Operating instructions

50420288

ERE 220

G

10.03-

01.06

0108

.GB

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

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

Safety instructions and important explanations are indicated by the followinggraphics:

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

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

Z Used before notices and explanations.

t Used to indicate standard equipment.

o Used to indicate optional equipment.

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

Copyright

Copyright of these operating instructions remains with JUNGHEINRICH AG.

Jungheinrich Aktiengesellschaft

Am Stadtrand 3522047 Hamburg - GERMANY

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

www.jungheinrich.com

0108

.GB

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

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

Safety instructions and important explanations are indicated by the followinggraphics:

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

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

Z Used before notices and explanations.

t Used to indicate standard equipment.

o Used to indicate optional equipment.

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

Copyright

Copyright of these operating instructions remains with JUNGHEINRICH AG.

Jungheinrich Aktiengesellschaft

Am Stadtrand 3522047 Hamburg - GERMANY

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

www.jungheinrich.com

0108

.GB

0108

.GB

I 1

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Table of contentsA Correct use and application of the truck

B Truck description

1 Application ........................................................................................... B 12 Assemblies .......................................................................................... B 23 Technical data ..................................................................................... B 33.1 Performance data ................................................................................ B 33.2 Dimensions ......................................................................................... B 43.3 EN standards ...................................................................................... B 53.4 Conditions for application .................................................................... B 54 Location of instruction labels and identification plates ........................ B 64.1 Truck identification plate ..................................................................... B 7

C Transportation and commissioning

1 Transportation by crane ...................................................................... C 12 Commissioning .................................................................................... C 23 Moving the truck with the drive unit inoperative .................................. C 3

D Battery - Servicing, recharging, replacement

1 Safety regulations governing the handling of lead-acid batteries ........ D 12 Battery types ....................................................................................... D 23 Exposing the battery ........................................................................... D 23.1 Standard version ................................................................................. D 23.2 Battery removal from the side (o) ....................................................... D 34 Charging the battery ............................................................................ D 45 Removing and installing the battery .................................................... D 55.1 Removal - standard version ................................................................ D 55.2 Removal “Battery removal from the side” (o) ..................................... D 65.3 Installation of the battery ..................................................................... D 6

I 1

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Table of contentsA Correct use and application of the truck

B Truck description

1 Application ........................................................................................... B 12 Assemblies .......................................................................................... B 23 Technical data ..................................................................................... B 33.1 Performance data ................................................................................ B 33.2 Dimensions ......................................................................................... B 43.3 EN standards ...................................................................................... B 53.4 Conditions for application .................................................................... B 54 Location of instruction labels and identification plates ........................ B 64.1 Truck identification plate ..................................................................... B 7

C Transportation and commissioning

1 Transportation by crane ...................................................................... C 12 Commissioning .................................................................................... C 23 Moving the truck with the drive unit inoperative .................................. C 3

D Battery - Servicing, recharging, replacement

1 Safety regulations governing the handling of lead-acid batteries ........ D 12 Battery types ....................................................................................... D 23 Exposing the battery ........................................................................... D 23.1 Standard version ................................................................................. D 23.2 Battery removal from the side (o) ....................................................... D 34 Charging the battery ............................................................................ D 45 Removing and installing the battery .................................................... D 55.1 Removal - standard version ................................................................ D 55.2 Removal “Battery removal from the side” (o) ..................................... D 65.3 Installation of the battery ..................................................................... D 6

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E Operation

1 Safety regulations governing the operation of the fork-lift truck .......... E 12 Description of the operating controls and displays .............................. E 23 Starting up the truck ............................................................................ E 63.1 Truck variants ...................................................................................... E 63.2 Switching on the truck ......................................................................... E 64 Operation of the fork-lift truck .............................................................. E 74.1 Safety regulations applicable when operating the truck ...................... E 74.2 Driving, steering, braking .................................................................... E 84.3 Picking up and setting down loads ...................................................... E 144.4 Safe parking of the truck ..................................................................... E 155 Keyboard (CANCODE) (o) ................................................................. E 165.1 Code lock ............................................................................................ E 165.2 Drive programme ................................................................................ E 185.3 Parameters .......................................................................................... E 185.4 Parameter settings .............................................................................. E 195.5 Travel parameters ............................................................................... E 236 Display instrument (CANDIS) (o) ....................................................... E 256.1 Discharge monitor function ................................................................. E 266.2 Operating hours display ...................................................................... E 266.3 Switch-on test ...................................................................................... E 267 Fault location ....................................................................................... E 27

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E Operation

1 Safety regulations governing the operation of the fork-lift truck .......... E 12 Description of the operating controls and displays .............................. E 23 Starting up the truck ............................................................................ E 63.1 Truck variants ...................................................................................... E 63.2 Switching on the truck ......................................................................... E 64 Operation of the fork-lift truck .............................................................. E 74.1 Safety regulations applicable when operating the truck ...................... E 74.2 Driving, steering, braking .................................................................... E 84.3 Picking up and setting down loads ...................................................... E 144.4 Safe parking of the truck ..................................................................... E 155 Keyboard (CANCODE) (o) ................................................................. E 165.1 Code lock ............................................................................................ E 165.2 Drive programme ................................................................................ E 185.3 Parameters .......................................................................................... E 185.4 Parameter settings .............................................................................. E 195.5 Travel parameters ............................................................................... E 236 Display instrument (CANDIS) (o) ....................................................... E 256.1 Discharge monitor function ................................................................. E 266.2 Operating hours display ...................................................................... E 266.3 Switch-on test ...................................................................................... E 267 Fault location ....................................................................................... E 27

I 3

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1 Operational safety and environmental protection ................................ F 12 Safety regulations applicable to truck maintenance ............................ F 13 Servicing and inspection ..................................................................... F 34 Maintenance checklist ........................................................................ F 45 Lubrication schedule ........................................................................... F 65.1 Consumption-type materials ............................................................... F 76 Description of the servicing and maintenance operations ................... F 86.1 Preparing the truck for the performance of the servicing and

maintenance operations ...................................................................... F 86.2 Opening the front hood ....................................................................... F 86.3 Opening the front hood ....................................................................... F 86.4 Checking the mounting and the attachment of the drive wheel .......... F 96.5 Checking the hydraulic oil level ........................................................... F 96.6 Checking the electric fuses ................................................................. F 106.7 Recommissioning the truck ................................................................. F 117 Decommissioning the fork-lift truck ..................................................... F 117.1 Operations to be performed prior to decommissioning ....................... F 117.2 Measures to be taken during decommissioning .................................. F 117.3 Recommissioning the truck ................................................................. F 128 Safety checks to be performed at regular intervals and following any

untoward incidents (D: Accident prevention check according to BGV D27) ........................................................................................ F 12

I 3

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F Maintenance of the fork-lift truck

1 Operational safety and environmental protection ................................ F 12 Safety regulations applicable to truck maintenance ............................ F 13 Servicing and inspection ..................................................................... F 34 Maintenance checklist ........................................................................ F 45 Lubrication schedule ........................................................................... F 65.1 Consumption-type materials ............................................................... F 76 Description of the servicing and maintenance operations ................... F 86.1 Preparing the truck for the performance of the servicing and

maintenance operations ...................................................................... F 86.2 Opening the front hood ....................................................................... F 86.3 Opening the front hood ....................................................................... F 86.4 Checking the mounting and the attachment of the drive wheel .......... F 96.5 Checking the hydraulic oil level ........................................................... F 96.6 Checking the electric fuses ................................................................. F 106.7 Recommissioning the truck ................................................................. F 117 Decommissioning the fork-lift truck ..................................................... F 117.1 Operations to be performed prior to decommissioning ....................... F 117.2 Measures to be taken during decommissioning .................................. F 117.3 Recommissioning the truck ................................................................. F 128 Safety checks to be performed at regular intervals and following any

untoward incidents (D: Accident prevention check according to BGV D27) ........................................................................................ F 12

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A 1

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A Correct use and application of the truck

Z The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) areincluded in the scope of delivery for this truck. The guidelines are part of these oper-ating 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 suitablefor lifting and transporting loads.It must be used, operated and maintained according to the information in these oper-ating instructions. Any other uses are outside the design envelope and can lead toinjury to persons or damage to equipment and property. Above all, overloadingcaused 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 labelshown on the truck. The fork lift truck must not be operated in spaces subject to fireor 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 onwhose behalf it is used. In special cases (e.g. leasing or renting), the user is consid-ered the person, who, in accordance with existing contractual agreements betweenthe owner and the user of the fork lift truck, is charged with the observance of the op-erating duties.The user must ensure that the truck is not abused and only used within its design lim-its and that all danger to life and limb of the operator, or third parties, is avoided. Inaddition to this, it must be ensured that the relevant accident prevention regulationsand other safety-related provisions, as well as the operating, servicing and mainte-nance guidelines, are observed. The user must also ensure that all persons operatingthe truck have read and understood these operating instructions.

M If these operating instructions are not observed the warranty becomes void. Thesame applies if improper works are carried out at the device by the customer and/orthird parties without permission of our Customer Service.

Mounting of attachments: The mounting or installation of any attachments whichwill 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 oflocal authorities has to be obtained.Any approval obtained from local authorities does not, however, make the approvalby the manufacturer unnecessary.

A 1

0600

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A Correct use and application of the truck

Z The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) areincluded in the scope of delivery for this truck. The guidelines are part of these oper-ating 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 suitablefor lifting and transporting loads.It must be used, operated and maintained according to the information in these oper-ating instructions. Any other uses are outside the design envelope and can lead toinjury to persons or damage to equipment and property. Above all, overloadingcaused 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 labelshown on the truck. The fork lift truck must not be operated in spaces subject to fireor 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 onwhose behalf it is used. In special cases (e.g. leasing or renting), the user is consid-ered the person, who, in accordance with existing contractual agreements betweenthe owner and the user of the fork lift truck, is charged with the observance of the op-erating duties.The user must ensure that the truck is not abused and only used within its design lim-its and that all danger to life and limb of the operator, or third parties, is avoided. Inaddition to this, it must be ensured that the relevant accident prevention regulationsand other safety-related provisions, as well as the operating, servicing and mainte-nance guidelines, are observed. The user must also ensure that all persons operatingthe truck have read and understood these operating instructions.

M If these operating instructions are not observed the warranty becomes void. Thesame applies if improper works are carried out at the device by the customer and/orthird parties without permission of our Customer Service.

Mounting of attachments: The mounting or installation of any attachments whichwill 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 oflocal authorities has to be obtained.Any approval obtained from local authorities does not, however, make the approvalby the manufacturer unnecessary.

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B 1

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B Truck description1 Application

The truck is an electric control shaft lift truck with hinged driver's platform and safetyframes.A fixed driver standing platform is available as an option.The truck has been designed for lifting operations and transportation on level groundand is able to pick up, outside the load-bearing wheel range, pallets with open basesor lateral boards, as well as trolleys. The rated capacity of the truck is shown on theidentification plate or can be seen on the capacity label Qmax.

B 1

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B Truck description1 Application

The truck is an electric control shaft lift truck with hinged driver's platform and safetyframes.A fixed driver standing platform is available as an option.The truck has been designed for lifting operations and transportation on level groundand is able to pick up, outside the load-bearing wheel range, pallets with open basesor lateral boards, as well as trolleys. The rated capacity of the truck is shown on theidentification plate or can be seen on the capacity label Qmax.

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B 2

2 Assemblies

Item Designation Item Designation1 t Controller 8 t Hinged driver standing platform2 t Control shaft 9 t Collision guard3 o Display instrument

(CANDIS)10 t Safety extension

4 t Key switch 11 t Master switch5 o Keyboard

(CANCODE)12 o Fixed driver standing platform

6 t Supporting wheel 13 o Deadman key7 t Driven wheelt = Standard equipment o = Optional equipment

1 2

3 4 5

66

9

10

11

8

7

12

13

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B 2

2 Assemblies

Item Designation Item Designation1 t Controller 8 t Hinged driver standing platform2 t Control shaft 9 t Collision guard3 o Display instrument

(CANDIS)10 t Safety extension

4 t Key switch 11 t Master switch5 o Keyboard

(CANCODE)12 o Fixed driver standing platform

6 t Supporting wheel 13 o Deadman key7 t Driven wheelt = Standard equipment o = Optional equipment

1 2

3 4 5

66

9

10

11

8

7

12

13

B 3

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3 Technical data

Z Indication of technical data according to VDI 2198.Subject to modification and supplements.

3.1 Performance data

* approx. 465 mm with fixed driver standing platform** Chassis height

DesignationQ Capacity 2.000 kg c Load centre distance 600 mm

Travelling speed, pedestrian-controlled operation with/without load

4.5 km/h

Travelling speed, stand-on operating mode with/without load

8.6 / 10.6 km/h

Lifting time with/without load 3.0 / 2.6 sLowering time with/without load 2.0 / 3.0 sMax. climbing capacity (5 min.) with/without load 8.0 / 15.0 %

**

*

B 3

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3 Technical data

Z Indication of technical data according to VDI 2198.Subject to modification and supplements.

3.1 Performance data

* approx. 465 mm with fixed driver standing platform** Chassis height

DesignationQ Capacity 2.000 kg c Load centre distance 600 mm

Travelling speed, pedestrian-controlled operation with/without load

4.5 km/h

Travelling speed, stand-on operating mode with/without load

8.6 / 10.6 km/h

Lifting time with/without load 3.0 / 2.6 sLowering time with/without load 2.0 / 3.0 sMax. climbing capacity (5 min.) with/without load 8.0 / 15.0 %

**

*

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3.2 Dimensions

(all dimensions in mm)

Length including fork back I2 = 788 mm (pedestrian-controlled operation)

1)Lifted: - 90 mm

2)Stand-on operating mode: +388 mm

3)Short version (I2=723 mm):- 65 mm

Designationh13 Height of fork when lowered 85h2 Lift 125b5 Distance between forks, outside 510 / 540 / 670b3 Distance between forks, inside 170 / 200 / 330e Fork width 170

b11 Track width 340 / 370 / 500a Safety distance 200 Dead weight: Refer to truck identification label

l I1 3) y1

1)3) x 1) I6 b12 Wa1)2)3) Ast

2)3)1.000 1.723 1.509 814 1.000 800 1.619 2.0051.150 1.873 1.659 964 1.200 800 1.768 2.2041.200 1.923 1.709 1.014 1.200 800 1.817 2.2031.400 2.193 1.979 1.214 1.400 700 2.016 2.4021.600 2.393 2.179 1.414 1.600 1.200 2.215 2.6011.950 2.743 2.529 1.392 2.000 800 2.193 3.0012.150 2.943 2.729 1.592 2.100 700 2.392 3.1002.400 3.193 2.979 1.840 2.400 1.200 2.639 3.399

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3.2 Dimensions

(all dimensions in mm)

Length including fork back I2 = 788 mm (pedestrian-controlled operation)

1)Lifted: - 90 mm

2)Stand-on operating mode: +388 mm

3)Short version (I2=723 mm):- 65 mm

Designationh13 Height of fork when lowered 85h2 Lift 125b5 Distance between forks, outside 510 / 540 / 670b3 Distance between forks, inside 170 / 200 / 330e Fork width 170

b11 Track width 340 / 370 / 500a Safety distance 200 Dead weight: Refer to truck identification label

l I1 3) y1

1)3) x 1) I6 b12 Wa1)2)3) Ast

2)3)1.000 1.723 1.509 814 1.000 800 1.619 2.0051.150 1.873 1.659 964 1.200 800 1.768 2.2041.200 1.923 1.709 1.014 1.200 800 1.817 2.2031.400 2.193 1.979 1.214 1.400 700 2.016 2.4021.600 2.393 2.179 1.414 1.600 1.200 2.215 2.6011.950 2.743 2.529 1.392 2.000 800 2.193 3.0012.150 2.943 2.729 1.592 2.100 700 2.392 3.1002.400 3.193 2.979 1.840 2.400 1.200 2.639 3.399

B 5

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3.3 EN standards

Continuous sound level: 68 dB(A)

according to EN 12053 as stipulated in ISO 4871

Z The continuous sound level is a value averaged according to standard regulations,taking the sound pressure level into account when driving, lifting and idling. Thesound pressure level is measured at the ear.

Vibration: 0.67 m/s2

according to EN 13059

Z The swinging acceleration acting on the body in its operating position is, according tostandard regulations, the linear integrated, weighted acceleration in the verticalplane. It is determined by driving over bumps with a constant speed.

Electromagnetic compatibility (EMC)

The manufacturer confirms compliance with the limit val-ues for electromagnetic emission and interference immu-nity as well as testing of static electricity discharge ac-cording to EN 12895 and the references to otherstandards contained therein.

Z Electrical or electronic components and their arrangement may only be modified afterwritten approval by the manufacturer has been obtained.

3.4 Conditions for application

Ambient temperature

- during operation: 5 °C to 40 °C

Z Industrial trucks must be specially equipped and approved for continuous use in en-vironments with temperatures below 5 °C or in cold stores respectively with extremetemperatures or humidity changes.

B 5

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3.3 EN standards

Continuous sound level: 68 dB(A)

according to EN 12053 as stipulated in ISO 4871

Z The continuous sound level is a value averaged according to standard regulations,taking the sound pressure level into account when driving, lifting and idling. Thesound pressure level is measured at the ear.

Vibration: 0.67 m/s2

according to EN 13059

Z The swinging acceleration acting on the body in its operating position is, according tostandard regulations, the linear integrated, weighted acceleration in the verticalplane. It is determined by driving over bumps with a constant speed.

Electromagnetic compatibility (EMC)

The manufacturer confirms compliance with the limit val-ues for electromagnetic emission and interference immu-nity as well as testing of static electricity discharge ac-cording to EN 12895 and the references to otherstandards contained therein.

Z Electrical or electronic components and their arrangement may only be modified afterwritten approval by the manufacturer has been obtained.

3.4 Conditions for application

Ambient temperature

- during operation: 5 °C to 40 °C

Z Industrial trucks must be specially equipped and approved for continuous use in en-vironments with temperatures below 5 °C or in cold stores respectively with extremetemperatures or humidity changes.

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B 6

4 Location of instruction labels and identification plates

Z The truck identification plate (14) is visible after the front hood has been opened (refer to chapter F).

The battery identification plate (18) is visible after the battery hood has been opened (refer to chapter D).

Item Designation14 Truck identification plate15 Caution: Heed the operating instructions! (see chapter C)16 Rated capacity17 Attachment point of hooks for transportation by crane18 Battery identification plate19 Accident prevention inspection label

1615

17

1814

19

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B 6

4 Location of instruction labels and identification plates

Z The truck identification plate (14) is visible after the front hood has been opened (refer to chapter F).

The battery identification plate (18) is visible after the battery hood has been opened (refer to chapter D).

Item Designation14 Truck identification plate15 Caution: Heed the operating instructions! (see chapter C)16 Rated capacity17 Attachment point of hooks for transportation by crane18 Battery identification plate19 Accident prevention inspection label

1615

17

1814

19

B 7

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4.1 Truck identification plate

Z In the event of queries relating to the truck or spare part orders, please give the serialNo. (21) of the truck.

Item Designation Item Designation20 Type 26 Manufacturer logo21 Serial No. 27 Min./max. battery weight in kg22 Rated capacity in kg 28 Drive power in kW23 Battery voltage 29 Load centre distance in mm24 Empty weight without battery in kg 30 Year of manufacture25 Manufacturer 31 Option

31

30

29

28

27

26

20

21

22

23

24

25

B 7

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4.1 Truck identification plate

Z In the event of queries relating to the truck or spare part orders, please give the serialNo. (21) of the truck.

Item Designation Item Designation20 Type 26 Manufacturer logo21 Serial No. 27 Min./max. battery weight in kg22 Rated capacity in kg 28 Drive power in kW23 Battery voltage 29 Load centre distance in mm24 Empty weight without battery in kg 30 Year of manufacture25 Manufacturer 31 Option

31

30

29

28

27

26

20

21

22

23

24

25

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B 8

C 1

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C Transportation and commissioning1 Transportation by crane

F Only lifting gear of adequate capacitymust be used (for the weight of thetruck, refer to the truck identificationplate - see chapter B).

Z Attachment points (1) are provided onthe chassis and the fork for transport-ing the truck with lifting gear.

– Park the truck and render it safe (re-fer to chapter E).

– Secure the lifting gear to the attach-ment points (1).

M The lifting gear must be attached to theattachment points in such a mannerthat it cannot slip and does not comeinto contact with any attachments!

M If the battery hood is marked according to the figure, proceed as follows.

– Lift up battery hood (2) by meansof handle recess and fold over (t).

– Unlock hood lock by pushing down, fold battery hood forward, unlock hood safetylock, and fold down battery hood and place on the load fork (o) (refer to chapter D).

Z The battery compartment contains a spanner (19 SW ring/open-end) and the disas-sembly and assembly instructions for the transport plugs.

1 12

1

C 1

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C Transportation and commissioning1 Transportation by crane

F Only lifting gear of adequate capacitymust be used (for the weight of thetruck, refer to the truck identificationplate - see chapter B).

Z Attachment points (1) are provided onthe chassis and the fork for transport-ing the truck with lifting gear.

– Park the truck and render it safe (re-fer to chapter E).

– Secure the lifting gear to the attach-ment points (1).

M The lifting gear must be attached to theattachment points in such a mannerthat it cannot slip and does not comeinto contact with any attachments!

M If the battery hood is marked according to the figure, proceed as follows.

– Lift up battery hood (2) by meansof handle recess and fold over (t).

– Unlock hood lock by pushing down, fold battery hood forward, unlock hood safetylock, and fold down battery hood and place on the load fork (o) (refer to chapter D).

Z The battery compartment contains a spanner (19 SW ring/open-end) and the disas-sembly and assembly instructions for the transport plugs.

1 12

1

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C 2

2 Commissioning

M The truck must only be operated on battery current! Rectified alternate current willdamage the electronic components. Cables connected to the battery (trailing cables)must be less than 6 meters in length.

Z For trucks starting from February 2001, transport plugs have been introduced.

F When there is no battery in the truck, the truck cannot be braked with counter-currentbrake and service brake.

In the front hood area there is a warning sign for the transport plugs (3), which mustbe removed after installing the battery.

– Fold down the foldable standing platform.– Open front hood (see chapter F).– Loosen nut M12 (19 SW) and remove transport plugs.– Leave the transport plugs at the truck for later transports of the battery.

3

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C 2

2 Commissioning

M The truck must only be operated on battery current! Rectified alternate current willdamage the electronic components. Cables connected to the battery (trailing cables)must be less than 6 meters in length.

Z For trucks starting from February 2001, transport plugs have been introduced.

F When there is no battery in the truck, the truck cannot be braked with counter-currentbrake and service brake.

In the front hood area there is a warning sign for the transport plugs (3), which mustbe removed after installing the battery.

– Fold down the foldable standing platform.– Open front hood (see chapter F).– Loosen nut M12 (19 SW) and remove transport plugs.– Leave the transport plugs at the truck for later transports of the battery.

3

C 3

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.GBIn order to prepare the truck for work following delivery or transportation, the followingoperations must be performed:

– Check the truck for completeness and satisfactory condition of the equipment.– If necessary, install the battery. Do not damage the battery cable. – Charge the battery (refer to chapter D).– If necessary, check whether the setting of the combined instrument matches the

type of battery (refer to chapter D)– Start the truck as described (refer to chapter E).

Z When parked, the running surface of the tyres will flatten. The flattening will disappearafter a short operating time of the truck.

3 Moving the truck with the drive unit inoperative

F This operating mode is not permitted when negotiating inclines and gradients.

If the truck has to be moved after a failu-re affecting proper operation has rende-red it immobile, proceed as follows:

– Set the master switch to position“OFF”.

– Set the key switch to position “OFF”and withdraw the key.

– Immobilise the truck, ensuring that itcannot move.

– Open the front hood and remove it (re-fer to chapter F).

– Loosen the lock nuts (5) and tightenthe screws (4).

This releases the brake so that the truckcan now be moved.

F After arriving at the destination, ensurethat the brake system is restored to itsinitial state. The truck must on no ac-count be parked with the brake in the re-leased condition.

– Turn out the screws (4) by approx. 5mm again and secure them with thelock nuts (5).

The brake is now applied again.

5

4

C 3

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In order to prepare the truck for work following delivery or transportation, the followingoperations must be performed:

– Check the truck for completeness and satisfactory condition of the equipment.– If necessary, install the battery. Do not damage the battery cable. – Charge the battery (refer to chapter D).– If necessary, check whether the setting of the combined instrument matches the

type of battery (refer to chapter D)– Start the truck as described (refer to chapter E).

Z When parked, the running surface of the tyres will flatten. The flattening will disappearafter a short operating time of the truck.

3 Moving the truck with the drive unit inoperative

F This operating mode is not permitted when negotiating inclines and gradients.

If the truck has to be moved after a failu-re affecting proper operation has rende-red it immobile, proceed as follows:

– Set the master switch to position“OFF”.

– Set the key switch to position “OFF”and withdraw the key.

– Immobilise the truck, ensuring that itcannot move.

– Open the front hood and remove it (re-fer to chapter F).

– Loosen the lock nuts (5) and tightenthe screws (4).

This releases the brake so that the truckcan now be moved.

F After arriving at the destination, ensurethat the brake system is restored to itsinitial state. The truck must on no ac-count be parked with the brake in the re-leased condition.

– Turn out the screws (4) by approx. 5mm again and secure them with thelock nuts (5).

The brake is now applied again.

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D Battery - Servicing, recharging, replace-ment

1 Safety regulations governing the handling of lead-acid batteries

The truck must be parked and rendered safe before any operations on batteries areundertaken (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 of the manufacturer of the battery and of the battery rechargingstation, must be observed when performing the above operations.

Fire protection measures: Smoking and naked flames are not permitted when han-dling batteries. No inflammable substances or spark-generating materials must bepresent or stored within a distance of 2 meters of the truck parked for battery recharg-ing. The location must be well ventilated and fire fighting equipment must be keptready.

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 besecurely tightened. Batteries with bare terminal posts must be covered using a non-skid insulating mat.

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 dam-aged.

F Batteries contain dissolved acid which is toxic and caustic. For this reason, protectiveclothing and goggles must be worn whenever work is undertaken on batteries. Avoidphysical contact with battery acid.If clothing, skin or eyes accidentally come into contact with battery acid, liberally flushthe affected parts with clean water. Consult a doctor when skin or eyes come into con-tact with battery acid. Spilled battery acid must be immediately neutralized.

M Only batteries with closed tray may be used.

F Battery weight and dimensions have considerable influence on operational safety ofthe truck. Changing the battery equipment is not permitted without prior approval bythe manufacturer.

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D Battery - Servicing, recharging, replace-ment

1 Safety regulations governing the handling of lead-acid batteries

The truck must be parked and rendered safe before any operations on batteries areundertaken (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 of the manufacturer of the battery and of the battery rechargingstation, must be observed when performing the above operations.

Fire protection measures: Smoking and naked flames are not permitted when han-dling batteries. No inflammable substances or spark-generating materials must bepresent or stored within a distance of 2 meters of the truck parked for battery recharg-ing. The location must be well ventilated and fire fighting equipment must be keptready.

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 besecurely tightened. Batteries with bare terminal posts must be covered using a non-skid insulating mat.

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 dam-aged.

F Batteries contain dissolved acid which is toxic and caustic. For this reason, protectiveclothing and goggles must be worn whenever work is undertaken on batteries. Avoidphysical contact with battery acid.If clothing, skin or eyes accidentally come into contact with battery acid, liberally flushthe affected parts with clean water. Consult a doctor when skin or eyes come into con-tact with battery acid. Spilled battery acid must be immediately neutralized.

M Only batteries with closed tray may be used.

F Battery weight and dimensions have considerable influence on operational safety ofthe truck. Changing the battery equipment is not permitted without prior approval bythe manufacturer.

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2 Battery types

The battery types meet the EN 60254-2 standards.The following table shows the battery combinations and battery capacities:

The battery weight is indicated on the battery identification plate.

Depending on the type of battery used, it is also possible to use models with en-hanced performance or maintenance-free batteries.

F When replacing or installing batteries, ensure that the battery is correctly secured inthe battery compartment of the truck.

3 Exposing the battery

F Park the truck and render it safe (refer to chapter E).

3.1 Standard version

– Set the master switch (1) to position “OFF”.– Lift up and swing forward the battery hood (2) using the handle (3).

Battery type Battery compartment ap-prox. 225 mm

Battery compartment ap-prox. 295 mm

24 V batteries 3 EPzB 300 Ah 3 EPzS 345 Ah24 V batteries

(performance-enhanced) 3 EPzS 375 Ah

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2 Battery types

The battery types meet the EN 60254-2 standards.The following table shows the battery combinations and battery capacities:

The battery weight is indicated on the battery identification plate.

Depending on the type of battery used, it is also possible to use models with en-hanced performance or maintenance-free batteries.

F When replacing or installing batteries, ensure that the battery is correctly secured inthe battery compartment of the truck.

3 Exposing the battery

F Park the truck and render it safe (refer to chapter E).

3.1 Standard version

– Set the master switch (1) to position “OFF”.– Lift up and swing forward the battery hood (2) using the handle (3).

Battery type Battery compartment ap-prox. 225 mm

Battery compartment ap-prox. 295 mm

24 V batteries 3 EPzB 300 Ah 3 EPzS 345 Ah24 V batteries

(performance-enhanced) 3 EPzS 375 Ah

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3.2 Battery removal from the side (o)

– Set the master switch (7) to position “OFF”.– Unlock the hood locking mechanism (4) by pressing it down,

tilt the battery hood (5) towards the front and unlock the hood catch (6)r.– Fold the battery hood (5) down and place it onto the fork.

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3.2 Battery removal from the side (o)

– Set the master switch (7) to position “OFF”.– Unlock the hood locking mechanism (4) by pressing it down,

tilt the battery hood (5) towards the front and unlock the hood catch (6)r.– Fold the battery hood (5) down and place it onto the fork.

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4 Charging the battery

– Park the truck and render it safe (refer to chapter E).

F Do not connect or disconnect the battery connector and the socket unless the truckis switched off.

– 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 tostarting the recharging operation, check all cable connections and plugged connec-tions for visible damage.All safety instructions as provided by the supplier of the battery and the charging sta-tion must be strictly observed.

– Disconnect the battery connector (8).– If present, remove any insulating mats from the battery.– Connect the charging cable (9) to the battery connector (8) and switch on the bat-

tery charger.

M Recharge the battery observing the instructions provided by the battery supplier andby the charging station supplier.

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4 Charging the battery

– Park the truck and render it safe (refer to chapter E).

F Do not connect or disconnect the battery connector and the socket unless the truckis switched off.

– 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 tostarting the recharging operation, check all cable connections and plugged connec-tions for visible damage.All safety instructions as provided by the supplier of the battery and the charging sta-tion must be strictly observed.

– Disconnect the battery connector (8).– If present, remove any insulating mats from the battery.– Connect the charging cable (9) to the battery connector (8) and switch on the bat-

tery charger.

M Recharge the battery observing the instructions provided by the battery supplier andby the charging station supplier.

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5 Removing and installing the battery

F The truck must be parked on level ground. To prevent short-circuits, batteries with ex-posed poles or cell connectors must be covered using rubber matting. Place the bat-tery connector or the battery cable, respectively, in such a way that they will not catchbehind any truck protrusions when the battery is withdrawn.

Z When transporting batteries with the aid of a crane, ensure that the crane is of ade-quate capacity (the battery weight is indicated on the battery identification plate at thebattery trough). The lifting gear must pull in a vertical direction to prevent damage tothe battery trough. The lifting gear hooks must be secured to the attachment points(12) in such a way that the lifting gear, when slack, cannot collapse on the batterycells.

5.1 Removal - standard version

– Expose the battery (refer to section 3).– Loosen the screw (10) of the battery support (11).– Lift and pull out the battery support.– Disconnect the battery.– Fix the lifting gear to the attachment points (12) and lift out the battery.

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5 Removing and installing the battery

F The truck must be parked on level ground. To prevent short-circuits, batteries with ex-posed poles or cell connectors must be covered using rubber matting. Place the bat-tery connector or the battery cable, respectively, in such a way that they will not catchbehind any truck protrusions when the battery is withdrawn.

Z When transporting batteries with the aid of a crane, ensure that the crane is of ade-quate capacity (the battery weight is indicated on the battery identification plate at thebattery trough). The lifting gear must pull in a vertical direction to prevent damage tothe battery trough. The lifting gear hooks must be secured to the attachment points(12) in such a way that the lifting gear, when slack, cannot collapse on the batterycells.

5.1 Removal - standard version

– Expose the battery (refer to section 3).– Loosen the screw (10) of the battery support (11).– Lift and pull out the battery support.– Disconnect the battery.– Fix the lifting gear to the attachment points (12) and lift out the battery.

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5.2 Removal “Battery removal from the side” (o)

– Expose the battery (refer to section 3).– Push the battery against the chassis in order to relieve the battery support (13).– Lift the battery support r, push it a short distance into the chassis p, lift r and with-

draw it u.– Disconnect the battery.– Pull the battery laterally onto the battery exchange point.

F Heed the operating instructions of the manufacturer of the battery exchange point!

Z The battery can also be removed using crane gear.

5.3 Installation of the battery

Installation is in the reverse order of steps.

F Following reinstallation of the battery, check all cable connections and plugged con-nections for any visible damage.Standard version: Before starting up the truck again, fasten the battery support (11)with the screw (10) and make sure that the battery hood is closed safely with the hoodlocking mechanism. Truck with battery removal from the side: Before starting up the truck again, check:

– that the battery support is installed and,– that the battery hood is safely locked.

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5.2 Removal “Battery removal from the side” (o)

– Expose the battery (refer to section 3).– Push the battery against the chassis in order to relieve the battery support (13).– Lift the battery support r, push it a short distance into the chassis p, lift r and with-

draw it u.– Disconnect the battery.– Pull the battery laterally onto the battery exchange point.

F Heed the operating instructions of the manufacturer of the battery exchange point!

Z The battery can also be removed using crane gear.

5.3 Installation of the battery

Installation is in the reverse order of steps.

F Following reinstallation of the battery, check all cable connections and plugged con-nections for any visible damage.Standard version: Before starting up the truck again, fasten the battery support (11)with the screw (10) and make sure that the battery hood is closed safely with the hoodlocking mechanism. Truck with battery removal from the side: Before starting up the truck again, check:

– that the battery support is installed and,– that the battery hood is safely locked.

13

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E Operation1 Safety regulations governing the operation of the fork-lift truck

Driving permission: The fork-lift truck must only be operated by persons who havebeen trained in the operation of trucks, who have demonstrated to the user or his rep-resentative their capability of moving and handling loads, and who have expresslybeen 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 rightsand duties; trained in the operation of the fork-lift truck; and familiar with the contentsof these operating instructions. All necessary rights must be granted to him. If thefork-lift truck can be used in the pedestrian-controlled mode, the driver must wearsafety boots when operating the truck.

Prohibition of unauthorised use: The driver is responsible for the fork-lift truck dur-ing working time. He must forbid unauthorised persons to drive or operate the fork-lifttruck. It is forbidden to transport or lift persons.

Damage and defects: Damage or defects noted on the fork-lift truck or on the attach-ments must immediately be brought to the notice of the person in charge. Fork-lifttrucks 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 authorisation, the driver is not allowedto perform any repairs or modifications on the fork-lift truck. Under no circumstancesmust the driver change the setting of switches or safety installations or render themineffective.

Danger area: A “danger area” is considered to be the area within which persons areendangered by the travelling or lifting movements of the fork-lift truck or its load liftingdevices (e.g. fork or attachments), or by the loads being transported. This also in-cludes the area within reach of falling loads or falling/lowering truck attachments.

F Unauthorised persons must be asked to leave the danger area. The driver must givea warning signal whenever a situation presenting danger to persons might develop.The fork-lift truck must immediately be brought to a standstill if persons, althoughasked, do not leave the danger area.

Safety devices and warning labels: The safety devices, warning labels and warningnotes described in the present operating instructions must always be heeded.

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E Operation1 Safety regulations governing the operation of the fork-lift truck

Driving permission: The fork-lift truck must only be operated by persons who havebeen trained in the operation of trucks, who have demonstrated to the user or his rep-resentative their capability of moving and handling loads, and who have expresslybeen 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 rightsand duties; trained in the operation of the fork-lift truck; and familiar with the contentsof these operating instructions. All necessary rights must be granted to him. If thefork-lift truck can be used in the pedestrian-controlled mode, the driver must wearsafety boots when operating the truck.

Prohibition of unauthorised use: The driver is responsible for the fork-lift truck dur-ing working time. He must forbid unauthorised persons to drive or operate the fork-lifttruck. It is forbidden to transport or lift persons.

Damage and defects: Damage or defects noted on the fork-lift truck or on the attach-ments must immediately be brought to the notice of the person in charge. Fork-lifttrucks 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 authorisation, the driver is not allowedto perform any repairs or modifications on the fork-lift truck. Under no circumstancesmust the driver change the setting of switches or safety installations or render themineffective.

Danger area: A “danger area” is considered to be the area within which persons areendangered by the travelling or lifting movements of the fork-lift truck or its load liftingdevices (e.g. fork or attachments), or by the loads being transported. This also in-cludes the area within reach of falling loads or falling/lowering truck attachments.

F Unauthorised persons must be asked to leave the danger area. The driver must givea warning signal whenever a situation presenting danger to persons might develop.The fork-lift truck must immediately be brought to a standstill if persons, althoughasked, do not leave the danger area.

Safety devices and warning labels: The safety devices, warning labels and warningnotes described in the present operating instructions must always be heeded.

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2 Description of the operating controls and displays

Item Operating control or display Function1 Hinged standing platform t Pedestrian-controlled operation:

– Driver standing platform in folded-up position: Truck travelling speed is limited to 4.5 km/h.

Stand-on operating mode, standing platform serves as the deadman switch:– Unweighted driver standing platform in folded-up

position: Travelling function blocked.

– Driver standing platform in folded-down position,with driver standing on it: Travelling function released.

2 Hinged safety extensions t The travelling function is blocked if the safety ex-tensions are not folded out when the standing plat-form is folded down:Truck travelling speed is limited to 4.5 km/h.

3 Master switch (emergency cut-out)

t The electric circuit is interrupted, all electrically controlled functions are switched off and the truck is automatically braked.

4 Anti-collision key t Pedestrian-controlled operation:Safety function which, when operated, will force the truck for approx. 5 seconds in the opposite trav-elling direction (R) and which will then switch off the travelling function until the controller has been briefly moved to its neutral position.Stand-on operating mode:without function

5 Controller t Controls the direction of travel as well as the trav-elling speed (refer to section 4.2).

6 Display instrument(CANDIS)

o Operating hours meterBattery capacity displayShows the residual capacity of the battery and the accumulated operating hours of the truck

7 Key switch t Switches the control current on and off. The truck cannot be operated by unauthorised persons when the key has been removed from the switch.

8 Keyboard(CANCODE)

o Code settingsDrive programme release

9 Control shaft t Movable control shaft.Steering and braking:– Swivelling the control shaft into the braking

range (B): The truck is mechanically braked.

– Swivelling the control shaft into the driving range(F): This releases the brake so that the truck can bemoved.

t = Standard equipment o = Optional equipment

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2 Description of the operating controls and displays

Item Operating control or display Function1 Hinged standing platform t Pedestrian-controlled operation:

– Driver standing platform in folded-up position: Truck travelling speed is limited to 4.5 km/h.

Stand-on operating mode, standing platform serves as the deadman switch:– Unweighted driver standing platform in folded-up

position: Travelling function blocked.

– Driver standing platform in folded-down position,with driver standing on it: Travelling function released.

2 Hinged safety extensions t The travelling function is blocked if the safety ex-tensions are not folded out when the standing plat-form is folded down:Truck travelling speed is limited to 4.5 km/h.

3 Master switch (emergency cut-out)

t The electric circuit is interrupted, all electrically controlled functions are switched off and the truck is automatically braked.

4 Anti-collision key t Pedestrian-controlled operation:Safety function which, when operated, will force the truck for approx. 5 seconds in the opposite trav-elling direction (R) and which will then switch off the travelling function until the controller has been briefly moved to its neutral position.Stand-on operating mode:without function

5 Controller t Controls the direction of travel as well as the trav-elling speed (refer to section 4.2).

6 Display instrument(CANDIS)

o Operating hours meterBattery capacity displayShows the residual capacity of the battery and the accumulated operating hours of the truck

7 Key switch t Switches the control current on and off. The truck cannot be operated by unauthorised persons when the key has been removed from the switch.

8 Keyboard(CANCODE)

o Code settingsDrive programme release

9 Control shaft t Movable control shaft.Steering and braking:– Swivelling the control shaft into the braking

range (B): The truck is mechanically braked.

– Swivelling the control shaft into the driving range(F): This releases the brake so that the truck can bemoved.

t = Standard equipment o = Optional equipment

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Item Operating control or display Function10 Operating key - Horn t Issues a warning signal.11 Operating key “Lowering” t Lowers the fork.12 Operating key “Lifting” t Lifts the fork.13 Brake switch

(variant “Suspended standing platform”)

o Emergency stop and service brake

14 Control shaft (electrical steering)

o Steering

15 Rigid safety barriers o Only stand-on operation is possible.16 Deadman key

(The function depends on the control shaft variant.)

o Truck with moveable control shaft:– Deadman key pressed:

Travelling function released.– Deadman key released:

Truck coasts to a stop.Truck with rigid control shaft:– Deadman key pressed:

Truck is ready for operation.– Deadman key released:

Truck is braked.17 Fixed driver standing platform o Only stand-on operation is possible.18 Rigid safety barriers

(variant “Suspended standing platform”)

o Only stand-on operation is possible.

19 Fixed driver standing platform (suspended) (variant “Suspended standing platform”)

o Stand-on operation with weighted standing platform.

t = Standard equipment o = Optional equipment

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Item Operating control or display Function10 Operating key - Horn t Issues a warning signal.11 Operating key “Lowering” t Lowers the fork.12 Operating key “Lifting” t Lifts the fork.13 Brake switch

(variant “Suspended standing platform”)

o Emergency stop and service brake

14 Control shaft (electrical steering)

o Steering

15 Rigid safety barriers o Only stand-on operation is possible.16 Deadman key

(The function depends on the control shaft variant.)

o Truck with moveable control shaft:– Deadman key pressed:

Travelling function released.– Deadman key released:

Truck coasts to a stop.Truck with rigid control shaft:– Deadman key pressed:

Truck is ready for operation.– Deadman key released:

Truck is braked.17 Fixed driver standing platform o Only stand-on operation is possible.18 Rigid safety barriers

(variant “Suspended standing platform”)

o Only stand-on operation is possible.

19 Fixed driver standing platform (suspended) (variant “Suspended standing platform”)

o Stand-on operation with weighted standing platform.

t = Standard equipment o = Optional equipment

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E 6

3 Starting up the truck

F The driver must make sure that nobody is within the danger area of the truck beforethe 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 steering wheel play.– Ensure through a visual inspection that the battery is securely locked in place and

that the cable connections are in order.

3.1 Truck variants

F Commissioning and operation of the truck depend on the truck variant and truck con-figuration.

3.2 Switching on the truck

– Pull out the master switch (3).– Use the key to set the key switch (7) to

position “I”.– Check the horn (10) for proper func-

tioning.

F When swivelling the hinged standingplatform upwards (if available), do notreach between the standing platformand the truck’s side wall. Check the braking function (refer to section 4.2).

The truck is now ready for operation.The display instrument (CANDIS (6)(o)) shows the available battery capaci-ty.

Truck variantTruck configuration Hinged driver

standing platform

Fixed driver standing platform

Suspended driver standing

platformControl shaft – movable t t --

– rigid -- o tSteering – mechanic t t --

– electric o o tSafetyextension

– hinged t -- --– rigid -- t t

Operating mode

– pedestrian oper. t -- --– stand-on oper. t t t

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3 Starting up the truck

F The driver must make sure that nobody is within the danger area of the truck beforethe 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 steering wheel play.– Ensure through a visual inspection that the battery is securely locked in place and

that the cable connections are in order.

3.1 Truck variants

F Commissioning and operation of the truck depend on the truck variant and truck con-figuration.

3.2 Switching on the truck

– Pull out the master switch (3).– Use the key to set the key switch (7) to

position “I”.– Check the horn (10) for proper func-

tioning.

F When swivelling the hinged standingplatform upwards (if available), do notreach between the standing platformand the truck’s side wall. Check the braking function (refer to section 4.2).

The truck is now ready for operation.The display instrument (CANDIS (6)(o)) shows the available battery capaci-ty.

Truck variantTruck configuration Hinged driver

standing platform

Fixed driver standing platform

Suspended driver standing

platformControl shaft – movable t t --

– rigid -- o tSteering – mechanic t t --

– electric o o tSafetyextension

– hinged t -- --– rigid -- t t

Operating mode

– pedestrian oper. t -- --– stand-on oper. t t t

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4 Operation of the fork-lift truck

4.1 Safety regulations applicable when operating the truck

Driving lanes and work areas: Only such lanes and routes that are specially allo-cated for truck traffic must be used. Unauthorised persons must stay away from workareas. 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 narrowpassages, when passing through swing doors and at blind spots. The driver must al-ways observe an adequate braking distance between the fork-lift truck and the vehi-cle in front and he must be in control of his truck at all times. Sudden stopping (exceptin emergencies), rapid U-turns and overtaking at dangerous or blind spots is not per-mitted. It is forbidden to lean or reach out of or reach beyond the working and operat-ing area. It is forbidden to transport or lift persons.

Visibility: The driver must look in the direction of travel and must always have a clearview of the route ahead. When loads blocking the view are carried, the fork-lift truckmust be driven with the load at the rear. If this is not possible, a second person mustwalk in front of the fork-lift truck to give suitable warnings.

Negotiating slopes and inclines: Negotiating slopes and inclines is permitted onlywhen they are recognised lanes, when they are clean and non-slipping, and when thetechnical 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, cuttingobliquely over slopes or inclines and parking the fork-lift truck on slopes or inclines isnot permitted. Inclines must only be negotiated at slow speed, with the driver readyto brake at any moment.

Use of lifts and driving on loading platforms: Lifts and loading platforms must onlybe used if they are of adequate load bearing capacity, if suitable for driving on, and ifauthorised by the user of the truck for truck traffic. The fork-lift truck driver has to sat-isfy himself accordingly before driving into lifts or onto loading platforms. The truckmust enter lifts with the load in front and must take up a position which does not allowit to come into contact with the walls of the lift shaft.Persons riding in the lift together with the fork-lift truck must only enter the lift after thefork-lift truck has come safely to a standstill, and must leave the lift before the fork-lifttruck.

Nature of the loads carried: Only loads that have been safely and correctly securedmust be carried. Never transport loads stacked higher than the top of the fork car-riage, or stacked higher than the guard grille.

Towing trailers: The maximum trailer load given for the fork-lift truck for braked and/or unbraked trailers must not be exceeded. The trailer load must be properly securedand must not exceed the dimensions permitted for the driving routes. After attachingthe trailer but before starting driving, the driver must check that the trailer attachmentis secured against detachment. Towing fork-lift trucks must be operated in such amanner that safe driving and braking of the truck and the trailer is guaranteed for alldriving movements.

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4 Operation of the fork-lift truck

4.1 Safety regulations applicable when operating the truck

Driving lanes and work areas: Only such lanes and routes that are specially allo-cated for truck traffic must be used. Unauthorised persons must stay away from workareas. 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 narrowpassages, when passing through swing doors and at blind spots. The driver must al-ways observe an adequate braking distance between the fork-lift truck and the vehi-cle in front and he must be in control of his truck at all times. Sudden stopping (exceptin emergencies), rapid U-turns and overtaking at dangerous or blind spots is not per-mitted. It is forbidden to lean or reach out of or reach beyond the working and operat-ing area. It is forbidden to transport or lift persons.

Visibility: The driver must look in the direction of travel and must always have a clearview of the route ahead. When loads blocking the view are carried, the fork-lift truckmust be driven with the load at the rear. If this is not possible, a second person mustwalk in front of the fork-lift truck to give suitable warnings.

Negotiating slopes and inclines: Negotiating slopes and inclines is permitted onlywhen they are recognised lanes, when they are clean and non-slipping, and when thetechnical 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, cuttingobliquely over slopes or inclines and parking the fork-lift truck on slopes or inclines isnot permitted. Inclines must only be negotiated at slow speed, with the driver readyto brake at any moment.

Use of lifts and driving on loading platforms: Lifts and loading platforms must onlybe used if they are of adequate load bearing capacity, if suitable for driving on, and ifauthorised by the user of the truck for truck traffic. The fork-lift truck driver has to sat-isfy himself accordingly before driving into lifts or onto loading platforms. The truckmust enter lifts with the load in front and must take up a position which does not allowit to come into contact with the walls of the lift shaft.Persons riding in the lift together with the fork-lift truck must only enter the lift after thefork-lift truck has come safely to a standstill, and must leave the lift before the fork-lifttruck.

Nature of the loads carried: Only loads that have been safely and correctly securedmust be carried. Never transport loads stacked higher than the top of the fork car-riage, or stacked higher than the guard grille.

Towing trailers: The maximum trailer load given for the fork-lift truck for braked and/or unbraked trailers must not be exceeded. The trailer load must be properly securedand must not exceed the dimensions permitted for the driving routes. After attachingthe trailer but before starting driving, the driver must check that the trailer attachmentis secured against detachment. Towing fork-lift trucks must be operated in such amanner that safe driving and braking of the truck and the trailer is guaranteed for alldriving movements.

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4.2 Driving, steering, braking

F Be extremely careful when driving and steering, especially when parts of the bodyprotrude from the truck contour.Make sure to keep sufficient distance when the truck is operated with an accompany-ing person.

The electric steering system is self-monitoring.

The steering control systems monitors the fault frequency over a certain period. If thesame fault is detected several times during this period, the steering control reducesthe driving speed of the truck to low speed. If such a fault occurs, the driving speedis not reset to normal speed by switching the truck off and on again. This method pre-vents the cancellation of a fault without eliminating the fault.

F As the steering system is a safety-relevant component, the fault must be eliminatedby trained service personnel.

Cut-out

Depress the master switch (3). This will switch off all electric functions.

Emergency stop

Depending on the truck variant, the emergency stop function can be triggered in dif-ferent ways.

Truck with movable control shaft (t):

When the control shaft (9) is released, the truck is automatically braked (emergencystop). The control shaft will automatically move into the upper braking range (B).

F If the control shaft is sluggish in moving into the braking range, the cause must beestablished and eliminated. If necessary, the gas pressure spring must be replaced.

Truck with rigid control shaft (o):

The emergency stop function is triggered when the deadman switch (16) in the stand-ing platform is released.

Truck with rigid control shaft and suspended standing platform (variant “Suspended standing platform”) (o):

The emergency stop function is released when:

– the brake switch (13) on the control shaft is pressed.– the standing platform (17) is no longer weighted.

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4.2 Driving, steering, braking

F Be extremely careful when driving and steering, especially when parts of the bodyprotrude from the truck contour.Make sure to keep sufficient distance when the truck is operated with an accompany-ing person.

The electric steering system is self-monitoring.

The steering control systems monitors the fault frequency over a certain period. If thesame fault is detected several times during this period, the steering control reducesthe driving speed of the truck to low speed. If such a fault occurs, the driving speedis not reset to normal speed by switching the truck off and on again. This method pre-vents the cancellation of a fault without eliminating the fault.

F As the steering system is a safety-relevant component, the fault must be eliminatedby trained service personnel.

Cut-out

Depress the master switch (3). This will switch off all electric functions.

Emergency stop

Depending on the truck variant, the emergency stop function can be triggered in dif-ferent ways.

Truck with movable control shaft (t):

When the control shaft (9) is released, the truck is automatically braked (emergencystop). The control shaft will automatically move into the upper braking range (B).

F If the control shaft is sluggish in moving into the braking range, the cause must beestablished and eliminated. If necessary, the gas pressure spring must be replaced.

Truck with rigid control shaft (o):

The emergency stop function is triggered when the deadman switch (16) in the stand-ing platform is released.

Truck with rigid control shaft and suspended standing platform (variant “Suspended standing platform”) (o):

The emergency stop function is released when:

– the brake switch (13) on the control shaft is pressed.– the standing platform (17) is no longer weighted.

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Driving

Truck with hinged standing platform and movable control shaft:

There are two different travelling modes:

F When swivelling the standing platform upwards, do not reach between the standingplatform and the truck’s side wall.

– Pedestrian-controlled operation: Starting with safety extension (2.2), swivel thesafety extensions (2.1 and 2.2) inwards and then fold up the standing platform (1).The truck can only be operated at a reduced travelling speed.

– Stand-on operating mode: Swivel the safety extensions (2.1 and 2.2) outwards andthen fold down the standing platform (1). The truck can be operated at the maxi-mum travelling speed.

General:

– Swivel the control shaft (9) into the driving range (F). – Set the controller (5) to the required travelling direction (V or R).

Z The travelling function is blocked if the driver is not standing on the platform and thesafety extensions are not folded out. The truck can only be operated at a reduced travelling speed when the standing plat-form is weighted and the safety extensions are not folded out.

o Truck with rigid standing platform and movable control shaft:

– Step on the standing platform (19).– Press the deadman switch (16).– Swivel the control shaft (14) into the driving range (F). – Set the controller (5) to the required travelling direction (V or R).

Truck with rigid standing platform and rigid control shaft (o):

– Step on the standing platform (19).– Press the deadman switch (16).– Set the controller (5) to the required travelling direction (V or R).

Truck with rigid, lowered and suspended standing platform (variant “Suspended standing platform”) (o):

– Step on the suspended standing platform (19).– Set the controller (5) to the required travelling direction (V or R).

F Do not drive the truck unless the hoods are closed and locked in the stipulated man-ner. When passing through swing doors or similar, take care that the anti-collision key(13) is not inadvertently operated.

– Start up the truck (refer to section 3).

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Driving

Truck with hinged standing platform and movable control shaft:

There are two different travelling modes:

F When swivelling the standing platform upwards, do not reach between the standingplatform and the truck’s side wall.

– Pedestrian-controlled operation: Starting with safety extension (2.2), swivel thesafety extensions (2.1 and 2.2) inwards and then fold up the standing platform (1).The truck can only be operated at a reduced travelling speed.

– Stand-on operating mode: Swivel the safety extensions (2.1 and 2.2) outwards andthen fold down the standing platform (1). The truck can be operated at the maxi-mum travelling speed.

General:

– Swivel the control shaft (9) into the driving range (F). – Set the controller (5) to the required travelling direction (V or R).

Z The travelling function is blocked if the driver is not standing on the platform and thesafety extensions are not folded out. The truck can only be operated at a reduced travelling speed when the standing plat-form is weighted and the safety extensions are not folded out.

o Truck with rigid standing platform and movable control shaft:

– Step on the standing platform (19).– Press the deadman switch (16).– Swivel the control shaft (14) into the driving range (F). – Set the controller (5) to the required travelling direction (V or R).

Truck with rigid standing platform and rigid control shaft (o):

– Step on the standing platform (19).– Press the deadman switch (16).– Set the controller (5) to the required travelling direction (V or R).

Truck with rigid, lowered and suspended standing platform (variant “Suspended standing platform”) (o):

– Step on the suspended standing platform (19).– Set the controller (5) to the required travelling direction (V or R).

F Do not drive the truck unless the hoods are closed and locked in the stipulated man-ner. When passing through swing doors or similar, take care that the anti-collision key(13) is not inadvertently operated.

– Start up the truck (refer to section 3).

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Steering

F In narrow bends, the driver will be positioned at the outer contours of the truck.

– Swivel the control shaft (9, 14) to the left or right.

Braking

F The braking behaviour of the truck strongly depends on the state of the floor. Thismust be taken into account by the driver for his driving behaviour.

There are two ways to brake the truck:

– by means of the counter-current brake– by means of the service brake

Braking by means of the counter-current brake:

Truck with movable control shaft (t):

– Turn the controller (5) into the opposite travelling direction until the truck has cometo a standstill.

The truck is braked with the counter-current brake.

Braking by means of the service brake:

– Swivel the control shaft (9, 14) into one of the braking ranges (B) or release the con-trol shaft.

The drive motor is mechanically braked by means of the motor brake.When the truck is parked, the service brake acts as a parking brake.

Z When the control shaft is released, it automatically swivels into the upper brakingrange (B).

Truck with rigid control shaft (o) :

– Release the foot switch (17) in the standing platform.

Variant “Suspended standing platform”(o):

– Press the brake key (13) in the control shaft head.

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Steering

F In narrow bends, the driver will be positioned at the outer contours of the truck.

– Swivel the control shaft (9, 14) to the left or right.

Braking

F The braking behaviour of the truck strongly depends on the state of the floor. Thismust be taken into account by the driver for his driving behaviour.

There are two ways to brake the truck:

– by means of the counter-current brake– by means of the service brake

Braking by means of the counter-current brake:

Truck with movable control shaft (t):

– Turn the controller (5) into the opposite travelling direction until the truck has cometo a standstill.

The truck is braked with the counter-current brake.

Braking by means of the service brake:

– Swivel the control shaft (9, 14) into one of the braking ranges (B) or release the con-trol shaft.

The drive motor is mechanically braked by means of the motor brake.When the truck is parked, the service brake acts as a parking brake.

Z When the control shaft is released, it automatically swivels into the upper brakingrange (B).

Truck with rigid control shaft (o) :

– Release the foot switch (17) in the standing platform.

Variant “Suspended standing platform”(o):

– Press the brake key (13) in the control shaft head.

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4.3 Picking up and setting down loads

M Before picking up a load, the driver hasto check that the load rests properly onits pallet and that it does not exceed thecapacity of his truck.

– Pass the fork tines as far as possibleunder the load. It is not permitted topick up long loads crosswise.

M When picking up the load, ensure that itdoes not project excessively from thetips of the tines (less than 50 mm).

Lifting and lowering

Z When operating the keys “Lifting” or“Lowering”, the lifting or lowering move-ment will be at a fixed speed.

Lifting

– Press the operating key “Lifting” (12). Keep the key depressed until the required lift-ing height is reached.

Lowering

– Depress operating key “Lowering” (11); the fork is lowered.

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4.3 Picking up and setting down loads

M Before picking up a load, the driver hasto check that the load rests properly onits pallet and that it does not exceed thecapacity of his truck.

– Pass the fork tines as far as possibleunder the load. It is not permitted topick up long loads crosswise.

M When picking up the load, ensure that itdoes not project excessively from thetips of the tines (less than 50 mm).

Lifting and lowering

Z When operating the keys “Lifting” or“Lowering”, the lifting or lowering move-ment will be at a fixed speed.

Lifting

– Press the operating key “Lifting” (12). Keep the key depressed until the required lift-ing height is reached.

Lowering

– Depress operating key “Lowering” (11); the fork is lowered.

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4.4 Safe parking of the truck

When the truck is parked and left unat-tended, it must be rendered safe even ifit is left unattended for only a short peri-od of time.

– Never park the truck on a slope or in-cline.

– Completely lower the fork.– Switch the key switch (7) to position

“0” and remove the key from the keyswitch.

– Set the master switch (3) to position“OFF”.

– Swing in the hinged safety extensions(if available).

F When swivelling the hinged standingplatform upwards (if available), do notreach between the standing platformand the truck’s side wall.

– Use one of the bevelled edges toswing the driver’s standing platform upwards (if available).

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4.4 Safe parking of the truck

When the truck is parked and left unat-tended, it must be rendered safe even ifit is left unattended for only a short peri-od of time.

– Never park the truck on a slope or in-cline.

– Completely lower the fork.– Switch the key switch (7) to position

“0” and remove the key from the keyswitch.

– Set the master switch (3) to position“OFF”.

– Swing in the hinged safety extensions(if available).

F When swivelling the hinged standingplatform upwards (if available), do notreach between the standing platformand the truck’s side wall.

– Use one of the bevelled edges toswing the driver’s standing platform upwards (if available).

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5 Keyboard (CANCODE) (o)

The operator keyboard is composed of 10 nu-meric keys, a Set key and an o-key.The green LED in key 1 indicates that the driveprogramme was switched on with key 1.The o-key indicates operating conditions by ared/green LED.

It has the following functions:

– Code lock function (setting the truck into oper-ation).

– Setting the travel and battery parameters, only in conjunction with the indicator in-strument (CANDIS (o)).

The o-key has top priority and reset the truck from any condition to the basic condi-tion without modifying any settings.

5.1 Code lock

After entering the correct code, the truck is ready for operation. It is possible to assignan individual code to every truck, operator or even operator group.

Z When delivered from the factory, the operator code (factory setting 2-5-8-0) is indicat-ed on a removable sticker.

M Change the master and operator codes when setting the truck into operation for thefirst time! (refer to section 5.4).

1 2 3

4 5 6

7 8 9

0Set

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5 Keyboard (CANCODE) (o)

The operator keyboard is composed of 10 nu-meric keys, a Set key and an o-key.The green LED in key 1 indicates that the driveprogramme was switched on with key 1.The o-key indicates operating conditions by ared/green LED.

It has the following functions:

– Code lock function (setting the truck into oper-ation).

– Setting the travel and battery parameters, only in conjunction with the indicator in-strument (CANDIS (o)).

The o-key has top priority and reset the truck from any condition to the basic condi-tion without modifying any settings.

5.1 Code lock

After entering the correct code, the truck is ready for operation. It is possible to assignan individual code to every truck, operator or even operator group.

Z When delivered from the factory, the operator code (factory setting 2-5-8-0) is indicat-ed on a removable sticker.

M Change the master and operator codes when setting the truck into operation for thefirst time! (refer to section 5.4).

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7 8 9

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After switching on the master switch and, if required, the key switch, the LED (20)lights up red.

After entering the correct operator code (factory setting 2-5-8-0) the LED (20) lightsup red.

When an incorrect code has been entered, LED (20) lights up red for two seconds.After that you can enter a new code.

Z The Set key (21) has no function in operating mode.

Switching off

The truck is switched off by actuating the o -key (25).

Z The truck can be switched off automatically after a preset time. For that purpose thecorresponding code lock parameter must be set (refer to section 5.4).

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7 8 9

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Commissioning

After switching on the master switch and, if required, the key switch, the LED (20)lights up red.

After entering the correct operator code (factory setting 2-5-8-0) the LED (20) lightsup red.

When an incorrect code has been entered, LED (20) lights up red for two seconds.After that you can enter a new code.

Z The Set key (21) has no function in operating mode.

Switching off

The truck is switched off by actuating the o -key (25).

Z The truck can be switched off automatically after a preset time. For that purpose thecorresponding code lock parameter must be set (refer to section 5.4).

1 2 3

4 5 6

7 8 9

0Set

22

21

20

25

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5.2 Drive programme

The truck features one drive programme. The green LED (22) indicates the activeprogramme, buttons 2 and 3 have no function.

Z The drive programme can be individually adapted to match the truck application.

5.3 Parameters

In the programming mode, the operating keyboard allows code lock and drive pro-gramme to be adapted. Additionally, the battery parameters can be set.

Z For trucks without indicator instrument (CANDIS (o)) only the code lock parameterscan be set.

Parameter groups

The parameter number is composed of three digits. The first digit designated the pa-rameter group according to table 1. The second and third digits are sequentially num-bered from 00 to 99.

No. Parameter group0xx Code lock settings

(codes, drive programme release, automatic cut-out, etc.)1xx Travel programme 1 parameters

(Acceleration, coasting brake, speed, etc.)4xx Programme-independent parameters

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5.2 Drive programme

The truck features one drive programme. The green LED (22) indicates the activeprogramme, buttons 2 and 3 have no function.

Z The drive programme can be individually adapted to match the truck application.

5.3 Parameters

In the programming mode, the operating keyboard allows code lock and drive pro-gramme to be adapted. Additionally, the battery parameters can be set.

Z For trucks without indicator instrument (CANDIS (o)) only the code lock parameterscan be set.

Parameter groups

The parameter number is composed of three digits. The first digit designated the pa-rameter group according to table 1. The second and third digits are sequentially num-bered from 00 to 99.

No. Parameter group0xx Code lock settings

(codes, drive programme release, automatic cut-out, etc.)1xx Travel programme 1 parameters

(Acceleration, coasting brake, speed, etc.)4xx Programme-independent parameters

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5.4 Parameter settings

To change the truck settings the master code must be entered.

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

M Change the master code when setting the truck into operation for the first time (referto section 5.1).

F Safety notes for trucks with indicator instrument (CANDIS (o))

– Parameter settings must be made carefully and only by special trained personnel .If in doubt, consult the manufacturer's service.

– Every setting procedure must be monitored on the LC display of the indicatorinstrument (CANDIS (o)). If in doubt, the setting procedure must be cancelled bypressing the o-key (25).

– Since the truck's travel behaviour is changed, you must perform a trial in a speciallyassigned and suitable working area run after changing any of the parameters.

Entering the master code:

– Press the o-key– Enter master code

Code lock parameters

Setting procedure for trucks without indicator instrument (CANDIS (o)):

– Enter the three-digit parameter number and confirm with Set key (21).– Enter or change the setting value according to the parameter list and confirm with

Set key (21).

Z When the input is incorrect, the LED (20) of the o-key (25) lights up red. Afterentering the parameter number again, the setting value can be entered or changed.

Repeat the procedure to enter further parameters. To terminate the input, press theo-key (25).

Display instrument (CANDIS)

LED (20)o-key

LED (22)Key 1

LED (23)Key 2

LED (24)Key 3

Operating hoursare indicated 284.0 green

flashingoff off off

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5.4 Parameter settings

To change the truck settings the master code must be entered.

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

M Change the master code when setting the truck into operation for the first time (referto section 5.1).

F Safety notes for trucks with indicator instrument (CANDIS (o))

– Parameter settings must be made carefully and only by special trained personnel .If in doubt, consult the manufacturer's service.

– Every setting procedure must be monitored on the LC display of the indicatorinstrument (CANDIS (o)). If in doubt, the setting procedure must be cancelled bypressing the o-key (25).

– Since the truck's travel behaviour is changed, you must perform a trial in a speciallyassigned and suitable working area run after changing any of the parameters.

Entering the master code:

– Press the o-key– Enter master code

Code lock parameters

Setting procedure for trucks without indicator instrument (CANDIS (o)):

– Enter the three-digit parameter number and confirm with Set key (21).– Enter or change the setting value according to the parameter list and confirm with

Set key (21).

Z When the input is incorrect, the LED (20) of the o-key (25) lights up red. Afterentering the parameter number again, the setting value can be entered or changed.

Repeat the procedure to enter further parameters. To terminate the input, press theo-key (25).

Display instrument (CANDIS)

LED (20)o-key

LED (22)Key 1

LED (23)Key 2

LED (24)Key 3

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Setting procedure for trucks with and without indicator instrument (CANDIS (o)):

– Enter the three-digit parameter number and confirm with Set key (21).– The indicator instrument (CANDIS (o)) continues to display the operating hours. If

the display changes, cancel the setting procedure with the o-key (25) and restartfrom the beginning.

– Enter or change the setting value according to the parameter list and confirm withSet key (21).

Z When the input is incorrect, the LED (20) of the o-key (25) lights up red. After enter-ing the parameter number again, the setting value can be entered or changed.

Repeat the procedure to enter further parameters. To terminate the input, press theo-key (25).

The following parameters can be entered:

Code lock parameter list

No. Function RangeSetting value

DefaultSetting value

CommentsWork flow

Codeschloss000 Change master code

The length of the master code (4 to 6 digits) also determines the length (4 to 6 digits) of the operator code. As long as operator codes have been programmed, only new codes with the same length can be entered. If the code length is to be changed, all operator codes must be deleted first.

0000 - 9999or

00000 - 99999or

000000 - 999999

7295 (LED 22 flashes)Enter the current

code

confirm (Set)

(LED 23 flashes)Enter a new code

confirm (Set)

(LED 24 flashes)Repeat new code

Confirm (Set)001 Add operator code

(max. 600)0000 - 9999

or00000 - 99999

or000000 - 999999

2580 (LED 23 flashes)Enter a code

confirm (Set)

(LED 24 flashes)Repeat the code en-

try

Confim (Set)

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Setting procedure for trucks with and without indicator instrument (CANDIS (o)):

– Enter the three-digit parameter number and confirm with Set key (21).– The indicator instrument (CANDIS (o)) continues to display the operating hours. If

the display changes, cancel the setting procedure with the o-key (25) and restartfrom the beginning.

– Enter or change the setting value according to the parameter list and confirm withSet key (21).

Z When the input is incorrect, the LED (20) of the o-key (25) lights up red. After enter-ing the parameter number again, the setting value can be entered or changed.

Repeat the procedure to enter further parameters. To terminate the input, press theo-key (25).

The following parameters can be entered:

Code lock parameter list

No. Function RangeSetting value

DefaultSetting value

CommentsWork flow

Codeschloss000 Change master code

The length of the master code (4 to 6 digits) also determines the length (4 to 6 digits) of the operator code. As long as operator codes have been programmed, only new codes with the same length can be entered. If the code length is to be changed, all operator codes must be deleted first.

0000 - 9999or

00000 - 99999or

000000 - 999999

7295 (LED 22 flashes)Enter the current

code

confirm (Set)

(LED 23 flashes)Enter a new code

confirm (Set)

(LED 24 flashes)Repeat new code

Confirm (Set)001 Add operator code

(max. 600)0000 - 9999

or00000 - 99999

or000000 - 999999

2580 (LED 23 flashes)Enter a code

confirm (Set)

(LED 24 flashes)Repeat the code en-

try

Confim (Set)

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LED 22-24 are located in the key pad fields 1-3 (refer to section 5.2).

No. Function RangeSetting value

DefaultSetting value

CommentsWork flow

Code lock002 Change operator code 0000 - 9999

or00000 - 99999

or000000 - 999999

(LED 22 flashes)Enter the current

code

Confirm (Set)

(LED 23 flashes)Enter a new code

Confirm (Set)

(LED 24 flashes)Repeat the code en-

try

Confirm003 Delete operator code 0000 - 9999

or00000 - 99999

or000000 - 999999

(LED 23 flashes)Enter a code

Confirm (Set)

(LED 24 flashes)Repeat the code en-

try

Confirm (Set)004 Clear code memory

(deletes all operator codes)

3265 3265 = delete

other entry = do not delete

010 automatic switch-off 00 - 31 00 00 = noneSwitch-off

01 to 30 =Switch-off time in

minutes

31 = switch-off after 10 seconds

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LED 22-24 are located in the key pad fields 1-3 (refer to section 5.2).

No. Function RangeSetting value

DefaultSetting value

CommentsWork flow

Code lock002 Change operator code 0000 - 9999

or00000 - 99999

or000000 - 999999

(LED 22 flashes)Enter the current

code

Confirm (Set)

(LED 23 flashes)Enter a new code

Confirm (Set)

(LED 24 flashes)Repeat the code en-

try

Confirm003 Delete operator code 0000 - 9999

or00000 - 99999

or000000 - 999999

(LED 23 flashes)Enter a code

Confirm (Set)

(LED 24 flashes)Repeat the code en-

try

Confirm (Set)004 Clear code memory

(deletes all operator codes)

3265 3265 = delete

other entry = do not delete

010 automatic switch-off 00 - 31 00 00 = noneSwitch-off

01 to 30 =Switch-off time in

minutes

31 = switch-off after 10 seconds

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*) only in conjunction with indicator instrument (CANDIS (o))

Keyboard error messages

The following errors are indicated by a red flashing LED (20):

– New master code is already operator code.– New operator code is already master code.– Operator code to be changed does not exist.– Tried to change the operator code to an existing code.– Operator code to be deleted does not exist.

Code memory full.

No. Function RangeSetting value

DefaultSetting val-

ue

CommentsWork flow

Code lock030 Display of the number of

used operator codes*)

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*) only in conjunction with indicator instrument (CANDIS (o))

Keyboard error messages

The following errors are indicated by a red flashing LED (20):

– New master code is already operator code.– New operator code is already master code.– Operator code to be changed does not exist.– Tried to change the operator code to an existing code.– Operator code to be deleted does not exist.

Code memory full.

No. Function RangeSetting value

DefaultSetting val-

ue

CommentsWork flow

Code lock030 Display of the number of

used operator codes*)

E 23

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5.5 Travel parameters

Z For trucks without indicator instrument (CANDIS (o)) the code lock parameters canonly be set by the manufacturer's service.

The following example shows the parameter setting for the acceleration of travel pro-gram 1 (parameter 101).

Acceleration example

– Select the edited travel program after changing the parameter value, confirm withthe Set key (21).

– Check the LC display of the indicator instrument (CANDIS (o)) (parameter numberand current parameter value are displayed).

Z If there is no input for approx. 5 seconds, the display switches back to operating hoursindication.

F If another parameter number than the one displayed is desired, you must wait untilthe operating hours are displayed again.

– Enter or change the parameter value according to the parameter list.– Check the LC display of the indicator instrument (CANDIS (o)) (confirm with the

Set key (21)).– The LED (20) of the o-key (25) switches briefly to steady light and start flashing

again after approx. 2 seconds.

Z When the input is incorrect, the LED (20) of the o-key (25) lights up red. Afterentering the parameter number again, the setting value can be entered or changed.

Repeat the procedure to enter further parameters as soon as the LED (20) of theo-key (25) flashes. To terminate the input, press the o-key (25).

Display instrument (CANDIS)

LED (20)o-key

LED (22)Key 1

LED (23)Key 2

LED (24)Key 3

current setting is displayed 101 6

greenflashing

off off off

changed setting is displayed 101 8

greenflashing

off off off

Parameter number

Parame-ter set-

ting value

E 23

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5.5 Travel parameters

Z For trucks without indicator instrument (CANDIS (o)) the code lock parameters canonly be set by the manufacturer's service.

The following example shows the parameter setting for the acceleration of travel pro-gram 1 (parameter 101).

Acceleration example

– Select the edited travel program after changing the parameter value, confirm withthe Set key (21).

– Check the LC display of the indicator instrument (CANDIS (o)) (parameter numberand current parameter value are displayed).

Z If there is no input for approx. 5 seconds, the display switches back to operating hoursindication.

F If another parameter number than the one displayed is desired, you must wait untilthe operating hours are displayed again.

– Enter or change the parameter value according to the parameter list.– Check the LC display of the indicator instrument (CANDIS (o)) (confirm with the

Set key (21)).– The LED (20) of the o-key (25) switches briefly to steady light and start flashing

again after approx. 2 seconds.

Z When the input is incorrect, the LED (20) of the o-key (25) lights up red. Afterentering the parameter number again, the setting value can be entered or changed.

Repeat the procedure to enter further parameters as soon as the LED (20) of theo-key (25) flashes. To terminate the input, press the o-key (25).

Display instrument (CANDIS)

LED (20)o-key

LED (22)Key 1

LED (23)Key 2

LED (24)Key 3

current setting is displayed 101 6

greenflashing

off off off

changed setting is displayed 101 8

greenflashing

off off off

Parameter number

Parame-ter set-

ting value

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E 24

The following parameters can be entered:

Drive programme

Drive programme-independent parameters

Z For trucks without indicator instrument (CANDIS (o)) the code lock parameters canonly be set by the manufacturer's service.

The parameters are set in the same way as for the travel parameters.

The following parameters can be entered:

Setting value 0 / 1 is to be interpreted as: 0 = off 1 = on

No. Function RangeSetting value

StandardSetting value

Comments

101 Acceleration 0 - 9 9102 Coasting brake 0 - 9 9104 Maximum speed in drive

direction via controller0 - 9 8 depending on

controller105 Pedestrian-controlled op-

eration speed in drive di-rection via controller

0 - 9 5 depending oncontroller

108 Maximum speed in fork di-rection via controller

0 - 9 8 depending oncontroller

109 Pedestrian-controlled op-eration speed in fork di-rection via controller

0 - 9 5 depending oncontroller

No. Function RangeSetting value

StandardSetting value

Comments

Battery parameters411 Battery type (normal/

high-power/dry)0 - 2 0 0 = Normal (wet)

1 = High-power (wet)

2 = Dry(maintenance-free)

412 Discharge monitor func-tion

0 / 1 1

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The following parameters can be entered:

Drive programme

Drive programme-independent parameters

Z For trucks without indicator instrument (CANDIS (o)) the code lock parameters canonly be set by the manufacturer's service.

The parameters are set in the same way as for the travel parameters.

The following parameters can be entered:

Setting value 0 / 1 is to be interpreted as: 0 = off 1 = on

No. Function RangeSetting value

StandardSetting value

Comments

101 Acceleration 0 - 9 9102 Coasting brake 0 - 9 9104 Maximum speed in drive

direction via controller0 - 9 8 depending on

controller105 Pedestrian-controlled op-

eration speed in drive di-rection via controller

0 - 9 5 depending oncontroller

108 Maximum speed in fork di-rection via controller

0 - 9 8 depending oncontroller

109 Pedestrian-controlled op-eration speed in fork di-rection via controller

0 - 9 5 depending oncontroller

No. Function RangeSetting value

StandardSetting value

Comments

Battery parameters411 Battery type (normal/

high-power/dry)0 - 2 0 0 = Normal (wet)

1 = High-power (wet)

2 = Dry(maintenance-free)

412 Discharge monitor func-tion

0 / 1 1

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6 Display instrument (CANDIS) (o)

The instrument indicates:

– Remaining battery charge (LEDbars (27)),

– Operating hours(LC display (29)).

In addition, error messages of theelectronic components and parame-ter changes are displayed.

Discharge status indication

Depending on the battery type set, switch-on limits for the additional “Warning” (26)and “Stop” (28) indicators may result.

NumberBars

Charging condition

Wet battery Maintenance-free batteryLED (yellow)

WarningLED (red)

StopLED (yellow)

WarningLED (red)

Stop10 90.1- 100% Off Off Off Off9 80.1 - 90% Off Off Off Off8 70.1 - 80% Off Off Off Off7 60.1 - 70% Off Off Off Off6 50.1 - 60% Off Off Off Off5 40.1 - 50% Off Off On Off4 30.1 - 40% Off Off On On3 20.1 - 30% On Off On On2 10.1 - 20% On On On On

Avoid falling below the 20% limit for wet batteries resp. 40% limitfor maintenance-free batteries.

26

27

28

29�

E 25

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6 Display instrument (CANDIS) (o)

The instrument indicates:

– Remaining battery charge (LEDbars (27)),

– Operating hours(LC display (29)).

In addition, error messages of theelectronic components and parame-ter changes are displayed.

Discharge status indication

Depending on the battery type set, switch-on limits for the additional “Warning” (26)and “Stop” (28) indicators may result.

NumberBars

Charging condition

Wet battery Maintenance-free batteryLED (yellow)

WarningLED (red)

StopLED (yellow)

WarningLED (red)

Stop10 90.1- 100% Off Off Off Off9 80.1 - 90% Off Off Off Off8 70.1 - 80% Off Off Off Off7 60.1 - 70% Off Off Off Off6 50.1 - 60% Off Off Off Off5 40.1 - 50% Off Off On Off4 30.1 - 40% Off Off On On3 20.1 - 30% On Off On On2 10.1 - 20% On On On On

Avoid falling below the 20% limit for wet batteries resp. 40% limitfor maintenance-free batteries.

26

27

28

29�

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E 26

6.1 Discharge monitor function

With the discharge monitor function enabled, the lifting function switches of whenreaching the discharge limit (the Stop LED switches on). Travelling and lowering isstill possible. For wet batteries the residual capacity is 20%, for maintenance-free bat-teries it is 40%. At 30% for wet batteries resp. 50% for maintenance-free batteries thebatteries should be recharged (the yellow LED lights up as warning indication).

6.2 Operating hours display

Display range between 0.0 and 99,999.0 hours. Travel and lifting movements arelogged. This is a backlit display.

Z For maintenance-free batteries a “T” symbol is shown in the operating hours display(29).

Error messages

The operating hours display is also used for indicating errors. The error is displayedin two parts and starts with a “C” for component and a three-digit component number,then an “E” for error with alternating three-digit error number.If several errors occur they are displayed one after the other. The errors are displayedas long as they are present (always in combination Cxxx / Exxx). Errors are displayedas long as they persist. The operating hours display is overwritten with an error mes-sage. Most errors cause the emergency stop to be triggered. The error display ismaintained until the control circuit is switched off (Code lock).

Z Detailed component descriptions including error codes are available at the manufac-turers service.

Display for parameter changes (travel programmes)

The LC display (29) is used in conjunction with the operator keyboard (CANCODE(o)) to display the setting parameters. The first three digits of the display show theparameter numbers, the last three digits indicate the parameter value.

Z Setting values of parameter group 0XX (code lock) are not displayed.

6.3 Switch-on test

After switching on the display shows:

– the software version of the display instrument (short-term), – the operating hours– the charging condition

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E 26

6.1 Discharge monitor function

With the discharge monitor function enabled, the lifting function switches of whenreaching the discharge limit (the Stop LED switches on). Travelling and lowering isstill possible. For wet batteries the residual capacity is 20%, for maintenance-free bat-teries it is 40%. At 30% for wet batteries resp. 50% for maintenance-free batteries thebatteries should be recharged (the yellow LED lights up as warning indication).

6.2 Operating hours display

Display range between 0.0 and 99,999.0 hours. Travel and lifting movements arelogged. This is a backlit display.

Z For maintenance-free batteries a “T” symbol is shown in the operating hours display(29).

Error messages

The operating hours display is also used for indicating errors. The error is displayedin two parts and starts with a “C” for component and a three-digit component number,then an “E” for error with alternating three-digit error number.If several errors occur they are displayed one after the other. The errors are displayedas long as they are present (always in combination Cxxx / Exxx). Errors are displayedas long as they persist. The operating hours display is overwritten with an error mes-sage. Most errors cause the emergency stop to be triggered. The error display ismaintained until the control circuit is switched off (Code lock).

Z Detailed component descriptions including error codes are available at the manufac-turers service.

Display for parameter changes (travel programmes)

The LC display (29) is used in conjunction with the operator keyboard (CANCODE(o)) to display the setting parameters. The first three digits of the display show theparameter numbers, the last three digits indicate the parameter value.

Z Setting values of parameter group 0XX (code lock) are not displayed.

6.3 Switch-on test

After switching on the display shows:

– the software version of the display instrument (short-term), – the operating hours– the charging condition

E 27

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7 Fault location

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.

Z If it was not possible to eliminate the fault by performing the remedial actions indicat-ed above, please inform the manufacturer’s service organisation as more intricatefaults can only be rectified by specially trained and qualified service staff.

Fault Possible cause RemedyTruckdoes not move

– Battery connector notconnected

– Check the battery connector and con-nect if necessary.

– Master switch de-pressed

– Release the master switch.

– Key switch inposition “0”

– Set the key switch to position “I”.

– Battery exhausted – Check the charging condition of the bat-tery and recharge if necessary.

– Fuse defective – Check fuses F1, 1F1 and 3F9.Load cannot be lifted

– Truck not operative – Perform all remedial actions listed un-der the fault “Truck does not move”.

– Hydraulic oil level toolow

– Check the hydraulic oil level.

– Load is too heavy – Heed the maximum capacity (see theidentification plate).

– The battery dischargemonitor has switched offand indicates “STOP”

– Charge the battery.

– Fuse defective – Check fuse 2F1.No display on the battery discharge monitor

– Truck not operative – Check the battery connector and con-nect if necessary.

– Master switch de-pressed

– Release the master switch.

– Fuse defective – Check fuse 6F1.

E 27

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7 Fault location

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.

Z If it was not possible to eliminate the fault by performing the remedial actions indicat-ed above, please inform the manufacturer’s service organisation as more intricatefaults can only be rectified by specially trained and qualified service staff.

Fault Possible cause RemedyTruckdoes not move

– Battery connector notconnected

– Check the battery connector and con-nect if necessary.

– Master switch de-pressed

– Release the master switch.

– Key switch inposition “0”

– Set the key switch to position “I”.

– Battery exhausted – Check the charging condition of the bat-tery and recharge if necessary.

– Fuse defective – Check fuses F1, 1F1 and 3F9.Load cannot be lifted

– Truck not operative – Perform all remedial actions listed un-der the fault “Truck does not move”.

– Hydraulic oil level toolow

– Check the hydraulic oil level.

– Load is too heavy – Heed the maximum capacity (see theidentification plate).

– The battery dischargemonitor has switched offand indicates “STOP”

– Charge the battery.

– Fuse defective – Check fuse 2F1.No display on the battery discharge monitor

– Truck not operative – Check the battery connector and con-nect if necessary.

– Master switch de-pressed

– Release the master switch.

– Fuse defective – Check fuse 6F1.

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F 1

F Maintenance of the fork-lift truck1 Operational safety and environmental protection

The checks and servicing operations contained in this chapter must be performed inaccordance with the intervals as indicated in the servicing checklists.

F Modifications of fork-lift truck assemblies, especially of the safety installations, are notpermitted. 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 withthe applicable environmental protection regulations. For oil changes, the oil serviceof the manufacturer is available to you.

Upon completion of any checking and servicing activities, the operations contained inthe 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 servicedand maintained by trained personnel of the manufacturer. The service organizationof the manufacturer has external technicians trained especially for these assign-ments. We thus recommend signing a maintenance contract with the relevant servicelocation of the manufacturer.

Lifting and jacking up: When a fork-lift truck is to be lifted, the lifting gear must onlybe secured to the points specially provided for this purpose. When the truck is to bejacked 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 liftingdevice must only be carried out when the fork is immobilised and supported by achain 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-oper-ated fork-lift trucks, the battery plug must be removed. Only weak indraft, weak com-pressed air and non-conducting, antistatic brushes must be used for the cleaning ofelectric or electronic assemblies.

M If the fork-lift truck is to be cleaned using a water jet or a high-pressure cleaner, allelectric and electronic components must be carefully covered beforehand becausemoisture 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.

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F 1

F Maintenance of the fork-lift truck1 Operational safety and environmental protection

The checks and servicing operations contained in this chapter must be performed inaccordance with the intervals as indicated in the servicing checklists.

F Modifications of fork-lift truck assemblies, especially of the safety installations, are notpermitted. 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 withthe applicable environmental protection regulations. For oil changes, the oil serviceof the manufacturer is available to you.

Upon completion of any checking and servicing activities, the operations contained inthe 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 servicedand maintained by trained personnel of the manufacturer. The service organizationof the manufacturer has external technicians trained especially for these assign-ments. We thus recommend signing a maintenance contract with the relevant servicelocation of the manufacturer.

Lifting and jacking up: When a fork-lift truck is to be lifted, the lifting gear must onlybe secured to the points specially provided for this purpose. When the truck is to bejacked 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 liftingdevice must only be carried out when the fork is immobilised and supported by achain 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-oper-ated fork-lift trucks, the battery plug must be removed. Only weak indraft, weak com-pressed air and non-conducting, antistatic brushes must be used for the cleaning ofelectric or electronic assemblies.

M If the fork-lift truck is to be cleaned using a water jet or a high-pressure cleaner, allelectric and electronic components must be carefully covered beforehand becausemoisture 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.

F 2

0106

.GBWork on the electric system: Work on the electric system of the truck must only beperformed by personnel specially trained for such operations. Before commencingany work on the electric system, all measures required to prevent electric shockshave to be taken. For battery-operated fork-lift trucks, the truck must also be depow-ered by removing the battery plug.

Welding operations: To prevent any damage to electric or electronic components,these have to be removed from the fork-lift truck before any welding operations areundertaken.

Settings: When repairing or replacing hydraulic, electric or electronic components orassemblies, all truck-specific settings have to be retained.

Tyres: The quality of the tyres greatly affects the stability and the driving behaviourof the fork-lift truck. Changes must only be made following consultations with themanufacturer. When replacing wheels or tyres, it must be ensured that the fork-lifttruck remains level (tyres and wheels must always be replaced in pairs, i.e. left andright together).

Lift chains: The lift chains wear rapidly if not lubricated. The intervals in the servicechecklist 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 2

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Work on the electric system: Work on the electric system of the truck must only beperformed by personnel specially trained for such operations. Before commencingany work on the electric system, all measures required to prevent electric shockshave to be taken. For battery-operated fork-lift trucks, the truck must also be depow-ered by removing the battery plug.

Welding operations: To prevent any damage to electric or electronic components,these have to be removed from the fork-lift truck before any welding operations areundertaken.

Settings: When repairing or replacing hydraulic, electric or electronic components orassemblies, all truck-specific settings have to be retained.

Tyres: The quality of the tyres greatly affects the stability and the driving behaviourof the fork-lift truck. Changes must only be made following consultations with themanufacturer. When replacing wheels or tyres, it must be ensured that the fork-lifttruck remains level (tyres and wheels must always be replaced in pairs, i.e. left andright together).

Lift chains: The lift chains wear rapidly if not lubricated. The intervals in the servicechecklist 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.

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F 3

3 Servicing and inspection

Thorough and expert servicing is one of the most important preconditions for safe op-eration 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 op-erating conditions. For applications in dusty environments, or involving large temper-ature fluctuations or multiple-shift operation, the servicing intervals must beshortened 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:

W = every 50 operating hours, but at least once per weekA = every 500 operating hours, or at least every six monthsB = every 1000 operating hours, or at least annuallyC = every 2000 operating hours, or at least annually

Z W service intervals are to be performed by the customer.

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

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F 3

3 Servicing and inspection

Thorough and expert servicing is one of the most important preconditions for safe op-eration 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 op-erating conditions. For applications in dusty environments, or involving large temper-ature fluctuations or multiple-shift operation, the servicing intervals must beshortened 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:

W = every 50 operating hours, but at least once per weekA = every 500 operating hours, or at least every six monthsB = every 1000 operating hours, or at least annuallyC = every 2000 operating hours, or at least annually

Z W service intervals are to be performed by the customer.

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

F 4

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4 Maintenance checklist

Maintenance intervalsStandard = t W A B CCold store = k

Chassis/super-structure:

1.1 Check all load bearing elements for damage t1.2 Check all bolted connections t1.3 Check platform for correct functioning and damage t

Drive unit: 2.1 Check the transmission for noises and leakage t2.2 Checking the transmission oil level t2.3 Change the transmission oil k t

Wheels: 3.1 Check for wear and damage t3.2 Check the wheel bearings and ensure secure

fastening of wheels k t

Steering: 4.1 Check the steering wheel play t4.2 Check the steering chain and the chain sprocket for wear;

adjust and greasek t

4.3 Check the mechanical parts of the steering column; grease if necessary

t

Brake system:

5.1 Check performance and adjustment k t5.2 Check the gas spring for proper resetting function, for

leaks and for damaget

5.3 Check the brake linings for wear t5.4 Check the brake linkage; adjust and grease if necessary k t

Hydraulic system:

6.1 Performance check k t6.2 Check all connections for leakage and damage k t6.3 Check the hydraulic cylinders for leakage, damage and

secure attachmentk t

6.4 Check the oil level k t6.5 Replace the hydraulic oil and the filter cartridge k t6.6 Check the pressure relief valves for correct functioning k t

Electrical system:

7.1 Performance check t7.2 Check all cables for secure connection and damage t7.3 Check the fuses for correct amperage t7.4 Check switches and trip cams for secure attachment and

correct functioningt

7.5 Check contactors and relays; replace wearing parts if nec-essary

t

7.6 Check the warning installations and safety circuits for cor-rect functioning

k t

Electric motors:

8.1 Check the carbon brushes for wear t8.2 Check the motor for secure attachment t8.3 Clean motor housing by means of a vacuum cleaner and

check the commutator for weark t

F 4

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4 Maintenance checklist

Maintenance intervalsStandard = t W A B CCold store = k

Chassis/super-structure:

1.1 Check all load bearing elements for damage t1.2 Check all bolted connections t1.3 Check platform for correct functioning and damage t

Drive unit: 2.1 Check the transmission for noises and leakage t2.2 Checking the transmission oil level t2.3 Change the transmission oil k t

Wheels: 3.1 Check for wear and damage t3.2 Check the wheel bearings and ensure secure

fastening of wheels k t

Steering: 4.1 Check the steering wheel play t4.2 Check the steering chain and the chain sprocket for wear;

adjust and greasek t

4.3 Check the mechanical parts of the steering column; grease if necessary

t

Brake system:

5.1 Check performance and adjustment k t5.2 Check the gas spring for proper resetting function, for

leaks and for damaget

5.3 Check the brake linings for wear t5.4 Check the brake linkage; adjust and grease if necessary k t

Hydraulic system:

6.1 Performance check k t6.2 Check all connections for leakage and damage k t6.3 Check the hydraulic cylinders for leakage, damage and

secure attachmentk t

6.4 Check the oil level k t6.5 Replace the hydraulic oil and the filter cartridge k t6.6 Check the pressure relief valves for correct functioning k t

Electrical system:

7.1 Performance check t7.2 Check all cables for secure connection and damage t7.3 Check the fuses for correct amperage t7.4 Check switches and trip cams for secure attachment and

correct functioningt

7.5 Check contactors and relays; replace wearing parts if nec-essary

t

7.6 Check the warning installations and safety circuits for cor-rect functioning

k t

Electric motors:

8.1 Check the carbon brushes for wear t8.2 Check the motor for secure attachment t8.3 Clean motor housing by means of a vacuum cleaner and

check the commutator for weark t

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F 5

Maintenance intervalsStandard = t W A B CCold store = k

Battery: 9.1 Check acid density, acid level and cell voltage t9.2 Check the terminals for secure attachment and apply

greaset

9.3 Clean the battery connections; check for tight fitting t9.4 Check the battery cables for damage, renew if necessary t

Lifting device:

10.1 Check performance, wear and adjustment t10.2 Perform a visual check of rollers, sliding elements, and

stopst

10.3 Check the fork tines and fork carrier for wear and damage tLubrication: 11.1 Grease the vehicle in accordance with the lubrication

schedulet

General measure-ments:

12.1 Check the electrical system for a grounding fault t12.2 Check the driving speed and braking distance t12.3 Check the lifting and lowering speed t12.4 Check safety and shutdown devices t

Demon-stration:

13.1 Perform a trial run under a nominal load t13.2 Upon completion of servicing operations, demonstrate the

vehicle to the person responsiblet

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F 5

Maintenance intervalsStandard = t W A B CCold store = k

Battery: 9.1 Check acid density, acid level and cell voltage t9.2 Check the terminals for secure attachment and apply

greaset

9.3 Clean the battery connections; check for tight fitting t9.4 Check the battery cables for damage, renew if necessary t

Lifting device:

10.1 Check performance, wear and adjustment t10.2 Perform a visual check of rollers, sliding elements, and

stopst

10.3 Check the fork tines and fork carrier for wear and damage tLubrication: 11.1 Grease the vehicle in accordance with the lubrication

schedulet

General measure-ments:

12.1 Check the electrical system for a grounding fault t12.2 Check the driving speed and braking distance t12.3 Check the lifting and lowering speed t12.4 Check safety and shutdown devices t

Demon-stration:

13.1 Perform a trial run under a nominal load t13.2 Upon completion of servicing operations, demonstrate the

vehicle to the person responsiblet

F 6

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5 Lubrication schedule

g Slide surfaces 1) Compound for cold store usage 1:1s Grease nipple

Filler plug for hydraulic oil 2) 1.25 l - 1.3 l depending on the transmission variant (level must always reach the lower edge of the filler neck)

b Filler plug for transmission oila Drain plug for transmission oil

Cold store operation

Es F

A0,7lA+C

1)

bB B+C

1)

G

C

a

E F

E F s g

Es F

1,25l - 1,3l2)

F 6

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5 Lubrication schedule

g Slide surfaces 1) Compound for cold store usage 1:1s Grease nipple

Filler plug for hydraulic oil 2) 1.25 l - 1.3 l depending on the transmission variant (level must always reach the lower edge of the filler neck)

b Filler plug for transmission oila Drain plug for transmission oil

Cold store operation

Es F

A0,7lA+C

1)

bB B+C

1)

G

C

a

E F

E F s g

Es F

1,25l - 1,3l2)

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F 7

5.1 Consumption-type materials

Handling consumption-type materials: Consumption-type materials must alwaysbe handled properly. Manufacturer's instructions are to be observed.

Z Improper handling is injurious to health, life, and environment. Consumption-type ma-terials must be stored in adequate containers. They might be inflammable and, there-fore, must not come into contact with hot components or open fire.

When filling in consumption-type materials, use clean containers only. It is prohibitedto mix consumption type materials of different grades or qualities, except if mixing isexpressively prescribed in these operating instructions.

Avoid spilling. Spilt liquid must be removed immediately using a suitable bindingagent, and the mixture of consumption-type material and binding agent is to be dis-posed of according to the regulations.

Grease data

Code Order-no. Supply qty. Designation Used for:A 50 449 669 5.0 l H-LP 46, DIN 51524 Hydraulic systemB 50 380 904 5.0 l Fuchs Titan Cytrac

HSY 75W-90Transmission

C 29 200 810 5.0 l H-LP 10, DIN 51524 Hydraulic systemD 29 200 150 1,0 l Brake fluid Brake systemE 29 201 430 1.0 kg Grease, DIN 51825 LubricationF 29 200 100 1.0 kg Grease, TTF52 LubricationG 29 201 280 0.51 kg Chain spray Chains

Code Saponification Dropping point °C

Worked penetr. at 25°C

NLG1 class

Operating tem-perature °C

E Lithium 185 265-295 2 -35/+120F -- -- 310-340 1 -52/+100

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5.1 Consumption-type materials

Handling consumption-type materials: Consumption-type materials must alwaysbe handled properly. Manufacturer's instructions are to be observed.

Z Improper handling is injurious to health, life, and environment. Consumption-type ma-terials must be stored in adequate containers. They might be inflammable and, there-fore, must not come into contact with hot components or open fire.

When filling in consumption-type materials, use clean containers only. It is prohibitedto mix consumption type materials of different grades or qualities, except if mixing isexpressively prescribed in these operating instructions.

Avoid spilling. Spilt liquid must be removed immediately using a suitable bindingagent, and the mixture of consumption-type material and binding agent is to be dis-posed of according to the regulations.

Grease data

Code Order-no. Supply qty. Designation Used for:A 50 449 669 5.0 l H-LP 46, DIN 51524 Hydraulic systemB 50 380 904 5.0 l Fuchs Titan Cytrac

HSY 75W-90Transmission

C 29 200 810 5.0 l H-LP 10, DIN 51524 Hydraulic systemD 29 200 150 1,0 l Brake fluid Brake systemE 29 201 430 1.0 kg Grease, DIN 51825 LubricationF 29 200 100 1.0 kg Grease, TTF52 LubricationG 29 201 280 0.51 kg Chain spray Chains

Code Saponification Dropping point °C

Worked penetr. at 25°C

NLG1 class

Operating tem-perature °C

E Lithium 185 265-295 2 -35/+120F -- -- 310-340 1 -52/+100

F 8

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6 Description of the servicing and maintenance operations

6.1 Preparing the truck for the performance of the servicing and maintenance op-erations

All required safety measures must be taken to prevent any accidents in the course ofthe servicing and maintenance operations. The following preparatory operationsmust be performed:

– Park the truck and render it safe (refer to chapter E).

Z For opening the battery hood, refer tochapter D.

– Disconnect the battery plug (2) so thatthe truck cannot be started by unau-thorised persons.

– When work is to be carried out underthe jacked up truck, immobilise thetruck in such a way that it cannot sinkin, tip over or slip.

F When lifting the truck, also refer to the in-structions contained in chapter “Trans-port and commissioning” (seechapter C).

6.2 Opening the front hood

Refer to chapter D.

6.3 Opening the front hood

Trucks with hinged standing platform:

– Swing down the standing platform (5).

General:

– Release the cover lock (3) using asize 8 Allen key.

– Lift the hood (4) and deposit it next tothe truck.

Refit the cover (4) upon completion ofthe work.

21 21

3

4

3

5

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6 Description of the servicing and maintenance operations

6.1 Preparing the truck for the performance of the servicing and maintenance op-erations

All required safety measures must be taken to prevent any accidents in the course ofthe servicing and maintenance operations. The following preparatory operationsmust be performed:

– Park the truck and render it safe (refer to chapter E).

Z For opening the battery hood, refer tochapter D.

– Disconnect the battery plug (2) so thatthe truck cannot be started by unau-thorised persons.

– When work is to be carried out underthe jacked up truck, immobilise thetruck in such a way that it cannot sinkin, tip over or slip.

F When lifting the truck, also refer to the in-structions contained in chapter “Trans-port and commissioning” (seechapter C).

6.2 Opening the front hood

Refer to chapter D.

6.3 Opening the front hood

Trucks with hinged standing platform:

– Swing down the standing platform (5).

General:

– Release the cover lock (3) using asize 8 Allen key.

– Lift the hood (4) and deposit it next tothe truck.

Refit the cover (4) upon completion ofthe work.

21 21

3

4

3

5

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6.4 Checking the mounting and the attachment of the drive wheel

– Prepare the truck for the performanceof servicing and maintenance opera-tions (refer to section 6.1).

– Open the front hood (refer to section6.2).

– Separate the control lead connectionsto the standing platform (6).

– Unscrew the standing platform attach-ment screws (7) and remove thestanding platform (this step also ap-plies to the fixed driver standing plat-form).

– Raise the truck so that the drivenwheel (8) can rotate freely.

– Turn the driven wheel by hand andcheck that it runs noiselessly.

– Lower the truck to the ground again.– Swivel the control shaft fully to the left.– Using a torque wrench, tighten the

wheel screws (9) crosswise.

Z Tightening torque

– Step 1 - MA = 10 Nm– Step 2 - MA = 105 Nm– Mount the standing platform (4) and secure it in place by means of the attachment

screws.– Reconnect the control lead connections to the standing platform.

6.5 Checking the hydraulic oil level

– Prepare the truck for the performanceof servicing and maintenance opera-tions (refer to section 6.1).

– Open the front hood (refer tosection 6.2).

– Check the hydraulic oil level at the hy-draulic oil reservoir (11).

Z The hydraulic oil reservoir is providedwith markings (10). With the fork in thelowered position, the oil level must bebetween the markings “max.” and“min.”.

If necessary, top up to the “max.” mark-ing using hydraulic oil of the prescribedspecification (refer to the hydraulic oilspecification, section 5).

JUNGHEINRICH

JUNGHEINRICHJUNGHEINRICH

7 7

6

8 / 9

min

max

11

10

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6.4 Checking the mounting and the attachment of the drive wheel

– Prepare the truck for the performanceof servicing and maintenance opera-tions (refer to section 6.1).

– Open the front hood (refer to section6.2).

– Separate the control lead connectionsto the standing platform (6).

– Unscrew the standing platform attach-ment screws (7) and remove thestanding platform (this step also ap-plies to the fixed driver standing plat-form).

– Raise the truck so that the drivenwheel (8) can rotate freely.

– Turn the driven wheel by hand andcheck that it runs noiselessly.

– Lower the truck to the ground again.– Swivel the control shaft fully to the left.– Using a torque wrench, tighten the

wheel screws (9) crosswise.

Z Tightening torque

– Step 1 - MA = 10 Nm– Step 2 - MA = 105 Nm– Mount the standing platform (4) and secure it in place by means of the attachment

screws.– Reconnect the control lead connections to the standing platform.

6.5 Checking the hydraulic oil level

– Prepare the truck for the performanceof servicing and maintenance opera-tions (refer to section 6.1).

– Open the front hood (refer tosection 6.2).

– Check the hydraulic oil level at the hy-draulic oil reservoir (11).

Z The hydraulic oil reservoir is providedwith markings (10). With the fork in thelowered position, the oil level must bebetween the markings “max.” and“min.”.

If necessary, top up to the “max.” mark-ing using hydraulic oil of the prescribedspecification (refer to the hydraulic oilspecification, section 5).

JUNGHEINRICH

JUNGHEINRICHJUNGHEINRICH

7 7

6

8 / 9

min

max

11

10

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6.6 Checking the electric fuses

– Prepare the truck for the performance of servicing and maintenance operations (re-fer to section 6.1).

– Open the front hood (refer to section 6.2).– Refer to the table and check all fuses for correct rating. Replace if required.

Item Designation Protection of: Value10 3F9 Steering motor (o) 30 A11 1F10 Field - driving 40 A12 2F1 Pump motor 150 A13 1F1 Drive motor 150 A14 F1 General control fuse 10 A15 6F2 Battery discharge monitor / operating hour meter 10 A16 -- Steering control system (o) --

16

14

15

11

10

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6.6 Checking the electric fuses

– Prepare the truck for the performance of servicing and maintenance operations (re-fer to section 6.1).

– Open the front hood (refer to section 6.2).– Refer to the table and check all fuses for correct rating. Replace if required.

Item Designation Protection of: Value10 3F9 Steering motor (o) 30 A11 1F10 Field - driving 40 A12 2F1 Pump motor 150 A13 1F1 Drive motor 150 A14 F1 General control fuse 10 A15 6F2 Battery discharge monitor / operating hour meter 10 A16 -- Steering control system (o) --

16

14

15

11

10

1312

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6.7 Recommissioning the truck

Recommissioning of the truck following the performance of cleaning or maintenancework is permitted only after the following operations have been performed:

– Check the horn for proper functioning.– Check the master switch for correct functioning.– Check the brake for correct functioning.– Lubricate truck according to lubrication schedule.

7 Decommissioning the fork-lift truck

If the fork-lift truck is to be decommissioned for more than two months, it must beparked in a frost-free and dry location and all measures to be taken before, during andfollowing decommissioning must be performed as detailed below.

M During decommissioning, the fork-lift truck must be jacked up, ensuring that thewheels are clear of the ground. Only this measure will ensure that wheels and wheelbearings do not suffer damage.

If the fork-lift truck is to be decommissioned for more than 6 months, additional meas-ures must be discussed with the Service Department of the manufacturer.

7.1 Operations to be performed prior to decommissioning

– Thoroughly clean the fork-lift 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 fork-lift 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.

Z In addition to this, all instructions given by the battery supplier must 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 Battery-operated fork-lift trucks:Regular recharging of the battery is very important; otherwise, exhaustive depletionof the battery caused by self-discharging would occur. Owing to sulfatisation, this willresult in the destruction of the battery.

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6.7 Recommissioning the truck

Recommissioning of the truck following the performance of cleaning or maintenancework is permitted only after the following operations have been performed:

– Check the horn for proper functioning.– Check the master switch for correct functioning.– Check the brake for correct functioning.– Lubricate truck according to lubrication schedule.

7 Decommissioning the fork-lift truck

If the fork-lift truck is to be decommissioned for more than two months, it must beparked in a frost-free and dry location and all measures to be taken before, during andfollowing decommissioning must be performed as detailed below.

M During decommissioning, the fork-lift truck must be jacked up, ensuring that thewheels are clear of the ground. Only this measure will ensure that wheels and wheelbearings do not suffer damage.

If the fork-lift truck is to be decommissioned for more than 6 months, additional meas-ures must be discussed with the Service Department of the manufacturer.

7.1 Operations to be performed prior to decommissioning

– Thoroughly clean the fork-lift 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 fork-lift 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.

Z In addition to this, all instructions given by the battery supplier must 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 Battery-operated fork-lift trucks:Regular recharging of the battery is very important; otherwise, exhaustive depletionof the battery caused by self-discharging would occur. Owing to sulfatisation, this willresult in the destruction of the battery.

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7.3 Recommissioning the truck

– Thoroughly clean the fork-lift truck.– Lubricate the fork-lift 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 fork-lift truck (refer to chapter E).

Z Battery-operated fork-lift trucks:If switching troubles are experienced in the electric system, spray the exposed con-tacts with contact spray and remove any oxide layer on the contacts of the operatingcontrols 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 untowardincidents (D: Accident prevention check according to BGV D27)

At least once yearly, or after any untoward incident, the fork-lift truck has to be chek-ked by a qualified inspector. The inspector must assess the condition of the truck froma standpoint purely concerned with safety aspects, uninfluenced by any company oreconomic circumstances. The inspector must be adequately informed and experi-enced to be able to assess the condition of the fork-lift truck and the effectiveness ofthe safety installations based on the technical rules and principles governing the in-spection of fork-lift trucks.

The inspection must comprise a comprehensive check of the technical condition ofthe fork-lift truck with regard to accident prevention aspects. Apart from this, the fork-lift truck must be thoroughly inspected for damage possibly caused by incorrect useof the fork-lift truck. The inspection results must be recorded in an inspection reportwhich must be kept available for a period spanning at least the next two inspectionintervals.

The user has to ensure that all defects are eliminated without delay.

Z The manufacturer has set up a special safety service with specially qualified staff. Asvisual proof that the fork-lift truck has passed the safety inspection, a plaque is affixedto 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 fork-lift truck.– Lubricate the fork-lift 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 fork-lift truck (refer to chapter E).

Z Battery-operated fork-lift trucks:If switching troubles are experienced in the electric system, spray the exposed con-tacts with contact spray and remove any oxide layer on the contacts of the operatingcontrols 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 untowardincidents (D: Accident prevention check according to BGV D27)

At least once yearly, or after any untoward incident, the fork-lift truck has to be chek-ked by a qualified inspector. The inspector must assess the condition of the truck froma standpoint purely concerned with safety aspects, uninfluenced by any company oreconomic circumstances. The inspector must be adequately informed and experi-enced to be able to assess the condition of the fork-lift truck and the effectiveness ofthe safety installations based on the technical rules and principles governing the in-spection of fork-lift trucks.

The inspection must comprise a comprehensive check of the technical condition ofthe fork-lift truck with regard to accident prevention aspects. Apart from this, the fork-lift truck must be thoroughly inspected for damage possibly caused by incorrect useof the fork-lift truck. The inspection results must be recorded in an inspection reportwhich must be kept available for a period spanning at least the next two inspectionintervals.

The user has to ensure that all defects are eliminated without delay.

Z The manufacturer has set up a special safety service with specially qualified staff. Asvisual proof that the fork-lift truck has passed the safety inspection, a plaque is affixedto it. This plaque indicates in which month of which year the next test will be due.