04.13 -

06.1551171581

ETV Q20/Q25

Operating instructions G

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0903

.GBImportant notes on transporting and mounting load lifting devicesto reach trucks

Transport

Depending on the overall height of the lifting mast and the local conditions transportcan be performed in three different ways

– Standing, with the lifting mast mounted (for trucks with low overall height)– Standing, with martially mounted lifting mast tilted towards the overhead guard (for

trucks with medium overall height). Hydraulic line for the lifting function is interrup-ted.

– Standing, with the lifting mast dismounted (for trucks with large overall height)

Safety Instructions for Assembly and Commissioning

f The assembly of the truck on site, commissioning the truck and instructing the drivermust be carried out by personnel trained and authorised by the manufacturerConnect the hydraulic lines to the basic machine / mast interface and commission thetruck only after having installed the mast as per the instructions.

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NForewordNotes on the operating instructions

The 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 and the pages arenumbered continuously.

The operator manual details different industrial truck models. When operating andservicing the industrial truck, make sure that the particular section applies to yourtruck model.

Our trucks are subject to ongoing development. We reserve the right to alter thedesign, equipment and technical features of the system. No guarantee of particularfeatures of the truck should therefore be assumed from the present operatinginstructions.

Safety notices and text mark-ups

Safety instructions and important explanations are indicated by the followinggraphics:

DANGER!

Indicates an extremely hazardous situation. Failure to comply with this instruction willresult in severe irreparable injury and even death.

WARNING!

Indicates an extremely hazardous situation. Failure to comply with this instructionmay result in severe irreparable injury and even death.

CAUTION!

Indicates a hazardous situation. Failure to comply with this instruction may result inslight to medium injury.

NOTE

Indicates a material hazard. Failure to comply with this instruction may result inmaterial damage.

Z Used before notices and explanations.

t Indicates standard equipmento Indicates optional equipment

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Copyright

Copyright of these operating instructions remains with JUNGHEINRICH AG.

Jungheinrich Aktiengesellschaft

Am Stadtrand 3522047 Hamburg - Germany

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

www.jungheinrich.com

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NContents

A Correct Use and Application ................................................... 11

1 General.................................................................................................... 112 Correct application................................................................................... 113 Approved application conditions.............................................................. 124 Proprietor responsibilities ........................................................................ 135 Adding attachments and/or optional equipment ...................................... 13

B Truck Description .................................................................... 15

1 Application ............................................................................................... 152 Truck models and rated capacity............................................................. 153 Travel direction definition......................................................................... 164 Assembly description............................................................................... 175 Functional Description ............................................................................. 186 Technical Specifications .......................................................................... 226.1 Performance data .................................................................................... 226.2 Dimensions.............................................................................................. 236.3 Weights.................................................................................................... 256.4 Tyre type.................................................................................................. 266.5 Battery ..................................................................................................... 266.6 Hydraulics................................................................................................ 266.7 Mast weights............................................................................................ 276.8 EN norms................................................................................................. 286.9 Conditions of use..................................................................................... 296.10 Electrical Requirements........................................................................... 297 Identification Points and Data Plates....................................................... 307.1 Overview of marking points ..................................................................... 307.2 Data plate ................................................................................................ 327.3 Truck capacity plate................................................................................. 338 Stability .................................................................................................... 358.1 Wind loads............................................................................................... 35

C Transport and Commissioning ................................................ 37

1 Transport ................................................................................................. 372 Lifting by crane ........................................................................................ 382.1 Lifting the truck by crane ......................................................................... 393 Securing the truck during transport ......................................................... 424 Using the Truck for the First Time ........................................................... 43

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D Battery - Servicing, Recharging, Replacement ....................... 45

1 Safety Regulations Governing the Handling of Lead-Acid Batteries ....... 451.1 General notes on handling batteries........................................................ 462 Battery types............................................................................................ 473 Exposing the battery................................................................................ 484 Charging the battery ................................................................................ 515 Battery removal and installation .............................................................. 525.1 Removing and Installing the Battery with Crane Lifting Gear .................. 535.2 Lateral Battery Removal .......................................................................... 54

E Operation ................................................................................ 57

1 Safety Regulations for the Operation of the Forklift Truck....................... 572 Displays and Controls.............................................................................. 592.1 Display unit .............................................................................................. 613 Preparing the Truck for Operation ........................................................... 663.1 Checks and Operations to Be Performed Before Starting Daily Work .... 663.2 Entry and exit........................................................................................... 683.3 Setting up the operator position............................................................... 694 Starting up the truck ................................................................................ 764.1 Safety regulations for truck operation...................................................... 764.2 Preparing the truck for operation ............................................................. 784.3 Emergency Disconnect............................................................................ 804.4 Emergency stop....................................................................................... 804.5 Travel....................................................................................................... 814.6 Brakes ..................................................................................................... 834.7 Steering ................................................................................................... 864.8 Adjusting the forks ................................................................................... 914.9 Lifting, transporting and depositing loads ................................................ 944.10 Operating attachments ............................................................................ 1014.11 Fitting additional attachments.................................................................. 1064.12 Emergency lowering ................................................................................ 1074.13 Parking the truck securely ....................................................................... 1085 Troubleshooting....................................................................................... 1095.1 Recovering the truck................................................................................ 1095.2 Warning messages.................................................................................. 1186 Optional equipment ................................................................................. 1196.1 CanCode keypad..................................................................................... 1196.2 ISM access module (o)........................................................................... 1226.3 Work lights............................................................................................... 1236.4 Camera system ....................................................................................... 1246.5 Beacon .................................................................................................... 1286.6 Height cut out .......................................................................................... 1296.7 Electric lift limit ......................................................................................... 1306.8 Sideshifter centre position ....................................................................... 1346.9 Converter 12 V DC/24 V DC.................................................................... 1356.10 Forks horizontal button ............................................................................ 1366.11 Weigher ................................................................................................... 1376.12 “Clamp function release” button .............................................................. 1386.13 Weatherproof cab .................................................................................... 139

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F Industrial Truck Maintenance .................................................. 141

1 Operational Safety and Environmental Protection................................... 1412 Maintenance Safety Regulations............................................................. 1422.1 Cleaning .................................................................................................. 1422.2 Working on the electrical system............................................................. 1432.3 Consumables and used parts.................................................................. 1432.4 Tyre type.................................................................................................. 1432.5 Lift Chains................................................................................................ 1442.6 Hydraulic system ..................................................................................... 1442.7 Energy saving components ..................................................................... 1453 Lubricants and Lubrication Schedule ...................................................... 1463.1 Handling consumables safely.................................................................. 1463.2 Lubrication Schedule ............................................................................... 1483.3 Consumables........................................................................................... 1494 Maintenance and repairs ......................................................................... 1504.1 Preparing the truck for maintenance and repairs .................................... 1504.2 Lifting and jacking up the truck safely...................................................... 1514.3 Removing the seat panel......................................................................... 1524.4 Checking the hydraulic oil level ............................................................... 1524.5 Checking electrical fuses......................................................................... 1544.6 Checking the Wheel Mounting................................................................. 1585 Decommissioning the Industrial Truck..................................................... 1595.1 Prior to decommissioning ........................................................................ 1605.2 During decommissioning ......................................................................... 1605.3 Restoring the truck to service after decommissioning ............................. 1616 Safety tests to be performed at intervals and after unusual incidents ..... 1627 Final de-commissioning, disposal............................................................ 1638 Human vibration measurement ............................................................... 1639 Servicing and Inspection ......................................................................... 16410 Maintenance checklist ............................................................................. 16410.1 Operating Company ................................................................................ 16410.2 Customer Service .................................................................................... 168

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0506

.GBAppendix

JH Traction Battery Operating Instructions

Z These operating instructions apply only to Jungheinrich battery models. If usinganother brand, refer to the manufacturer's operating instructions.

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NA Correct Use and Application1 General

The truck must be used, operated and serviced in accordance with the presentinstructions. All other types of use are beyond its scope of application and may resultin damage to personnel, the industrial truck or property.

2 Correct application

NOTE

The maximum load and load distance are indicated on the capacity plate and mustnot be exceeded.The load must rest on the load handler or be lifted by an attachment approved by themanufacturer.The load must be fully raised, see "Lifting, transporting and depositing loads" onpage 94.

CAUTION!

Loss of stability can cause accidents Extended mast sections when the truck is travelling with or without load will reducethe truck's stability.

Always travel with the mast holder retracted, the mast tilted back and the loadhandler lowered.

– Lifting and lowering loads.– Stacking / retrieving loads.– Transporting lowered loads.– Do not travel with a raised load (>30 cm).– Do not transport or lift passengers.– Do push or pull load units.

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3 Approved application conditions

DANGER!

Do not exceed the permissible surface and point loading on the travel lanes.At blind spots get a second person to assist.The driver must ensure that the loading dock /dock leveller cannot be removed orcome loose during loading/unloading.

– Operation in industrial and commercial environments.– Permissible temperature range -25°C to +40°C.– Operation only on secure, level surfaces with sufficient capacity.– Do not exceed the permissible surface and spot load limits on the travel routes.– Operation only on routes that are visible and approved by the operating company.– Negotiating inclines up to a maximum of 15 %.– Do not travel across or at an angle on inclines. Travel with the load facing uphill.– Operation in partially public traffic.

Z Special equipment and authorisation are required if the truck is to be constantlyused in extreme conditions.The truck is not authorised for use in areas at risk of explosion.

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N4 Proprietor responsibilities

For the purposes of the present operating instructions the “operating company” isdefined as any natural or legal person who either uses the industrial truck himself, oron whose behalf it is used. In special cases (e.g. leasing or renting) the proprietor isconsidered the person who, in accordance with existing contractual agreementsbetween the owner and user of the industrial truck, is charged with operational duties.The proprietor must ensure that the industrial truck is used only for the purpose it isintended for and that danger to life and limb of the user and third parties are excluded.Furthermore, accident prevention regulations, safety regulations and operating,servicing and repair guidelines must be followed. The operating company mustensure that all users have read and understood these operating instructions.

NOTE

Failure to comply with the operating instructions invalidates the warranty. The sameapplies if improper work is carried out on the truck by the customer or third partieswithout the permission of the manufacturer.

5 Adding attachments and/or optional equipment

The mounting or installation of additional equipment which affects or enhances theperformance of the industrial truck requires the written permission of themanufacturer. Local authority approval may also need to be obtained.Local authority approval however does not constitute the manufacturer’s approval.

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NB Truck Description1 Application

The ETV Q20/Q25 is a three-wheel electric side seat, clear view reach truck. It isdesigned to lift and transport goods on level surfaces. Open bottom pallets or palletswith transverse boards can be lifted inside or outside the area of the load wheels orroll cage. Loads can be stacked, unstacked and transported over long distances.

2 Truck models and rated capacity

The rated capacity depends on the model. The rated capacity can be derived fromthe model name.

The rated capacity is not generally the same as the permissible capacity. Thecapacity can be found on the capacity plate attached to the truck.

ETVQ20

ETV Model nameQ Series20 Rated capacity x 100 kg

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3 Travel direction definition

The following conventions have been agreed for travel direction specification:

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Item Travel direction1 Left2 Drive direction3 Load direction4 Right

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N4 Assembly description

5 6 7 8 9

13 14 17 18 1915 16

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Item Component Item Component5 t Overhead guard 12 t Control and display unit6 t Control unit 13 t Battery trolley unlatch pedal7 t Mast 14 t Deadman switch8 t Free lift cylinder 15 t Brake pedal9 t Solo-Pilot 16 t Accelerator pedal

o Multi-Pilot 17 t Drive wheel62 t Emergency Disconnect

switch18 t Wheel arms

11 t Key switch 19 t Load wheelso CANCODEo ISM Access Module

t Standard equipment o Optional equipment

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5 Functional Description

Safety mechanisms

An enclosed truck perimeter with rounded edges ensures safe handling of the ETVQ20/Q25. The driver is protected by the overhead guard (5). The drive wheel (17) andload wheels (19) are protected by a solid skirt.

Z A slight danger remains for third parties, even when a drive wheel cover is used.Pressing the EMERGENCY DISCONNECT switch (62) rapidly disconnects allelectrical functions in hazardous situations.

Line brake safety devices in the lift cylinders limit the load lowering speed in the eventof a hydraulic system failure.

Emergency Stop safety feature

If a fault is identified the Emergency Stop automatically brakes the truck until it comesto a halt. Control displays on the control and display unit indicate the EmergencyStop. Whenever the truck is switched on, the system performs a self-diagnosis whichonly releases the parking brake (emergency stop) if the functional test is positive.

Deadman switch

The deadman switch (14) in the left leg well must be depressed to allow the driver tooperate the truck. Lifting and travel are inhibited if the driver takes his foot off thedeadman switch (14). Steering and braking remain enabled. The deadman switchcan be adjusted so that when the deadman switch (14) is released the parking brakeapplies after a set time (prevents the truck from accidentally rolling away).

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Operator position

The operator position is ergonomically designed with ample legroom. The driver’sseat, steering arm and SOLO-PILOT (9) can be adjusted by the driver to ensure acomfortable posture. The accelerator pedal and brake pedal (16, 15) are of“automotive” design.

Curve Control

Automatic speed reduction for cornering. Curve Control limits the speed andacceleration when cornering. This reduces the risk of oscillations or tipovers.

Drive system

The entire drive unit is bolted onto the chassis of the truck. A fixed 6,9 kW ACthreephase motor controls the drive wheel (17) via a bevel spur gearbox.The electronic traction current controller ensures a smooth drive motor speed and asa result smooth start-up, powerful acceleration and electronically controlled brakingwith energy recovery.

Controls and displays

Controls and displays are clearly arranged in the driver’s cab. The logically designedSOLO-PILOT (9) enables single handed operation of travel direction, lift/lowering,forward / reverse reach, mast tilt, sideshift left or right and auxiliary hydraulics HF5(o).

Displays

Control and display unit (12) with residual time display, battery discharge indicator, liftand travel profile settings and steer angle mode display. The battery dischargeindicator and hourmeter are combined on the control and display unit (12). Thedischarge indicator is designed as a monitor which cuts out lifting when the battery isdischarged, in order to avoid depletion.

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Brake System

The hydraulic / electric braking system consists of three independent brake systems.Applying the brake pedal (15) decelerates the drive motor. The load wheel brakes arehydraulically activated.

The parking brake is electrically operated and acts mechanically (compressionspring) on a magnet brake mounted on the drive unit. It is also used for emergencybraking. A warning indicator appears when the brake is applied. Faults in the steeringand brake systems (which trigger an emergency stop) are shown on the control anddisplay unit.

Steering

Electric all wheel steering, electronically controlled for various steer modes. The drivewheel (17) and load wheels (19) are steered individually by steer motors. Anelectronic control provides the ideal wheel positions for moving in confined areas. Thesteering modes and steering mode functional displays can be selected on the controlunit (6). The adjustable steering wheel acts as a steering transmitter.

Electrical system

48 volt, twin cable system. Standard electronic drive, lift and steering control system.The electronic drive controller provides infinite travel speed control and allows thetruck to plug when changing direction. Travel and lift parameters can be set asrequired via the control and display unit (12). Warning displays, operator errors andservice functions can also be shown on the control and display unit.Battery types see "Battery types" on page 47.

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Mast

The trucks are equipped with fork tilt devices or telescopic clear view mastspositioned in the mast support. Adjustable side rollers and slide pieces take up thelateral pressure exerted on the fork carriage if the load is positioned on one side. Theforks are fitted to the fork carriage and are adjustable. With the two-stage triplex mast(DZ) a free lift cylinder (8) initially lifts the load carriage (free lift) without changing theoverall height of the truck.

Hydraulic system

The hydraulic system is driven by a pump unit with a threephase motor and a quietrunning precision high pressure pump. The hydraulic system is controlled via theSolo-Pilot (9).

Mast support

The mast support is mounted on support rollers. A single telescopic reach cylinderextends and retracts the support. The mast support rails are bolted on to theoutriggers (18).

Mast reach damping (o)

Damping of vibration of extended mast and speed reduction to inching when the loadis extended beyond free lift.

Free lift speed increase

For trucks with a lift height above 3600 mm the free lift traverse and tilt speed is raisedto improve turnover. These high speeds cannot be achieved for mast lift. When youchange from free lift to mast lift, the traverse and tilt speeds are automaticallyreduced.

Attachments

The truck can be optionally fitted with mechanical and hydraulic attachments.

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6 Technical Specifications

Z The technical specification is given according to the German guideline "Typesheets for industrial trucks". Technical modifications and additions reserved.

6.1 Performance data

a) Mast-dependent

Component ETV Q20 ETV Q25Q Capacity (where c = 600 mm) 2000 2500 kg

Travel speed in drive direction with / without load

14.0 14.0 km/h

Travel speed in forks direction with / without load

11.0 11.0 km/h

Lift speed with / without load 0.32/0.60 0.30/0.60 m/s (±10%)

Lowering speed with / without load

0.50/0.50 0.50/0.50 m/s(-15%)

Reach speed with / without load a)

0.12/0.12 0.12/0.12 m/s

Gradeability with / without load 7/11 6/11 %Max. gradeability (5 min on time rating) w / w.o. load

10/15 10/15 %

Acceleration with / without load 4.6/4.3 5.0/4.4 m/sDrive motor, output S2 60 min 6.9 6.9 kWLift motor, output at S3 15% 10.0 10.0 kW

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m2210

h1

h2

h3

h4

l

c

Q

s

h8

l4h6

h7

l2

l7

xx1

y

a2

a2

b2 b11 b1b5

e

b4

Ast

Wk D

Wa

� �

b3

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a)Values apply to battery size 48V/620Ah, other battery sizes will change thesevalues

b)Mast-dependent

c) In forks direction 11 km/h

d)Turning on the spot: 1230 mm

Model ETV Q20 ETV Q25s/e/l Fork dimensions 50/140/1150 50/140/1150 mmc Load centre distance 600 600 mmx Load distance, mast retracteda) 380 503 mmx1 Load distance, mast extendeda) 230 230 mmy Wheelbase 1528 1683 mmh6 Overhead guard height 2150 2150 mmh7 Seat height / standing height 960 960 mmh8 Support arm height 442 442 mml1 Overall lengtha) 2433 2518 mml2 Length incl. fork shanka) 1283 1368 mml4 Reacha) 664 721 mml7 Length across support arms 1957 2112 mmb1/ b2

Overall width 1760/1270 mm

b3 Fork carriage width 800 mmb4 Inside straddle 940 mmb5 Width across forks (min/max) 356/737 mmb11 Track width, rear 1420 mmWa Turning radiusd) 1741 1893 mmAst Working aisle widtha)

for pallets 1000 x 1200 longit.2763 2858 mm

Ast Working aisle widtha)for pallets 800 x 1200 transv.

2802 2878 mm

D Truck diagonald) 2277 2432 mmm2 Ground clearance centre

wheelbase95 mm

Mast tilt / b) 1/5 °

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N6.2.1 Standard mast version dimensions

6.3 Weights

a) Values apply to battery size 48V/620Ah, other battery sizes and masts will changethese values

Description Triplex mast(DZ)

Duplex mast(DZ) reinforced

h1 Mast height retracted 2400 2400 mmh2 Free lift 1670 1670 mmh3 Lift 5300 5300 mmh4 Mast height extended 6046 6046 mm

Model Triplex mast(DZ)

Duplex mast(DZ) reinforced

Net weight incl. batterya) 4060 4150 kgAxle load, w.o. load front/rear 2310/1750 2490/1660 kgAxle loading forks fwd. w. load front/rear

670/5390 600/6050 kg

Axle loading forks back w. load front/rear

1940/4120 2260/4390 kg

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6.4 Tyre type

6.5 BatteryApproved battery types see "Battery types" on page 47.

6.6 Hydraulics

Description ETV Q20 ETV Q25Tyre type VulkollanTyre size, front (drive wheel) 343 x 140 mmTyre size, rear (load wheels) 343 x 140 mmWheels, number front / rear (x = driven)

1x/2

Description ETV Q20 ETV Q25Available working pressure for attachments

150 150 bar

Oil flow for attachments 20 20 l/min

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N6.7 Mast weights

The weight of the mast can be calculated using the formulae given below. Thenecessary details such as truck name, model and length of the extended mast (liftheight) can be taken from the data plate. The weight of the truck and the battery canbe found on the data plate.

6.7.1 Mast weight calculation example

– Truck name (20): ETV Q20– Mast (22): Section reinforcement, fork tiltE– Mast weight = 1.1 x lift height (22) + 490 kg– Mast weight = 1.1 * 740 + 490 kg = 1304

6.7.2 Overview of formulae to be applied

1306/1371 kg

ETV Q20

3750 kg

GNE 160 740 DZ

20 21 22

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Truck series Design CalculationETV Q20/Q25 Standard Weight = 1.0 x lift height + 415 kgETV Q20/Q25 Section reinforcement;

fork tiltWeight = 1.2 x lift height + 425 kg

ETV Q20/Q25 Fork positioner Weight = 1.0 x lift height + 900 kg

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6.8 EN normsNoise emission level

– ETV Q20/Q25: 70 dB(A)

in accordance with EN 12053 as harmonised with ISO 4871.

Z The noise emission level is calculated in accordance with standard procedures andtakes into account the noise level when travelling, lifting and when idle. The noiselevel is measured at the level of the driver's ear.

Vibration

– ETV Q20/Q25 MSG 20: 66 m/s²– ETV Q20/Q25 MSG 65: 0,81 m/s²

in accordance with EN 13059

Z The vibration acceleration acting on the body in the operating position is, inaccordance with standard procedures, the linearly integrated, weightedacceleration in the vertical direction. It is calculated when travelling over thresholdsat constant speed. These recordings were taken on a single occasion and must notbe confused with the human vibrations of the "2002/44/EC/Vibrations" operatordirective. The manufacturer offers a special service to measure these humanvibrations, see "Human vibration measurement" on page 163.

Z The internal accuracy of the measuring chain for at 21°C at ± 0,02 m/s². Furtherdeviations may occur in particular through the positioning of the sensor anddifferent driver weights.

Electromagnetic compatibility (EMC)

The manufacturer confirms that the truck adheres to the limits for electromagneticemissions and resistance as well as the static electricity discharge test in accordancewith EN 12895 as well as the standardised instructions contained therein.

Z No changes to electric or electronic components or their arrangement may bemade without the written agreement of the manufacturer.

WARNING!

Medical equipment can be damaged by non-ionised radiationElectrical equipment on the truck emitting non-ionised radiation (e.g. wireless datatransmission) can affect operators' medical equipment (pacemakers, hearing aidsetc.) and result in malfunctions. Consult a doctor or the manufacturer of the medicalequipment to clarify whether it can be used near the industrial truck.

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N6.9 Conditions of use

Ambient temperature

– operating at -25°C to +40°C

Z Special equipment and authorisation are required if the truck is to be usedcontinually in conditions of extreme temperature or condensing air humidityfluctuations.

6.10 Electrical RequirementsThe manufacturer certifies compliance with the requirements for the design andmanufacture of electrical equipment, according to EN 1175 "Industrial Truck Safety -Electrical Requirements", provided the truck is used according to its purpose.

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7 Identification Points and Data Plates

7.1 Overview of marking points

mV1,5 V

39

28 2924

3837

25, 26, 27

30

31

32

36

34

33

35

31

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Item Component24 Wear seat belt25 Capacity plate, capacity / sideshifter26 Capacity plate, capacity / load centre of gravity/ lift height 27 Capacity plate, capacity / load centre of gravity, forks 28 Warning "No standing under the load lifting"29 Warning: "Do not reach through the mast"30 “Final inspection completed” label31 Strap points for crane lifting32 Test plaque (o)33 Truck serial no. 34 Truck data plate 35 Overview of electronic component part numbers36 Warning notice "Caution: Low voltage electronic system”37 Attention: Read operating instructions.38 Hydraulic oil filler neck39 Jack contact points

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7.2 Data plate

Z For queries regarding the truck or ordering spare parts always quote the truck serialnumber (40).

7.2.1 Serial number position

The serial number is located on the traverse wall at the bottom left of the batterycompartment (33)

20 40 4241 21

47

44

46

23

45

4322

Item Description Item Description20 Type 43 Year of manufacture40 Serial number 44 Load centre (mm)41 Rated capacity (kg) 45 Output42 Battery voltage (V) 23 Min./max. battery weight (kg)21 Net weight w.o. battery (kg) 46 Manufacturer22 Option 47 Manufacturer’s logo

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N7.3 Truck capacity plate

7.3.1 Capacity plate

The capacity plate (26) gives the capacity (Q) of the truck in kg for a vertical mast.The maximum capacity is shown as a table with a standard load centre of gravitydistance * C (in mm) and the required lift height H (in mm). The arrow shape markings(48) on the inner and outer masts show the driver when the specified lift limits havebeen reached.

*)The standard load centre of gravity distance takes into account the width as well asthe height of the load.

Capacity plate version in accordance with Australian guidelines (59)

Example of how to calculate the maximum capacity

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

7.3.2 Attachment Load Chart

The attachment capacity plate is next to the truck's capacity plate and gives thetruck’s capacity Q (in kg) in conjunction with the respective attachment. The serialnumber for the attachment indicated on the capacity plate must match the data plateof the attachment.

500 600 700

850850600

X.XXXX.XX.XX

12501105850

12501105850

290036004250

26

48

59

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7.3.3 Sideshifter capacity plate

The capacity plate (25) gives the reduced capacity Q (in kg) when the sideshift isextended.

7.3.4 Jack contact points

The "Jack contact point" decal (39) indicates where the truck may be lifted and jackedup (see "Industrial Truck Maintenance" on page 141)

25

39

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N8 Stability

The truck's stability has been tested according to latest technological standards.These take into account the dynamic and static tipover forces that can occur if usedcorrectly.

Stability can also be affected by the following factors:– Battery size and weight– Tyre type– Mast– Attachment– Transported load (size, weight and centre of gravity)– Ground clearance, e.g. modification of the support columns– Position of the mast holder stops

Changing the components can alter the stability.

Batteries that are pushed forward or unlocked can alter the stability.

8.1 Wind loadsWind forces can affect the stability of a truck when lifting, lowering and transportingloads with large surface areas.

Light loads must be especially secured when they are subjected to wind forces. Thiswill prevent the load from sliding or falling.

Stop the truck in both cases.

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NC Transport and Commissioning1 Transport

Depending on the height of the mast and local conditions, the truck can betransported in three different ways:

– Vertically, with the mast assembled (for low heights)– Vertically, with the mast partially assembled and leaning against the overhead

guard (for medium heights), lifting hydraulic line disconnected.– Horizontally, with the mast dismantled (for large heights), all mechanical

connections and hydraulic lines between the basic truck and the mast separated.

Safety instructions for assembly and commissioning

WARNING!

The assembly of the truck at the application site, commissioning and driver trainingmust only be performed by the manufacturer's customer service representatives whohave been specially trained for these tasks.

The hydraulic lines may only be connected to the basic truck / mast interface and thetruck commissioned when the mast has been properly assembled.

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2 Lifting by crane

WARNING!

Incorrect lifting by crane can result in accidentsImproper use or use of unsuitable lifting gear and can cause the truck to fall whenbeing lifted by crane.Prevent the truck from hitting other objects during lifting, and avoid uncontrolledmovements. If necessary, secure the truck with guide ropes.

The truck should only be loaded by personnel trained in the use of lifting slings andtools.Wear personal protective equipment (e. g. safety shoes, safety helmet, hi-visjacket, protective gloves, etc.) when loading by crane.Do not stand under suspended loads.Do not enter or stand in a hazardous area.Always use lifting gear with sufficient capacity (for truck weight see truck ratingplate).Always attach the crane lifting gear to the prescribed strap points and prevent themfrom slipping.Use the lifting slings only in the prescribed loading direction.Crane slings should be fastened in such a way that they do not come into contactwith any attachments when lifting.

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N2.1 Lifting the truck by crane

CAUTION!

The mast can get damagedLoading by crane is only intended for the initial transport before the truck is usedfor the first time.Loading must be carried out by specially trained staff in accordance withrecommendations contained in Guidelines VDI 2700 and VDI 2703

DANGER!

Crane slings can tear, resulting in accidentsOnly use crane lifting gear with sufficient capacity.Loading weight = Net weight of truck (+ battery weight for electric trucks).The mast must be tilted back fully. The crane lifting gear on the mast must have a minimum clear length of 2 m.Crane slings should be fastened in such a way that they do not come into contactwith any attachments or the overhead guard when lifting.Do not stand under a swaying load.The truck should only be handled by people who are trained in using lifting slingsand tools.Wear safety shoes when lifting the truck by crane.Do not walk into or stand in a hazardous area.Always attach the crane lifting gear to the prescribed strap points and prevent themfrom slipping.

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40

Lifting the truck by crane

Requirements– Park the truck securely, see "Parking the

truck securely" on page 108.

Tools and Material Required– Crane lifting gear– Lifting slings– Wedges

Procedure• Route rope slings around the two strap

points (49) of the overhead guard strut.• Secure crane lifting gear to the two strap

points (50) on the wheel arms.• Load the truck. • Park the truck securely, see "Parking the

truck securely" on page 108.• Secure the truck with wedges to prevent it from rolling away.

The truck is now loaded.

49

50

41

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Lifting the truck and cab by crane

Requirements–Park the truck securely, see "Parkingthe truck securely" on page 108.

Tools and Material Required–Sufficiently wide cross member–Crane lifting gear with hook–Wedges

Procedure•Secure the crane lifting gear to the strappoints (51).ZThe lifting of trucks with a weather-proof cab (o) or cold store cab (o) issubject to restrictions. Because of therisk to the window, the crane lifting gearand rope slings must not pass over thefront door.•Load the truck. •Park the truck securely, see "Parkingthe truck securely" on page 108.•Secure the truck with wedges to preventit from rolling away.

The truck is now loaded.

51 51

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42

3 Securing the truck during transport

WARNING!

Accidental movement during transportImproper fastening of the truck and mast during transport can result in seriousaccidents.

Loading must only be performed by specialist personnel trained for this purpose.The specialist personnel must be instructed in securing loads on road vehicles andhandling load securing devices. In each case correct measurements must be takenand appropriate safety measures applied.The truck must be securely fastened when transported on a lorry or a trailer.The lorry or trailer must have fastening rings.Use wedges to prevent the truck from moving.Use only fastening belts with sufficient strength.Use non-slip materials to securing the load aids (pallet, wedges, ...) e. g. non-slipmats.

Securing the industrial truck for transport

Requirements– 2 tensioning belts

Procedure• Pull the fastening belts (53) through the

guide on the overhead guard strut.• Secure the fastening belts (53) to the

fastening rings.• Tighten the fastening belts (53) with the

tensioner (52).

The truck is now secured for transport.

5253

43

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N4 Using the Truck for the First Time

WARNING!

Incorrect assembly can result in accidentsThe assembly of the truck at the application site, commissioning and operator trainingmust only be performed by the manufacturer's customer service representatives whohave been specially trained for these tasks.

WARNING!

The use of unsuitable energy sources can be hazardousRectified AC current will damage the assemblies (controllers, sensors, motors etc.)of the electronic system.Unsuitable cable connections (too long, insufficient wire cross-section) to the battery(tow cables) can overheat, setting the truck and battery on fire.

The truck must only be operated with battery current.Cable connections to the battery (tow leads) must be less than 6 m long and havea minimum cross-section of 50 mm².

Procedure• Check the equipment is complete.• If necessary, install the battery, see "Battery removal and installation" on page 52.

Do not damage the battery cable.• Charge the battery, see "Charging the battery" on page 51.

Z The truck settings must match the battery model (if the customer is charging thebattery).

• Check the hydraulic oil level and top up if necessary (see "Checking the hydraulicoil level" on page 152).

• Start up the truck (see "Starting up the truck" on page 76).

Truck is operational.

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44

45

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ND Battery - Servicing, Recharging,

Replacement1 Safety Regulations Governing the Handling of Lead-Acid

Batteries

Maintenance personnel

Batteries may only be charged, serviced or replaced by trained personnel. Theseoperating instructions and the manufacturer’s instructions concerning batteries andcharging stations must be observed when carrying out the work.

Fire Protection

Do not smoke and avoid naked flames when handling batteries. Wherever anindustrial truck is parked for charging there must be no inflammable material orconsumables capable of creating sparks within a minimum distance of 2 m from thetruck. The room must be ventilated. Fire protection equipment must be available.

CAUTION!

The use of unsuitable fire protection equipment can result in scaldingExtinguishing fires with water can cause a reaction with the battery acid. This canresult in scalding from the acid.

Use powder extinguishers.Never extinguish a burning battery with water.

Battery maintenance

The battery cell covers must be kept dry and clean. Terminals and cable shoes mustbe clean, lightly greased with terminal grease and must be securely tightened.Batteries with non insulated terminals must be covered with a non slip insulating mat.

CAUTION!

Before closing the battery panel make sure that the battery cable cannot bedamaged. There is a risk of short circuits with damaged cables.

Battery disposal

Batteries may only be disposed of in accordance with national environmentalprotection regulations or disposal laws. The manufacturer’s disposal instructionsmust be observed.

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1.1 General notes on handling batteries

WARNING!

Batteries can be hazardousBatteries contain an acid solution which is poisonous and corrosive. Avoid contactwith battery acid at all times.

Dispose of used battery acid in accordance with regulations.Always wear protective clothing and goggles when working with batteries.Do not let battery acid come into contact with skin, clothing or eyes. If necessary,rinse with plenty of clean water.In the event of physical damage (e.g. skin or eye contact with battery acid) call fora doctor immediately.Spilled battery acid should be neutralised immediately with plenty of water.Only batteries with a sealed battery container may be used.Follow national guidelines and legislation.

WARNING!

Using unsuitable batteries can cause accidentsThe weight and dimensions of the battery have a considerable effect on theoperational safety and capacity of the industrial truck. Changing the battery featuresrequires the manufacturer’s approval, as compensating weights are required ifsmaller batteries are fitted. When replacing/installing the battery make sure thebattery is securely located in the battery compartment of the truck.

Park the truck securely before carrying out any work on the batteries (see "Parkingthe truck securely" on page 108).

47

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N2 Battery types

CAUTION!

Always use batteries with insulated covers or live components.

The battery weights are indicated on the battery data plate.

The truck will be equipped with different battery models, depending on theapplication. The following table shows which combinations are included as standard:

Battery type Capacity High performance (HX)

Mass [kg]1

1. tolerance range +/- 5%

48 V - 4PzS 560 Ah 620 Ah 97048 V - 5PzS 700 Ah 775 Ah 117048 V - 6PzS 840 Ah 930 Ah 1360

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48

3 Exposing the battery

CAUTION!

Moving parts can cause accidentsThe mast moves when the battery is exposed. This constitutes a risk of accidents andtrapping in the hazardous area.

Instruct any persons to leave the hazardous area.Make sure there is nothing between the battery and the mast holder when youmove the mast holder.

Exposing the battery

Requirements– Truck prepared for operation, see

"Preparing the Truck for Operation" onpage 66.

Procedure• Pull the SOLO-PILOT lever (55) in the

direction of the arrow (U) and move themast holder towards the battery until itlocks in position. Release the SOLO-PILOT (9) (mast is located in the limitposition).

• Pull the SOLO-PILOT (9) again in thedirection of the arrow (U) and move themast support further towards thebattery as far as the stop position (preparation for unlatching the battery) and holdit in this position.

9

54

U

T

955

49

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N• Press on the battery unlatch pedal (56) with your right foot and hold it in this

position.

Z The “battery unlocked” button (red graphic symbol) (54) lights up on the displayunit.

• Move the SOLO-PILOT lever (55) in the direction of the arrow (T) and extend themast support with the coupled battery trolley until the battery is exposed formaintenance.

• Release the battery unlatch pedal (56).• Turn the Emergency Disconnect switch and key switch off.

Z The battery unlatch safety switch only allows for travel at crawl speed if the batterytrolley is unlatched and the indicator (54) is still on. Before starting up the truckagain, the battery trolley must be restored to its initial position in order to uncouplethe battery trolley and the mast support. The indicator (54) must be off

The battery is exposed.

56

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50

Battery retracted

Requirements– Truck prepared for operation, see "Preparing the Truck for Operation" on page 66.– Battery exposed.

Procedure• Pull the SOLO-PILOT lever (55) in the direction of the arrow (U) and retract the

mast holder.Z The “battery unlocked” (red graphic symbol) (54) goes out on the display unit.Z The battery unlatch safety switch only allows for travel at crawl speed if the battery

trolley is unlatched and the indicator (54) is still on. Before starting up the truckagain, the battery trolley must be restored to its initial position in order to uncouplethe battery trolley and the mast support. The indicator (54) must be off

The battery is now retracted.

51

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N4 Charging the battery

WARNING!

The gases produced during charging can cause explosionsThe battery produces a mixture of nitrogen and hydrogen (electrolytic gas) duringcharging. Gassing is a chemical process. This gas mixture is highly explosive andmust not be ignited.

Switch the charging station and truck off first before connecting/disconnecting thecharging cable of the battery charging station to/from the battery connector.The charger must be adapted to the battery in terms of voltage and chargecapacity.Before charging, check all cables and plug connections for visible signs of damage.Ventilate the room in which the truck is being charged.The battery cell surfaces must be exposed during charging to ensure adequateventilation.Do not smoke and avoid naked flames when handling batteries.Wherever an industrial truck is parked for charging there shall be no inflammablematerial or lubricants capable of creating sparks within 2 m around the truck.Fire protection equipment must be on hand.Do not lay any metallic objects on battery.It is essential to follow the safety regulations of the battery and charger stationmanufacturers.

Charge the battery

Requirements– Battery exposed, see "Exposing the battery" on page 48.– Remove any insulating mats from the battery.

Procedure• Connect the charger lead of the battery charger station with the battery connector.• Charge the battery in accordance with the battery and charging station

manufacturers' instructions.

Battery is charged.

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5 Battery removal and installation

WARNING!

Accident risk during battery removal and installationDue to the battery weight and acid there is a risk of trapping or scalding when thebattery is removed and installed.

Note the "Safety regulations for handling acid batteries" section in this chapter.Wear safety shoes when removing and installing the battery.Use only batteries with insulated cells and terminal connectors.Park the truck on a level surface to prevent the battery from sliding out.Make sure the crane slings have sufficient capacity to replace the battery.Use only approved battery replacement devices (battery roller stand, replacementtrolley etc.).Make sure the battery is securely located in the truck's battery compartment.

53

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N5.1 Removing and Installing the Battery with Crane Lifting Gear

Removing the battery

Requirements– Battery exposed, see "Exposing the battery" on page 48.

Tools and Material Required– Crane lifting gear

Procedure• Loosen the jam nut (58) on the battery lock (57).• Undo the retaining screw (59).• Pull out the battery stop (57).• Remove the battery cover.• Strap the crane lifting gear to both sides of the battery container.

Z The hooks must be fitted in such a way that when the crane lifting gear isslackened, they do not fall onto the battery cells. The lifting gear must exert avertical pull so that the battery container is not compressed.

• Lift the battery clear and move out to the side.

The battery is now removed.

57 5958

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54

Battery installation

Requirements– Battery removed.– Battery cover removed.

Tools and Material Required– Crane lifting gear

Procedure• Strap the crane lifting gear to both sides of the battery container.• Lift the battery with the crane lifting gear, lift it in from the side and lower it.• Insert the battery stop (57).• Tighten the retaining screw (59) and jam nut (58) or handle (60) on the battery stop

(57).• Attach the battery connector to the truck connector. • Fit the battery cover.

The battery is now assembled.

5.2 Lateral Battery Removal

57 60

55

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NRemoving the battery with the battery trolley

Tools and Material Required– Battery trolley

Procedure

CAUTION!An unsecured battery can result in accidentsWhen the battery stop (57) is removed, the battery can roll out if the truck is nothorizontal.

Park the truck on a horizontal surface.

• Release the handle (o) (60).• Pull out the battery stop (57).• Remove the battery cover.• Pull the battery out to the side onto the battery trolley.

The battery is now removed.

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56

NOTE

Trapped battery cables can cause damageWhen the battery is inserted the batterycable can be damaged if fitted without acable duct.

Always install the battery with a cableduct (61).The cable duct (61) must match thebattery used. The battery cable lengthdepends on the battery type.Contact the manufacturer's servicedepartment when replacing the factory-fitted battery.

Installing the battery with the batterytrolley

Requirements– Battery removed.– Battery cover removed.

Tools and Material Required– Battery trolley

Procedure• Bring the battery trolley with the battery up to the truck.• Push the battery off the trolley into the battery compartment.• Insert the battery stop (57).• Tighten the retaining screw (59) and jam nut (58) or handle (60) on the battery stop

(57).• Attach the battery connector to the truck connector. • Fit the battery cover.

The battery is now installed.

61

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NE Operation1 Safety Regulations for the Operation of the

Forklift Truck

Driver authorisation

The truck may only be used by suitably trained personnel, who have demonstrated tothe proprietor or his representative that they can drive and handle loads and havebeen authorised to operate the truck by the proprietor or his representative.

Operator’s rights, obligations and responsibilities

The operator must be informed of his duties and responsibilities and be instructed inthe operation of the truck and shall be familiar with the operating instructions.

Unauthorised use of truck

The operator is responsible for the truck during the time it is in use. The operator mustprevent unauthorised persons from driving or operating the truck. Do not carrypassengers or lift other people.

Damage and faults

The supervisor must be informed immediately of any damage or faults to the truck orattachment. Trucks which are unsafe for operation (e.g. wheel or brake problems)must not be used until they have been rectified.

Repairs

The operator must not carry out any repairs or alterations to the truck withoutauthorisation and the necessary training to do so. The operator must never disable oradjust safety mechanisms or switches.

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58

Hazardous area

WARNING!

Risk of accidents/injury in the hazardous area of the truck A hazardous area is defined as the area in which people are at risk due to travel orlifting operations of the truck, its load handler or the load. This also includes the areawithin reach of falling loads or lowering/falling operating equipment.

Instruct unauthorised persons to leave the hazardous area.In case of danger to third parties, give a warning signal in good time.If unauthorised persons are still within the hazardous area, stop the truckimmediately.

WARNING!

Falling objects can cause accidentsFalling objects can injure the operator while the truck is being operated.

The operator must remain within the protected area of the overhead guard whilethe truck is being operated.

Safety devices, warning signs and warning instructions

Safety devices, warning signs (see "Identification Points and Data Plates" onpage 30) and warning instructions in the present operating instructions must bestrictly observed.

CAUTION!

Reduced headroom can cause injuriesTrucks with reduced headroom are equipped with a warning label within theoperator's line of sight.

The max. recommended body size indicated on this warning sign must beobserved.The headroom is also reduced when you wear a protective helmet.

CAUTION!

Loss of stability can cause accidents Extended mast sections when the truck is travelling with or without load will reducethe truck's stability.

Always travel with the mast holder retracted, the mast tilted back and the loadhandler lowered.

59

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N2 Displays and Controls

13 11 62 63

64

12

65

68

70

9

66

67

71

161514

69

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60

Item Control and display item

Function

963

SOLO-PILOT t Operates the following functions:

– Fwd/rev. travel direction – Load handler lift / lower– Mast forward / reverse tilt– Horn button– Sideshifter left / right (o)– Auxiliary hydraulics (o)– Mast reach forward / reverse

MULTI-PILOT o

11 Key switch t Switches control current on and off. Removing the key prevents the truck from being switched on by unauthorized personnel.

ISM Access Module o Used to set codes and to switch on the truck.Code lock

12 Control and display unit t Displays important travel and lift parameters, displays steering modes, warnings, incorrect operation notes and service displays

13 Battery trolley unlocking device

t Unlocks the battery trolley

14 Deadman button t – Not pressed: Travel and hydraulic functions inhibited, truck decelerates.

– Pressed: Travel and hydraulic functions enabled.

15 Brake pedal t Provides infinitely variable braking control.16 Accelerator pedal t Provides infinitely variable travel speed

control62 Emergency Disconnect

switchThe supply circuit is disconnected. All electrical functions are deactivated. The truck stops.

64 Grip t65 Steering column stop t66 Steer angle switch t Changes the steering range between 180° /

360°.67 Sideshift centre position

switcho Moves the sideshifter to the centre position.

68 Weighing button o Weighs the load69 Forks horizontal button o Positions the forks horizontally70 Limit switch system and

lift height display override button

o Prevents damage to the truck and the load

71 Armrest lock t Armrest longitudinal adjuster116 Travel mode control unit t Selects travel modes

61

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N2.1 Display unit

Description

The driver’s display unit represents the operator-truck interface. It acts both as adisplay and control unit for the operator.

Adjustments to the truck can be made by pressing the four keys (92, 93, 95, 96). TheLEDs of the 11 luminous buttons (54, 89-89) can show 3 conditions: on, flashing oroff.

The display unit gives information on the travel direction, steer angle, battery chargecondition and other selected truck parameters.

8786

72 74 75 76 77 78 79 80

81

8485

969592 93

83

88

82

54

89

90 91

73

94

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62

Item Component Function54 Battery lock

displayThe red icon lights up when the battery is unlocked.

72 Slow travel display The green icon lights up when slow travel is set. The travel speed is restricted.

73 Sideshift centre position display

The green icon lights up when the sideshifter is centred.

74 Service mode Yellow icon– flashes when the service interval has

expired.– flashes rapidly when the service PC and

truck are connected.75 Steer angle Displays the steer angle in 30° increments.76 Direction display Displays travel direction and steer mode

– Semi-circle = 180° – Circle = 360° endless steering

77 Residual time display

Displays the residual run time with on-board battery (hours: minutes)

78 Time Displays the time in hours:minutes79 Charge status

display Shows the battery charge status.

80 Discharge indicator

Shows the battery charge status.

81 Travel speed display

Shows the speed setting (drive direction) for current profile (in bars from 1 to 5).

82 Forks horizontal The green icon lights up when the load handler is horizontal.

83 Lift speed display Shows the speed setting (lift) for current profile (in bars from 1 to 5).

84 Lift limit display Yellow icon – lights up when the lift limit is reached.– flashes when the height is below the safety

height.85 Performance

setting numberDisplays the performance setting number (1,2 or 3).

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86 Deadman switch Yellow icon– lights up if the deadman switch is not

pressed. The truck is not operational.– flashes if the deadman switch is pressed

while the system starts up. 87 Overtemperature Red icon lights up for engine or a controller

over temperature.

88 Warning and error message display

Displays warning, error and information messages as plain text.

89 Warning symbol display

Red icon – lights up when faults occur.– flashes when system messages appear in

the display.90 Parking brake

indicatorRed icon lights up when the parking brake is applied.

91 Stop sign display Red icon lights up when faults occur.

92 Slow travel Travel mode setting button.

93 Parking brake button

Parking brake activation button.

94 Warning and error message display

Displays warning, error and information messages as plain text.

95 Shift key Display change button.

96 Performance setting button

Button to select performance level 1, 2 or 3.

Item Component Function

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64

2.1.1 Battery discharge indicator

The battery charge status is shown on the truck display via a battery symbol (79).When a battery is discharged to the permissible discharge level, the battery symbol(79) is displayed empty.

Z The standard setting for the battery discharge indicator (80) is based on standardbatteries.

2.1.2 Battery discharge monitor

If the residual capacity falls below the required level, lifting is inhibited. An alternatingdisplay (88) appears. Lifting is only released when the battery connected is at least70% charged.

2.1.3 Residual time display

The residual run time display (77) shows the time remaining until the battery'sresidual capacity is reached.

Display residual run time

Procedure• Press the Shift key (95) for 3 seconds.

The time (78) changes to residual run time, the residual run time display icon (77)is displayed.

The residual run time is displayed.

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N2.1.4 Hourmeter

Service hours are counted if the truck is released for operation via the key switch, ISMaccess module or code lock and the deadman button is pressed.

Press the Shift key (95 briefly to change the layout of the display fields (88 and 94).If Rack Height Select (o) and load sensing (o) are not available, the lift height or loadweight rows will be bypassed.

Z If Rack Height Select (o) and load sensing (o) are available, the display field onthe right (88) remains empty.

2.1.5 Energy recovery for regenerative lowering and braking

During the energy recovery stage, the discharge indicator on the driver’s displaychanges so that the bars in the battery container fill from bottom to top. This takesplace cyclically and irrespective of the battery’s charge status (full or partiallydischarged). The display goes out once energy recovery is complete.

Display field left (94) Display field right (88)Service hours Load weightService hours Lift heightLift height Load weightLoad weight Lift height

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66

3 Preparing the Truck for Operation

3.1 Checks and Operations to Be Performed Before Starting Daily Work

WARNING!

Damage and other truck or attachment (optional equipment) defects can resultin accidents.If damage or other truck or attachment (optional equipment) defects are discoveredduring the following checks, the truck must be taken out of service until it has beenrepaired.

Report any defects immediately to your supervisor.Mark defective truck and take out of service.Do not return the industrial truck to service until you have identified and rectified thefault.

Checking the truck before daily operation

Procedure• Visually inspect the entire truck (in particular wheels and wheel bolts) for damage. • Check the load handler for visible signs of damage such as cracks, bent or severely

worn forks.• Check the fork stop and fork retainer (117), see "Adjusting the forks" on page 91.• Visually inspect the hydraulic system in the visible area for damage and leaks.• Make sure the driver’s seat is locked in position.• Test the horn and reversing buzzer (o) where applicable.• Check that the load chart and warning labels are legible.• Test the controls and displays.• Test the steering.• Check the steer angle display, turn the steering wheel in both directions as far as

the stop and check that the wheel position is displayed on the control panel.• Make sure the load chains are evenly tensioned.• Test the seat belt (o). The belt should jam if extracted suddenly.• Test the lift/lower, tilt and if applicable the attachment hydraulic control functions.• Visually inspect the battery attachment and cable connections.• Check the battery connectors are secure.• Check that the battery is positioned securely.• Makes sure the battery is locked.

67

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N• Integral sideshifter (o): Check the screws on the restraint system and the fork

locking system (97) are secure, tighten if necessary. Torque (98): 190 Nm. Torque(97): 85 Nm.

Z Top illustration: ETM sideshifter, bottom illustration: ETV sideshifter.The truck is now checked.

98

97

98

97

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68

3.2 Entry and exitEntry and exit

Procedure• To enter, grab hold of the handle (64), see "Displays and Controls" on page 59.• Enter or leave the truck.

69

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N3.3 Setting up the operator positionZ Before starting to travel, adjust the driver’s seat, steering column and armrest (if

necessary) so that all the controls are within reach and can be applied withouthaving to strain.

3.3.1 Adjusting the driver’s seat

Z The procedure for adjusting the driver’s seat applies to standard models. For othermodels, follow the manufacturer’s setting instructions. When adjusting, ensure thatall controls are within easy reach.

CAUTION!

Moving the driver's seat is a trapping hazardDo not reach between the seat and the side wall or overhead guard when adjustingthe seat.

Z The optional seat heating (49) is operated via the switch on the driver's seat.

Adjusting the driver's weight

NOTE

To achieve optimal seat cushioning thedriver’s seat must be set to the driver’sweight. Set the driver's weight when the seat isunoccupied.Seat cushioning setting range: 50 - 130Kg.

Procedure• Pull the weight adjustment lever (101) in

the direction of the arrow as far as thestop and then return it.The weight setting is set to a minimum value.

• Pull the weight adjustment lever (101) in the arrow direction until you reach therequired weight on the scales.

• Restore the weight adjustment lever (101) to its original position.

The driver’s weight is now set.

100 101 10299

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70

Adjusting the backrest

Procedure• Sit on the driver’s seat.• Pull the lever (100) to adjust the backrest.• Adjust the backrest tilt.• Release the lever (100) again. The backrest is locked.

The backrest is now set.

Adjusting the seat position

CAUTION!

An unsecured driver's seat can cause injuryAn unsecured driver's seat can slide out of its guide during travel, resulting inaccidents.

The driver's seat must be locked in position.Do not adjust the driver’s seat while travelling.

Procedure• Sit on the driver’s seat.• Pull up the driver’s seat locking lever (102) in the direction of the arrow.• Push the driver’s seat forwards or backwards to the desired position.• Engage the driver’s seat locking lever (102) in position.

The seat position is now correctly set.

Switching the seat heating on and off

Procedure• Press the seat heating switch (99).

Switch setting 1 = Seat heating on.Switch setting 0 = Seat heating off.

71

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N3.3.2 Adjusting the comfort seat (o)

CAUTION!

Moving the driver's seat is a trapping hazardDo not reach between the seat and the side wall or overhead guard when adjustingthe seat.

Adjusting the driver's weight

NOTE

To achieve optimal seat cushioning thedriver’s seat must be set to the driver’sweight. Set the driver's weight when the seat isoccupied.

Procedure• Fold out the weight adjustment lever

(101) as far as it will go in the arrowdirection

• Move the weight adjustment lever (101)up and down to set the seat to a higher weight.

• Move the weight adjustment lever (101) up and down to set the seat to a lowerweight.

Z The driver's weight is correct when the arrow is in the middle of the display window(103). The minimum or maximum weight setting is reached when you can feel areturn stroke on the lever.

• After setting the weight, move the lever (101) back in full.

The driver’s weight is now set.

Adjusting the backrest

Procedure• Sit on the driver’s seat.• Pull the lever (100) to adjust the backrest.• Adjust the backrest tilt.• Release the lever (100) again. The backrest is locked.

The backrest is now set.

101

100102

103

99 104

o

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72

Adjusting the seat position

CAUTION!

An unsecured driver's seat can cause injuryAn unsecured driver's seat can slide out of its guide during travel, resulting inaccidents.

The driver's seat must be locked in position.Do not adjust the driver’s seat while travelling.

Procedure• Sit on the driver’s seat.• Pull up the driver’s seat locking lever102 in the direction of the arrow.• Push the driver’s seat forwards or backwards to the desired position• Engage the driver’s seat locking lever (102) in position.

The seat position is now correctly set.

Switching the seat heating on and off

Procedure• Press the seat heating switch (99).

Switch setting 1 = Seat heating on.Switch setting 0 = Seat heating off.

Adjusting the lumbar vertebrae support

Procedure• Turn the hand wheel (104) to the required position.

Position 0 = no warping in lumbar vertebrae area.Position 1 = increasing warping in upper lumbar vertebrae area.Position 2 = increasing warping in lower lumbar vertebrae area.

The lumbar vertebrae support is now set.

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N3.3.3 Adjusting the steering column

Adjusting the steering column

Procedure• Release the steering column stop (65).• Position the steering head (105).• Fix the steering column stop (65) in

position.

The steering column is now positioned.

3.3.4 Adjusting the armrest

Adjusting the armrest

Procedure• Raise the armrest lock (71).• Set the armrest (106) to the required

position (longitudinal direction).• Release the armrest lock (71).

The armrest is now set.

65

105

71

106

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74

3.3.5 Seat belt (o)

NOTE

Seat belt optional equipmentOn request from the customer, the truck can be fitted with a seat belt for specialapplications.

Always put on the seat belt before starting the industrial truck.Do not modify the seat belt.Damaged or non-operational seat belts must be replaced by trained personnel.Seat belts must always be replaced after an accident.Only original spare parts must be used for retrofits or repairs.

Z Protect the seat belt from contamination (e.g. cover it when the truck is idle) andclean it regularly. Frozen belt locks or pulleys must be thawed out and dried toprevent them from freezing up again.The temperature of the warm air should not exceed +60 °C!

Putting on the seat belt

Procedure• Adjust the seat belt height (107) to suit

your body size.• Sit on the driver's seat so that your back

is resting against the backrest.• Pull the seat belt smoothly out of the

retractor.• Place the seat belt tight against your

body. Take care not to twist it.• Engage the latch (108) in the lock (109).

The seat belt is now in place

Taking off the seat belt

Procedure• Hold onto the lock tongue (108) with one hand.• Press the red button on the lock (109).• Guide the lock tongue (108) manually back into the reel.

The seat belt is now removed.

108

109

107

o

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NStarting the industrial truck on steep slopes

The automatic blocking system locks the belt in the retractor when the truck ispositioned on a steep slope. This prevents the belt from being pulled out of theretractor.

Z Carefully drive the truck off the slope and then put on the belt.

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4 Starting up the truck

4.1 Safety regulations for truck operationTravel routes and work areas

Only use lanes and routes specifically designated for truck traffic. Unauthorised thirdparties must stay away from work areas. Loads must only be stored in placesspecially designated for this purpose.The truck must only be operated in work areas with sufficient lighting to avoid dangerto personnel and materials. Additional equipment is necessary to operate the truck inareas of insufficient lighting.

DANGER!

Do not exceed the permissible surface and point loading on the travel lanes.At blind spots get a second person to assist.The driver must ensure that the loading dock /dock leveller cannot be removed orcome loose during loading/unloading.

Travel conduct

The operator must adapt the travel speed to local conditions. The truck must bedriven at slow speed when negotiating bends or narrow passageways, when passingthrough swing doors and at blind spots. The operator must always observe anadequate braking distance between the forklift truck and the vehicle in front and mustbe in control of the truck at all times. Abrupt stopping (except in emergencies), rapidU turns and overtaking at dangerous or blind spots are not permitted. Do not lean outor reach beyond the working and operating area.

Travel visibility

The operator must look in the direction of travel and must always have a clear viewof the route ahead. If the truck is carrying loads that affect visibility, the truck musttravel against the load direction. If this is not possible, a second person must walkalongside the truck as a lookout to observe the travel route while maintaining eyecontact with the operator. Proceed only at walking pace and with particular care. Stopthe truck as soon as you lose eye contact.

DANGER!

Tipovers can result in fatal accidentsIf the truck is in danger of tipping over, incorrect operator action can result in seriousinjury and death.

Do not jump off the truck if it tips over.Lean your upper body over the steering wheel and hold on with both hands.Tilt your body in the opposite direction of fall.Do not remove the seat belt (o).

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Negotiating slopes and inclines

Negotiating slopes and inclines up to 15 % is only permitted when they arerecognised lanes. The slopes and inclines must be clean, have a non-slip surface,and negotiating them safely must be within the technical specifications of the truck.The truck must always be driven with the load facing uphill. The industrial truck mustnot be turned, operated at an angle or parked on inclines or slopes. Inclines must onlybe negotiated at slow speed, with the driver ready to brake at any moment.

Negotiating lifts, loading ramps and docks

Lifts may only be negotiated if they have sufficient capacity, are suitable for driving onand authorised for truck traffic by the owner. The driver must satisfy himself of theabove before entering these areas. The truck must enter lifts with the load in front andmust take up a position which does not allow it to come into contact with the walls ofthe lift shaft. Persons riding in the lift with the forklift truck must only enter the lift afterthe truck has come to a rest and must leave the lift before the truck. The driver mustensure that the loading ramp / dock cannot move or come loose during loading /unloading.

Type of loads to be carried

The operator must make sure that the load is in a satisfactory condition. Loads mustalways be positioned safely and carefully. Use suitable precautions to prevent partsof the load from tipping or falling down.

Work platforms

WARNING!

The use of working platforms is governed by national law. In some states the use ofworking platforms is prohibited on industrial trucks. Observe the applicable law.Working platforms can only be used in the country of application if the law permits it.

Contact the national authorities before using a working platform.

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4.2 Preparing the truck for operation

Z The truck carries out a self-test when itis switched on. Do not activate anycontrols, such as the deadman button,during the self-test.

Switching on the truck

Requirements– For checks and operations to be

performed before starting dailyoperation, see "Checks and Operationsto Be Performed Before Starting DailyWork" on page 66.

Procedure• Pull the Emergency Disconnect (62) to

switch it on.• Switch on the truck, to do this

• Insert the key in the key switch (11) and turn it as far to the right as it will go, or• Enter the code in the code lock (o). Start PIN 2580 or• Hold the card or transponder in front of the ISM access module and depending

on the setting press the green button on the ISM access module (o).• Test the steering.• Test the brakes (15).• Test the warning signal button.• Test the deadman switch (14).• Test the accelerator pedal (16).• Test lifting operations.

The truck is operational

161514

11 62

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Setting the time (78)

Procedure• Press the Shift key (95) for 8 secs. until the "Set Clock Time" menu is displayed.• Set the time with the Up (92) and Down (93) keys.• Confirm with the Shift key (95).• Set the minutes with the Up (92) and Down (93) keys.• Confirm with the Shift (95) or profile (96) keys to return to normal operating mode.

The time is now set.

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4.3 Emergency DisconnectPress the Emergency Disconnect switch

Procedure• Press the Emergency Disconnect (62).

All electrical functions are deactivated. The truck brakes to a halt.

4.4 Emergency stopThe truck is fitted with an emergency stop device. If a system fault is detected, thetruck automatically brakes until it comes to a halt. If a fault is detected in the steeringor brake systems, an information message will appear on the display and controlunit (12), see "Displays and Controls" on page 59.

Re-setting the emergency stop

Procedure• Press the Emergency Disconnect (62).• Pull the Emergency Disconnect (62) to unlock it.

The emergency stop is reset.

Z If the emergency stop is shown on the control and display unit (12) after repeatedlyresetting the emergency stop, notify the manufacturer’s service department.

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DANGER!

Tipovers can result in fatal accidentsIf the truck is in danger of tipping over, incorrect operator action can result in seriousinjury and death.

Do not jump off the truck if it tips over.Lean your upper body over the steering wheel and hold on with both hands.Tilt your body in the opposite direction of fall.Do not remove the seat belt (o).

WARNING!

Improper travel can result in accidents Do not get up from the driver’s seat during travel.Make sure that the travel area is clear.Adapt the travel speed to the conditions of the route, the work area and the load.Tilt the mast back and raise the fork carriage approx. 200 mm.Make sure you have enough visibility when reversing.

CAUTION!

Loss of stability can cause accidents Extended mast sections when the truck is travelling with or without load will reducethe truck's stability.

Always travel with the mast holder retracted, the mast tilted back and the loadhandler lowered.

Z Each time the truck is started the operation of the emergency stop safety switch istested. The fault display is shown on the display unit for the duration of the safetycheck. Travel and steering are only enabled if the condition is satisfactory.

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Travel

Requirements– Truck prepared for operation, see "Preparing the truck for operation" on page 78.

Procedure• Release the parking brake. To do this press the brake button (93).• Select the travel direction (R). To do this push the direction button (110) in the

direction of the arrow.Z Keep pressing the travel switch to change direction.

• Apply the deadman switch (14) and the accelerator pedal (16) simultaneously.Z The deadman button (14) ensures that the driver's feet do not extend beyond the

geometry of the truck during travel. If it is not pressed, travel and lifting functionsare inhibited with the exception of steering, the control and display unit and thehorn. The truck coasts according to the coasting brake parameter setting and aftera short time comes to a halt via the drive brake.

Z The travel speed is governed by the accelerator (16).The truck travels in the direction selected.

1615

110

14

93

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The truck’s brake pattern depends largely on the ground conditions. The driver musttake this into consideration when handling the truck.

The truck can brake in three different ways:– With the service brake– With the coasting brake– With the reversing brake

WARNING!

Individual parameter settings can cause accidentsIf the truck is operated by several drivers (e.g. multi-shift operation) and theparameters are individually set, be aware of the different brake and travel patterns.

Test the truck's response on start-up.

WARNING!

Accident riskThe brake pattern of the truck depends largely on the ground conditions.

The driver must be aware of travel route conditions and them into account whenbraking.Brake with care to prevent the load from slipping.Allow for increased braking distance when travelling with an attached load.Use the service brake in emergencies.

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4.6.1 Braking with the reversing brake

Braking with the reversing brake

Procedure• Set the travel direction switch (110) to the opposite direction while travelling.

The truck decelerates until it starts to travel in the opposite direction.

Z This method reduces energy consumption. Energy is recovered, which is controlledby the traction current controller. The energy recovery is indicated on the controland display unit.

110

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Braking with the coasting brake

Procedure• Take your foot off the accelerator pedal

(16).

The truck decelerates.

4.6.3 Braking with the service brake

Braking with the service brake

Procedure• Depress the brake pedal (15) until you

feel the brake pressure.

The truck decelerates depending on thebrake pedal position.

Z If the brake pedal is applied suddenly just before the truck stops, the drive brakealso applies and is released when the brake pedal is released.

16

15

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4.7 Steering

4