is left unattended for only a short period of time.
f
Never park the truck on a slope or incline. The load lifting device must always be completely lowered.
– Press the parking brake switch (11).
– Completely lower the load lifting de-
vice and move it to a horizontal positi-
on.
– Completely retract the mast holder.
– Depress the master switch (15) to the
position "OFF".
– Switch the key switch (13) to the posi-
tion "0" and remove the key from the
key switch.
1513
11
1005.GB
E 16
4.7 Rendering vehicle safe when parking
When the vehicle is parked and left unattended, it has to be rendered safe, even if it
is left unattended for only a short period of time.
f
Never park the truck on a slope or incline. The load lifting device must always be com-
pletely lowered.
– Press the parking brake switch (11).
– Completely lower the load lifting de-
vice and move it to a horizontal positi-
on.
– Completely retract the mast holder.
– Depress the master switch (15) to the
position "OFF".
– Switch the key switch (13) to the posi-
tion "0" and remove the key from the
key switch.
1513
11
E 17
1005.GB
5 Information and service display (LISA)
The display (25) of the LCD information and service display (LISA) shows the operation data, the battery charge, the service hours as well as service data and diagnostical data. Below the display there are six LEDs (26) - (31). The keyboard (four keys
(32) - (35) serves for the selection, the reading and the modification of vehicle parameters.
A
The vehicle is delivered with two different keys:
for the user Key code: 702 (red):
Use of vehicle possible,
LISA only displays current driving data.
for service / workshop Key code: 738 (grey):
Use of vehicle possible,
LISA allows modifications of vehicle
parameters in the user mode
(see section 5.4).
m
Modifications in the service mode must only be performed by authorized service personnel of the manufacturer!
26 27 28 29 30 31 32 33 34 35
25
E 17
1005.GB
5 Information and service display (LISA)
The display (25) of the LCD information and service display (LISA) shows the opera-
tion data, the battery charge, the service hours as well as service data and diagnosti-
cal data. Below the display there are six LEDs (26) - (31). The keyboard (four keys
(32) - (35) serves for the selection, the reading and the modification of vehicle para-
meters.
A
The vehicle is delivered with two different keys:
for the user Key code: 702 (red):
Use of vehicle possible,
LISA only displays current driving data.
for service / workshop Key code: 738 (grey):
Use of vehicle possible,
LISA allows modifications of vehicle
parameters in the user mode
(see section 5.4).
m
Modifications in the service mode must only be performed by authorized service per-
sonnel of the manufacturer!
26 27 28 29 30 31 32 33 34 35
25
1005.GB
E 18
5.1 LED warning lamps
Six red light-emitting diodes indicate the following states:
5.2 Key assignment
Item Function
26 Direction of motion forward (drive direction) (green LED)
27 Parking brake applied (red LED)
28 Direction of motion backward (load direction) (green LED)
29 Brake liquid level too low (red LED)
30 Lateral traversing device in center position (green LED)
31 Battery unlocked (red LED)
Item Function
32
Double function
- incremental increase of the selected parameter
- selection of the individual menu items in ascending order
33
Double function
- incremental decrease of the selected parameter
- selection of the individual menu items in descending order
34
Double function
- release of a selection menu from the main menu
- acknowledging a query with "NO" -> "x"
35
Quadruple function
– exiting from a selected menu point
– storing of modified parameters
– acknowledging a query with "YES" -> "
q"
– Display change between „service hours“ / „time“
1005.GB
E 18
5.1 LED warning lamps
Six red light-emitting diodes indicate the following states:
5.2 Key assignment
Item Function
26 Direction of motion forward (drive direction) (green LED)
27 Parking brake applied (red LED)
28 Direction of motion backward (load direction) (green LED)
29 Brake liquid level too low (red LED)
30 Lateral traversing device in center position (green LED)
31 Battery unlocked (red LED)
Item Function
32
Double function
- incremental increase of the selected parameter
- selection of the individual menu items in ascending order
33
Double function
- incremental decrease of the selected parameter
- selection of the individual menu items in descending order
34
Double function
- release of a selection menu from the main menu
- acknowledging a query with "NO" -> "x"
35
Quadruple function
– exiting from a selected menu point
– storing of modified parameters
– acknowledging a query with "YES" -> "
q"
– Display change between „service hours“ / „time“
E 19
1005.GB
5.3 Displays
The display shows operating data and fault messages. The user menu permits the
setting of the following driving parameters:
Here the time between max. operation of
the controller and 100 % control by the
electronics is set.
When releasing the controller, the drive
current control system will start braking
the truck. The value is between 0%
(rolling to a standstill) and a max. value,
which is equal to the minimum value for
counter-current braking.
The setting of the counter-current brake
affects braking when changing direction.
Actual braking when changing direction
is also a function of the accelerator position.
Adjustment of maximum speed in drive
wheel direction af motion.
Adjustment of maximum speed in drive
wheel direction af motion when actuating the slow speed switch.
Adjustment of maximum speed in load
part direction af motion.
Adjustment of maximum speed in load
part direction af motion when actuating
the slow speed switch.
Issues an acoustic alarm in case of operating errors.
Preset values can be called up and adjusted.
Time adjustment.
Select hour or minute with key 34. Modify adjustment with keys 32 and 33.
ACCEL ERAT I ON
L
RELEASE BRAKE
L
I NVERS I ON BRAKE
L
MAX . SPEED FORW.
L
CUT BACK FORW.
L
MAX REVERS . SPEED
L
CUT BACK REVERS .
L
BUZZER ON / OFF
O FF L
RELOAD
L
ADJUST T IME
12 : 22
E 19
1005.GB
5.3 Displays
The display shows operating data and fault messages. The user menu permits the
setting of the following driving parameters:
Here the time between max. operation of
the controller and 100 % control by the
electronics is set.
When releasing the controller, the drive
current control system will start braking
the truck. The value is between 0%
(rolling to a standstill) and a max. value,
which is equal to the minimum value for
counter-current braking.
The setting of the counter-current brake
affects braking when changing direction.
Actual braking when changing direction
is also a function of the accelerator posi-
tion.
Adjustment of maximum speed in drive
wheel direction af motion.
Adjustment of maximum speed in drive
wheel direction af motion when actua-
ting the slow speed switch.
Adjustment of maximum speed in load
part direction af motion.
Adjustment of maximum speed in load
part direction af motion when actuating
the slow speed switch.
Issues an acoustic alarm in case of ope-
rating errors.
Preset values can be called up and adju-
sted.
Time adjustment.
Select hour or minute with key 34. Mo-
dify adjustment with keys 32 and 33.
ACCEL ERAT I ON
L
RELEASE BRAKE
L
I NVERS I ON BRAKE
L
MAX . SPEED FORW.
L
CUT BACK FORW.
L
MAX REVERS . SPEED
L
CUT BACK REVERS .
L
BUZZER ON / OFF
O FF L
RELOAD
L
ADJUST T IME
12 : 22
1005.GB
E 20
5.4 Changing truck parameters
f
Changing of truck parameters will also change the driving behaviour of the truck. This
must be taken into account when commissioning the truck!Parameters may only be
changed while the truck is at a standstill and no lifting movements are performed.
– Commission the truck (refer to chapter E, section 3).
Insert key (738) into key switch and turn to the right until reaching the limit stop.
The display shows the user menu with vehicle name for about three seconds, after
that the battery charge and the service hours are indicated.
– Press the selection menu key (34).
The display shows „acceleration" with the corresponding parameter.
– To view or change the truck parameters, proceed in accordance with the following
diagram.
– Moving between the 10 setting parameters is effected by means of the keys (32)
and (33).
1) L = Operating parameters are read out (Reading mode)
2) S = The chosen operational parameter can be modified (Writing mode)
3) Service hours display
4) Time display
5) Selection of parameters
6) Changing parameters
no
Acceleration
L
1)
Release brake
Adjust time
XX:XX
Inversion brake
Maximum speed
forward
Cut-back speed
forward
Maximum reversing
speed
Cut-back speed
reversing
Buzzer on/off
OFF
Acceleration
S
2)
Release brake
Adjust time
XX:XX
Inversion brake
Maximum speed
forward
Cut-back speed
forward
Maximum reversing
speed
Cut-back speed
reversing
Buzzer on/off
ON/OFF
Are you
sure?
yes
BATT xxx % xxh
3)
BATT xxx % xx:xx
4)
Reload
Reload
5) 6)
1005.GB
E 20
5.4 Changing truck parameters
f
Changing of truck parameters will also change the driving behaviour of the truck. This
must be taken into account when commissioning the truck!Parameters may only be
changed while the truck is at a standstill and no lifting movements are performed.
– Commission the truck (refer to chapter E, section 3).
Insert key (738) into key switch and turn to the right until reaching the limit stop.
The display shows the user menu with vehicle name for about three seconds, after
that the battery charge and the service hours are indicated.
– Press the selection menu key (34).
The display shows „acceleration" with the corresponding parameter.
– To view or change the truck parameters, proceed in accordance with the following
diagram.
– Moving between the 10 setting parameters is effected by means of the keys (32)
and (33).
1) L = Operating parameters are read out (Reading mode)
2) S = The chosen operational parameter can be modified (Writing mode)
3) Service hours display
4) Time display
5) Selection of parameters
6) Changing parameters
no
Acceleration
L
1)
Release brake
Adjust time
XX:XX
Inversion brake
Maximum speed
forward
Cut-back speed
forward
Maximum reversing
speed
Cut-back speed
reversing
Buzzer on/off
OFF
Acceleration
S
2)
Release brake
Adjust time
XX:XX
Inversion brake
Maximum speed
forward
Cut-back speed
forward
Maximum reversing
speed
Cut-back speed
reversing
Buzzer on/off
ON/OFF
Are you
sure?
yes
BATT xxx % xxh
3)
BATT xxx % xx:xx
4)
Reload
Reload
5) 6)
E 21
1005.GB
6 Fault locating operations
This chapter enables the user to locate and to remedy simple faults or the consequences of operating errors. Fault locating operations should be performed in the order as set out in the table below.
A
If the fault could not be eliminated after performing the "troubleshooting procedures",
contact the customer service of the manufacturer since all follow-up troubleshooting
can only be performed by specially trained and qualified service staff.
Fault Possible cause Remedy
Truck does not
move
Battery connector
not connected
Check the battery connector, or con-
nect, if required
Master switch depressed Release the master switch
Key switch in position "0" Switch the key switch to position "I"
Battery charge too low Check the charge condition of the
battery and recharge if required
Defective fuse Check fuses
Parking brake applied Release the parking brake
Foot switch not pressed Press foot switch
Load cannot be
raised
Truck not operative Perform all remedial actions indica-
ted under fault "Truck does not mo-
ve"
Hydraulic oil level
too low
Check the hydraulic oil level
Battery charge too low,
lift cut-out active
Check the charge condition of the
battery and recharge if required
Defective fuse Check fuses
Load too high Comply with maximum load
(see nameplate)
E 21
1005.GB
6 Fault locating operations
This chapter enables the user to locate and to remedy simple faults or the conse-
quences of operating errors. Fault locating operations should be performed in the or-
der as set out in the table below.
A
If the fault could not be eliminated after performing the "troubleshooting procedures",
contact the customer service of the manufacturer since all follow-up troubleshooting
can only be performed by specially trained and qualified service staff.
Fault Possible cause Remedy
Truck does not
move
Battery connector
not connected
Check the battery connector, or con-
nect, if required
Master switch depressed Release the master switch
Key switch in position "0" Switch the key switch to position "I"
Battery charge too low Check the charge condition of the
battery and recharge if required
Defective fuse Check fuses
Parking brake applied Release the parking brake
Foot switch not pressed Press foot switch
Load cannot be
raised
Truck not operative Perform all remedial actions indica-
ted under fault "Truck does not mo-
ve"
Hydraulic oil level
too low
Check the hydraulic oil level
Battery charge too low,
lift cut-out active
Check the charge condition of the
battery and recharge if required
Defective fuse Check fuses
Load too high Comply with maximum load
(see nameplate)
1005.GB
E 22
7 Auxiliary electrical systems
7.1 Seat heating
A
All auxiliary electrical systems are activated regardless of the key switch position. The
battery master switch must have been switched on (see section, “Switching on the
truck”). To prevent discharge of the battery after the truck has been parked, always
heed section, “Rendering vehicle safe when parking”.
7.2 Floodlight
A
The floodlight is equipped with a joint that can be swivelled in all directions.
Item Designation
36
o
Heatable seat surface (fabric or imitation leather)
37
o
Control lamp - seat heating
38
o
Switch - seat heating ON/OFF
Item Designation
39
o
Floodlight
40
o
Switch - floodlight ON/OFF
36
37 38
39 40
1005.GB
E 22
7 Auxiliary electrical systems
7.1 Seat heating
A
All auxiliary electrical systems are activated regardless of the key switch position. The
battery master switch must have been switched on (see section, “Switching on the
truck”). To prevent discharge of the battery after the truck has been parked, always
heed section, “Rendering vehicle safe when parking”.
7.2 Floodlight
A
The floodlight is equipped with a joint that can be swivelled in all directions.
Item Designation
36
o
Heatable seat surface (fabric or imitation leather)
37
o
Control lamp - seat heating
38
o
Switch - seat heating ON/OFF
Item Designation
39
o
Floodlight
40
o
Switch - floodlight ON/OFF
36
37 38
39 40
E 23
1005.GB
7.3 360° warning light
7.4 Flash lamp
7.5 DC/DC transformer on/off switch
Switches the DC/DC transformer 48/24V
or 48/12V respectively on or offOverride
button (ESA / Electrical lifting limitation)
Item Designation
41
o
360° warning light
42
o
Switch - 360° warning light ON/OFF
Item Designation
43
o
Flash lamp
44
o
Switch - flash lamp ON/OFF
Item Designation
45 o Switch DC/DC transformer.
43
44
45
E 23
1005.GB
7.3 360° warning light
7.4 Flash lamp
7.5 DC/DC transformer on/off switch
Switches the DC/DC transformer 48/24V
or 48/12V respectively on or offOverride
button (ESA / Electrical lifting limitation)
Item Designation
41
o
360° warning light
42
o
Switch - 360° warning light ON/OFF
Item Designation
43
o
Flash lamp
44
o
Switch - flash lamp ON/OFF
Item Designation
45 o Switch DC/DC transformer.
43
44
45
1005.GB
E 24
7.6 Override switch ESA
o Bridge switch
Lateral traversing device
When the mast slide is below the safety height in front of the wheel arms, the mast
slide retraction movement is blocked by limit switches.
When the lateral traversing device is between the wheel arms and below the safety
height, the lateral traversing movement is blocked by limit switches.
The blocking of the mast holder retraction movement and the lateral traversing device
movement, respectively, performed by the safety switch (ESA), can be bridged by
pressing the bridge switch (46) and simultaneous use of the control lever (2) or the
pushbutton (21), respectively.
Lifting limitation
When the mast slide reaches the adjusted disconnection height, further lifting movements are blocked. It is possible to surpass the disconnection height by pressing the
bridging switch (46) and simultaneous use of the control lever (3).
7.7 LED Lateral traversing device in centre position
When the lateral traversing device is out of the centre position, and the mast slide is
below the safety height in front of the wheel arms, the mast slide retraction movement
is blocked by limit switches. The mast slide retraction movement is unblocked when
the green LED (30) lights up.
When the lateral traversing device is between the wheel arms and below the safety
height, the lateral traversing movement is blocked by limit switches. It unblocks when
the mast slide is lifted above the safety height.
Item Designation
46
o
Override switch
46
2
30
21
3
1005.GB
E 24
7.6 Override switch ESA
o Bridge switch
Lateral traversing device
When the mast slide is below the safety height in front of the wheel arms, the mast
slide retraction movement is blocked by limit switches.
When the lateral traversing device is between the wheel arms and below the safety
height, the lateral traversing movement is blocked by limit switches.
The blocking of the mast holder retraction movement and the lateral traversing device
movement, respectively, performed by the safety switch (ESA), can be bridged by
pressing the bridge switch (46) and simultaneous use of the control lever (2) or the
pushbutton (21), respectively.
Lifting limitation
When the mast slide reaches the adjusted disconnection height, further lifting move-
ments are blocked. It is possible to surpass the disconnection height by pressing the
bridging switch (46) and simultaneous use of the control lever (3).
7.7 LED Lateral traversing device in centre position
When the lateral traversing device is out of the centre position, and the mast slide is
below the safety height in front of the wheel arms, the mast slide retraction movement
is blocked by limit switches. The mast slide retraction movement is unblocked when
the green LED (30) lights up.
When the lateral traversing device is between the wheel arms and below the safety
height, the lateral traversing movement is blocked by limit switches. It unblocks when
the mast slide is lifted above the safety height.
Item Designation
46
o
Override switch
46
2
30
21
3
F 1
0903.GB
F Maintenance of the fork-lift truck
1 Operational safety and environmental protection
The checks and servicing operations contained in this chapter must be performed in
accordance with the intervals as indicated in the servicing checklists.
f
Modifications of fork-lift truck assemblies, especially of the safety installations, are not
permitted. On no account must the operational speeds of the truck be changed.
m
Only original spare parts have been certified by our quality assurance service. To ensure safe and reliable operation of the fork-lift truck, only spare parts of the manufacturer must be used. Used parts, oils and fuels must be disposed of in accordance with
the applicable environmental protection regulations. For oil changes, the oil service
of the manufacturer is available to you.
Upon completion of any checking and servicing activities, the operations contained in
the section “Recommissioning” must be performed (refer to chapter F).
2 Safety regulations applicable to truck maintenance
Servicing and maintenance personnel: The fork-lift truck must only be serviced
and maintained by trained personnel of the manufacturer. The service organization
of the manufacturer has external technicians trained especially for these assignments. We thus recommend signing a maintenance contract with the relevant service
location of the manufacturer.
Lifting and jacking up: When a fork-lift truck is to be lifted, the lifting gear must only
be secured to the points specially provided for this purpose. When the truck is to be
jacked up, suitable measures must be taken to prevent the truck from slipping or tipping over (use of wedges, wooden blocks). Work underneath the raised load lifting
device must only be carried out when the fork is immobilised and supported by a
chain of adequate strength.
Cleaning operations: No inflammable liquids must be used when cleaning the forklift truck. Prior to commencing cleaning operations, all safety measures that are required to prevent sparking (e.g. by short-circuits) have to be taken. For battery-operated fork-lift trucks, the battery plug must be removed. Only weak indraft, weak
compressed air and non-conducting, antistatic brushes must be used for the cleaning
of electric or electronic assemblies.
m
If the fork-lift truck is to be cleaned using a water jet or a high-pressure cleaner, all
electric and electronic components must be carefully covered beforehand because
moisture can lead to incorrect functioning.
Cleaning by means of a steam jet is not permitted.
Upon completion of cleaning work, the operations detailed in the section “Recommissioning” must be performed.
F 1
0903.GB
F Maintenance of the fork-lift truck
1 Operational safety and environmental protection
The checks and servicing operations contained in this chapter must be performed in
accordance with the intervals as indicated in the servicing checklists.
f
Modifications of fork-lift truck assemblies, especially of the safety installations, are not
permitted. On no account must the operational speeds of the truck be changed.
m
Only original spare parts have been certified by our quality assurance service. To en-
sure safe and reliable operation of the fork-lift truck, only spare parts of the manufac-
turer must be used. Used parts, oils and fuels must be disposed of in accordance with
the applicable environmental protection regulations. For oil changes, the oil service
of the manufacturer is available to you.
Upon completion of any checking and servicing activities, the operations contained in
the section “Recommissioning” must be performed (refer to chapter F).
2 Safety regulations applicable to truck maintenance
Servicing and maintenance personnel: The fork-lift truck must only be serviced
and maintained by trained personnel of the manufacturer. The service organization
of the manufacturer has external technicians trained especially for these assign-
ments. We thus recommend signing a maintenance contract with the relevant service
location of the manufacturer.
Lifting and jacking up: When a fork-lift truck is to be lifted, the lifting gear must only
be secured to the points specially provided for this purpose. When the truck is to be
jacked up, suitable measures must be taken to prevent the truck from slipping or tip-
ping over (use of wedges, wooden blocks). Work underneath the raised load lifting
device must only be carried out when the fork is immobilised and supported by a
chain of adequate strength.
Cleaning operations: No inflammable liquids must be used when cleaning the fork-
lift truck. Prior to commencing cleaning operations, all safety measures that are re-
quired to prevent sparking (e.g. by short-circuits) have to be taken. For battery-ope-
rated fork-lift trucks, the battery plug must be removed. Only weak indraft, weak
compressed air and non-conducting, antistatic brushes must be used for the cleaning
of electric or electronic assemblies.
m
If the fork-lift truck is to be cleaned using a water jet or a high-pressure cleaner, all
electric and electronic components must be carefully covered beforehand because
moisture can lead to incorrect functioning.
Cleaning by means of a steam jet is not permitted.
Upon completion of cleaning work, the operations detailed in the section “Recommis-
sioning” must be performed.
0903.GB
F 2
Work on the electric system: Work on the electric system of the truck must only be
performed by personnel specially trained for such operations. Before commencing
any work on the electric system, all measures required to prevent electric shocks
have to be taken. For battery-operated fork-lift trucks, the truck must also be depowered by removing the battery plug.
Welding operations: To prevent any damage to electric or electronic com-ponents,
these have to be removed from the fork-lift truck before any welding operations are
undertaken.
Settings: When repairing or replacing hydraulic, electric or electronic compo-nents
or assemblies, all truck-specific settings have to be retained.
Tyres: The quality of the tyres greatly affects the stability and the driving behaviour
of the fork-lift truck. Changes must only be made following consultations with the manufacturer. When replacing wheels or tyres, it must be ensured that the fork-lift truck
remains level (tyres and wheels must always be replaced in pairs, i.e. left and right
together).
Lift chains: The lift chains wear rapidly if not lubricated. The intervals in the service
checklist apply to normal duty. If requirements are higher (dust, temperature), lubrication is required more often. The specified chain spray must be used as specified.
The external application of grease does not provide sufficient lubrication.
Hydraulic hoses: The hoses must be renewed every six years. When replacing hydraulic components, also renew the hoses in this hydraulic system.
0903.GB
F 2
Work on the electric system: Work on the electric system of the truck must only be
performed by personnel specially trained for such operations. Before commencing
any work on the electric system, all measures required to prevent electric shocks
have to be taken. For battery-operated fork-lift trucks, the truck must also be depowe-
red by removing the battery plug.
Welding operations: To prevent any damage to electric or electronic com-ponents,
these have to be removed from the fork-lift truck before any welding operations are
undertaken.
Settings: When repairing or replacing hydraulic, electric or electronic compo-nents
or assemblies, all truck-specific settings have to be retained.
Tyres: The quality of the tyres greatly affects the stability and the driving behaviour
of the fork-lift truck. Changes must only be made following consultations with the ma-
nufacturer. When replacing wheels or tyres, it must be ensured that the fork-lift truck
remains level (tyres and wheels must always be replaced in pairs, i.e. left and right
together).
Lift chains: The lift chains wear rapidly if not lubricated. The intervals in the service
checklist apply to normal duty. If requirements are higher (dust, temperature), lubri-
cation is required more often. The specified chain spray must be used as specified.
The external application of grease does not provide sufficient lubrication.
Hydraulic hoses: The hoses must be renewed every six years. When replacing hy-
draulic components, also renew the hoses in this hydraulic system.
F 3
0903.GB
3 Servicing and inspection
Thorough and expert servicing is one of the most important preconditions for safe
operation of the fork-lift truck. The neglect of regular servicing intervals can lead to
fork-lift truck failure and constitutes a potential hazard to personnel and equipment.
m
The indicated servicing intervals are based on single-shift operation under normal
operating conditions. For applications in dusty environments, or involving large temperature fluctuations or multiple-shift operation, the servicing intervals must be shortened accordingly.
The following servicing checklist indicates the operations to be performed and the respective intervals to be observed. The servicing intervals are defined as follows:
W1 = Every 50 operating hours, but at least once per week
M3 = Every 500 operating hours, but at least every 3 months
M6 = Every 1000 operating hours, but at least every 6 months
M12 = Every 2000 operating hours, but at least every 12 months
In the running-in phase of the truck, the following additional operations have to be carried out:
After the first 100 operating hours:
– Check the wheel nuts for security and retighten, if required.
– Check the hydraulic connections for leaks and retighten, if required.
– Check steering chain tension, adjust if necessary.
After the first 500 operating hours:
– Replace the hydraulic oil and the filter cartridge.
F 3
0903.GB
3 Servicing and inspection
Thorough and expert servicing is one of the most important preconditions for safe
operation of the fork-lift truck. The neglect of regular servicing intervals can lead to
fork-lift truck failure and constitutes a potential hazard to personnel and equipment.
m
The indicated servicing intervals are based on single-shift operation under normal
operating conditions. For applications in dusty environments, or involving large tem-
perature fluctuations or multiple-shift operation, the servicing intervals must be shor-
tened accordingly.
The following servicing checklist indicates the operations to be performed and the re-
spective intervals to be observed. The servicing intervals are defined as follows:
W1 = Every 50 operating hours, but at least once per week
M3 = Every 500 operating hours, but at least every 3 months
M6 = Every 1000 operating hours, but at least every 6 months
M12 = Every 2000 operating hours, but at least every 12 months
In the running-in phase of the truck, the following additional operations have to be car-
ried out:
After the first 100 operating hours:
– Check the wheel nuts for security and retighten, if required.
– Check the hydraulic connections for leaks and retighten, if required.
– Check steering chain tension, adjust if necessary.
After the first 500 operating hours:
– Replace the hydraulic oil and the filter cartridge.
0903.GB
F 4
4 Maintenance Check
A
The maintenance intervals refer to normal service conditions. In case of aggravated conditions, the intervals must be reduced as required.
Maintenance intervals
standard = t WMMM
cold store = k 13612
Chassis and
superstruct.:
1.1 Check all load bearing elements for damage
t
1.2 Check all bolted connections
t
1.3 Check driver’s protective roof and load guard for secure
fastening
kt
Drive unit: 2.1 Check the transmission for noises and leakage
t
2.2 Check whether the drive support plate and screws are fitted
tightly
t
2.3 Check the transmission oil level
t
2.4 Check the mechanical pedal linkage; adjust, if necessary
t
2.5 Change the transmission oil
kt
Wheels: 3.1 Check for wear and damage
t
3.2 Check the wheel bearings and ensure secure
fastening of wheels
kt
Steering: 4.1 Check the steering chain and chain sprocket for wear, adjust
and grease
kt
4.2 Check mechanical parts of the steering head
t
4.3 Check the steering for correct function and adjustment
t
4.4 Check the hydraulic assemblies for correct functioning and leakage
t
4.5 Check and, if necessary, adjust the steering angle limiter
t
Brake
system:
5.1 Check the brake linings for wear
t
5.2 Performance and adjustment check
kt
5.3 Check the brake linkage, adjust and grease, if necessary
kt
5.4 Check the brake lines and connections
t
5.5 Change the brake fluid
kt
5.6 Check brake cable of the parking brake and replace it, if
necessary
t
Hydraulic
system:
6.1 Performance check
kt
6.2 Check all connections for leakage and damage
kt
6.3 Check hydraulic cylinders for leakage, damage and secure
attachment
kt
6.4 Check the oil level
kt
6.5 Replace the hydraulic oil, the filter cartridge and
the vent filter
kt
6.6 Check the hose run for correct functioning and damage
kt
6.7 Check the pressure relief valves for correct functioning
kt
6.8 Remove and rinse the coarse strainer in the control valve
t
0903.GB
F 4
4 Maintenance Check
A
The maintenance intervals refer to normal service conditions. In case of aggravated conditi-
ons, the intervals must be reduced as required.
Maintenance intervals
standard = t WMMM
cold store = k 13612
Chassis and
superstruct.:
1.1 Check all load bearing elements for damage
t
1.2 Check all bolted connections
t
1.3 Check driver’s protective roof and load guard for secure
fastening
kt
Drive unit: 2.1 Check the transmission for noises and leakage
t
2.2 Check whether the drive support plate and screws are fitted
tightly
t
2.3 Check the transmission oil level
t
2.4 Check the mechanical pedal linkage; adjust, if necessary
t
2.5 Change the transmission oil
kt
Wheels: 3.1 Check for wear and damage
t
3.2 Check the wheel bearings and ensure secure
fastening of wheels
kt
Steering: 4.1 Check the steering chain and chain sprocket for wear, adjust
and grease
kt
4.2 Check mechanical parts of the steering head
t
4.3 Check the steering for correct function and adjustment
t
4.4 Check the hydraulic assemblies for correct functioning and lea-
kage
t
4.5 Check and, if necessary, adjust the steering angle limiter
t
Brake
system:
5.1 Check the brake linings for wear
t
5.2 Performance and adjustment check
kt
5.3 Check the brake linkage, adjust and grease, if necessary
kt
5.4 Check the brake lines and connections
t
5.5 Change the brake fluid
kt
5.6 Check brake cable of the parking brake and replace it, if
necessary
t
Hydraulic
system:
6.1 Performance check
kt
6.2 Check all connections for leakage and damage
kt
6.3 Check hydraulic cylinders for leakage, damage and secure
attachment
kt
6.4 Check the oil level
kt
6.5 Replace the hydraulic oil, the filter cartridge and
the vent filter
kt
6.6 Check the hose run for correct functioning and damage
kt
6.7 Check the pressure relief valves for correct functioning
kt
6.8 Remove and rinse the coarse strainer in the control valve
t
F 5
0903.GB
Maintenance intervals
standard = t WMMM
cold store = k 13612
Electrical
system:
7.1 Performance check
t
7.2 Check all cables for secure connection and damage
t
7.3 Check the fuses for correct amperage
t
7.4 Check switches and trip cams for secure attachment and correct functioning
t
7.5 Check the warning installation for correct functioning
kt
7.6 Check contactors, replace wearing parts, if necessary
t
7.7 Check the electronic boards for tight seat and cleanliness
t
Electric
motors
8.1 Check the carbon brushes for wear
t
8.2 Check the motor for secure attachment
t
8.3 Clean motor housing by means of a vacuum cleaner and check
the commutator for wear
kt
Battery: 9.1 Check the battery cables for damage, renew, if necessary
t
9.2 Check battery trolley locking, performance and adjustment
t
9.3 Check acid density, acid level and cell voltage
kt
9.4 Check the terminals for secure attachment and apply grease
kt
9.5 Clean battery connections, check for tight seat
kt
Hoist frame: 10.1 Check the mast anchorage
t
10.2 Check lifting chains and chain guides for wear, adjust and
grease
kt
10.3 Check support and attachment of tilt cylinder
t
10.4 Check the tilt angle of mast
t
10.5 Perform sight check of rollers, sliding elements, and stops
kt
10.6 Check hoist frame bearing
t
10.7 Check the traversing systems for wear and damage, adjust lateral play, if necessary
t
10.8 Check fork tines and fork carrier for wear and damage
kt
Mounted
implement:
11.1 Performance check
kt
11.2 Check the attachment to the vehicle and all load bearing elements
kt
11.3 Check bearings, guide elements, and stops for wear and damage, grease
t
General measurements:
12.1 Check the electrical system for a grounding fault
t
12.2 Check the driving speed and braking distance
t
12.3 Check the lifting and lowering speed
t
12.4 Check safety and shutdown devices
t
Lubrication: 13.1 Grease the vehicle in accordance with the lubrication schedule
kt
Demonstration:
14.1 Perform a trial run under nominal load
t
14.2 Upon completion of servicing operations, demonstrate the vehicle to the person responsible
kt
F 5
0903.GB
Maintenance intervals
standard = t WMMM
cold store = k 13612
Electrical
system:
7.1 Performance check
t
7.2 Check all cables for secure connection and damage
t
7.3 Check the fuses for correct amperage
t
7.4 Check switches and trip cams for secure attachment and cor-
rect functioning
t
7.5 Check the warning installation for correct functioning
kt
7.6 Check contactors, replace wearing parts, if necessary
t
7.7 Check the electronic boards for tight seat and cleanliness
t
Electric
motors
8.1 Check the carbon brushes for wear
t
8.2 Check the motor for secure attachment
t
8.3 Clean motor housing by means of a vacuum cleaner and check
the commutator for wear
kt
Battery: 9.1 Check the battery cables for damage, renew, if necessary
t
9.2 Check battery trolley locking, performance and adjustment
t
9.3 Check acid density, acid level and cell voltage
kt
9.4 Check the terminals for secure attachment and apply grease
kt
9.5 Clean battery connections, check for tight seat
kt
Hoist frame: 10.1 Check the mast anchorage
t
10.2 Check lifting chains and chain guides for wear, adjust and
grease
kt
10.3 Check support and attachment of tilt cylinder
t
10.4 Check the tilt angle of mast
t
10.5 Perform sight check of rollers, sliding elements, and stops
kt
10.6 Check hoist frame bearing
t
10.7 Check the traversing systems for wear and damage, adjust la-
teral play, if necessary
t
10.8 Check fork tines and fork carrier for wear and damage
kt
Mounted
implement:
11.1 Performance check
kt
11.2 Check the attachment to the vehicle and all load bearing ele-
ments
kt
11.3 Check bearings, guide elements, and stops for wear and da-
mage, grease
t
General mea-
surements:
12.1 Check the electrical system for a grounding fault
t
12.2 Check the driving speed and braking distance
t
12.3 Check the lifting and lowering speed
t
12.4 Check safety and shutdown devices
t
Lubrication: 13.1 Grease the vehicle in accordance with the lubrication schedule
kt
Demonstrati-
on:
14.1 Perform a trial run under nominal load
t
14.2 Upon completion of servicing operations, demonstrate the ve-
hicle to the person responsible
kt
0903.GB
F 6
5 Lubrication Schedule
A
D 0,2 l
G
G
EF
E
F
J
Min. = 14 l
Max.= 18 l
BB+C
1)
3,7 l
E
F
140 Nm
2)
1
2
3
4
5
g Gliding surfaces
s Grease nipples
Filter plug hydraulic oil
c Drain plug hydraulik oil
b Filter plug gear oil
a Drain plug gear oil
t Filter plug brake fluid
Cold store usage
1) Compound cold store 1:1
2)
Filling level: refer to the table on section 5.2
0903.GB
F 6
5 Lubrication Schedule
A
D 0,2 l
G
G
EF
E
F
J
Min. = 14 l
Max.= 18 l
BB+C
1)
3,7 l
E
F
140 Nm
2)
1
2
3
4
5
g Gliding surfaces
s Grease nipples
Filter plug hydraulic oil
c Drain plug hydraulik oil
b Filter plug gear oil
a Drain plug gear oil
t Filter plug brake fluid
Cold store usage
1) Compound cold store 1:1
2)
Filling level: refer to the table on section 5.2
F 7
0903.GB
5.1 Fuels, coolants and lubricants
Handling consumption type material: Consumption type material must always be
handled properly. Manufacturer's instructions to be observed.
f
Improper handling is injurious to health, life, and environment. Consumption type materials must be stored in adequate containers. They might be inflammable and, therefore, must not come into contact with hot components or open fire.
When filling in consumption type materials use clean containers only. It is prohibited
to mix consumption type materials of different grades or qualitiies resp., except if mixing is expressively prescribed in these operating instructions.
Avoid spilling. Spilt liquid must be removed immediately using a suitable binding
agent, and the mixture of consumption type material and binding agent is to be disposed of according to the regulations.
Grease data
5.2 Reservoir filling level ETM/V 110, 112, 114
*) See “Type” on the truck identification plate.
Code Order-no. Supply Qty Designation Used for:
A 29 200 670 5,0 l H-LP 46, DIN 51524 Hydraulic system
B 29 200 680 5,0 l CLP 100, DIN 51517 Transmission
C 29 200 810 5,0 l H-LP 10, DIN 51524 Transmission, hydraulic
system
D 29 200 150 1,0 l Brake fluid Brake system
E 29 201 430 1,0 kg Grease, DIN 51825 Lubrication
F 29 200 100 1,0 kg Grease, TTF52 Lubrication
G 29 201 280 0,51 kg Chain spray Chains
J 29 202 020 5,0 l Aero Shell Fluid 4 Hydraulic system
Code Saponification Dropp. point°CWorked penetr.
at 25 °C
NLG1
class
Service
temperat. °C
E Lithium 185 265-295 2 -35/+120
F -- -- 310-340 1 -52/+100
Marking
upper level
Litre Lift. height (h
3
) in cm
ZT ZZ DZ
5 ca. 30 - - 4 ca. 25 - - 3 ca. 23 - - bis 6800
2 ca. 20 bis 5290 bis 3790 bis 5000
1 ca. 16 bis 3590 bis 2890 -
F 7
0903.GB
5.1 Fuels, coolants and lubricants
Handling consumption type material: Consumption type material must always be
handled properly. Manufacturer's instructions to be observed.
f
Improper handling is injurious to health, life, and environment. Consumption type ma-
terials must be stored in adequate containers. They might be inflammable and, the-
refore, must not come into contact with hot components or open fire.
When filling in consumption type materials use clean containers only. It is prohibited
to mix consumption type materials of different grades or qualitiies resp., except if mi-
xing is expressively prescribed in these operating instructions.
Avoid spilling. Spilt liquid must be removed immediately using a suitable binding
agent, and the mixture of consumption type material and binding agent is to be dis-
posed of according to the regulations.
Grease data
5.2 Reservoir filling level ETM/V 110, 112, 114
*) See “Type” on the truck identification plate.
Code Order-no. Supply Qty Designation Used for:
A 29 200 670 5,0 l H-LP 46, DIN 51524 Hydraulic system
B 29 200 680 5,0 l CLP 100, DIN 51517 Transmission
C 29 200 810 5,0 l H-LP 10, DIN 51524 Transmission, hydraulic
system
D 29 200 150 1,0 l Brake fluid Brake system
E 29 201 430 1,0 kg Grease, DIN 51825 Lubrication
F 29 200 100 1,0 kg Grease, TTF52 Lubrication
G 29 201 280 0,51 kg Chain spray Chains
J 29 202 020 5,0 l Aero Shell Fluid 4 Hydraulic system
Code Saponification Dropp. point°CWorked penetr.
at 25 °C
NLG1
class
Service
temperat. °C
E Lithium 185 265-295 2 -35/+120
F -- -- 310-340 1 -52/+100
Marking
upper level
Litre Lift. height (h
3
) in cm
ZT ZZ DZ
5 ca. 30 - - -
4 ca. 25 - - -
3 ca. 23 - - bis 6800
2 ca. 20 bis 5290 bis 3790 bis 5000
1 ca. 16 bis 3590 bis 2890 -
0903.GB
F 8
6 Instructions for the servicing operations
6.1 Preparing the truck for the performance of servicing and maintenance
operations
All required safety measures must be taken to prevent any accidents in the course of
the servicing and maintenance operations. The following preparatory operations
must be performed:
– Park and secure the truck (refer to chapter E).
– Disconnect the battery plug (1) to prevent accidental starting of the truck.
f
When work has to be performed under the raised fork or under the jacked up truck,
suitable measures must be taken to prevent any dropping, tilting or slipping of the fork
or truck. When lifting the truck, the instructions contained in chapter "Transportation
and commissioning" have to be observed.
When performing work on the parking brake, the truck must be secured against moving.
6.2 Opening the hood
– loosen six screws (2)
– Swing the (3) hood upward..
A
The drive current control system and the truck fuses are readily accessible for servicing purposes.
1
2 2
3
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F 8
6 Instructions for the servicing operations
6.1 Preparing the truck for the performance of servicing and maintenance
operations
All required safety measures must be taken to prevent any accidents in the course of
the servicing and maintenance operations. The following preparatory operations
must be performed:
– Park and secure the truck (refer to chapter E).
– Disconnect the battery plug (1) to prevent accidental starting of the truck.
f
When work has to be performed under the raised fork or under the jacked up truck,
suitable measures must be taken to prevent any dropping, tilting or slipping of the fork
or truck. When lifting the truck, the instructions contained in chapter "Transportation
and commissioning" have to be observed.
When performing work on the parking brake, the truck must be secured against mo-
ving.
6.2 Opening the hood
– loosen six screws (2)
– Swing the (3) hood upward..
A
The drive current control system and the truck fuses are readily accessible for ser-
vicing purposes.
1
2 2
3
2
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6.3 Opening the battery doors and the seat hood
– Unlock the battery door (4) using the service key and remove it.
– Unlock the seat hood (6) using the service key and screw out the securing screw
(5).
– Swing the seat hood sideways in the direction of the arrow.
A
The drive unit and the hydraulic unit are accessible for servicing purposes.
6.4 Checking the hydraulic oil level
– Prepare the truck for servicing and
maintenance.
(Refer to chapter F, sections 6.1 and 6.3
- "Opening the seat hood").
– Open the seat hood
(see chapter F, section 6.3).
– Check the hydraulic oil level in the hy-
draulic reservoir (7)
A
The oil level must be checked at the hydraulic reservoir with the load lifting device
completely lowered.
– If necessary, top up through the filler
neck (8) using oil of the correct specification.
For the hydraulic oil specification, refer
to chapter F, section 5.1.
– Lock the seat hood again and screw in
the securing screw.Lock the seat hood
again and screw in the securing
screw.
7
9
8
7
10
11
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6.3 Opening the battery doors and the seat hood
– Unlock the battery door (4) using the service key and remove it.
– Unlock the seat hood (6) using the service key and screw out the securing screw
(5).
– Swing the seat hood sideways in the direction of the arrow.
A
The drive unit and the hydraulic unit are accessible for servicing purposes.
6.4 Checking the hydraulic oil level
– Prepare the truck for servicing and
maintenance.
(Refer to chapter F, sections 6.1 and 6.3
- "Opening the seat hood").
– Open the seat hood
(see chapter F, section 6.3).
– Check the hydraulic oil level in the hy-
draulic reservoir (7)
A
The oil level must be checked at the hy-
draulic reservoir with the load lifting device
completely lowered.
– If necessary, top up through the filler
neck (8) using oil of the correct specifi-
cation.
For the hydraulic oil specification, refer
to chapter F, section 5.1.
– Lock the seat hood again and screw in
the securing screw.Lock the seat hood
again and screw in the securing
screw.
7
9
8
7
10
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F 10
6.5 Checking the brake fluid level
f
Brake fluid is poisonous and must therefore be stored in the closed original containers.
A
Lack of brake fluid is indicated by a red
LED on the information and service display.
– Park and secure the truck (refer to
chapter E).
– Visually check the brake fluid level on
the brake fluid reservoir (9); if necessary, add brake fluid (refer to chapter
F, section 5.1)
A
The brake fluid level must be visible between the “Min.” and “Max.” marks.
m
Replaced oils and lubricants must be disposed of as specified by the applicable environment protection laws.
6.6 Safety belt maintenance o
It is recommended that the driver checks daily condition and function of the safety belt
daily before starting up the floor conveyor. Only regular checks ensure that a fault or
defective is detected in time.
– Pull out the belt completely and check the fibres for wear and tear.
– Check the function of the belt buckle and control whether the belt is perfectly win-
ding up in the reel-up device.
Checking the blocking mechanism:
– Park the floor conveyor in horizontal position.
– Pull out the belt jerkily.
m
The mechanism must block the pull-out movement.
f
Do not operate the floor conveyor with a defective safety belt - have it exchanged immediately!
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F 10
6.5 Checking the brake fluid level
f
Brake fluid is poisonous and must there-
fore be stored in the closed original con-
tainers.
A
Lack of brake fluid is indicated by a red
LED on the information and service dis-
play.
– Park and secure the truck (refer to
chapter E).
– Visually check the brake fluid level on
the brake fluid reservoir (9); if neces-
sary, add brake fluid (refer to chapter
F, section 5.1)
A
The brake fluid level must be visible bet-
ween the “Min.” and “Max.” marks.
m
Replaced oils and lubricants must be disposed of as specified by the applicable en-
vironment protection laws.
6.6 Safety belt maintenance o
It is recommended that the driver checks daily condition and function of the safety belt
daily before starting up the floor conveyor. Only regular checks ensure that a fault or
defective is detected in time.
– Pull out the belt completely and check the fibres for wear and tear.
– Check the function of the belt buckle and control whether the belt is perfectly win-
ding up in the reel-up device.
Checking the blocking mechanism:
– Park the floor conveyor in horizontal position.
– Pull out the belt jerkily.
m
The mechanism must block the pull-out movement.
f
Do not operate the floor conveyor with a defective safety belt - have it exchanged im-
mediately!
12
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6.7 Checking the electric fuses
– Prepare the truck for servicing and maintenance (refer to section 6.1).
– Check all fuses for correct value according to table, replace if necessary. .
Item Designation Value / type
10 F8 Main fuse 355 A
11 1F10 Fuse, field “Driving” 30 A
12 - - 13 9F4 Fuse, options 10 A
14 1F9 Control fuse, driving / lifting electronics 3 A
15 1F8 Control fuse, interface 3 A
16 F1 Overall control system fuse 30 A
19
18
17
16
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6.7 Checking the electric fuses
– Prepare the truck for servicing and maintenance (refer to section 6.1).
– Check all fuses for correct value according to table, replace if necessary. .
Item Designation Value / type
10 F8 Main fuse 355 A
11 1F10 Fuse, field “Driving” 30 A
12 - - -
13 9F4 Fuse, options 10 A
14 1F9 Control fuse, driving / lifting electronics 3 A
15 1F8 Control fuse, interface 3 A
16 F1 Overall control system fuse 30 A
19
18
17
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F 12
6.8 Recommissioning the truck
Recommissioning of the truck following the performance of cleaning or mainten-ance
work is permitted only, after the following operations have been performed:
– Check the horn for proper functioning
– Check the master switch for correct function.
– Check the brake for correct function.
7 Decommissioning the truck
If the truck is to be decommissioned for more than two months, it must be parked in
a frost-free and dry location and all measures to be taken before, during and following
decommissioning must be performed as detailed below.
m
During decommissioning the truck must be jacked up ensuring that the wheels are
clear of the ground. Only this measure will ensure that wheels and wheel bearings do
not suffer damage.
If the truck is to be decommissioned for periods in excess of six months, the
JUNGHEINRICH service must be contacted for further measures to be taken.
7.1 Operations to be performed prior to decommissioning
– Thoroughly clean the truck.
– Check the brakes for correct function.
– Check the hydraulic oil level and top up, if required (refer to chapter F).
– Apply a thin film of oil or grease to all parts not protected by a paint coating.
– Grease the truck as detailed in the lubrication chart (refer to chapter F).
– Recharge the battery (refer to chapter D).
– Disconnect and clean the battery. Apply pole grease to the battery poles.
A
In addition to this, all instructions as given by the battery supplier have to be observed.
– Spray all exposed electrical contacts with a suitable contact spray.
7.2 Measures to be taken during decommissioning
Every 2 months:
– Recharge the battery (refer to chapter D).
m
Regular recharging of the battery is very important, as otherwise, caused by self-discharging, excessive depletion of the battery would occur, which, owing to sulfatization, will result in the destruction of the battery.
0903.GB
F 12
6.8 Recommissioning the truck
Recommissioning of the truck following the performance of cleaning or mainten-ance
work is permitted only, after the following operations have been performed:
– Check the horn for proper functioning
– Check the master switch for correct function.
– Check the brake for correct function.
7 Decommissioning the truck
If the truck is to be decommissioned for more than two months, it must be parked in
a frost-free and dry location and all measures to be taken before, during and following
decommissioning must be performed as detailed below.
m
During decommissioning the truck must be jacked up ensuring that the wheels are
clear of the ground. Only this measure will ensure that wheels and wheel bearings do
not suffer damage.
If the truck is to be decommissioned for periods in excess of six months, the
JUNGHEINRICH service must be contacted for further measures to be taken.
7.1 Operations to be performed prior to decommissioning
– Thoroughly clean the truck.
– Check the brakes for correct function.
– Check the hydraulic oil level and top up, if required (refer to chapter F).
– Apply a thin film of oil or grease to all parts not protected by a paint coating.
– Grease the truck as detailed in the lubrication chart (refer to chapter F).
– Recharge the battery (refer to chapter D).
– Disconnect and clean the battery. Apply pole grease to the battery poles.
A
In addition to this, all instructions as given by the battery supplier have to be obser-
ved.
– Spray all exposed electrical contacts with a suitable contact spray.
7.2 Measures to be taken during decommissioning
Every 2 months:
– Recharge the battery (refer to chapter D).
m
Regular recharging of the battery is very important, as otherwise, caused by self-di-
scharging, excessive depletion of the battery would occur, which, owing to sulfatiza-
tion, will result in the destruction of the battery.
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7.3 Recommissioning the truck
– Thoroughly clean the truck.
– Lubricate the truck according to the lubrication chart (refer to chapter F).
– Clean the battery. Grease the pole screws using pole grease and reconnect the
battery.
– Recharge the battery (refer to chapter D).
– Check if the gear oil contains condensed water and change, if required.
– Check if the hydraulic oil contains condensed water and change, if required.
– Start up the truck (refer to chapter E).
A
If switching troubles are experienced in the electric system, spray the exposed contacts with contact spray and remove a possible oxide layer on the contacts of the operating controls by repeated operation.
f
Perform several brake tests immediately after recommissioning the truck.
8 Safety checks to be performed at regular intervals and following any untoward
incidents (D: Accident prevention check according to BGV D27)
At least once yearly, or after any untoward incident, the truck has to be checked by a
qualified inspector. The inspector must assess the condition of the truck from a standpoint purely concerned with safety aspects, uninfluenced by any company or economic circumstances. The inspector must be adequately informed and experienced to
be able to assess the condition of the truck and the effectiveness of the safety installations based on the technical rules and principles governing the inspection of trucks.
The inspection must comprise a comprehensive check of the technical condition of
the truck with regard to accident prevention aspects. Apart from this, the truck must
be thoroughly inspected for damage possibly caused by incorrect use of the truck.
The inspection results must be recorded in an inspection report which has to be kept
available for a period spanning at least the next two inspection intervals.
The user has to ensure that all defects are eliminated without delay.
A
The manufacturer has set up a special safety service with specially qualified staff. As
visual proof that the truck has passed the safety inspection, a plaque will be affixed
to it. This plaque indicates in which month of which year the next test will be due.
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7.3 Recommissioning the truck
– Thoroughly clean the truck.
– Lubricate the truck according to the lubrication chart (refer to chapter F).
– Clean the battery. Grease the pole screws using pole grease and reconnect the
battery.
– Recharge the battery (refer to chapter D).
– Check if the gear oil contains condensed water and change, if required.
– Check if the hydraulic oil contains condensed water and change, if required.
– Start up the truck (refer to chapter E).
A
If switching troubles are experienced in the electric system, spray the exposed con-
tacts with contact spray and remove a possible oxide layer on the contacts of the ope-
rating controls by repeated operation.
f
Perform several brake tests immediately after recommissioning the truck.
8 Safety checks to be performed at regular intervals and following any untoward
incidents (D: Accident prevention check according to BGV D27)
At least once yearly, or after any untoward incident, the truck has to be checked by a
qualified inspector. The inspector must assess the condition of the truck from a stand-
point purely concerned with safety aspects, uninfluenced by any company or econo-
mic circumstances. The inspector must be adequately informed and experienced to
be able to assess the condition of the truck and the effectiveness of the safety instal-
lations based on the technical rules and principles governing the inspection of trucks.
The inspection must comprise a comprehensive check of the technical condition of
the truck with regard to accident prevention aspects. Apart from this, the truck must
be thoroughly inspected for damage possibly caused by incorrect use of the truck.
The inspection results must be recorded in an inspection report which has to be kept
available for a period spanning at least the next two inspection intervals.
The user has to ensure that all defects are eliminated without delay.
A
The manufacturer has set up a special safety service with specially qualified staff. As
visual proof that the truck has passed the safety inspection, a plaque will be affixed
to it. This plaque indicates in which month of which year the next test will be due.
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