EFG 110-115 10.

09

Operating instructions en-GB

51151449
10.20

EFG 110k
EFG 110
EFG 113
EFG 115
2
 Declaration of Conformity

Manufacturer

Jungheinrich AG, 22039 Hamburg, Germany

Description

Industrial truck

Type Option Serial no. Year of

manufacture
EFG 110k
EFG 110
EFG 113
EFG 115

On behalf of

Date

EU DECLARATION OF CONFORMITY

The undersigned hereby declare that the powered truck described in detail complies
with the current versions of European Directives 2006/42/EG (Machinery Directive)
and 2014/30/EU (Electromagnetic Compatibility - EMC). The manufacturer is
authorised to compile the technical documentation.
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4
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 Foreword
Notes on the operating instructions

The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide

sufficient instruction for the safe operation of the industrial truck. The information is
provided clearly and concisely. The chapters are arranged by letter and the pages
are numbered continuously.

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

Our trucks are subject to ongoing development. We reserve the right to alter the
design, equipment and technical features of the system. No guarantee of particular
features of the truck should therefore be assumed from the present operating
instructions.
Safety notices and text mark-ups

Safety instructions and important explanations are indicated by the following

graphics:

DANGER!
Indicates an extremely hazardous situation. Failure to comply with this instruction will
result in severe irreparable injury and even death.

WARNING!
Indicates an extremely hazardous situation. Failure to comply with this instruction
may result in severe irreparable injury and even death.

CAUTION!
Indicates a hazardous situation. Failure to comply with this instruction may result in
slight to medium injury.
NOTICE
Indicates a material hazard. Failure to comply with this instruction may result in
material damage.

Z Used before notices and explanations.

t Indicates standard equipment

o Indicates optional equipment
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 Copyright

Copyright of these operating instructions remains with JUNGHEINRICH AG.

Jungheinrich Aktiengesellschaft

Friedrich-Ebert-Damm 129
22047 Hamburg - Germany

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

www.jungheinrich.com

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 Contents
.
A Correct Use and Application 11
.
1 General 11
2 Correct application 11
3 Approved application conditions 13
3.1 Internal Operation in Cold Stores with Cold Store Equipment (o) 13
4 Proprietor responsibilities 14
5 Adding attachments and/or optional equipment 14
6 Removal of components 14
.
B Truck Description 15
.
1 Application 15
1.1 Truck models and rated capacity 15
2 Assemblies and Functional Description 16
2.1 Travel direction definition 16
2.2 Assembly Overview 17
2.3 Functional Description 18
3 Technical Specifications 20
3.1 Performance data 21
3.2 Dimensions 22
3.3 Weights 24
3.4 Mast versions 24
3.5 Tyre type 25
3.6 Engine Data 26
3.7 EN norms 27
3.8 Conditions of use 28
3.9 Electrical Requirements 28
3.10 Specifications according to RED guideline (Radio Equipment
Directive) for radio units 29
4 Identification points and data plates 30
4.1 Indication Points 30
4.2 Data plate 32
4.3 Truck capacity plate 33
4.4 Attachment capacity plate 35
5 Stability 36
5.1 Wind loads 37
.
C Transport and Commissioning 39
.
1 Transport 39
2 Truck laden 39
2.1 Centre of gravity of the truck 39
2.2 Lifting the truck by crane 40
2.3 Loading with another industrial truck 42
3 Securing the truck during transport 43
4 Using the Truck for the First Time 45
.
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D Battery - Servicing, Recharging, Replacement 47

.
1 General notes on handling batteries 47

7
1.1 Potential hazards 47
1.2 Touch voltage hazard 48
2 Safety Regulations for Handling Lead-Acid Batteries 49
3 Battery types 50
4 Battery dimensions 50
5 Exposing the battery 51
6 Battery removal and installation 53
7 Charging the battery 55
7.1 Charging the battery with a stationary charger 55
8 Closing the battery cover 57
.
E Operation 59
.
1 Safety Regulations for the Operation of Forklift Trucks 59
2 Displays and Controls 61
2.1 Control panel with display unit 66
2.2 Side compartment control panel switch (o) 68
2.3 Instrument panel switches (o) 68
2.4 Display 69
3 Preparing the Truck for Operation 71
3.1 Checks and operations to be performed before starting daily operation 71
3.2 Entry and exit 74
3.3 Trucks with reduced headroom (o) 74
3.4 Setting up the operator position 75
3.5 Restraint systems 80
3.6 Seat Belt 81
4 Industrial Truck Operation 83
4.1 Safety regulations for truck operation 83
4.2 Preparing the truck for operation 86
4.3 Setting the time 87
4.4 Parking the truck securely 88
4.5 Emergency Disconnect 89
4.6 Travel 90
4.7 Steering 92
4.8 Brakes 93
4.9 Adjusting the forks 96
4.10 Replacing the forks 97
4.11 Lifting, transporting and depositing loads 98
4.12 Operating the lift mechanism and integrated attachments 101
4.13 Safety instructions for operating additional attachments 108
4.14 Operating additional attachments for the SOLO-PILOT 113
4.15 Operating additional attachments for the Multi Pilot 115
4.16 Fitting additional attachments 116
5 Towing trailers 119
6 Optional Equipment 121
6.1 Assistance systems 121
6.2 BODYGUARD 123
6.3 Panel door 123
6.4 Removable load backrest 124
6.5 Lift cutout override 126
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6.6 Fire extinguisher 126

6.7 Tilt angle display 127
6.8 Rockinger coupling with hand lever or remote control 127

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 6.9 Camera system 128
6.10 Control layout “N” 129
6.11 Floor-Spot 130
7 Troubleshooting 132
7.1 Troubleshooting 132
7.2 Operating the truck without its own drive system 134
7.3 Emergency lowering 135
.
F Industrial Truck Maintenance 137
.
1 Spare Parts 137
2 Operational Safety and Environmental Protection 138
3 Maintenance Safety Regulations 139
3.1 Consumables and used parts 140
3.2 Wheels 140
3.3 Attachment Repairs and Inspection 140
3.4 Lift Chains 141
3.5 Hydraulic system 142
4 Lubricants and Lubrication Schedule 143
4.1 Handling consumables safely 143
4.2 Lubrication Schedule 145
4.3 Consumables 146
5 Maintenance and repairs 148
5.1 Preparing the truck for maintenance and repairs 148
5.2 Lifting and jacking up the truck safely 149
5.3 Opening the battery panel 150
5.4 Checking the wheel attachments. 152
5.5 Replacing wheels 153
5.6 Hydraulic system 155
5.7 Check the gear oil level 157
5.8 Adding window washer system fluid 158
5.9 Checking electrical fuses 159
5.10 Cleaning 162
5.11 Working on the electrical system 165
5.12 Restoring the truck to service after maintenance and repairs 166
6 Decommissioning the industrial truck 167
6.1 Prior to decommissioning 168
6.2 During decommissioning 168
6.3 Restoring the truck to service after decommissioning 169
7 Safety tests to be performed at intervals and after unusual incidents 170
8 Final de-commissioning, disposal 171
9 Human vibration measurement 171
.
G Maintenance, Inspection and Changing of Maintenance
Parts Requiring Replacement 173
.
1 Maintenance Contents EFG 110-115 174
1.1 Owner 174
1.2 Customer Service 178
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10
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 A Correct Use and Application
1 General
The truck must be used, operated and serviced in accordance with the present
instructions. All other types of use are beyond its scope of application and may result
in damage to personnel, the industrial truck or property.

2 Correct application
NOTICE
The maximum load and load distance are indicated on the capacity plate and must
not be exceeded.
The load must rest on the load handler or be lifted by an attachment approved by the
manufacturer.
The load must be fully raised,see page 98.
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 The following operations are in accordance with regulations and are permitted:
– Lifting and lowering of loads.
– Stacking and retrieving loads
– Transporting lowered loads over short distances.
– The mast must be tilted back when transporting loads that are not secured
against slipping and falling.
– Picking up and using attachments and accessories approved by the manufacturer;
this may require additional approval from local authorities or an expert opinion.
– When travelling with a load, bring the mast into tilted-back position.
– The mast must be tilted back when transporting loads that are not secured against
slipping and falling.
– The operator must adjust the travel speed so that the load does not slip off the
load handler during acceleration and braking, changes in direction and when
driving on ramps.
– Occasional towing of trailer loads with the trailer coupling.

Z When towing trailers, the load must be secured on the trailer. The permissible trailer
load must not be exceeded.

The following operations are prohibited:

– Do not travel with a raised load (>30 cm).
– Carrying and lifting persons without approved attachments or optional equipment
a)

– Pushing or pulling loads, with the exception of occasional towing of trailers with
the trailer coupling
– Transporting suspended loads without expert certification and without authorised
optional equipment

Z If the truck is to be operated with suspended loads, proof of sufficient operational

stability under local operating conditions must be obtained from a specialist
assessor.

a) Lifting passengers with a working platform or a work basket may be

permitted in some countries. This must be verified by the owner.

Z Germany: DGUV information 208-031 (BGI/GUV-5183) Use of Working Platforms on

Industrial Trucks with Masts

Z Australia: AS 2359.1 Powered Industrial Trucks, General Requirements; AS 2359.2

Powered Industrial Trucks, Operations
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 3 Approved application conditions

WARNING!
Do not exceed the permissible surface and point loading limits on the travel paths.
A second person is required as a lookout at blind spots.
The operator must ensure that the loading ramp/dock cannot move or come loose
during loading/unloading.

WARNING!
Use under extreme conditions
Using the truck under extreme conditions can result in malfunctions and accidents.
uSpecial equipment and authorisation are required if the truck is to be constantly
used in extreme conditions, especially in dusty or corrosive atmospheres.
uThe truck cannot be used in areas at risk of explosion.
uIn adverse weather conditions (thunder, lightning) the industrial truck must not be
operated outside or in endangered areas.

– Operation in industrial and commercial environments.

– Permissible temperature range -20°C to 40°C.
– Operation only on secure, level surfaces with sufficient capacity.
– Do not exceed the permissible surface and point load limits on the travel routes.
– Operation only on travel paths 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.

3.1 Internal Operation in Cold Stores with Cold Store Equipment (o)
In addition to the permissible operating conditions in industrial and commercial
environments, the truck remains primarily in cold stores. The truck should only leave
the cold store briefly to hand over a load.
– Permissible temperature range -30°C to +40°C.
– Maximum air humidity 95% non-condensing.
– Thawing is permissible only if the truck can be subsequently dried thoroughly.
– In cold store areas below -20°C the truck must be operated permanently and
should not be parked securely for more than 15 minutes.
– Do not charge the battery below +5°C.
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4 Proprietor responsibilities
For the purposes of the present operating instructions the “operating company” is
defined as any natural or legal person who either uses the industrial truck himself, or
on whose behalf it is used. In special cases (e.g. leasing or renting) the proprietor is
considered the person who, in accordance with existing contractual agreements
between the owner and user of the industrial truck, is charged with operational
duties.
The proprietor must ensure that the industrial truck is used only for the purpose it is
intended for and that danger to life and limb of the user and third parties are
excluded. Furthermore, accident prevention regulations, safety regulations and
operating, servicing and repair guidelines must be followed. The operating company
must ensure that all users have read and understood these operating instructions.

NOTICE
Failure to comply with the operating instructions invalidates the warranty. The same
applies if improper work is carried out on the truck by the customer or third parties
without the permission of the manufacturer.

5 Adding attachments and/or optional equipment

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

6 Removal of components
It is forbidden to modify or remove truck components, particularly protective and
safety equipment.

Z If in doubt, contact the manufacturer's customer service department.

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 B Truck Description
1 Application
The EFG 110 - 115 is a three-wheel electric sit-down forklift truck. It is a cantilever
counterbalanced truck which can lift, transport and deposit loads using the load
handler attached in front.
Closed bottom pallets can also be lifted.

1.1 Truck models and rated capacity

The rated capacity depends on the model. The rated capacity can be derived from
the model name.
EFG110
EFG Model name
1 Series
10 Rated capacity x 100 kg

The rated capacity is not generally the same as the permissible capacity. The
capacity can be found on the capacity plate attached to the truck.
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2 Assemblies and Functional Description

2.1 Travel direction definition

The following determinations have been made for travel direction specification:

2 3

The following conventions have been agreed for travel direction specification:

Item Travel direction

1 Left
4 Reverse
2 Forward
3 Right

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 2.2 Assembly Overview

1 2
3

10

13 12 11

Item Component
1 t Driver's seat
2 t Overhead guard
3 t Mast
4 t Steering wheel
5 t Control and display unit
6 t Lifting mechanism control
7 t Emergency Disconnect switch
8 t Forks
9 t Fork carriage
10 t Battery cover
11 t Drive
12 t Trailer coupling
13 t Counterweight
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t Standard equipment

17
2.3 Functional Description

Chassis

The chassis, in conjunction with the counterweight, forms the supporting base
structure of the truck. It is used to support the main components.
Operator position and overhead guard

The overhead guard comes in a range of models and protects the operator from
falling objects and other external
influences. All the controls are ergonomically arranged. The steering column and
driver's seat can be adjusted individually.

The controls and warnings on the control and display unit enable the system to be
monitored during operation, thereby ensuring a very high level of safety.
Steering

A low steer effort of 15 N as well as a favourable transmission ratio of 5 steering

wheel revolutions for an 180° steer angle. A hydraulic steer motor actuates the drive
wheel via a gear wheel pair. Efficient energy deployment through the load sensing
system. The steering column is adjustable.
Wheels

There is a choice of super elastic or fully rubber tyres as well as optional pneumatic
tyres.
Brake System

The hydraulically activated drum servo brake acting on both front wheels provides
effective deceleration with minimal pedal force. The truck also brakes to a halt
regeneratively via the traction motor. This makes the foot brake virtually redundant,
minimising energy consumption and brake wear.

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 Drive system

The entire drive unit is enclosed in the counterweight. The steered rear wheel is also
the drive wheel. A fixed, low-noise three-phase motor is driven via a transmission.
The electronic traction controller ensures the smooth rotation of the drive motor and
as a result consistently smooth travel, powerful acceleration and electrically
controlled braking with energy recovery. With steer angle detection (o) the system
automatically reduces the travel speed as a function of the steer angle.
Hydraulic system

A multi-pilot valve allows for sensitive operation of the functions via the controls. A
speed-controlled hydraulic pump ensures a proportionate and efficient supply to the
hydraulic functions.
Mast

Two or three-stage masts, optionally with free lift function; narrow mast sections
ensure excellent visibility of the forks and attachments. Fork carriage and mast run
on permanently lubricated and hence maintenance-free support rollers.
Attachments

The trucks can be optionally fitted with mechanical and hydraulic attachments.
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3 Technical Specifications
All technical details refer to standard trucks.
Values indicated with *) may vary, depending on the
types of equipment used (e.g. mast, cabin, tyres etc.).

Z The technical specifications comply with the German "Industrial Truck Data Sheet"
Guidelines.
Technical modifications and additions reserved.

Load centre distance

G G

D d1
d2 d2

D D

The load centre distance D of the load handler is specified as the horizontal distance
from the front face and the vertical distance from the upper edge of the load handler.

Z The capacity plate for standard load handlers specifies valid load centre distances of
500 mm, 600 mm and 700 mm.

The distances d1 and d2 depicted in the illustration between the load handler and the
actual centre of gravity G of the load must be smaller or equal to the load centre
distance D (d1 ≤ D and d2 ≤ D) to avoid the risk of overturning, see page 98.

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 3.1 Performance data
Model EFG 110k EFG 110 EFG 113 EFG 115
Q Rated capacity
(where 1000 1000 1250 1500 kg
C = 500 mm)1)
C Load centre distance 500 500 500 500 mm
Travel speed, w. /
12/12.5 12/12.5 12/12.5 12/12.5 km/h
w.o. load *)
Lift speed, with /
0.28/0.50 0.29/0.50 0.25/0.50 0.24/0.50 m/s
without load *)
Lowering speed
0.58/0.60 0.58/0.60 0.58/0.60 0.58/0.60 m/s
with / without load *)
Gradeability
(30 min) 8.5/12 8/11.5 7/11 6.5/10.5 %
w. / w.o. load *)
Max. gradeability
(5 mins) 13/18 12.5/17.5 11/16.5 10/16 %
w / w.o. load *)
Acceleration
(10 min) 5.1/4.6 5.1/4.6 5.4/4.7 5.6/4.8 s
w / w.o. load *)
Max. operating
160 160 185 210 bar
pressure
Oil flow for
14 14 14 14 l/min
attachments
1) for vertical mast.
2) The values shown represent the maximum gradeability to overcome short
differences in height and surface unevenness (surface edges). The truck must not
operate on inclines of more than 15%.
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3.2 Dimensions
Description EFG 110k EFG 110 EFG 113 EFG 115
a/2 Safety distance 100 100 100 100 mm
h1 Mast height retracted *) 2000 2000 2000 2000 mm
h2 Free lift *) 150 150 150 150 mm
h3 Lift *) 3000 3000 3000 3000 mm
h4 Mast height extended *) 3550 3550 3550 3550 mm
Overhead guard height
h6 2090 2090 2090 2090 mm
*)
h7 Seat height *) 900 900 900 900 mm
h10 Coupling height 635 635 635 635 mm
α Mast tilt, fwd. 5 5 5 5 °
β Mast tilt, back 6 6 6 6 °
L1 Length including forks *) 2719 2773 2881 2935 mm
L2 Headlength*) 1569 1623 1731 1785 mm
b Overall width *) 990 990 990 990 mm
e Fork width *) 100 100 100 100 mm
Ground clearance with
m1 90 90 90 90 mm
load below mast
Ground clearance centre
m2 100 100 100 100 mm
wheelbase
Aisle width
Ast for pallets 800 x 1200 3020 3074 3182 3236 mm
longit.
Aisle width
Ast for pallets 1200 x 1000 2898 2952 3060 3114 mm
longit.
Wa Turning radius 1239 1293 1401 1455 mm
x Load distance *) 330 330 330 330 mm
y Wheelbase 984 1038 1146 1200 mm
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 10.20 en-GB

h4
b h3
h1
h2

2
a
e
Q
c

x
m1

Ast
L1
m2
L2
y

W
a
h10 h7 H1

2
a
h6

23
3.3 Weights

Z All dimensions in kg.

Model EFG 110k EFG 110 EFG 113 EFG 115

Net weight *)
2490 2570 2760 2870
(including battery)
Front axle load (without lifting
1095 1145 1235 1270
load) *)
Front axle load (with lifting load)
2940 2945 3390 3805
*)
Rear axle load (without lifting
1395 1425 1525 1600
load) *)
Rear axle load (with lifting load)
550 625 620 565
*)

3.4 Mast versions

Z All dimensions in mm.

Mast table EFG 110k/110/113/115

VDI 3596 Lift Free lift Retracted height Extended height
Designation h3 h2 h1 h4
ZT 2300 150 1650 2850
3000 150 2000 3550
3100 150 2050 3650
3300 150 2150 3850
3600 150 2300 4150
4000 150 2500 4550
4500 150 2800 5050
5000 150 3050 5550
2300 1055 1605 2850
3000 1405 1955 3550
3100 1455 2005 3650
ZZ
3300 1555 2105 3850
3600 1705 2255 4150
4000 1905 2455 4550
4350 1405 1955 4900
4500 1455 2005 5050
4800 1555 2105 5350
DZ
5000 1630 2180 5550
5250 1705 2255 5800
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5500 1805 2355 6050

Special trucks are not included in this overview.

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 3.5 Tyre type
WARNING!
The use of tyres that do not match the manufacturer's specifications can result
in accidents.
The quality of tyres affects the stability and performance of the truck.
Uneven wear affects the truck's stability and increases the stopping distance.
uWhen replacing tyres make sure the truck is not skewed.
uAlways replace tyres in pairs, i.e. left and right at the same time.

Z When replacing rims and tyres fitted at the factory, only use the manufacturer’s
original spare parts. Otherwise the manufacturer’s specifications cannot be ensured.
If you have any queries contact the manufacturer's customer service department.

Description EFG 110 EFG 113 EFG 115

SE *) 18 x 7-8
Full rubber*) 18 x 6 x 12 1/8“
Front tyres Pneumatic*) 180 / 70-8; Diagonal, 16PR;
Tyre pressure bar 10
Torque (Nm) 170
SE*) 18 x 7-8
Full rubber*) 18 x 6 x 12 1/8"
Rear tyres Pneumatic*) 180 / 70-8; Diagonal, 16PR;
Tyre pressure bar 10
Torque (Nm) 170

*) The models listed in the table correspond to the standard version. Other tyres can
be used depending on the truck's equipment.
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3.6 Engine Data
Designation EFG110-115
Drive motor 4 kW
Lift motor 6 kW

Designation EFG 110k EFG 110 EFG 113 EFG 115

Energy consumption 2.6 kWh/h 2.7 kWh/h
according to EN cycle
CO2 equivalent 1.40 kg/h 1.46 kg/h
according to EN 16796
Throughput performance 60 t/h 76 t/h 93 t/h
Energy consumption at 3.2 kWh/h 3.3 kWh/h 3.5 kWh/h 3.7 kWh/h
max. throughput
performance

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 3.7 EN norms
Noise emission level

– EFG 110-115: 63 dB(A)

*+/- 3 dB(A) depending on the truck's equipment

in accordance with 12053 as harmonised with ISO 4871.

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

Vibration
– EFG 110-115: 0,62m/s²
in accordance with EN 13059.

Z The vibration acceleration acting on the body in its operating position is the linearly
integrated, weighted acceleration in the vertical axis according to the standard. It is
calculated when travelling over thresholds at constant speed (standard truck
version). These recordings were taken on a single occasion for the truck and must
not be confused with the human vibrations of the operator directive. The
manufacturer offers a special service to measure these human vibrations, see
page 171.

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

Electromagnetic compatibility (EMC)

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

Z No changes to electric or electronic components or their arrangement may be made

without the written agreement of the manufacturer.

WARNING!
Medical equipment can be damaged by non-ionised radiation
Electrical equipment on the truck emitting non-ionised radiation (e.g. wireless data
transmission) can affect operators' medical equipment (pacemakers, hearing aids
etc.) and result in malfunctions. Consult a doctor or the manufacturer of the medical
equipment to clarify whether it can be used near the industrial truck.
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3.8 Conditions of use

Ambient temperature

– operating at -20°C to 40°C

Z Special equipment and authorisation are required if the truck is to be used

continually in conditions of extreme temperature or condensing air humidity
fluctuations.

3.9 Electrical Requirements

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

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 3.10 Specifications according to RED guideline (Radio Equipment
Directive) for radio units

Z The table contains any components installed according to the European Directive
2014/53/EU. The table shows the affected frequency range and the emitted
transmission power for each component.

Component Frequency range Transmission power

Radio module (ISM Online) 433.05 - 434.79 MHz < 10 mW
Access module (ISM Online) 13.56 MHz < 100 mW
EasyAccess StandAlone 13.56 MHz < 100 mW
Transponder reader (EasyKey) 2.4 GHz ≤ 67,6 mW
Transponder reader (EasyKey) 5.8 GHz ≤ 66,1 mW
Indoor/outdoor detection 24.00 - 24.25 GHz 100 mW
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4 Identification points and data plates

4.1 Indication Points

Z Warnings and notices such as capacity charts, strap points and data plates must be
legible at all times. Replace if necessary.

14 15 16 17 18 19
(mm) Q (kg)

D (mm)

20

21

22

23

24

25

26
28 27
18

Item Description
14 Capacity (or reduced capacity)
15 Wear seat belt
16 Do not travel with a raised load or operate the mast forward tilt with a
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raised load
17 Tipover warning

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 Item Description
18 Attachment points for loading by crane
19 Do not step onto or beneath the load: risk of trapping with moving mast
20 Serial number, on chassis below the battery panel
21 Warning: optical radiation (Floor-Spot)
22 Max. body size
23 Inspection plaque (o)
24 Data plate
25 Jacking points
26 Model description
27 Do not carry passengers
28 Observe the operating instructions
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4.2 Data plate

Z The illustration shows the standard version for EU member states. The data plate
may differ in other countries.

33 34 29 30 31 32

35

36

37

38

39
40

41

Item Model Item Model

29 Rated capacity (kg) 36 Load centre distance (mm)
30 Battery voltage (V) 37 Drive output
31 Net weight w.o. battery (kg) 38 Min./max. battery weight (kg)
32 Option 39 Manufacturer
33 Model 40 QR code
34 Serial number 41 Manufacturer's logo
35 Year of manufacture

Z For queries regarding the truck or when ordering spare parts, always quote the truck
serial number (34).

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 4.3 Truck capacity plate
CAUTION!
Accident risk from fork replacement
If you replace the forks with ones that differ from the originals, the capacity will
change.
uWhen replacing the forks you must attach an additional capacity plate to the truck.
uTrucks supplied without forks are given a capacity plate for standard forks (length:
1150 mm).

The capacity plate (14) gives the capacity Q (in kg) of the truck for a vertical mast. A
table indicates the maximum capacity with a given load centre distance D (in mm)
and the required lift height h3 (in mm).

42 43

14

The truck capacity plate specifies the type and serial number of the truck and
indicates the capacity with the fork arms (t) (42) or the fork extensions (o) (43) in
as-delivered condition.

Capacity plate version in accordance with Australian guidelines (44)

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 44

Example of how to calculate the maximum capacity

With a load centre distance (D) of 600 mm and a maximum lift height of (h3) 3600
mm the max. capacity (Q) is 1105 kg.
Lift height limits

The arrow shaped markings (45 and 46) on the inner and outer masts show the
operator when the prescribed lift limits have been reached.

45 46

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 4.4 Attachment capacity plate
The attachment capacity plate is next to the truck capacity plate and gives the truck
capacity Q (in kg) in conjunction with the attachment and the specified fork arms (t)
(47) and where applicable fork extensions (o) (48).

The model name and/or serial number for the attachment indicated on the
attachment capacity plate must match the data plate of the attachment.

47 48

4.4.1 Attachment with More Than 100 mm Side Shift

The capacity plate of the attachment with more than 100 mm possible side shift for a
current working position in the centre position (49) or pushed out offset to max. 100
mm side shift is affixed next to the truck capacity plate.

49
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35
 WARNING!
Risk of accident from offset load centre of gravity
The capacity of the truck is reduced when using side shifts that are more than 100
mm outside the truck centre.
uNote the capacity plate with the reduced capacity.

The capacity plate of the attachment with more than 100 mm possible side shift for a
current clear offset working position with 100 mm side shift pushed out (50) is affixed
separately to the other capacity plates.

50

5 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 used
correctly.
Stability can also be affected by the following factors:
– Tyre type
– Mast
– Attachment
– Transported load (size, weight and centre of gravity)

WARNING!
Loss of stability can cause accidents
Changing the components can alter the stability.
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36
 5.1 Wind loads
Wind forces can affect the stability of a truck when lifting, lowering and transporting
loads with large surface areas.
Light loads must be especially secured when they are subjected to wind forces. This
will prevent the load from sliding or falling.

Stop the truck in both cases.

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37
38
10.20 en-GB
 C Transport and Commissioning
1 Transport
Transport can be carried out in two different ways, depending on the height of the
mast and the local conditions.

– Vertically, with the mast assembled (for low heights)

– Vertically, with the mast dismantled (for large heights), all mechanical connections
and hydraulic lines between the basic truck and the mast separated.

2 Truck laden

2.1 Centre of gravity of the truck

WARNING!
An altered centre of gravity can result in tipovers when cornering.
The overall centre of gravity can vary depending on the truck's equipment (especially
the mast version).
For trucks without a mast the centre of gravity will move significantly in the direction
of the counterweight.
uDrive carefully and with modified speed to avoid tipping over.

The picture shows the approximate centre of gravity location.

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39
2.2 Lifting the truck by crane
WARNING!
All persons involved in loading by crane must be trained
Incorrect crane loading procedures due to untrained personnel can cause the truck
to fall. There is a risk of injury to personnel and a risk of material damage to the
truck.
uLoading must only be performed by specialist personnel trained for this purpose.
The specialist personnel must be instructed in securing loads on road vehicles and
handling load securing devices. In each case correct measurements must be
taken and appropriate safety measures applied.

DANGER!
Crane slings can tear, resulting in accidents
uOnly use crane lifting gear with sufficient capacity.
uLoading weight = Net weight of truck (+ battery weight for electric trucks).
uThe mast must be tilted back fully.
uThe crane lifting gear on the mast must have a minimum clear length of 2 m.
uCrane slings should be fastened in such a way that they do not come into contact
with any attachments or the overhead guard when lifting.
uDo not stand under a swaying load.
uThe truck should only be handled by people who are trained in using lifting slings
and tools.
uWear safety shoes when lifting the truck by crane.
uDo not walk into or stand in a hazardous area.
uAlways attach the crane lifting gear to the prescribed strap points and prevent
them from slipping.

Z Truck net weight: see page 32.

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40
 Lifting the truck by crane 51

Requirements
– Park the truck securely, see page 88.
52
Procedure
• Secure the crane slings to the attachment
points (51) and (52.
• Raise and load the truck.
• Lower and deposit the truck carefully (see
page 88).
• Secure the truck with wedges to prevent it
from rolling away.

This concludes the loading by crane.

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2.3 Loading with another industrial truck
WARNING!
The truck can be damaged
The truck to be loaded can be damaged when loading with another industrial truck.
uOnly trained specialist personnel should load the truck.
uUse only trucks with sufficient capacity for loading.
uOnly for loading and unloading.
uThe forks of the second industrial truck must be sufficiently long
uTransporting over long distances prohibited.
NOTICE
Pick up the truck only from the left-hand side of the truck. Make sure that the truck is
not picked up from the battery door.
Loading the truck with a second industrial truck

Requirements
– Park the truck securely, see page 88.
Procedure
• Raise the truck with the forks at the side between the axles.
• Raise the truck slightly and make sure it is securely positioned on the forks. If
necessary adjust or secure the forks with stops.
• Carefully load/unload the truck, see page 98.
• Lower the truck slowly onto the ground and prevent it from rolling away.

The truck is now loaded.

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 3 Securing the truck during transport

WARNING!
Accidental movement during transport
Improper fastening of the truck and mast during transport can result in serious
accidents.
uLoading must only be performed by specialist personnel trained for this purpose.
The specialist personnel must be instructed in securing loads on road vehicles and
handling load securing devices. In each case correct measurements must be
taken and appropriate safety measures applied.
uThe truck must be securely fastened when transported on a lorry or a trailer.
uThe lorry or trailer must have fastening rings.
uUse wedges to prevent the truck from moving.
uUse only fastening belts with sufficient strength.
uUse non-slip materials to securing the load aids (pallet, wedges, ...) e. g. non-slip
mats.

Securing with a mast Securing without a mast

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 Securing the industrial truck for
3 transport

Requirements
53
– Position the industrial truck
securely on a lorry or trailer, see
page 88.
54
12 Tools and Material Required
– 2 fastening belts with a tensioner
– Retaining wedges.
Procedure
• Secure the truck with the fastening
belt (53) at the top cross member of
the mast (3) and the trailer
coupling (12) or on the overhead
guard (2) and the trailer coupling
2
(12).
• Tighten the fastening belt (53) with
53 the tensioner (54).

The truck is now secured for

transport.

12

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 4 Using the Truck for the First Time

Safety instructions for assembly and commissioning

WARNING!
Incorrect assembly can result in accidents
The assembly of the truck at the application site, commissioning and operator
training must only be performed by the manufacturer's customer service
representatives who have been specially trained for these tasks.

WARNING!
The use of unsuitable energy sources can be hazardous
Rectified AC current will damage the assemblies (controllers, sensors, motors etc.)
of the electronic system.
Unsuitable cable connections (too long, insufficient wire cross-section) to the battery
(tow cables) can overheat, setting the truck and battery on fire.
uThe truck must only be operated with battery current.
uCable connections to the battery (tow leads) must be less than 6 m long and have
a minimum cross-section of 6 yd² (50 mm²).
Preparing the truck for operation after delivery or transport

Procedure
• Check the equipment is complete.
• Check the hydraulic oil level, see page 156.
• Check the transmission oil level, see page 157.
• Install the battery if necessary, see page 53.
• Charge the battery, see page 71.

The truck can now be started, see page 71.

Z To operate the truck without its own drive system, see page 134.
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46
10.20 en-GB
 D Battery - Servicing, Recharging,
Replacement
1 General notes on handling batteries

Maintenance personnel

Batteries may only be charged, serviced or replaced by trained personnel. These

operating instructions and the manufacturer’s instructions concerning batteries and
charging stations must be observed when carrying out the work.

Park the truck securely before carrying out any work on the batteries (see page 88).
Battery disposal

Batteries may only be disposed of in accordance with national environmental

protection regulations or disposal laws. The manufacturer’s disposal instructions
must be observed.

1.1 Potential hazards

WARNING!
Unsuitable batteries that have not been approved for the truck by the
manufacturer can be hazardous
The design, weight and dimensions of the battery have a considerable effect on the
operational safety of the truck, in particular its stability and capacity. The use of
unsuitable batteries that have not been approved for the truck by the manufacturer
can lead to a deterioration of the braking system during energy recovery operations
and also cause considerable damage to the electrical control system. The use of
batteries that have not been approved by the manufacturer can therefore affect the
health and safety of personnel.
uOnly manufacturer-approved batteries may be used on the truck.
uBattery equipment may only be replaced with the agreement of the manufacturer.
uWhen replacing/installing the battery, make sure the battery is securely located in
the battery compartment of the truck.
uDo not use batteries that have not been approved by the manufacturer.
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1.2 Touch voltage hazard
WARNING!
Hazardous contact voltages only arise in the event of a technical or physical defect.
The batteries are normally charged. There is still some residual voltage in a
discharged battery. This must be considered as a hazardous contact voltage.

With this kind of defect the battery must not be touched and must not come into
contact with metal objects see page 47.

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 2 Safety Regulations for Handling Lead-Acid Batteries

WARNING!
Batteries can be hazardous
Batteries contain an acid solution which is poisonous and corrosive. Avoid contact
with battery acid at all times.
uDispose of used battery acid in accordance with regulations.
uAlways wear protective clothing and goggles when working with batteries.
uDo not let battery acid come into contact with skin, clothing or eyes. If necessary,
rinse with plenty of clean water.
uIn the event of physical damage (e.g. skin or eye contact with battery acid) call for
a doctor immediately.
uSpilled battery acid should be neutralised immediately with plenty of water.
uOnly batteries with a sealed battery container may be used.
uFollow national guidelines and legislation.

Fire protection measures

WARNING!
Short circuits can result in fire
Damaged cables can cause short circuits, setting the forklift truck and battery on fire.
uBefore closing the battery cover make sure that the battery cables are not
damaged.

CAUTION!
The use of unsuitable fire-protection equipment can result in acid burns
In the event of fire, a reaction with the battery acid can occur if water is used to
extinguish the fire. This can lead to acid burns.
uUse powder extinguishers.
uNever extinguish burning batteries with water.

Do not smoke and avoid naked flames when handling batteries. Wherever an
industrial truck is parked for charging, there must be no inflammable material or
consumables capable of creating sparks within a minimum distance of 2,5 m from
the truck. The room must be ventilated. Fire protection equipment must be on hand.
Battery maintenance

The battery cell covers must be kept dry and clean. Terminals and cable shoes must
be 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 be
damaged. There is a risk of short circuits with damaged cables.
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3 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 the
application. The following table shows which combinations are included as standard:

Truck type Description Capacity

EFG 110k 24 V - 4PzS 500 Ah
EFG 110 24 V - 5PzS 625 Ah
EFG 113 24 V - 7PzS 875 Ah
EFG 115 24 V - 8PzS 1000 Ah

4 Battery dimensions
Traction battery 24 V
Dimension (mm) Rated
L max. B max. H1 +/- H2 +/- weight
Truck
2mm 2mm (-5/+8%) in
kg
EFG 110k 830 273 612 627 380
EFG 110 830 327 612 627 450
EFG 113 830 435 612 627 600
EFG 115 830 489 612 627 690

DANGER!
If the centre of gravity of the battery deviates from the geometrical centre of
gravity of the battery, contact the manufacturer.
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50
 5 Exposing the battery

CAUTION!
The drive motor operating temperature can cause injury
When you open the battery cover the high operating temperature of the drive
motor > 80° can result in injuries.
uDo not touch the drive motor, and allow it to cool down.

Exposing the battery with the SOLO-PILOT

Requirements 55
– Park the truck securely, see page 88.
– Load handler lowered.
– Key switch set to OFF.
– Key removed.
– Set the Emergency Disconnect OFF.
56
Procedure
• Press the lever (56) to unlock the cover (55)
and move it forward.
• Carefully lift back the battery cover and the
driver’s seat as far as the stop (opening angle = 90°).

The battery is now exposed.

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51
 Exposing the battery with the MULTI-PILOT (o)

Requirements
– Park the truck securely, see page 88.
– Load handler lowered.
– Key switch set to OFF.
– Key removed.
– Set the Emergency Disconnect OFF.
Procedure
• Release the steering column lock (58), push the steering column forward and
secure it in this position.
• Pull the panel (57) forward until it engages.
• Carefully lift back the battery cover and the
driver’s seat (1) as far as the stop (opening
angle = 90°).

The battery is now exposed.

57

Z On trucks with a rear window / canvas cover, open the rear window / canvas cover
before opening the battery cover.

58

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52
 6 Battery removal and installation

WARNING!
Accident risk during battery removal and installation
Due to the battery weight and acid there is a risk of trapping or scalding when the
battery is removed and installed.
uNote the "Safety regulations for handling acid batteries" section in this chapter.
uWear safety shoes when removing and installing the battery.
uUse only batteries with insulated cells and terminal connectors.
uPark the truck on a level surface to prevent the battery from sliding out.
uMake sure the crane slings have sufficient capacity to replace the battery.
uUse only approved battery replacement devices (battery roller stand, replacement
trolley etc.).
uMake sure the battery is securely located in the truck's battery compartment.

CAUTION!
Trapping hazard
Trapping hazard when replacing the battery.
uWhen replacing the battery do not reach between the battery and the chassis.
uWear safety shoes.
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53
 Battery Removal and Installation

Requirements
– Park the truck securely, see page 88.
– Battery exposed, see page 51.
– Battery disconnected.
Tools and Material Required
– Crane lifting gear
Procedure

• Strap the crane lifting gear vertically over the

recess in the overhead guard to the battery
tray.
Z Hooks must be fitted in such a way that when
the crane lifting gear is slackened, it does not
fall onto the battery cells.
• With the crane lifting gear raise the battery
above the chassis in the right hand travel
direction and then move it out sideways.

The battery is now removed.

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54
 7 Charging the battery

WARNING!
The gases produced during charging can cause explosions
The battery produces a mixture of oxygen and hydrogen (electrolytic gas) during
charging. Gassing is a chemical process. This gas mixture is highly explosive and
must not be ignited.
uSwitch the charging station and truck off first before connecting/disconnecting the
charging cable of the battery charging station to/from the battery connector.
uThe charger must be adapted to the battery in terms of voltage and charge
capacity.
uBefore charging, check all cables and plug connections for visible signs of
damage.
uVentilate the room in which the truck is being charged.
uThe battery cell surfaces must be exposed during charging to ensure adequate
ventilation.
uDo not smoke and avoid naked flames when handling batteries.
uWherever an industrial truck is parked for charging there shall be no inflammable
material or lubricants capable of creating sparks within 2,5 m around the truck.
uFire protection equipment must be on hand.
uDo not lay any metallic objects on battery.
uIt is essential to follow the safety regulations of the battery and charger station
manufacturers.

7.1 Charging the battery with a stationary charger

WARNING!
Risk of electric shock and fire due to lacking or inappropriate residual current
devices
A lack of residual current devices or the use of inappropriate residual current devices
can result in fatal injury due to electric shocks or electrical fires in the event of a fault.
uThe owner must conduct an operational risk assessment of the usage location.
uAn RCD switch (residual current device, circuit breaker) of type B or B+ must be
used where necessary.

Z When charging, the battery door must be exposed by at least 200 mm to provide
sufficient ventilation.

Requirements
– Park the truck securely, see page 88.
– Battery exposed.
– Charger switched off.
– Disconnect the battery connector (59) from
the truck connector (51). 59
Procedure
60
10.20 en-GB

• Connect the battery connector (59) to the

charging cable (60) of the stationary charger
and turn on the charger.

55
 The battery is now charged.

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56
 8 Closing the battery cover

Closing the Battery Cover with the SOLO- 61

PILOT

Requirements
– The battery cable is in the cable guide (61).
Procedure
• Close the battery cover with the driver's seat.
• Move the cover (55) back until it engages.

The battery cover is now closed.

Closing the
battery 55
cover with
the Multi 57
Pilot
(optional)
62

Requirements
– The battery cable is in the cable guide (61).
Procedure
• Push the cover (57) back with force.
• Engage the lock (62).
The battery cover is now closed.
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58
10.20 en-GB
 E Operation
1 Safety Regulations for the Operation of Forklift Trucks

Driver authorisation

The truck may only be used by suitably trained personnel, who have demonstrated
to the proprietor or his representative that they can drive and handle loads and have
been authorised to operate the truck by the proprietor or his representative.
Operator’s rights, obligations and responsibilities

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

The operator is responsible for the truck during the time it is in use. The operator
must prevent unauthorised persons from driving or operating the truck. Do not carry
passengers or lift other people.
Damage and faults

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

The operator must not carry out any repairs or alterations to the truck without
authorisation and the necessary training to do so. The operator must never disable
or adjust safety mechanisms or switches.
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 Hazardous area

WARNING!
Risk of accidents/injury in the hazardous area of the truck
A hazardous area is defined as the area in which people are at risk due to travel or
lifting operations of the truck, its load handler or the load. This also includes the area
within reach of falling loads or lowering/falling operating equipment.
uInstruct unauthorised persons to leave the hazardous area.
uIn case of danger to third parties, give a warning signal in good time.
uIf unauthorised persons are still within the hazardous area, stop the truck
immediately.

WARNING!
Falling objects can cause accidents
Falling objects can injure the operator while the truck is being operated.
uThe operator must remain within the protected area of the overhead guard while
the truck is being operated.

Safety devices, warning signs and warning instructions

Safety devices, warning signs (see page 30) and warning instructions in the present
operating instructions must be strictly observed.

CAUTION!
Reduced headroom can cause injuries
Trucks with reduced headroom are equipped with a warning label within the
operator's line of sight.
uThe max. recommended body size indicated on this warning sign must be
observed.
uThe headroom is also reduced when you wear a protective helmet.

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 2 Displays and Controls
63 65 64

66

67

68

69

70

71

72

75 74 69 73

Item Control/display Function

63 Parking-brake lever t Applies/releases the parking brake.
64 Control panel with t Displays the battery capacity, service
display unit hours, errors, key warning indicators, wheel
position and travel direction.
65 Steering wheel t Steers the truck.
66 soloPILOT t Controls the following functions:
multiPILOT o – Fwd/rev. travel direction
– Lifting/lowering load
– Mast forward/reverse tilt
– Horn button
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– Sideshifter left/right (o)

– Auxiliary hydraulics (o)

61
 Item Control/display Function
67 Key switch t Switches control current on and off.
Removing the key prevents the truck from
being switched on by unauthorised
personnel.
ISM access module o Switches the truck on.
Code lock
68 Side storage-facility t Switches electric options on and off
control panel
69 Brake pedal t Provides infinitely variable braking control.
70 Accelerator pedal t Provides infinitely variable travel speed
control
71 Warning indicator for belt If the seat belt is not fastened, the warning
lock control system indicator for the belt lock control system
illuminates.
72 Warning indicator for cab If the cab door is not closed, the warning
door monitoring indicator for the cab door monitoring
illuminates.
73 "Reverse" accelerator o The truck reverses when the accelerator
twin pedal control pedal is applied. Provides infinitely variable
travel speed.
74 “Forwards” accelerator o The truck travels forwards when the
twin pedal control accelerator pedal is applied. Provides
infinitely variable travel speed.
75 Emergency disconnect Switches power supply on and off.
switch

Z *If the truck is equipped with an ISM access module or Can Code refer to the “ISM
Access Module” or "CanCode" operator manuals.

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62
 63 65 64

66

67

68

69

70

71

72

75 74 69 73
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63
 Item Control / Display Function
71 Warning indicator for belt If the seat belt is not fastened, the warning
lock control system indicator for the belt lock control system
illuminates.
72 Warning indicator for cab If the cab door is not closed, the warning
door monitoring indicator for the cab door monitoring
illuminates.
76 Travel direction switch t Selects travel direction or neutral.
(not available with twin-
pedal control)
77 "Horn" button t Activates an audible warning signal.
78 Lever t Lever for operating the hydraulic functions.
79 Button o Hydraulic auxiliary function control button.
80 Additional hydraulic o Activates the additional hydraulic functions
function release button or hydraulics that require
acknowledgement.
76 77
78

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 76

77
79

80

72 71
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65
2.1 Control panel with display unit
The control panel display unit shows the operating data, the battery charge, the
service hours and error details and information. Pictograms in the left top section of
the control panel act as warning indicators.

81 82 83 84 85
86 87 88 89 90

91

92

93

94
95

Item Control / Function

Display
81 Warning indicator – Lights up to indicate controller
Controller overtemperature overtemperature
– Performance is continually reduced in
relation to the temperature
82 Warning indicator – Monitors the temperature of the drive motor
Drive motor – Performance is reduced if the temperature is
overtemperature excessive
83 Parking brake indicator Comfort feature, displayed when the parking
brake indicator (83) lights up.
Truck prevented from rolling away but not
parked securely.
Parking brake is automatically activated after a
set time when the truck stops.
The parking brake is automatically released
when the accelerator pedal is applied.
84 Truck in operation indicator – Key switch ON
85 Insufficient brake fluid – The brake fluid level can be checked through
sensors on the brake fluid reservoir
86 Hourmeter / time toggle – Truck key switch ON service hours
switch – "Eff" service hours can be switched ON or
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OFF via a code

– Time display

66
 Item Control / Function
Display
87 Warning indicator – Monitors the temperature of the pump motor
Pump motor, power and the power steering motor
steering overtemperature – Performance is reduced if the temperature is
excessive
88 Seat switch warning Seat switch not closed
indicator – Truck operational, but driver's seat not
occupied
89 Travel direction display – Right / left indicator lamps activated
indicator lamp
90 Service display – Service interval exceeded (1000 operating
hours) or annual FEM test due (flashing
indicator).
91 WARNING WARNING
– Flashes for faults, an audible warning
sounds
– Flashes when battery capacity is less than
10%
92 Slow travel button – Switches slow travel on and off
93 Program selector – Selects the travel program (moves up or
down a level in the travel program list.)
94 Operating program display – Displays the selected travel program (1 to 5)
95 Set button – Confirms the entries

81 82 83 84 85
86 87 88 89 90

91

92

93

94
95
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2.2 Side compartment control panel switch (o)
Function
Rear window heating

Slow travel

Beacon

Seat heating

Work lights

Lift cutout override

Windscreen washer system

2.3 Instrument panel switches (o)

Function
Truck lighting

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 2.4 Display

96 97 98

Item Function
96 Hourmeter display
Error display:
– If an error (Err) or a warning (Inf) occurs, the error or info code
is displayed.
– If several errors occur they are displayed alternately at
1.5 second intervals. A warning is sounded.
97 Battery capacity display
– Battery discharge status
98 Travel direction and wheel position display
– Indicates the pre-selected travel direction (forward or reverse)
or the position of the steered wheels.
– Flashing direction arrow = no travel direction selected
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2.4.1 Battery discharge indicator

NOTICE
Full discharge can damage the battery
The standard setting for the battery discharge indicator is based on standard
batteries. When using maintenance-free batteries (gel batteries), the display must be
reset.
uThis adjustment should only be made by the manufacturer’s customer service
department.
uThe battery discharge indicator shows the battery’s residual capacity.
uCharge the battery, see page 55.

The battery charge status is shown through a battery icon (97) in the truck display in
10% increments (100% = 100% battery capacity, 0% = 20% battery capacity).

2.4.2 Battery discharge monitor

If the residual capacity falls below the required level, lifting is inhibited and the travel
speed is reduced. An message appears in the display. Lifting is only released when
the battery connected is at least 40% charged.

Z In order to complete the lift cycle, the key switch must be turned off and on again.
Lifting is then enabled for 30 to 40 seconds.

2.4.3 Hourmeter
The service hours are counted when the truck is switched on and the seat switch is
closed.

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 3 Preparing the Truck for Operation

3.1 Checks and operations to be performed before starting daily

operation
WARNING!
Damage and other truck or attachment (optional equipment) defects can result
in accidents.
If damage or other truck or attachment (optional equipment) defects are discovered
during the following checks, the truck must be taken out of service until it has been
repaired.
uReport any defects immediately to your supervisor.
uMark defective truck and take out of service.
uDo not return the industrial truck to service until you have identified and rectified
the fault.
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 Checks before daily operation

Procedure
• Visually inspect the entire truck (in particular wheels,
wheel bolts and load handler) for damage.
• Check the fork stop (99) and fork retainer (100).
• Visually inspect the hydraulic system in the visible 99
area for damage and leaks.
• Make sure the driver’s seat is locked in position. 100
• Test the horn and reversing buzzer (o) where
applicable.
• Check that the capacity plate and warning labels are
legible.
• Test the controls and displays.
• Test the steering.
• Check the steer angle display (o), 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. (The belt should jam when extracted suddenly.)
• Check the function of the restraint system monitor.
• Test the function of the display unit. Belt lock control symbol (see page 61)
lights up when the belt is not locked.
• Test the function of the display unit. Cabin door monitoring symbol (see
page 61) lights up when the summer door, the folding gate or the cabin door is
not closed properly (o).
• Test the seat switch: when the driver's seat is vacated, it should not be possible to
activate the hydraulic functions.
• Test the restraint system (o).
• Test the driveCONTROL (o).
• Raise the fork carriage without load beyond the reference point on the mast.
The slow travel symbol lights up on the display.
• Slowly apply the accelerator pedal on a clear route with good visibility. The
maximum speed should be reduced to walking pace (3 km/h).
• Test the lift/lower, tilt and if applicable the attachment hydraulic control functions.
• Apply the accelerator pedal several times to test its freedom of movement with the
parking brake applied (the parking brake indicator on the display (83) lights up
and the parking brake lever (63) is applied) and to test the idling function.
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 •

•
• Visually inspect the battery attachment and cable connections.
• Check the battery latch is present and working.
• On trucks with lateral battery removal, check
the left and right stops (101) in the battery
compartment for damage.
• Check the fluid level of the windscreen
washing system, see page 158.

101
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3.2 Entry and exit

Requirements
– Truck stationary.
Procedure 102
• Cab door open (if applicable).
• To enter and exit the cab, hold onto the
handle (102). Always face the truck when
entering and exiting.

Z Always use the entry aid (102) provided to climb onto the truck.

Z An additional step is provided for the driver position extension (o).

3.3 Trucks with reduced headroom (o)

CAUTION!
An unsuitable workplace can damage your health
Failure to observe the recommended body size can
cause stress and endanger the operator and may lead
to lasting ill health due to an unhealthy posture and
excessive strain on the operator.
uThe operating company must ensure that truck
operators do not exceed the maximum body size
indicated.
uThe operating company must check that the
operators can sit in a normal and upright position
without having to strain.
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 3.4 Setting up the operator position
WARNING!
Accidents can occur if the driver's seat, steering column and armrest are not
engaged
The driver's seat, steering column and armrest can accidentally adjust during travel
and therefore cannot be operated safely.
uDo not adjust the driver’s seat, steering column or armrest while travelling.
Procedure
• 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 without
having to strain.
• Adjust the visibility aid equipment (mirrors, camera systems etc.) so that the
working environment can be clearly seen.

3.4.1 Adjusting the driver’s seat

WARNING!
Risk of accidents and damage to health
An incorrectly adjusted driver’s seat can result in accidents and damage to health.
uDo not adjust the driver’s seat while travelling.
uThe driver’s seat should lock in position after adjustment.
uCheck and adjust the individual driver's seat setting before starting up the truck.
uHold the weight setting lever only by the recess, do not reach through underneath
the lever.
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 Setting the driver's weight 104 103

NOTICE
Incorrectly adjusted seat cushioning
can damage your health
To achieve optimal seat cushioning, the
driver’s seat must be adjusted according
to the driver’s weight.
Set the driver's weight when the seat is
occupied.
uHold the weight adjustment lever only
by the recess; do not reach through 105
underneath the weight adjustment
lever.
Procedure
• Fold out the weight adjustment lever (103) as far as it will go in the arrow
direction.
• Move the weight adjustment lever (103) up and down to set the seat to a higher
weight.
• Move the weight adjustment lever (103) down and up to set the seat to a lower
weight.

Z The driver's weight is correctly set when the arrow is in the middle of the display
window (104). The minimum or maximum weight setting is reached when you can
feel a return stroke on the lever.
• After setting the weight, fully fold back in the weight adjustment lever (103).

The driver’s weight is now set.

Adjusting the backrest

Procedure
• Sit on the driver’s seat.
• Pull the lever (105) to adjust the backrest.
• Adjust the backrest tilt.
• Release the lever (105) again. The backrest is locked.

The backrest is now set.

Z Hold the weight setting lever (103) only by the recess, never reach through
underneath the lever.
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 Adjusting the seat position

CAUTION!
An unsecured driver's seat can cause
injury
An unsecured driver's seat can slide out of
its guide during travel, resulting in accidents.
uThe driver's seat must be locked in
position.
uDo not adjust the driver’s seat while
travelling.
Procedure 106
• Sit on the driver’s seat.
• Pull up the driver’s seat locking lever106
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 (106) in position.

The seat position is now correctly set.

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 Adjusting the backrest extension
(o)

CAUTION!
Accident risk when adjusting the
backrest during travel
uDo not adjust the backrest
extension while travelling.
Procedure
• The backrest extension height can
be adjusted by changing the
detent.
• Pull the backrest up and lock it in
place to extend the backrest.
• Push the backrest down and lock it
in place to shorten the backrest.

Adjusting the swivel seat (o)

Procedure
• Pull the locking lever (107) back
while simultaneously turning the
seat to the required position.
• Allow the lock to engage.

The swivel seat is adjusted and

locked in position.

Z Operate the truck only when the

swivel seat is locked in position.
107

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 Adjusting the lumbar support (o)

Procedure
• Turn the hand wheel (109) 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 support is now adjusted.

Switching the seat heating on and off (o)

Procedure
• Press the seat heating switch (108).
Switch setting 1 = Seat heating on.
Switch setting 0 = Seat heating off.

108 109
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3.4.2 Adjusting the steering column

Adjusting the steering column

Procedure
• Release the steering column stop (58).
• Set the steering column to the required
position (height and angle).
• Fix the steering column stop (58) in position.

The steering column is now positioned.

58

3.4.3 Adjusting the arm rest

Procedure
• Loosen the screw (110) and tilt the armrest up
or down.
• Re-tighten the screw (110).
• Loosen the screw (111) and set the armrest
vertical.
• Re-tighten the screw (111).
• Loosen the screw (112) and set the armrest
horizontal.
• Re-tighten the screw (112).
110 111 112
The armrest is now positioned.

3.5 Restraint systems

Restraint systems

Approved restraint systems:

– Seat belt (see page 81)

– Folding gate ()
– Summer door (see page 123)

Z At least one of these restraint systems must be in place and monitored electrically.
This applies to trucks from the production date 01/12/2020.
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 3.6 Seat Belt
WARNING!
Travelling without a seat belt increases the risk of injury.
Accidents or personal injury can result if the seat belt is not worn or is modified.
uAlways put the seat belt on before starting the industrial truck.
uDo not modify the seat belt.
uDamaged or non-operational seat belts must be replaced by trained personnel.
uSeat belts must always be replaced after an accident.
uOnly original spare parts must be used for retrofits or repairs.
uReport any defects immediately to your supervisor.
uRemove the truck from service until a functional seat belt has been fitted.

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

Belt lock control system

The truck is fitted with a belt lock control system. If the belt is not locked properly, the
following may occur:
– The warning indicator for the belt lock control system (see page 61) lights up.
– After max. 30 seconds, an acoustic signal sounds.
Starting the industrial truck on steep slopes

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

Z Carefully drive the truck off the slope and then put on the belt.
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 DANGER!
A faulty seat belt can cause injury
Using a faulty seat belt can result in injury.
uOnly operate the truck with the seat belt intact. A faulty seat belt should be
replaced immediately.
uThe truck must remain decommissioned until a functional seat belt has been fitted.
Checking the seat belt

Procedure
• Check the attachment points for wear and damage.
• Check the cover for damage.
• Pull the belt out fully from the retractor and check for damage (loose seams,
fraying and nicks).
• Test the belt buckle and make sure the belt returns correctly into the retractor.

Check the automatic locking system

Procedure
• Park the truck on a level surface.
• Jerk the seat belt out suddenly.

Z The locking system should prevent the belt from coming out.

The seat belt has now been checked.

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 4 Industrial Truck Operation

4.1 Safety regulations for truck operation

WARNING!
Magnetic fields can cause accidents
Electronic components can be affected or damaged by external magnetic fields. This
can lead to malfunctions or accidents.
uDo not use or keep magnets or clamping magnets in the immediate vicinity of the
controls.

Travel routes and work areas

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

DANGER!
Do not exceed the permissible surface and point loading on the travel lanes.
At blind spots get a second person to assist.
The driver must ensure that the loading dock /dock leveller cannot be removed or
come loose during loading/unloading.
NOTICE
Loads must not be deposited on travel or escape routes, in front of safety
mechanisms or operating equipment that must be accessible at all times.

Travel conduct

The operator must adapt the travel speed to local conditions. The truck must be
driven at slow speed when negotiating bends or narrow passageways, when passing
through swing doors and at blind spots. The operator must always observe an
adequate braking distance between the forklift truck and the vehicle in front and
must be in control of the truck at all times. Abrupt stopping (except in emergencies),
rapid U turns and overtaking at dangerous or blind spots are not permitted. Do not
lean out or reach beyond the working and operating area.

Do not use a mobile phone or walkie-talkie without a handsfree device while

operating the truck.
Hazardous situations

The operator must not jump off the truck. The operator must lean his upper body
over the steering wheel and hold on with both hands. Tilt your body in the opposite
direction of fall.
Travel visibility
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The operator must look in the direction of travel and must always have a clear view
of the route ahead. If the truck is carrying loads that affect visibility, the truck must

83
 travel against the load direction. If this is not possible, a second person must walk
alongside the truck as a lookout to observe the travel route while maintaining eye
contact with the operator. Proceed only at walking pace and with particular care.
Stop the truck as soon as you lose eye contact.

Z At a distance (D) of 4000 mm between the rear of the load (Y) and a person or
obstacle, the non-visible area (A) must not be larger than 1085 mm. If the height (C)
impairs visibility to the extent that A 1085 mm is exceeded, the truck must travel in
the opposite direction to the load direction.
Depending on the operating conditions and application of the truck, the operating
company or its representative is obligated to define a visible area which is
appropriate to the prevailing hazard(s).

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 Negotiating slopes and inclines

Negotiating slopes and inclines up to 15% is only permitted if they are specifically
designed as travel routes, are clean and have a non-slip surface and providing they
can be safely travelled along in accordance with the truck's technical specifications.
The truck must always be driven with the load facing uphill. The industrial truck must
not be turned, operated at an angle or parked on inclines and slopes. Inclines must
only be negotiated at slow speed, with the driver ready to brake at any moment.
Particular care is required when travelling near slopes and quay walls.

WARNING!
Danger of accidents due to regenerative braking fault
Regenerative braking faults can result in extended stopping distances and accidents,
particularly when travelling on inclines. Other persons can be injured in the truck's
hazardous area.
uKeep all persons out of the hazardous area during travel operations.
uInstruct other people to move out of the hazardous area of the truck. Stop using
the truck immediately if people do not vacate the hazardous area.
uThe truck must travel carefully and not faster than crawl speed when the
"Regenerative braking fault" warning notice appears on the display unit.
uIn emergencies, use the service brake via the brake pedal for braking.

Negotiating lifts, loading ramps and docks

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

The operator must make sure that the load is in a satisfactory condition. Loads must
always be positioned safely and carefully. Use suitable precautions to prevent parts
of the load from tipping or falling down. Prevent liquid loads from sloshing out.

Inflammable liquids (e.g. molten metal etc.) may only be transported with suitable
auxiliary equipment. Contact the manufacturer's customer service department.

Z For safety instructions on the nature of loads to be carried with attachments,see

page 98.

Towing trailers

Only use the truck for towing lightweight trailers internally, see page 119.
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4.2 Preparing the truck for operation

113

83

67
114
63

75

Switching on the truck

Requirements
– For checks and operations to be performed before starting daily operation, see
page 71.
Procedure
• Unlock the Emergency Disconnect switch (75) to do this
• Press the rocker in (s) and pull it up until you feel the Emergency Disconnect
switch engaging.
• Insert the key in the key switch (67) and turn it clockwise as far as it will go to the
“I” position.
• Test the brake pedal and parking brake (parking brake indicator (83) lights up and
parking brake lever (63) applied).

Truck is operational. The display (113) shows the remaining battery capacity.

Z When you have pulled the Emergency Disconnect and turned the key switch to the
right, the truck carries out a self test for approx. 3-4 seconds (tests the controllers
and motors). During this time the truck cannot move or lift. If the accelerator or a lift
mechanism lever is applied during this time, an information message will be
displayed.
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86
 4.3 Setting the time

86

93

95

Setting the time

Procedure
• Press the “h/time” (86) and up (93) keys simultaneously.
• The time is displayed. The first digit flashes.
Press the up/down key (93) to increase or decrease the flashing digit.
• Use the SET (95) key to toggle to the next digit. After the last digit the number is
accepted.

The time is now set.

Z Keep pressing the Up and Down keys to set the time and to change between 24
hour and 12 display (SET HOUR 24 H <-> SET HOUR 12 H).
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87
4.4 Parking the truck securely
WARNING!
An unsecured truck can cause accidents
Parking the truck on an incline, without the brakes applied or with a raised load / load
handler is dangerous and is strictly prohibited.
uAlways park the truck on a level surface. In special cases the truck may need to be
secured with wedges.
uAlways fully lower the mast and load handler.
uTilt the mast forward.
uAlways apply the parking brake lever before parking the truck.
uChoose a place to park where no other people are at risk of injury from lowering
forks.
uDo not park and abandon a truck on an incline.

63 113 67

114

Parking the Truck Securely (with the Parking Brake Lever)

Procedure
• Pull the parking brake lever (114) back.
• Turn the key in the key switch (67) to the “0” position.
• Remove the key from the key switch (67).
• Press the Emergency Disconnect switch (75) down.

The truck is now parked securely.

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 4.5 Emergency Disconnect
CAUTION!
Faulty or non-accessible emergency disconnect switches can cause accidents
A faulty or non-accessible emergency disconnect switch can cause accidents.
uThe operation of the emergency disconnect switch must not be affected by any
objects placed in its way.
uReport any defects on the emergency disconnect switch immediately to your
supervisor.
uMark the defective truck accordingly and take it out of service.
uDo not return the truck to service until you have identified and rectified the fault.

Operating the emergency disconnect switch

Procedure
• Press the emergency disconnect switch (75).

All electrical travel, steering and hydraulic

functions are cut out.

75

Releasing the Emergency Disconnect

Procedure
• Press the rocker in (s) and pull the Emergency Disconnect switch (75) up until
you feel the Emergency Disconnect (75) switch engaging.

All electrical functions are enabled and the truck is operational again (assuming the
truck was operational before the Emergency Disconnect was pressed).
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4.6 Travel
WARNING!
Improper travel can result in accidents
uDo not get up from the driver’s seat during travel.
uDo not drive the truck unless your are wearing a seat belt and the panels and
doors are properly locked.
uDo not lean out of the truck while travelling.
uMake sure that the travel area is clear.
uAdapt your travel speed to the route conditions in the work area and the load.
uTilt the mast back and raise the fork carriage approx. 200 mm.
uMake sure you have sufficient visibility when reversing.

Travel

76
Requirements
– Truck prepared for operation, see page 86.
63
Procedure
• Release the parking brake lever (63).
• Select the travel direction
with the travel direction switch (76). 115
• Select the travel speed if necessary, to do this
press the slow travel button (115).
• Raise the fork carriage approx. 200 mm.
70
• Tilt the mast back.
• Apply the accelerator pedal (70). The travel
speed is governed by the accelerator (70).

The truck travels in the direction selected.

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 Dual pedal (optional equipment)

Requirements
– Truck prepared for operation, see page 86. 63

Procedure

Z For trucks with a dual pedal the travel

direction is selected via the accelerator pedals
(118;116). When the driver leaves the truck,
the truck is automatically set to “Neutral”.
• Release the parking brake (63).
• Raise the fork carriage approx. 200 mm.
• Tilt the mast back.
• Apply the accelerator pedal (118) to travel
forward. The travel speed is governed by the
accelerator (118).
116
• Apply the accelerator pedal (116) to reverse.
The travel speed is governed by the 117
accelerator (116).
118
The truck travels in the direction selected.

Changing direction during travel

Procedure
• Set the travel direction switch (76) to the opposite direction while travelling.
• For the twin pedal version apply the accelerator pedal in the opposite direction to
the travel direction (116 or 118).

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

Z When the truck changes direction it can start travelling at high speed in the opposite
direction unless the accelerator pedal is released in time. Changing direction results
in braking deceleration.
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4.7 Steering
Requirements
– Truck prepared for operation, see page 86.
Procedure
• To negotiate a right-hand bend:
• Turn the steering wheel clockwise to match the desired steering radius.
• To negotiate a left-hand bend:
• Turn the steering wheel anti-clockwise to match the desired steering radius.

The truck travels in the required travel direction.

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 4.8 Brakes
WARNING!
Accident risk
The brake pattern of the truck depends largely on the ground conditions.
uThe operator must take into account the travel route conditions when braking.
uBrake with care to prevent the load from slipping.
uAllow for increased braking distance when travelling with an attached load.
uUse the service brake in emergencies.

The truck can brake in three different ways:

– Coasting brake
– Service brake
and for secure parking:
– Parking brake

4.8.1 Coasting Brake

WARNING!
Immediately after the battery has been charged the brake power of the coasting
brake may reduce of their own accord after long periods of application, e.g. ramp
operation.
uThe operator must instruct people to leave the hazardous area.
uThe operator must perform test braking.

WARNING!
Danger of accidents due to regenerative braking fault
Regenerative braking faults can result in extended stopping distances and accidents,
particularly when travelling on inclines. Other persons can be injured in the truck's
hazardous area.
uKeep all persons out of the hazardous area during travel operations.
uInstruct other people to move out of the hazardous area of the truck. Stop using
the truck immediately if people do not vacate the hazardous area.
uThe truck must travel carefully and not faster than crawl speed when the
"Regenerative braking fault" warning notice appears on the display unit.
uIn emergencies, use the service brake via the brake pedal for braking.
Braking with the coasting brake

Procedure
• Take your foot off the accelerator pedal (70).

The truck decelerates.

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93
 76

117

70

4.8.2 Service brake

Braking with the service brake

Procedure
• Depress the brake pedal (117) until you feel the brake pressure.

The truck decelerates depending on the brake pedal position.

4.8.3 Parking brake

DANGER!
Accident risk
uThe parking brake will hold the truck with maximum load on a clean ground
surface, on inclines of up to 15%.
uDo not park and abandon the truck on an incline.
uApplying the parking brake during travel will cause the truck to decelerate. This
may cause the load to slide off the fork arms. There is a greater risk of accidents
and injury!

The parking brake has the following function:

– Park the truck securely (parking brake lever (63) applied)

Pulling the parking brake lever (63) disables travel, the truck is secured. Pushing
the parking brake button (114) and the parking brake lever (63) forward releases
the parking brake and enables travel. This function of the parking brake
ensures that the truck is parked securely. The truck will not accelerate when
the accelerator pedal is depressed.
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94
 Parking brake

Procedure 114
• Press the button (114) and push the parking
brake lever (63) forward, the parking brake is 63
now released.
• Pull the parking brake lever (63) back, the
parking brake is now applied.

The truck is now secure.

Z The parking brake will hold the truck with maximum load on a clean ground surface,
on inclines of up to 15%.
Do not park and exit the truck on inclines.
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4.9 Adjusting the forks

WARNING!
Unsecured and incorrectly adjusted forks
can cause accidents
Before adjusting the forks make sure the
retaining bolts (100) are fitted.
uAdjust the forks so that both forks are
equidistant from the outside edge of the fork
carriage.
uEngage the locking pin in a groove to prevent
the forks from moving accidentally. 100
uThe load centre of gravity must be located
centrally between the forks.

WARNING!
Trapping hazard
There is a trapping hazard when you perform this operation.
uWear work gloves and safety shoes.

Adjusting the forks

Requirements
119
– Park the truck securely, see page 88.
120
Procedure
• Lift up the locking lever (119).
• Push the forks (120) into the correct position on the 121
fork carriage (121).

Z To lift the load securely, the forks (120) must be

spread as far apart as possible and positioned
centrally with respect to the fork carriage. The load
centre must lie centrally between the forks (120).
• Push the locking lever down (119) and move the forks
until the locking pin engages in a slot.

The forks are now adjusted.

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96
 4.10 Replacing the forks
WARNING!
Unsecured forks can cause injury
You can injure your legs when replacing the forks.
uNever pull the forks towards your body.
uAlways push the forks away from your body.
uSecure heavy forks with lifting slings and a crane before pushing them down from
the fork carriage.
uAfter replacing the forks fit the retaining bolts (100) and make sure the bolts are
seated correctly. Retaining bolt torque: 85 Nm.

Replacing the forks

Requirements
– Load handler lowered and forks not touching
the ground.
Procedure
99
• Disassemble the retaining bolts (100).
• Loosen the fork stop (99).
• Carefully push the forks off the fork carriage. 100

The forks are now dismantled from the fork

carriage and can be replaced.
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97
4.11 Lifting, transporting and depositing loads
WARNING!
Risk of accident when the load centre is outside the load centre distance
If the centre of gravity G of a raised load lies outside the load centre distance D
specified for the load handler in the horizontal or vertical planes, under unfavourable
conditions the raised load and also the truck can tip over while working.
uObserve load centre distances and capacities of the load handler, see page 33.
uPick up the load so that its centre of gravity lies between the load arms of the load
handler.
uArrange and pick up the load so that the load centre lies within the load centre
distance of the load handler (d1 ≤ D and d2 ≤ D, see area DD in the illustration).
uDo not pick up a load with a load centre outside the load centre distance of the
load handler (d1 > D and/or d2 > D), as this load case has not been checked on a
truck tested according to the test guideline.

d2
G G
DD
D DD d1 d2

D D

For loads with an even weight distribution, the load centre distance lies in the
geometric centre of the volume.

For rectangular loads with an even weight distribution over the entire volume the
load centre distance is in the middle, i.e. half the length, half the height and half the
width of the load.

WARNING!
Risk of accident due to unsecured and incorrectly positioned loads
Before lifting a load, the operator must make sure that it has been correctly
palletised and does not exceed the truck's rated capacity.
uInstruct people to move out of the hazardous area of the truck. Stop using the
truck immediately if people do not vacate the hazardous area.
uOnly transport loads that have been correctly secured and positioned. Use suitable
precautions to prevent parts of the load from tipping or falling down.
uDo not transport loads other than on the authorised load handler.
uDamaged loads must not be transported.
uIf the stacked load obscures forward visibility, then you must reverse the truck.
uDo not exceed the maximum loads specified on the capacity plate.
uCheck the fork spread before lifting the load and adjust if necessary.
uInsert the forks as far as possible underneath the load.
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uTilting the mast forward when the load handler is raised >300 mm beyond the
vertical position is permissible only in front of or above the load/rack.

98
 Lifting loads

Requirements
– Load correctly palletised.
– Fork spread for the pallet checked and
adjusted if necessary.
– Load weight matches the truck's capacity.
– Forks evenly loaded for heavy loads.
Procedure
• Drive the truck carefully up to the pallet.
• Set the mast vertical.
• Slowly insert the forks into the pallet until
the fork shank touches the pallet.
• Raise the load handler.
• Reverse carefully and slowly until the load is outside the storage area. Make sure
you have enough clear space to reverse into.
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99
 NOTICE
Loads must not be deposited on travel or escape routes, in front of safety
mechanisms or operating equipment that must be accessible at all times.

Transporting loads

Requirements
– Load raised correctly.
– Load handler lowered for transport
(approx. 150 - 200 mm above the
ground).
– Mast tilted back fully.
Procedure
• On slopes and inclines always carry the
load facing uphill, never approach at an
angle or turn.
• Accelerate and decelerate with care.
• Adapt your travel speed to the conditions of the route and the load you are
transporting.
• Watch out for other traffic at crossings and passageways.
• Always travel with a lookout at blind spots.

Depositing a load

Requirements
– Storage location suitable for storing the load.
Procedure
• Set the mast vertical.
• Drive the truck carefully up to the storage location.
• Press the "Lower load handler" button until the forks are clear of the load.

Z Do not set down the load abruptly in order to avoid damaging the load and the
load handler.
• Lowers the load handler.
• Carefully remove the forks from the pallet.

The load is deposited.

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 4.12 Operating the lift mechanism and integrated attachments
WARNING!
Operating the lifting device and integrated attachments can be hazardous
Other people can be injured in the truck's hazardous area.
The hazardous area is defined as the area in which people are at risk from the truck
movement, the load handler, attachments etc. This also includes areas which can be
reached by falling loads or lowering operating equipment.
Apart from the operator (in the normal operating position) there should be no other
people in the truck's hazardous area.
uInstruct other people to move out of the hazardous area of the truck. Stop working
with the truck if people do not leave the hazardous area.
uIf people do not leave the hazardous area despite the warning, prevent the truck
from being used by unauthorised people.
uOnly carry loads that have been correctly secured and positioned. Use suitable
precautions to prevent parts of the load from tipping or falling down.
uDo not exceed the maximum loads specified on the capacity plate.
uDo not stand underneath a raised load handler.
uDo not stand on the load handler.
uDo not lift other people on the load handler.
uDo not reach through the mast.
uThe controls should only be operated from the driver’s seat, and never suddenly.
uThe operator must be trained to handle the lift mechanism and the attachments.

WARNING!
An offset load centre can result in accidents
The capacity of the truck is reduced when using side shifts that are more than 100
mm outside the truck centre.
uObserve the capacity plate with the reduced capacity.
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101
4.12.1 Operating the lift mechanism with the SOLO PILOT

Lifting and lowering

S
Requirements
122
– To prepare the truck for operation, see
page 86
Procedure
• Pull the Solo-Pilot lever (122) in direction H to
H
raise the load.
• Push the Solo-Pilot lever (122)in direction S to
lower the load.

The load is now raised / lowered.

Z When the limit position for the operation has been reached (there will be a noise
from the pressure relief valve) release the lever. The lever will revert automatically to
neutral.

Tilting the mast forward / backward V 123

Requirements
– To prepare the truck for operation, see
page 86
Procedure R
• Pull the Solo-Pilot lever (123) in direction R to
tilt the mast back.
• Push the Solo-Pilot lever (123) in direction V
to tilt the mast forward.

The mast is now tilted back / forward.

Z When the limit position for the operation has been reached (there will be a noise
from the pressure relief valve) release the lever. The lever will revert automatically to
neutral. 10.20 en-GB

102
 Positioning the integrated sideshifter (option) 124
V
Requirements
– Truck prepared for operation, see page 86.
Procedure R
• Pull the Solo-Pilot lever (124) in direction R to
move the load handler to the right (from the
operator’s viewpoint).
• Pull the Solo-Pilot lever (124) in direction V to
move the load handler to the left (from the
operator’s viewpoint).

The sideshifter is now positioned.

Z When the limit position for the operation has been reached (there will be a noise
from the pressure relief valve) release the lever. The lever will revert automatically to
neutral.

Positioning the forks with an integrated fork V 125

positioner (option)

CAUTION!
Do not use the fork positioner to clamp loads. R
Requirements
– Truck prepared for operation, see page 86.
122
Procedure
• Press the toggle switch (125) and at the same
time pull the SOLO-PILOT (122) in direction Z: the forks will move towards each
other.
• Press the toggle switch (125) and at the same time push the SOLO-PILOT (122)
in direction A: the forks will spread apart.

The forks are now positioned.

Synchronising the alignment of the fork tines V 125

with an integrated fork positioner (optional
equipment)

Requirements R
– Truck prepared for operation, see page 86.
– The fork tines are no longer aligned.
Procedure
122
• Press the toggle switch (125) and at the same
time push the SOLO-PILOT (122) in direction
A and spread the fork tines apart as far as they will go.
10.20 en-GB

• Press the toggle switch (125) and at the same time pull the SOLO-PILOT (122) in
direction Z and bring the fork tines as close to each other as they will go.

103
 The fork tines are now synchronised.

Z When the limit position for the operation has been reached (there will be a noise
from the pressure relief valve) release the lever. The lever will revert automatically to
neutral.

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104
 4.12.2 Operating the lift mechanism with the Multi Pilot

Lifting and lowering

S

Requirements
– To prepare the truck for operation, see H
page 86 126
Procedure
• Pull the Multi-Pilot (126) in direction H to raise
the load.
• Push the Multi Pilot (126) in direction S to
lower the load.

The load is now raised / lowered.

Z When the limit position for the operation has been reached (there will be a noise
from the pressure relief valve) release the lever. The lever will revert automatically to
neutral.

Tilting the mast forward / backward 126

R
Requirements
– Truck prepared for operation, see page 86.
Procedure V
• Push the Multi-Pilot lever (126) in direction V
to tilt the mast forward.
• Push the Multi-Pilot lever (126) in direction R
to tilt the mast back.

The mast is now tilted back / forward.

Z When the limit position for the operation has been reached (there will be a noise
from the pressure relief valve) release the lever. The lever will revert automatically to
neutral.
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105
 Twin operation

Requirements
– To prepare the truck for operation, see page 86
Procedure
• To lower the load handler and tilt the mast forward
at the same time, push the Multi Pilot forward and
to the right.
• To lift the load handler and tilt the mast back at the
same time, push the Multi Pilot back and to the left.
• To lower the load handler and tilt the mast back at the same time, push the Multi
Pilot forward and to the left.

The mast is now tilted back / forward.

Positioning the integrated sideshifter (option)

127
Requirements
– Truck prepared for operation, see page 86.
Procedure 128
• Press the (128) button to move the load
handler to the right (from the driver's
viewpoint).
• Press the (127) button to move the load
handler to the left (from the driver's
viewpoint).

The sideshifter is now positioned.

Z When the limit position for the operation has been reached (there will be a noise
from the pressure relief valve) release the lever. The lever will revert automatically to
neutral.

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106
 Positioning the forks with an integrated fork
positioner (option)

CAUTION! 126 129

Do not use the fork positioner to clamp loads.

Requirements
– Truck prepared for operation, see page 86.
Procedure
• Press the (129) button and at the same time
turn the MULTI-PILOT (126) anti-clockwise, the forks will spread apart.
• Press the (129) button and at the same time turn the MULTI-PILOT (126) anti-
clockwise, the forks will move together.

The forks are now positioned.

Synchronising the alignment of the fork tines

with an integrated fork positioner (optional
equipment)
126 129
Requirements
– Truck prepared for operation, see page 86.
– The fork tines are no longer aligned.
Procedure
• Press the (129) button and at the same time
turn the MULTI-PILOT (126) anti-clockwise,
the forks will spread apart.
• Press the (129) button and at the same time turn the MULTI-PILOT (126) anti-
clockwise, the forks will move together.

The fork tines are now synchronised.

Z When the limit position for the operation has been reached (there will be a noise
from the pressure relief valve) release the lever. The lever will revert automatically to
neutral.
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107
4.13 Safety instructions for operating additional attachments
DANGER!
Attaching exchangeable equipment can result in accidents.
Other people can be injured when attaching exchangeable equipment. Use only
exchangeable equipment that has been deemed safe after a risk analysis carried out
by the owner.
uOnly use attachments that have been designed by the attachment manufacturer
for use with the respective industrial truck.
uOnly use attachments that are suitable for the operating pressure and oil flow
available at the hydraulic port, see page 20.
uOnly use attachments that have been fitted for the purpose by the owner.
uMake sure the operator has been instructed in the use of the attachment and that
he uses it for its correct purpose.
uRe-assess the residual capacity of the truck and, if it has been altered, attach an
additional capacity plate to the truck.
uNote the attachment manufacturer’s operating instructions.
uUse only attachments that do not restrict visibility in the travel direction.

WARNING!
Risk of accident due to overload and failure of the attachment or the load
falling or becoming damaged.
When using attachments that are not suitable for the operating pressure and oil flow
available, overload may give rise to damage and failure of the attachment, as well as
the load falling or becoming damaged.
uOnly use attachments that are suitable for the operating pressure and oil flow
available at the hydraulic port, see page 20.

CAUTION!
Risk of slipping and environmental damage due to leaked hydraulic oil
When using attachments that are not suitable for the operating pressure and oil flow
available, overload may give rise to leaks or broken lines with the potential for
hydraulic oil leaks.
Risk of slipping due to leaked hydraulic oil. The risk is greater when combined with
water.
uOnly use attachments that are suitable for the operating pressure and oil flow
available at the hydraulic port, see page 20.

Z Optionally, trucks can be fitted with one or more auxiliary hydraulic functions to
operate attachments. The auxiliary hydraulics are indicated with ZH1, ZH2 and ZH3.
Auxiliary hydraulic functions for exchangeable equipment are fitted with replacement
couplings on the fork carriage. To fit exchangeable equipment see page 116.

Z If visibility in the travel direction is impaired, the operating company must determine
and apply suitable measures to ensure the safe operation of the truck. A lookout
may have to be used or certain hazardous areas may have to be cordoned off. The
truck can also be equipped with optional visual aids such as a camera system or
mirrors. Travelling with visual aids requires plenty of practice at slow speed.
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108
 Safety instructions for sideshifter and fork positioner attachments

WARNING!
Restricted visibility and reduced tilt resistance can cause accidents
When using sideshifters and fork positioners, the change in centre of gravity can
result in reduced lateral tilt resistance and accidents. Note that this affects visibility
as well.
uAdapt the travel speeds to the visibility and load.
uMake sure you have sufficient visibility when reversing.

Safety instructions for clamping attachments (e.g. baling clamps, barrel

clamps, grabs etc.)

WARNING!
Falling loads can cause accidents
This can result in malfunctions and the load can fall accidentally.
uClamping attachments may only be added to trucks which have a button to enable
additional hydraulic functions.
uClamping attachments must only be operated on trucks will auxiliary hydraulics
ZH1, ZH2 or ZH3.
uWhen connecting the attachment make sure that the hydraulic lines of the
attachment are connected to the right ports, see page 116.

Safety instructions for rotary attachments

WARNING!
A non-centred load centre of gravity can result in accidents
When using rotary devices and non-centred loads, the centre of gravity can be
displaced from the centre with a high risk of accidents.
uAdapt the travel speed to the load.
uLift the load from the centre.

WARNING!
An offset load centre can result in accidents
The capacity of the truck is reduced when using side shifts that are more than 100
mm outside the truck centre.
uObserve the capacity plate with the reduced capacity.
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109
 Safety instructions for clamping attachments (e.g. baling clamps, barrel
clamps, grabs, etc.)

WARNING!
Risk of accidents due to falling loads
Operating errors can occur and the load can fall accidentally.
uClamping attachments must only be used on trucks that feature a button for
enabling additional hydraulic functions.
uClamping attachments must only be operated on trucks will auxiliary hydraulics
ZH1, ZH2 or ZH3 or ZH3.
uWhen connecting the attachment, make sure that the hydraulic lines of the
attachment are connected to the correct ports – see page 116.
uDo not use clamping attachments for clamping purposes or in clamping operation
while fork extensions are in use.

Z The highest auxiliary hydraulics after ZH2 must be released by the

acknowledgement button.

Safety instructions for rotary attachments

WARNING!
A non-centred load centre of gravity can result in accidents
When using rotary devices and non-centred loads, the centre of gravity can be
displaced from the centre with a high risk of accidents.
uAdapt the travel speed to the load.
uLift the load from the centre.

WARNING!
Risk of accidents due to falling loads
As the rotation of the rotary device increases, the load acting on the forks changes
from a vertical to a lateral force, until the load is only acting on one fork arm. If you
overload the forks or use unsuitable forks, this can result in damage and the load
may fall down accidentally.
uDo not use fork extensions to lengthen the forks on rotary devices.
uOnly use forks that are approved for use with the relevant rotary device.
uDamaged forks must be marked accordingly and taken out of service.
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110
 Safety instructions for telescopic attachments

WARNING!
Accident risk from increased tipover hazard and reduced residual capacity
There is a greater risk of tipover with extended telescopic attachments.
uDo not exceed the maximum loads specified on the capacity plate.
uOnly use the telescopic function for stacking and retrieving.
uRetract the telescopic attachment fully during transport.
uAdapt the travel speed to changed load centre of gravity.

Safety instructions for attachments when transporting suspended loads

WARNING!
Swinging loads and a reduced residual capacity can result in accidents.
Transporting hanging loads can reduce the stability of the truck.
uAdapt the travel speed to the load, less than walking pace.
uSecure swinging loads for example with lifting slings.
uReduce the residual capacity and have it certified by a expert.
uIf the truck is to be operated with hanging loads, proof of sufficient safety distance
under local operating conditions must be obtained from a specialist assessor.

Safety instructions for using loading buckets as attachments

WARNING!
Increased mast loading can cause accidents.
uWhen carrying out the daily checks and operations before starting, see page 71,
check in particular check the fork carriage, mast rails and mast rollers for damage.
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111
 Safety instructions for fork extensions

WARNING!
Unsecured and oversized fork extensions can cause accidents.
uOnly use fork extensions that are suitable and have been approved for the base
forks of the truck. Observe the data on the data plates of the fork extensions and
truck.
uThe basic fork length must be at least 60% of the length of the fork extension.
uPush out the fork extensions fully and lock onto the basic fork arms.
uLay the load as close to the fork shanks as possible. The distance between the
overall centre of gravity of the load and the fork shank must not exceed 50% of the
length of the fork extension.
uWhen carrying out checks and operations before daily starting, see page 71,
check the fork extension lock.
uMark any fork extensions with an incomplete or faulty lock and take them out of
service.
uDo not use trucks with an incomplete or faulty fork extension lock. Replace the fork
extension.
uOnly restore the fork extension to service when the fault has been rectified.
uUse only fork extensions which are free of dirt and foreign bodies near the entry
opening point. Clean the fork extensions as required.

Z The weight of the fork extensions reduces the residual capacity of the truck. When
determining the residual capacity, the increased load distance must be taken into
account, see the data plate and capacity plate of the fork extension.

WARNING!
Risk of accidents due to falling loads
In the case of an incorrect load or uneven load distribution, the fork extensions may
be damaged and the load can fall down accidentally.
uDo not use clamping attachments for clamping purposes or in clamping operation
while fork extensions are in use.
uDo not use fork extensions to lengthen the forks on rotary devices.
uDamaged fork extensions must be marked accordingly and taken out of service.

WARNING!
Risk of accidents due to falling loads
In the case of an incorrect load or uneven load distribution, the fork extensions may
be damaged and the load can fall down accidentally.
uDo not use clamping attachments for clamping purposes or in clamping operation
while fork extensions are in use.
uDo not use fork extensions to lengthen the forks on rotary devices.
uDamaged fork extensions must be marked accordingly and taken out of service.
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112
 4.14 Operating additional attachments for the SOLO-PILOT
WARNING!
Incorrect symbols can cause accidents
Symbols on controls that do not depict the function of the attachments can cause
accidents.
uMark the controls with symbols that indicate their function.
uSpecify the attachments’ direction of movement in accordance with ISO 3691-1 so
that they match the controls’ direction of movement.

4.14.1 Solo Pilot with control of ZH1 hydraulic port

Z
124
Depending on the attachments used the V
lever (124) is assigned the function of the
attachment. Levers that are not required are
void. For connections see page 116.
Procedure R
• Operating the hydraulic port ZH1:
Move the lever (124) in direction V or R.

The attachment’s function is performed.

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113
4.14.2 Solo Pilot with control of ZH1 and ZH2 hydraulic ports

124
Z Depending on the attachments used the lever / V 125
button (122, 124, 125) is assigned the function of
the attachment. Unused levers have no function.
For connections see page 116.
Procedure R
• Operating the hydraulic port ZH1:
Move the lever (124) in direction V or R.
• Operating the hydraulic port ZH2:
122
Press the toggle switch (125) and at the same
time move the lever (122) in the V or R
direction.

The attachment’s function is performed.

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114
 4.15 Operating additional attachments for the Multi Pilot
WARNING!
Incorrect symbols can cause accidents
Symbols on controls that do not depict the function of the attachments can cause
accidents.
uMark the controls with symbols that indicate their function.
uSpecify the attachments’ direction of movement in accordance with ISO 3691-1 so
that they match the controls’ direction of movement.

4.15.1 Multi Pilot with control of ZH1 hydraulic port

Z Depending on the attachments used the (128,

127) buttons are assigned the function of the 127
attachment. Unused buttons have no function.
For connections see page 116.
Procedure 128
• Operating hydraulic port ZH1:
Press the (128) button or the (127) button.

The attachment performs its operation.

4.15.2 Multi Pilot with control of ZH1 and ZH2 hydraulic ports

Z Depending on the attachments used the

127
buttons (128, 127) and the lever (126) are
assigned the function of the attachment. Levers
that are not required are void. For connections 128
126
see page 116.
129
Procedure
• Operating hydraulic port ZH1:
Press the (128) button or the (127) button.
• Operating hydraulic port ZH2:
Set the MULTI-PILOT (126) to neutral and
then turn it clockwise or anti-clockwise while
at the same time pressing the button (129).

The attachment performs its operation.

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115
4.16 Fitting additional attachments
WARNING!
Incorrectly connected attachments can cause accidents.
Attachments with incorrectly connected hydraulic attachments can result in
accidents.
uAttachments must only be assembled and commissioned by trained, specialist
personnel.
uObserve the manufacturer’s operating instructions.
uBefore starting, check the fasteners are positioned correctly and securely and
make sure they are complete.
uBefore starting, make sure the attachment is working correctly.

WARNING!
Hydraulic ports for clamping attachments
uClamping attachments may only be added to trucks which have a button to enable
additional hydraulic functions.
uOn trucks with auxiliary hydraulics ZH2 the clamping function should only be
attached to the coupling pair marked ZH2.
uOn trucks with auxiliary hydraulics ZH3 the clamping function should only be
attached to the coupling pair marked ZH3.

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116
 WARNING!
Unsecured hydraulic functions can cause accidents
Failure to secure hydraulic functions for releasing functions on attachments that hold
loads using force (e.g. paper clamps, load holder) can result in accidents.
uHydraulic functions for releasing functions that hold loads using force must be
secured such that they can be used only after actuation of the acknowledgement
button.
uBefore starting, make sure the pilot is set up correctly.

WARNING!
Incorrectly labelled hydraulic functions can cause accidents
Labels on the pilot that do not match the directions of movement and hydraulic
functions on the attachment can result in accidents.
uBefore starting, make sure the pilot is correctly labelled and adjust if necessary.
Connecting attachments hydraulically

Requirements
– Non-pressurised hydraulic hoses.
– The exchange ports on the truck are marked ZH1, ZH2 and ZH3.
– Attachment directions of movement defined to match the controls’ direction of
movement.
Procedure
• Non-pressurised hydraulic hoses
• Switch off the truck and wait a few minutes.
• Attach the plug connector and engage it in position.
• Mark the controls with symbols that indicate their function.

The attachment is now hydraulically connected.

Z Spilled hydraulic oil must be set using a suitable agent and disposed of in
accordance with environmental regulations.
If hydraulic oil comes into contact with the skin, wash it off immediately with soap
and water. If it comes into contact with the eyes rinse them immediately with flowing
water and call for a doctor.
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117
Z The manufacturer's customer
service department can
correctly connect the
attachment, adjust the
controls and actuation
directions on the pilot to the
connections and directions of
movement of the attachment,
and label the pilot accordingly.

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118
 5 Towing trailers

DANGER!
Inappropriate speeds and excessive trailer loads can be dangerous
If you do not adapt your speed and / or use an excessive trailer load, the truck can
pull apart when cornering and braking.
uThe truck should only be used occasionally to tow trailers.
uThe overall weight of the trailer should not exceed the capacity indicated on the
capacity plate, see page 30. If a load is also transported on the load handler, the
trailer load must be reduced by the same amount.
uDo not exceed the maximum speed of 5 km/h.
uA special trailer coupling must be used for frequent trailer operation.
uDo not use supporting loads.
uTowing must only be performed on level, secure travel routes.
uThe owner must test trailer operation with the permissible trailer load by means of
a trial run under the applicable operating conditions on site.
uSpecial approvals on request.
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119
 Attaching the trailer

CAUTION!
Trapping hazard
There is a trapping risk when you attach a trailer.
uFollow the instructions of the coupling manufacturer if using special trailer
couplings.
uSecure the trailer to prevent it from rolling away before coupling it.
uDo not get caught between the truck and the tiller when coupling the trailer.
uThe tiller must be horizontal, tilted down by no more than 10° and never facing up.

Attaching the trailer

130
Requirements
– Truck and trailer are on a level surface.
– Trailer prevented from rolling away.
Procedure
• Push the tow pin (130) down and turn it 90°.
• Pull the tow pin up and insert the tiller of the
trailer into the opening.
Z Reverse the truck for coupling until the tow
pin of the coupling and the hole in the tiller are
flush.
• Insert the tow pin, push it down, turn it 90
degrees and engage it.

The trailer is now attached to the truck.

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120
 6 Optional Equipment

6.1 Assistance systems

The Access, Drive and Lift Control systems help the driver operate the truck with
regard to safety regulations, see page 83 of the present operating instructions.
Travel conduct

The operator must adapt the travel speed to local conditions. The truck must be
driven at slow speed when negotiating bends or narrow passageways, when passing
through swing doors and at blind spots. The operator must always observe an
adequate braking distance between the forklift truck and the vehicle in front and
must be in control of the truck at all times. Abrupt stopping (except in emergencies),
rapid U turns and overtaking at dangerous or blind spots are not permitted. Do not
lean out or reach beyond the working and operating area.

6.1.1 Access Control

The truck is only released for operation if:
– The operator is seated.
– He is wearing the seat belt.

Z If the driver vacates the seat for a short while, the truck can be operated again when
he returns (seat occupied) and puts the seat belt back on again.

Z If travel is not enabled, an information message is issued. Items 1 to 3 must be

carried out again.
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121
6.1.2 Drive Control
This option restricts the travel speed of the truck as a function of the lift height. From
a factory-set lift height the maximum travel speed is reduced to walking pace
(approx. 3 km/h) and the slow travel indicator is activated. When the forks fall below
this height, the truck accelerates at reduced levels to the speed prescribed by the
accelerator pedal to prevent sudden acceleration when changing from slow travel to
normal travel. Normal acceleration is only activated again when the speed
prescribed by the accelerator pedal has been reached.

Z In addition to the daily checks before starting, see page 71 the driver must carry out
the following checks:

– Lift the empty load handler beyond the reference lift height and check if the slow
travel indicator lights up.

6.1.3 Lift Control

This option includes Drive Control and also monitors and controls the mast functions:

Tilt speed reduction as a function of the lift height (from approx. 1,5 m lift height).
– When the load handler is lowered below the limit height, the tilt speed increases
again.
Optional:
– Tilt angle display, see page 127.
In addition to the daily checks before starting, the driver must carry out the
following checks:

Procedure
• Lift the empty load handler beyond the reference lift height and check if the slow
travel display lights up and the tilt speed is clearly reduced.
• Steering when the truck is stationary: check if the steering wheel display is
working.
• Check the tilt angle display by tilting forward and back.

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122
 6.2 BODYGUARD

CAUTION!
Open doors can result in accidents
uDo not travel with an open door. When
opening the door make sure there is nobody
in the door’s swing range.
uAlways close the door tightly and make sure
it is locked.
Procedure
• Pull the handle (131) towards the operator
position, the door swings open.
• Pull the door (132) towards the operator;
the door closes.

CAUTION!
Risk of injury if the seat belt is not fastened
The following must be observed for trucks with approved restraint systems:
uThe seat belt also protects against injuries as a result of a rear-end collision.
uIn the case of trucks with multiple restraint systems, the use of the seat belt is not
always mandatory. However, the manufacturer recommends the additional use of
the seat belt, since the seat belt also prevents injuries caused by a rear-end
collision for example.

Trucks with Bodyguard monitoring may experience the following situations if the
Bodyguard is not locked:
– The warning indicator for cab door monitoring (see page 61) lights up.
– After max. 30 seconds, an acoustic signal sounds.
– Travel cut-off is activated (o).

6.3 Panel door

CAUTION!
Open doors can result in accidents
uDo not travel with an open door. When opening the door, make sure there is
nobody in the door's swing range.
uAlways close the door tightly and make sure it is locked.
uAfter closing the summer door, fasten the seat belt, see page 81.
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123
 CAUTION!
Risk of injury if the seat belt is not fastened
The following must be observed for trucks with approved restraint systems:
uThe seat belt also protects against injuries as a result of a rear-end collision.
uIn the case of trucks with multiple restraint systems, the use of the seat belt is not
always mandatory. However, the manufacturer recommends the additional use of
the seat belt, since the seat belt also prevents injuries caused by a rear-end
collision for example.

Z In the case of trucks with multiple restraint systems, the use of the seat belt is not
always mandatory. However, the manufacturer strongly recommends the additional
use of the seat belt, since the seat belt also prevents injuries caused by a rear-end
collision for example.

Trucks with summer door monitoring may experience the following situations if the
summer door is not locked:

– The warning indicator for cab door monitoring (see page 61) lights up.
– After max. 30 seconds, an acoustic signal sounds.
– Travel cut-off is activated (o).

Procedure
• Pull the handle (131) towards the operator
position, the door swings open.
• Pull the door (132) towards the operator; the
door closes.

131 132

6.4 Removable load backrest

CAUTION!
Trapping hazard and heavy load backrest weight
uWear safety gloves and safety shoes when carrying out this operation.
uTwo people are required to remove and attach the load backrest.
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124
 Load backrest disassembly

Procedure
• Loosen the screws (133).
• Remove the load backrest from the fork
carriage and put it down securely. 133
• Fit the fork retaining screws.

Load backrest assembly

Procedure
• Attach the load backrest to the top rail of the fork carriage.
• Fit the bolts and tighten them with a torque wrench.

Z Tightening torque = 85 Nm
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125
6.5 Lift cutout override

Z A lift cutout device can be factory fitted when working in areas of restricted height.
This interrupts lifting.

To continue lifting:

Procedure
122
• Press the lift cutout override button (see
page 68) .
• Pull the control lever (122).

Lift cutout is deactivated until the button is

pressed again or the fork carriage is lowered
below the height limit setting.

6.6 Fire extinguisher

Procedure
• Open the fasteners (134).
• Pull the fire extinguish out of its bracket.

Z To operate, refer to the illustrations on

the fire extinguisher.

134

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126
 6.7 Tilt angle display

NOTICE
The current tilt angle is shown in an additional
display that is attached on the right of the
dashboard. 135

– The green LED (135) indicates the vertical

position to the ground.

6.8 Rockinger coupling with hand lever or remote control

Z Refer to the instructions for towing trailers, see page 119.

137 136
CAUTION!
Incorrectly coupled trailers can cause
accidents
uMake sure the coupling is engaged securely
before starting the truck.
uThe contro pin (138) must be flush with the
control sleeve (139).
Rockinger coupling operation (attaching
trailers)

Procedure 138 139

• Prevent the trailer from rolling away.

• Adjusting the trailer pull rod to the height of
the coupling.
• Pull the hand lever (137) / remote control
(136) (o) up.

Z The remote control (136) (o) is located in

the overhead guard, depending on the
truck model.
• Slowly reverse the truck until the coupling
engages.
• Push the hand lever (137) / remote control
(136) (o) down.

Rockinger coupling operation (disconnecting trailers)

Procedure
• Prevent the trailer from rolling away.
• Pull the hand lever (137) / remote control (136) (o) up.
• Drive the truck forward.
• Push the hand lever (137) / remote control (136) (o) down.
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127
6.9 Camera system
CAUTION!
Accident risk from hidden work areas
uThe camera system acts as an aid to assist safe operation.
uPractice travelling and working with the camera system.
uAlign the camera so that the hidden work area can be seen.

Z When using the camera to reverse, the monitor automatically switches on when you
engage reverse gear.

140 141 142 143 144

Using the camera system

– Press the button (144) on the monitor to switch the camera system on or off.
– Press the button (143) to lighten or darken the screen (day / night settings).
– Press the button (140) to open the menu.

Z Pressing the button several times changes the menu item (contrast, brightness,
colour saturation, language, video, light reflection) or quits the menu.

Adjusting the menu items

– Press the button (142) to go one step forward.
– Press the button (141) to go one step back.

Z Clean a dirty screen or vent slots with a soft cloth or brush.

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 6.10 Control layout “N”
WARNING!
Persons standing under or on a raised load handler are at risk of accidents
Do not allow anyone to stand under or on a raised load handler.
uDo not stand on the load handler.
uDo not lift any persons on the load handler.
uInstruct other people to move out of the hazardous area of the truck.
uDo not stand underneath a raised and unsecured load handler.

Z With control layout “N”, the lift and tilt functions are swapped compared with the
standard operation. The Pilot must only be operated from the driver’s seat. The
operator must be trained to handle the lift mechanism and the attachments.
NOTICE
uThe lift/lower and tilt speeds are determined by the inclination of the Multipilot. Do
not deposit the load handler suddenly to avoid damaging the load and the racking.
Lifting

Procedure
• Push the Multipilot to the right (direction H) to raise the load.
• Push the Multipilot to the left (direction S) to lower the load.

Tilting V
S

CAUTION!
Trapping hazard from inclined mast R
H
uWhen tilting the mast back, keep all parts of
your body from between the mast and the front
wall.
Procedure
• Push the Multipilot forward (direction V) to tilt the load forward.
• Pull the Multipilot back (direction R) to tilt the load back.

Z When the limit position for the operation has been reached (there will be a noise
from the pressure relief valve) release the lever. The lever will revert automatically to
neutral.
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6.11 Floor-Spot
CAUTION!
Risk of accident due to dazzling
Looking directly into the light beam of the Floor-Spot can dazzle and temporarily
impair eyesight.
uDo not look directly into the light beam of the Floor-Spot.
uDo not adjust the position and alignment of the Floor-Spot on the truck.

The Floor-Spot serves as an auxiliary device and, with the travel direction selected,
projects a coloured dot on the floor at a distance of 4-4,5 m.
When the truck travels forward, the coloured dot is in front of the truck. When
reversing, it is behind the truck.

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 6.11.1 Additional information on Floor-Spot blue

Z Only for Floor-Spot blue (51466740/51631731)

The activated Floor-Spot gives persons advance warning of the travel path of the
forklift truck by projecting a blue dot onto the ground at a set distance.

CAUTION!
Risk of retinal damage due to blue light
The Floor-Spot on the truck is classified in risk group 2 according to the standard
IEC 62471: medium risk. In the range of 400 nm to 780 nm, blue light can potentially
damage the retina of the human eye.
uCheck that the warning notice: "Caution! Potentially dangerous optical radiation" is
present and legible, and replace if necessary.
uDo not look directly into the light beam of the Floor-Spot.
uWhen performing maintenance and repairs, take the Floor-Spot out of service, e.g.
by disconnecting the battery, and secure it against unintentional recommissioning.

Z The warning notice "Caution! Potentially dangerous optical radiation" is attached to

the side of the chassis or to the overhead guard. Small warning notices are attached
to the side of the Floor-Spot.
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7 Troubleshooting

7.1 Troubleshooting
This chapter enables the operator to localize and rectify basic faults or the results of
incorrect operation himself. When trying to locate a fault, proceed in the order shown
in the remedy table.

Z If, after carrying out the following remedial action, the truck cannot be restored to
operation or if a fault in the electronics system is displayed with a corresponding
error code, contact the manufacturer’s service department.
Troubleshooting must only be performed by the manufacturer’s customer service
department. The manufacturer has a service department specially trained for these
tasks.
In order for customer services to react quickly and specifically to the fault, the
following information is essential:
- Truck serial number
- Event message from the display unit (if applicable)
- Error description
- Current location of truck.

Info messages

Display Meaning
Info 03 Traction or lift controller temperature above 83°C
Accelerator pedal zero position
– Message can be set via parameters: either the zero position is
Info 35
only checked after power up or after every change of seat
switch status from open to closed.
Hydraulics zero position
Info 36 – Message can be set via parameters: message displayed or
not.
Overtemperature
Info 40
– Traction or lift motor above 145℃.
Travel against parking brake
Info 90 – Accelerator pressed while parking brake applied.
– Seat switch not occupied and parking brake not applied.
Hydraulics zero position on truck power up
Info 96 – A hydraulic function applied during power up.
– The hydraulic function applied will not be performed.
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 Fault Possible Cause Remedy
Truck does not start – Battery connector not – Check battery connector
plugged in. and plug in if necessary.
– Emergency Disconnect – Unlock the Emergency
switch pressed. Disconnect
– Key switch set to O. – Set the key switch to “I”.
– Battery charge too low. – Check battery charge,
– Faulty fuse. charge battery if
necessary.
– Check the fuses.
Load cannot be lifted – Truck not operational. – Carry out all measures
listed under “Truck does
– Hydraulic oil level too not start”.
low. – Check hydraulic oil level.
– Battery discharge – Charge the battery
monitor has switched – Check the fuses (o).
off. – Note the maximum
– Faulty fuse. capacity, see page 33.
– Load is too heavy.
Fault displays – Truck not operational. – Press the EMERGENCY
DISCONNECT isolator or
turn key switch to 0, after
approx. 3 seconds try to
perform the desired
operation again
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7.2 Operating the truck without its own drive system

7.2.1 Towing the truck

WARNING!
Accident risk
Other people can be injured if the truck is towed incorrectly.
uOnly use vehicles to tow the truck which have sufficient tow and brake forces for
the trailer load without its own braking system.
uAlways use a pull rod to tow.
uAlways tow the truck at walking pace.
uDo not park the truck with the parking brake released.
uOne person must be seated in the recovery truck to steer it and one person must
be seated on the towed truck.

52

Towing the truck

Requirements
– Park the truck securely.
– Disconnect the battery.
Procedure
• Connect the pull rod to the trailer coupling (52) of the towing truck and attach it to
the truck to be towed.
• Release the parking brake, see page 94.
• Tow the truck to its destination.
• Apply the parking brake, see page 94.
• Undo the tow connection.

The truck has now reached its destination and is secure.

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 7.3 Emergency lowering

Z The load handler can be lowered manually if a fault occurs in the hydraulic controller.

WARNING!
Lowering the mast can result in injuries
uInstruct other people to move out of the hazardous area of the truck during
emergency lowering.
uNever stand underneath a raised load handler.
uOnly operate the emergency lowering valve when standing next to the truck.
uEmergency lowering of the mast cannot be applied when the load handler is in the
rack.
uReport any defects immediately to your supervisor.
uTag out and decommission a faulty lift truck.
uOnly return the truck to service when you have identified and rectified the fault.

Emergency mast lowering - Solo

Pilot
55

Requirements
– Load handler is not in the rack.
– Turn the Emergency Disconnect
switch and key switch off.
– Disconnect the battery. 56

– Remove the panel, press the

lever (56) to unlock the cover (55)
and move the cover forward.
Procedure
• Slowly turn the emergency
lowering valve (145); the mast and
load handler will lower.
• Turn the emergency lowering
valve (145) in the opposite 145
direction as far as the stop; the
lowering process stops.

The mast is now lowered.

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 Emergency mast lowering - Multi
Pilot

Requirements
– Load handler is not in the rack.
– Turn the Emergency Disconnect
switch and key switch off.
– Disconnect the battery.
– Remove the panel, push the
steering column forward and pull
the cover (57) forward until it 145
engages.
Procedure
• Slowly turn the emergency
lowering valve (145); the mast
and load handler will lower.
• Turn the emergency lowering
valve (145) in the opposite
direction as far as the stop; the
lowering process stops.
57
The mast is now lowered.

WARNING!
Only return the truck to service when you have identified and rectified the fault.

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 F Industrial Truck Maintenance
1 Spare Parts
To ensure safe and reliable operation, use only the manufacturer's original spare
parts.

The manufacturer’s original spare parts are consistent with the manufacturer’s
specifications and guarantee the highest possible quality of safety, size accuracy
and material.

The installation or use of non-original spare parts can negatively affect the specified
properties of the product and impair safety. The manufacturer cannot be held liable
for damage caused by the use of non-original spare parts.

The product-related electronic spare parts catalogue can be found at

(www.jungheinrich.de/spare-parts-search) by entering the serial number.

Z The serial number can be found on the data plate, see page 32.
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2 Operational Safety and Environmental Protection
The inspections and maintenance tasks listed in chapter "Maintenance, Inspection
and Changing of Maintenance Parts Requiring Replacement" must be performed
according to the defined service intervals (see page 173).

The manufacturer recommends the replacement of the maintenance parts also listed
in chapter "Maintenance, Inspection and Changing of Maintenance Parts Requiring
Replacement" according to the specified replacement intervals (see page 173).

WARNING!
Risk of accidents and component damage
Any modification to the truck, in particular the safety mechanisms, is prohibited.

Exception: Operating companies should only make changes or have changes made
to powered industrial trucks if the manufacturer is no longer operating in the field and
there is no successor to the business; operating companies must however:
– Ensure that the changes to be made are planned, tested and performed by a
specialist engineer in industrial trucks taking safety into account.
– Keep permanent records of the construction, tests and completion of changes
– Carry out and have authorised the respective changes to the capacity data plates,
decals and stickers as well as the operating instructions and workshop manuals
– Attach a permanent and clearly visible marking to the truck indicating the types of
changes made, the date of the changes and the name and address of the
organisation responsible for the work.

NOTICE
Only original spare parts are subject to the manufacturer's quality control. To ensure
safe and reliable operation, use only the manufacturer's spare parts.

Z On completion of inspection and service work, carry out the operations listed in the
“Recommissioning the truck after cleaning or maintenance work” section (see
page 166).

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 3 Maintenance Safety Regulations

Maintenance and repair personnel

Z The manufacturer has a customer service department specially trained for these
tasks. A maintenance contract with the manufacturer will support trouble-free
operation.

Truck maintenance, repair work and changing of parts requiring replacement must
only be carried out by specialist personnel. The activities to be carried out are
divided into the following target groups.
Customer Services

Customer Services are specially trained in the use of the truck and are able to carry
out maintenance and repairs independently. Customer Services are aware of the
relevant standards, guidelines and safety regulations as well as potential risks.
Operating company

The maintenance personal of the operating company has the technical expertise and
experience to perform the activities in the maintenance check list for the operating
company. The maintenance and repair work to be performed by the operating
company are also written down, see page 137.
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3.1 Consumables and used parts
CAUTION!
Consumables and used parts are an environmental hazard
Used parts and consumables must be disposed of in accordance with the applicable
environmental-protection regulations. Oil changes should be carried out by the
manufacturer's customer service department, whose staff are specially trained for
this task.
uNote the safety regulations when handling these materials.

3.2 Wheels
WARNING!
The use of tyres that do not match the manufacturer's specifications can result
in accidents.
The quality of tyres affects the stability and performance of the truck.
Uneven wear affects the truck's stability and increases the stopping distance.
uWhen replacing tyres make sure the truck is not skewed.
uAlways replace tyres in pairs, i.e. left and right at the same time.

Z When replacing rims and tyres fitted at the factory, only use the manufacturer’s
original spare parts. Otherwise the manufacturer’s specifications cannot be ensured.
If you have any queries contact the manufacturer's customer service department.

3.3 Attachment Repairs and Inspection

WARNING!
A faulty attachment can be hazardous
Check the attachment daily for external signs of damage or defects. Faulty
attachments can cause the load to fall.
uReport any defects immediately to your supervisor.
uTag out and decommission a faulty lift truck.
uOnly return the truck to service when you have identified and rectified the fault.
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 3.4 Lift Chains
WARNING!
Risk of accident from non-lubricated and incorrectly cleaned lift chains
Lift chains are safety-critical parts. Lift chains must not show signs of serious
contamination. Lift chains and pivot pins must always be clean and sufficiently
lubricated.
uThe lift chains are cleaned by wiping or brushing. Significant contamination can be
softened by a paraffin derivative such as petroleum.
uDo not clean lift chains with high-pressure steam jets or chemical cleaning agents.
uImmediately after cleaning, dry the lift chain with compressed air and apply a chain
spray.
uLift chains must be unloaded when lubricated; to do this, fully lower the load
handler.
uLubricate a lift chain with particular care around the pulleys.

WARNING!
Diesel fuel can be hazardous
uDiesel fuel can cause irritation if it comes into contact with the skin. Rinse any
affected areas thoroughly.
uIf it comes into contact with the eyes rinse them immediately with flowing water
and call for a doctor.
uWear safety gloves when handling diesel fuels.
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3.5 Hydraulic system
WARNING!
Leaky hydraulic systems can result in accidents
Hydraulic oil can escape from leaky and faulty hydraulic systems.
uReport any defects immediately to your supervisor.
uMark defective truck and take out of service.
uDo not return the industrial truck to service until you have identified and rectified
the fault.
uRemove any spilled hydraulic immediately with an appropriate bonding agent.
uThe bonding agent / consumable mixture must be disposed of in accordance with
regulations.

WARNING!
Faulty hydraulic hoses can result in injury and infection
Pressurised hydraulic oil can escape from fine holes or hairline cracks in the
hydraulic hoses. Brittle hydraulic hoses can burst during operation. People standing
near the truck can be injured by the hydraulic oil.
uCall for a doctor immediately in the event of an injury.
uDo not touch pressurised hydraulic hoses.
uReport any defects immediately to your supervisor.
uMark defective truck and take it out of service.
uDo not return the industrial truck to service until you have identified and rectified
the fault.
NOTICE
Testing and replacing hydraulic hoses
Hydraulic hoses can become brittle through age and must be checked at regular
intervals. The application conditions of the industrial truck have a considerable
impact on the ageing of the hydraulic hoses.
uCheck the hydraulic hoses at least annually and replace if necessary.
uIf the operating conditions become more arduous the inspection intervals must be
reduced accordingly.
uIn normal operating conditions a precautionary replacement of the hydraulic hoses
is recommended after 6 years. The owner must carry out a risk assessment to
ensure safe, prolonged use. The resulting protection measures must be observed
and the inspection interval reduced accordingly.
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 4 Lubricants and Lubrication Schedule

4.1 Handling consumables safely

Handling consumables

Consumables must always be handled correctly. Follow the manufacturer’s

instructions.

WARNING!
Improper handling is hazardous to health, life and the environment
Consumables can be flammable.
uKeep consumables away from hot components and naked flames.
uAlways keep consumables in prescribed marked containers.
uAlways fill consumables in clean containers.
uDo not mix up different grades of consumable. The only exception to this is when
mixing is expressly stipulated in the Operating Instructions.

CAUTION!
Spilled consumables can cause slipping and endanger the environment
Risk of slipping from spilled consumables. The risk is greater when combined with
water.
uDo not spill consumables.
uSpilled consumables must be removed immediately with an appropriate bonding
agent.
uThe bonding agent / consumable mixture must be disposed of in accordance with
regulations.
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 WARNING!
Improper handling of oils can be hazardous
Oils (chain spray / hydraulic oil) are flammable and poisonous.
uDispose of used oils in accordance with regulations. Store used oil safely until it
can be disposed of in accordance with regulations.
uDo not spill oil.
uSpilled oils must be removed immediately with an appropriate bonding agent.
uThe mixture consisting of the bonding agent and oil must be disposed of in
accordance with regulations.
uObserve national regulations when handling oils.
uWear safety gloves when handling oils.
uPrevent oil from coming into contact with hot motor parts.
uDo not smoke when handling oil.
uAvoid contact and digestion. If you swallow oil do not induce vomiting but seek
medical assistance immediately.
uSeek fresh air after breathing in oil fumes or vapours.
uIf oil has come into contact with your skin, rinse your skin with water.
uIf oil has come into contact with your eyes, rinse them with water and seek medical
assistance immediately.
uReplace oil-soaked clothing and shoes immediately.

CAUTION!
Consumables and used parts are an environmental hazard
Used parts and consumables must be disposed of in accordance with the applicable
environmental-protection regulations. Oil changes should be carried out by the
manufacturer's customer service department, whose staff are specially trained for
this task.
uNote the safety regulations when handling these materials.

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 4.2 Lubrication Schedule

D G
0,4l

N
4,15 l

g Contact surfaces c Hydraulic oil drain plug

s Grease nipple b Gear oil filler neck

Hydraulic oil filler neck a Gear unit oil drain plug

t Brake fluid filler neck o Gear oil control screw

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4.3 Consumables
Cod Package
Order no. Capacity Description Used for
e quantity
Jungheinrich
51 132 827* 5l
hydraulic oil
50 426 072 20l HLPD 32 1)
Hydraulic
A 50 429 647 20l 14.5 l HLPD 22 2)
system
50 124 051 5l HV 68 3)
Plantosyn 46 HVI
51 082 888 5l
(BIO hydraulic oil)
Brake fluid
SAE J 1703 4)
Hydraulic
D 29 201 570 1l 0.25 l FMVSS 116
brake system
DOT 3 and DOT
4
Front wheel
Lubrication
bearings,
E 50 157 382 1kg grease
steering
K-L 3N 3)
transmission
G 29 201 280 400ml Chain spray Chains
Transmission oil
N 50 468 784 1l 4.15 l Transmission
EP 80
1) Valid for temperatures -5/+30 °C
2) Valid for temperatures -20/-5 °C
3) Valid for temperatures +30/+50 °C

Z *The trucks are factory-equipped with a special manufacturer's hydraulic oil (the
Jungheinrich hydraulic oil with a blue colouration) or the Plantosyn 46 HVI bio
hydraulic oil. This special hydraulic oil can only be obtained from the manufacturer's
customer service department. The use of named alternative hydraulic oils is not
prohibited, but may lead to a decline in functionality. This hydraulic oil may be mixed
with one of the named alternative hydraulic oils.
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 WARNING!
Industrial trucks are factory-equipped with "HLP D22/32" hydraulic oil or "+ 2%
Plantosyn 46 HVI" BIO hydraulic oil.
You cannot change from "Plantosyn 46 HVI" BIO hydraulic oil to the manufacturer's
hydraulic oil. The same applies to changing from the manufacturer's hydraulic oil to
"Plantosyn 46 HVI" bio hydraulic oil.
Do not mix the Plantosyn 46 HVI bio hydraulic oil with the manufacturer's hydraulic
oil or one of the named alternative hydraulic oils.

Grease guidelines

Code Saponification Dew point Worked NLG1 class Application

°C penetration temperature
at 25 °C °C
E Lithium 185 265 - 295 2 -35/+120
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5 Maintenance and repairs

5.1 Preparing the truck for maintenance and repairs

All necessary safety measures must be taken to avoid accidents when carrying out
maintenance and repairs. The following preparations must be made:
Procedure
• Park the truck securely, see page 88.
• Fully lower the load handler.
• Disconnect the battery to prevent the truck from being switched on accidentally.

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 5.2 Lifting and jacking up the truck safely
WARNING!
A truck tipover can cause accidents
In order to raise the truck, use only suitable lifting gear at the points specially
provided for this purpose.
uNote the weight of the truck on the data plate.
uAlways use a jack with a minimum capacity of 2500 kg kg.
uRaise the unladen truck on a level surface.
uWhen raising the truck, take appropriate measures to prevent it from slipping or
tipping over (e.g. wedges, wooden blocks).
Raising and jacking up the truck securely

Requirements
– Prepare the truck for maintenance and repairs (see page 148).
Tools and Material Required
– Jack
– Hard wooden blocks
Procedure
• Place the jack against the contact point.

Z Jack contact point, see page 30.

• Raise the truck.
• Support the truck with hard wooden blocks.
• Remove the jack.

The truck is now securely raised and jacked up.

Z To lower the truck, proceed in reverse order.

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5.3 Opening the battery panel

Open the battery cover with the SOLO-PILOT

Requirements 55
– Park the truck securely, see page 88.
– Load handler lowered.
– Key switch set to OFF.
– Key removed.
– Set the Emergency Disconnect OFF.
56
Procedure
• Press the lever (56) to unlock the cover (55)
and move it forward.
• Carefully lift back the battery cover and the
driver’s seat as far as the stop (opening angle = 90°).

The battery cover is now open. The fuses and other electrical components can now
be reached.

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 Opening the battery cover with the MULTI-
PILOT (o) 58

Requirements 1

– Park the truck securely, see page 88.

– Load handler lowered.
– Key switch set to OFF.
– Key removed.
– Set the Emergency Disconnect OFF.
Procedure
• Release the steering column lock (58), push
the steering column forward and secure it in
this position.
• Pull the
panel (57)
forward
until it
engages.
• Carefully
lift back
the
57
battery
cover and
the
driver’s seat (1) as far as the stop (opening angle = 90°).

The battery cover is now open. The fuses and other electrical components can now
be reached.

Z On trucks with a rear window / canvas cover, open the rear window / canvas cover
before opening the battery cover.
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5.4 Checking the wheel attachments.
WARNING!
Using different tyres can cause accidents
The quality of the tyres affects the operational stability and performance of the truck.
uThe diameter of the wheels must differ by no more than 15 mm.
uAlways replace tyres in pairs, i.e. left and right at the same time. After replacing
the tyres check the wheel nuts are secure after 10 service hours.
uAlways use tyres of the same make, model and profile.

Checking the mounting of wheels

Requirements
– Prepare the truck for maintenance and repairs
(see page 148).
Tools and Material Required 146

– Torque wrench
Procedure
• Torque the wheel nuts (146) crosswise with a
torque wrench; tightening torques see page 25.

The mounting of wheels is now checked.

Z When using pneumatic tyres check the air pressure, for the air pressure see page 25

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 5.5 Replacing wheels
WARNING!
A truck tipover can cause accidents
In order to raise the truck, use only suitable lifting gear at the points specially
provided for this purpose.
uNote the weight of the truck on the data plate.
uAlways use a jack with a minimum capacity of 2500 kg kg.
uRaise the unladen truck on a level surface.
uWhen raising the truck, take appropriate measures to prevent it from slipping or
tipping over (e.g. wedges, wooden blocks).

WARNING!
Falling wheels can cause injury
uThe wheels of the truck are very heavy. A single wheel can weigh up to 150 kg.
uAlways replace wheels with a suitable tool and protective equipment.

Removing the wheels

Requirements
– Prepare the truck for maintenance and repairs
(see page 148).
Tools and Material Required
– Jack 146
– Hard wooden blocks
– Mounting lever
– Torque wrench
Procedure
• Place the jack against the contact point.

Z Jack contact point, see page 30.

• Raise the truck.
• Support the truck with hard wooden blocks.
• Undo the wheel attachment (146).
• Remove the wheel, using a suitable mounting lever if necessary.

The wheel has now been removed.

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 Fitting the wheels

Procedure
• Fit the wheel using a suitable mounting lever if
necessary.
• Fit the wheel attachment.
• Remove the hard wooden blocks.
• Lower the truck. 146
• Torque the wheel attachment (146) crosswise
with a torque wrench; tightening torques see
page 25.

The wheel has now been fitted.

Z When using pneumatic tyres check the air pressure, for the air pressure see page 25

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 5.6 Hydraulic system
CAUTION!
The hydraulic oil is pressurised during operation and is a hazard to health and to the
environment.
uDo not touch pressurised hydraulic lines.
uDispose of used oil in accordance with regulations. Store used oil safely until it can
be disposed of in accordance with regulations.
uDo not spill hydraulic oil.
uRemove any spilled hydraulic immediately with an appropriate bonding agent.
uThe bonding agent / consumable mixture must be disposed of in accordance with
regulations.
uObserve national regulations when handling hydraulic oil.
uWear safety gloves when handling hydraulic oil.
uPrevent hydraulic oil from coming into contact with hot motor parts.
uDo not smoke when handling hydraulic oil.
uAvoid contact and digestion. If you swallow oil do not induce vomiting but seek
medical assistance immediately.
uSeek fresh air after breathing in oil fumes or vapours.
uIf oil has come into contact with your skin, rinse your skin with water.
uIf oil has come into contact with your eyes, rinse them with water and seek medical
assistance immediately.
uReplace oil-soaked clothing and shoes immediately.

CAUTION!
Consumables and used parts are an environmental hazard
Used parts and consumables must be disposed of in accordance with the applicable
environmental protection regulations. To change the oil contact the manufacturer's
customer service department, who have been specially trained for this task.
uNote the safety regulations when handling these materials.
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5.6.1 Checking the hydraulic oil level

CAUTION!
The use of unsuitable hydraulic oils can cause damage
Trucks with bio hydraulic oil have a warning notice on the hydraulic
reservoir: “Add hydraulic oil only”.
uUse only BIO hydraulic oil.

Checking the hydraulic oil level and

adding hydraulic oil 147

Requirements
– Park the truck on a level surface.
– Prepare the truck for maintenance and
repairs (see page 148).
– Battery cover open, see page 150.
Procedure
• Unscrew the air filter and dipstick (147).
• Visually inspect the hydraulic oil level on
the dipstick.

Z If the reservoir is sufficiently full, the hydraulic oil level will be at the top mark
(max.). If necessary add hydraulic oil up to the level indicated (20 mm on the
dipstick corresponds to approx. 1 l <hydraulic oil).

The hydraulic oil level is now checked.

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 5.6.2 Replacing the hydraulic oil filter

Replacing the oil filter

Requirements
– Park the truck on a level surface.
148
– Prepare the truck for maintenance and repair
work (see page 148).
Procedure
• Unscrew the hydraulic oil filter cap (148).
The filter element is located on the cap.
• Replace the filter insert; if the O ring is damaged it will also need to be replaced.
Apply a thin layer of oil to the O ring on assembly.
• Refit the cap with the new filter element in place.

5.7 Check the gear oil level

CAUTION!
Consumables and used parts are an environmental hazard
Used parts and consumables must be disposed of in accordance with the applicable
environmental protection regulations. To change the oil contact the manufacturer's
customer service department, who have been specially trained for this task.
uNote the safety regulations when handling these materials.
Check the gear oil level

Requirements
– Park the truck securely, see page 88
Tools and Material Required
– Oil sump
Procedure
• Place the oil sump underneath the transmission
• Unscrew the oil dipstick (151).
• Check gear oil level, top up if necessary through the filler hole (150).

Z The oil level should reach the bottom mark of the oil check hole (151).

The transmission oil level is now checked.

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 Draining the oil 149,150

Procedure
• Drain oil at operating temperature. 151
• Place the oil sump underneath the
transmission
• Unscrew the oil drain plug (152) and drain the 152
transmission oil.

Z To ensure swift and complete draining of the

transmission oil, unscrew the oil dipstick (151).

The oil is now drained.

Adding oil

Procedure
• Insert the oil drain plug (152).
• Remove the cap (149).
• Turn the steering axle wheel until the filler bore (150) is visible.
• Unscrew the oil control screw (151) and add new gear oil in the filler hole (150).

The oil has now been added.

5.8 Adding window washer system fluid

Procedure
• Make sure there is sufficient window fluid in
the container (153).
• If necessary top up with anti-freeze. 153

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 5.9 Checking electrical fuses
WARNING!
Electric currents can cause accidents
Make sure the electrical system is voltage-free before starting work on it. Before
starting maintenance on the electrical system:
uPark the truck securely (see page 88).
uPress the Emergency Disconnect.
uDisconnect the battery.
uRemove any rings or metal bracelets etc. before working on electrical
components.

CAUTION!
The use of incorrect fuses can cause fire and damage components
The use of incorrect fuses can damage the electrical system and result in fire. The
safety and functionality of the truck cannot be ensured.
uUse only fuses with the prescribed rated current, see page 160.
Checking electrical fuses

Requirements
– Prepare the truck for maintenance and repairs (see page 148).
Procedure
• Open the battery panel, see page 150.
• Remove the electrical system cap.
• Check condition and rating of the fuses in accordance with the table.
• Replace any damaged fuses in accordance with the table.
• Close the electrical system cap.
• Close the truck’s battery cover.

The electrical fuses are now checked.

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5.9.1 Fuse ratings

154

155

156

157
158

159

Rating /
Item Description Electric circuit
type
154 1F Drive motor fuse 250 A
155 2F1 Hydraulic motor fuse 250 A
156 F3.1 Control fuse 24 V 40 A
157 1F9 Travel / lift electronics fuse 10 A
158 4F1 Horn control fuse 10 A
159 F4 Main contactor control fuse 5A
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 160 161 162
163 164 165

166
167
168
169
170
171

Fuses for optional equipment

Item Description Electrical circuit Rating/type
Fuse, reversing lights or
160 5F3 10 A
rear work lights
161 5F1 Fuse, front work lights 10 A
162 9F2 Control fuse, seat heating 10 A
163 4F6 Fuse, brake light 10 A
164 4F4 Control fuse, warning beacon 5A
Control fuse, front/rear windscreen wiper
165 5F6 10 A
and rear windscreen heater
166 F1.1 Fuse, indicator relay 5A
167 5F5.2 Control fuse, reversing light 5A
168 5F4 Control fuse, RH tail light 5A
169 5F4.1 Control fuse, LH tail light 5A
170 5F5 Control fuse, RH lighting 5A
171 5F5.1 Control fuse, LH lighting 5A
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5.10 Cleaning

Z Cleaning tasks may only take place in the designated locations, which adhere to the
stipulations of the country of use.

5.10.1 Cleaning the truck

CAUTION!
Fire hazard
Do not use flammable liquids to clean the industrial truck.
uDisconnect the battery before starting cleaning work.
uCarry out all necessary safety measures to prevent sparking before cleaning (e.g.
by short-circuiting).

CAUTION!
Risk of component damage when cleaning the truck
Cleaning with a pressure washer can result in malfunctions due to humidity.
uCover all electronic system assemblies (controllers, sensors, motors etc.) before
cleaning the truck with a pressure washer.
uDo not hold the jet of the pressure washer by the marked points to avoid damaging
them (see page 30).
uDo not clean the truck with pressurised water.
NOTICE
Risk of damage when cleaning the truck with a high-pressure cleaner
Cleaning with a high-pressure cleaner can cause discolouration or other damage on
coated or painted surfaces.
uDo not clean the truck with hot water or steam jets.
uDo clean the truck using acidic or aggressive cleaning agents such as insect
removers.
uDo not clean the truck with insufficiently diluted cleaning agents.
uBefore using a cleaning agent, read the manufacturer's instructions. Test an
inconspicuous or concealed part of the coated or painted truck surface for
potential reactions to the cleaning agent.
uThoroughly rinse off any road salt before cleaning the truck.
uThe counterweight of the truck should ideally be cleaned using cold water and a
clean, soft cotton cloth.
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 NOTICE
Risk of damage to the roof window
Dry cleaning, cleaning with paper towels or cleaning with dirty or large-fibre cleaning
cloths can scratch the polycarbonate roof window. The static charge caused by dry
cleaning can attract more dust to the roof window. The use of unsuitable cleaning
agents can also damage the roof window.
External influences such as aggressive vapours, liquids or condensates can cause
discolouration and damage the roof window.
uOnly clean the roof window with a damp, soft cotton cloth.
uUse only glass cleaner with a low alcohol content or clean water without cleaning
additives.
uDo not dry clean or pre-wipe the roof window.
uIf necessary, rub the roof window dry using a clean, soft cotton cloth.
uReplace the roof window in the case of damage, scratched surfaces, poor visibility
or discolouration.
Cleaning the truck

Requirements
– Truck prepared for maintenance and repair work (see page 148).
Tools and Material Required
– Water-based solvents
– Sponge or cloth
Procedure
• Clean the surface of the truck with water-based solvents and water. Use a sponge
or cloth to clean.
• In particular, clean the following areas:
• Windscreens
• All walk-on areas
• Oil filler caps and their surroundings
• Grease nipples (before lubrication)
• Dry the truck after cleaning, e.g. with compressed air or a dry cloth.
• Carry out all the tasks in the section "Recommissioning the truck after cleaning or
maintenance work" (see page 169).

The truck is now clean.

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5.10.2 Cleaning the electrical system assemblies

CAUTION!
Risk of electrical system damage
Cleaning the assemblies (controllers, sensors, motors etc.) of the electronic system
with water can damage the electrical system.
uDo not clean the electrical system with water.
uClean the electrical system with weak suction or compressed air (use a
compressor with a water trap) and not a conductive, anti-static brush.
Cleaning the electrical system assemblies

Requirements
– Truck prepared for maintenance and repair work (see page 148).
Tools and Material Required
– Compressor with water separator
– Non-conductive, antistatic brush
Procedure
• Expose the electrical system, see page 150.
• Clean the electrical system assemblies with weak suction or compressed air (use
a compressor with a water separator) and a non-conductive, anti-static brush.
• Fit the electrical system panel, see page 150.
• Carry out all the tasks in the section "Recommissioning the truck after cleaning or
maintenance work" (see page 169).

The electrical system assemblies are now clean.

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 5.11 Working on the electrical system
WARNING!
Electrical current can cause accidents
Ensure the electrical system is de-energised before starting work. The capacitors in
the control must be completely discharged. The capacitors are fully discharged
approx. 10 minutes after disconnecting the electrical system from the battery.
Before starting maintenance on the electrical system:
uOnly suitably trained electricians may work on the truck's electrical system.
uBefore working on the electrical system, take all precautionary measures to avoid
electric shocks.
uPark the truck securely (see page 88).
uDisconnect the battery.
uRemove any rings, metal wristbands etc.
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5.12 Restoring the truck to service after maintenance and repairs
Procedure
• Thoroughly clean the truck – see page 162.
• Lubricate the forklift truck according to the lubrication schedule – see page 145.
• Equipped with lead-acid battery (t): Clean the battery, grease the battery terminal
screws with terminal grease and connect the battery.
• Equipped with lithium-ion battery (o) without interface converter on the battery:
Insert the truck-side control line into the connection on the battery trough.
• Equipped with lithium-ion battery (o) with interface converter on the battery:
• Pull the battery forward.
• Insert the control line into the battery connection at the top of the battery or the
inside of the trough.
• Slide the battery back in.
• Connect the battery to the truck.
• Close the battery connector lock: Tighten the bolted bar.
• Insert the truck control line into the interface converter on the battery.
• Charge the battery – see page 55.
• Commission the forklift truck – see page 71.

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 6 Decommissioning the industrial truck
If the truck is to be out of service for more than a month, it must be stored in a frost-
free and dry room. All necessary measures must be taken before, during and after
decommissioning as described hereafter.

When the truck is out of service it must be jacked up so that all the wheels are clear
of the ground. This is the only way of ensuring that the wheels and wheel bearings
are not damaged.

Z Jack up the truck, see page 149.

If the truck is to be out of service for more than 6 months, agree further measures
with the manufacturer's customer service department.
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6.1 Prior to decommissioning
Procedure
• Thoroughly clean the truck – see page 162.
• Prevent the truck from rolling away accidentally.
• Check the hydraulic oil level and replenish if necessary, see page 156.
• Apply a thin layer of oil or grease to any non-painted mechanical components.
• Lubricate the truck according to the lubrication diagram, see page 145.
• Charge the battery, see page 55.
• Disconnect and clean the battery.
• Clean the terminal screws, grease them with terminal grease and screw them into
the connection thread to prevent short circuits.

Z In addition, follow the battery manufacturer’s instructions.

6.2 During decommissioning

NOTICE
Full discharge can damage the battery
Self-discharge can cause the battery to fully discharge. Full discharge shortens the
useful life of the battery.
uCharge the battery at least every 2 months.

Z Charge the battery, see page 55.

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 6.3 Restoring the truck to service after decommissioning
Procedure
• Thoroughly clean the truck – see page 162.
• Lubricate the forklift truck according to the lubrication schedule – see page 145.
• Equipped with lead-acid battery (t): Clean the battery, grease the battery terminal
screws with terminal grease and connect the battery.
• Equipped with lithium-ion battery (o) without interface converter on the battery:
Insert the truck-side control line into the connection on the battery trough.
• Equipped with lithium-ion battery (o) with interface converter on the battery:
• Pull the battery forward.
• Insert the control line into the battery connection at the top of the battery or the
inside of the trough.
• Slide the battery back in.
• Connect the battery to the truck.
• Close the battery connector lock: Tighten the bolted bar.
• Insert the truck control line into the interface converter on the battery.
• Charge the battery – see page 55.
• Commission the forklift truck – see page 71.
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7 Safety tests to be performed at intervals and after unusual
incidents
The truck must be inspected at least annually (refer to national regulations) or after
any unusual event by a qualified inspector. The manufacturer offers a safety
inspection service which is performed by personnel specifically trained for this
purpose.

A complete test must be carried out on the technical condition of the truck with
regard to safety. The truck must also be examined thoroughly for damage.

The operating company is responsible for ensuring that faults are rectified
immediately.

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 8 Final de-commissioning, disposal

Z Final de-commissioning or disposal of the truck in must be performed in accordance

with the regulations of the country of use. In particular, regulations governing the
disposal of batteries, consumables and electronic and electrical systems must be
observed.
The truck must only be disassembled by trained personnel in accordance with the
procedures as specified by the manufacturer.

9 Human vibration measurement

Z Vibrations that affect the operator over the course of the day are known as human
vibrations. Excessive human vibrations will cause the operator long term health
problems. The European "2002/44/EC/Vibration" operator directive has therefore
been established to protect operators. To help operators to assess the application
situation, the manufacturer offers a service of measuring these human vibrations.
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172
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 G Maintenance, Inspection and Changing of
Maintenance Parts Requiring
Replacement
WARNING!
Lack of maintenance can result in accidents
Failure to perform regular maintenance and inspections can lead to truck failure and
poses a potential hazard to personnel and equipment.
uThorough and expert maintenance and inspections are among the most important
requirements for the safe operation of the industrial truck.
NOTICE
The application conditions of an industrial truck have a considerable impact on
component wear. The following service, inspection and replacement intervals are
based on single-shift operation under normal operating conditions. The intervals
must be reduced accordingly if more stringent requirements are placed on the
equipment, e.g., use in conditions of extreme dust, temperature fluctuations or
multiple shifts.
uTo prevent damage due to wear, the manufacturer recommends an on-site
application analysis to agree on appropriate intervals.

The following chapter defines the tasks to be performed, the respective intervals to
be observed and the maintenance parts for which replacement is recommended.

During the truck run-in period, after approx. 100 service hours, the operating
company must check the wheel nuts/bolts and re-tighten if necessary.
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1 Maintenance Contents EFG 110-115
Issued on: 2020-10-05 08:00

1.1 Owner
To be performed every 50 service hours, but at least once a week.

1.1.1 Maintenance contents

1.1.1.1 Standard equipment

Brakes
Test the function of the brakes

Hydraulic operations
Lubricate the load chains.
Correct the hydraulic oil level.

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 1.1.1.2 Optional equipment

Fork adjuster

Hydraulic operations
Clean and lubricate the attachment.

Clamping device

Hydraulic operations
Clean and lubricate the attachment.

Sideshifter

Hydraulic operations
Clean and lubricate the attachment.

Telescopic forks

Hydraulic operations
Clean and lubricate the attachment.

Wiper/washer system

Chassis/structure
Correct the fill level of the windscreen washer reservoir.

Pneumatic tyres

Travel
Correct the tyre pressure.

Lead-acid battery, international

Power supply
Correct the battery acid level using demineralised water.

Lead-acid battery

Power supply
Correct the battery acid level using demineralised water.
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1.1.2 Inspection contents

1.1.2.1 Standard equipment

The following points must be checked:

Electrical system
Warning and safety devices are in accordance with the operating instructions
Function of display and controls
The function of the emergency disconnect and for damage

Power supply
Battery and battery components for damage
The function and secure seating of the battery connector and for damage

Travel
Wheels for wear and damage

Chassis/structure
Labels are legible, complete and plausible
Doors or covers for damage
The function of the battery panel gas strut and for damage
The function of the driver's seat restraint system and for damage
The secure seating of the overhead guard and/or the cab for damage

Hydraulic operations
Check cylinders, hydraulic connections, pipes and hoses for leaks and damage
The function of the hydraulic system
The forks or load handler for wear and damage

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 1.1.2.2 Optional equipment
The following points must be checked:
Wiper/washer system

Chassis/structure
The windscreen washer reservoir for leaks and damage

Road traffic approval

Electrical system
The function of the lighting and for damage

Work lights

Electrical system
The function of the lighting and for damage

Weather proofing

Chassis/structure
The function of the doors and for damage

Optional equipment

Chassis/structure
The function of optional equipment such as mirrors, storage compartments, grips,
windscreen wipers and washing systems, etc. and for damage

Strobe light / beacon

Electrical system
Strobe light/warning beacon for function and damage

Lead-acid battery, international

Power supply
Battery and battery components for damage
Battery cable connections are secure

Lead-acid battery

Power supply
Battery cable connections are secure
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1.2 Customer Service
In accordance with the EFG 110-115 service interval, to be performed every 1000
service hours, but at least once a year.

1.2.1 Maintenance contents

1.2.1.1 Standard equipment

Brakes
Test the function of the brakes
Adjust and lubricate the brake mechanism.
Measure the water content of brake fluid.
The brake fluid level in the expansion tank.

Electrical system
Test the contactors and/or relays.
Clean the fan.
Carry out a chassis insulation-resistance test.

Travel
Correct the oil level or grease filling of the transmission.

Hydraulic operations
Adjust the slide pieces.
Adjust the load chains.
Lubricate the load chains.
Lubricate the running surfaces of the mast.
Test emergency lowering.
Correct the hydraulic oil level.
Test and adjust the pressure relief valve.
Where two tilt cylinders with the same stroke are used, measure their relative adjustment.

Agreed services
Carry out a test run with the rated load or a customer-specific load.
Demonstration after maintenance.
Lubricate truck according to the lubrication diagram.
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 1.2.1.2 Optional equipment

Boom

Hydraulic operations
Check that the attachment and retainer to protect against accidental displacement and
unhinging are present and function correctly.

Fork adjuster

Hydraulic operations
Clean and lubricate the attachment.
The axial play of the front and rear rollers.

Clamping device

Hydraulic operations
Adjust the attachment.
Check that the attachment and retainer to protect against accidental displacement and
unhinging are present and function correctly.
Clean and lubricate the attachment.
The axial play of the front and rear rollers.

Sideshifter

Hydraulic operations
Clean and lubricate the attachment.
Test the side shift adjustment.

Telescopic forks

Hydraulic operations
Clean and lubricate the attachment.

Wiper/washer system

Chassis/structure
Correct the fill level of the windscreen washer reservoir.

Data radio

System components
Clean the scanner and terminal.

Video system

System components
Clean the camera.
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Clean the display.

179
 Weigher sensors / switches

Electrical system
Test the weighing system.

Automatic crawl speed

Travel
Clean the sensors/switches.

Pneumatic tyres

Travel
Correct the tyre pressure.

Lead-acid battery, international

Power supply
Clean and grease the battery terminals.
Clean the battery.
Measure the acid density and battery voltage.
Correct the battery acid level using demineralised water.

Lead-acid battery

Power supply
Clean and grease the battery terminals.
Clean the battery.
Measure the acid density and battery voltage.
Correct the battery acid level using demineralised water.

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 1.2.2 Inspection contents
The following points must be checked:

1.2.2.1 Standard equipment

Brakes
Brake mechanism for function and damage
Brake linings for wear and damage

Electrical system
Cables and engine are secure and for damage
Warning and safety devices are in accordance with the operating instructions
Function of display and controls
Microswitches for function and damage
The function of the emergency disconnect and for damage
Contactors and/or relays for wear and damage
The function of the fan and for damage
The electric wiring for damage (insulation damage, connections) and the fuse ratings

Power supply
The function and secure seating of the battery connector and for damage

Travel
Drivetrain bearings for wear and damage
Transmission for noise and leaks
Wheel bearings and attachment for wear and damage
Wheels for wear and damage

Chassis/structure
The secure seating of the chassis and screw connections and for damage
Labels are legible, complete and plausible
Driver's seat for damage
The secure seating of the driver's seat and the function of the adjustment mechanism
Doors or covers for damage
The function of the battery panel gas strut and for damage
The counterweight is securely attached
The mast bearings for wear
The secure seating of the mast
The function of the trailer coupling or tow mechanism and for damage
Operator mat and steps are non-slip and free of damage
The function of the driver's seat restraint system and for damage
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The secure seating of the overhead guard and/or the cab for damage

181
Hydraulic operations
The function of the "hydraulic system" controls and for legibility, completeness and
plausibility
The hydraulic control elements for correct assignment.
The secure seating of the cylinders and piston rods and for leaks and damage
The function of the hose guide and for damage
Lateral play of the mast sections and fork carriage
Slides and stops for wear and damage
Load chain mounting elements and chain pins for wear and damage
The mast rollers and their running surfaces for wear and damage
Running surfaces of the mast for wear and damage
Check cylinders, hydraulic connections, pipes and hoses for leaks and damage
The function of the hydraulic system
The secure seating of the hydraulic connections, hoses and pipes and for leaks and
damage
The forks or load handler for wear and damage
Piston rod screw depth and counter-fixing/clamping
Tilt cylinders and mounting for leaks, wear and damage

Steering
The function of the hydraulic steering and its components and for damage
The mechanical parts of the steering column for wear and damage
Steering block for wear and damage

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 1.2.2.2 Optional equipment

Electrolyte circulation

Power supply
The function of the hose connections and pump

Aquamatik

Power supply
The function of the Aquamatik plug, hose connections and float and for leaks
The function of the flow indicator and for leaks

Battery refill system

Power supply
The function of the battery refill system and for leaks

Fork adjuster

Hydraulic operations
Attachment bearings, guides and stops for wear and damage
Sliding blocks are complete and for wear and damage
The function of the attachment and for damage
The secure seating of the hydraulic connections and for leaks
Cylinder rods and their bushings for wear and damage
Cylinder seals for leaks and damage

Clamping device

Hydraulic operations
The function of the acknowledgement button
Attachment bearings, guides and stops for wear and damage
Sliding blocks are complete and for wear and damage
The function of the attachment and for damage
The secure seating of the hydraulic connections and for leaks
Cylinder rods and their bushings for wear and damage
Cylinder seals for leaks and damage
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 Sideshifter

Hydraulic operations
Attachment bearings, guides and stops for wear and damage
Proper securing of the attachment to the truck and the load-bearing components for
secure fit and damage
Sliding blocks are complete and for wear and damage
The function of the attachment and for damage
The secure seating of the hydraulic connections and for leaks
Cylinder rods and their bushings for wear and damage
Cylinder seals for leaks and damage

Telescopic forks

Hydraulic operations
Attachment bearings, guides and stops for wear and damage
Proper securing of the attachment to the truck and the load-bearing components for
secure fit and damage
The function of the attachment and for damage
Cylinder seals for leaks and damage
Hydraulic connections, hoses and pipes are secure, and for leaks and damage
The pistons and piston rods for wear and damage

Crane hook

Hydraulic operations
Proper securing of the attachment to the truck and the load-bearing components for
secure fit and damage

Wiper/washer system

Chassis/structure
The windscreen washer reservoir for leaks and damage
The function of the windscreen wipers and for damage

Trailer coupling

Chassis/structure
The function of the trailer coupling and for damage

Seat heating

Electrical system
Connections and cables are secure and for insulation damage and other damage
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 Shock sensor / data recorder

Electrical system
The shock sensor/data recorder is secure and for damage

Data radio

System components
The function and secure seating of the scanner and terminal and for damage
The secure seating of the cables and for damage

Road traffic approval

Electrical system
The function of the lighting and for damage

Video system

System components
The secure seating of the cables and for damage
The function and secure seating of the camera and for damage
The function and secure seating of the monitor and for damage

Work lights

Electrical system
The function of the lighting and for damage

Fire extinguisher

Additional services
The fire extinguisher is present and secure and check the inspection interval

Weigher sensors / switches

Electrical system
The weighing system for damage

Access module

Electrical system
Access module is secure and functions correctly and for damage

Weather proofing

Electrical system
The function of the windscreen heating and for damage
The function of the doors and for damage
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Fuse ratings

185
Chassis/structure
The function of the windscreen heating and for damage
The function of the doors and for damage
Fuse ratings

Electrical optional equipment

Electrical system
The function of the optional electrical equipment and for damage

Optional equipment

Chassis/structure
The function of optional equipment such as mirrors, storage compartments, grips,
windscreen wipers and washing systems, etc. and for damage

Strobe light / beacon

Electrical system
Strobe light/warning beacon for function and damage

Overhead guard cover

Chassis/structure
Overhead guard cover is present and secure, and for damage

Audible warning devices

Electrical system
Buzzer/warning alarm is secure and functions correctly and for damage

Belt lock control

Chassis/structure
The function of the seat belt monitoring and for damage

Automatic crawl speed

Travel
Sensors/switches are secure and function correctly and for damage

Discharge strap

Electrical system
Electrostatic discharge strap or chain is present and for damage
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 Restraint system / SUN protector

Electrical system
The secure seating of the electrical connections and for damage.
Restraint system is complete and functions correctly and for damage
Connections and cables are secure and for insulation damage and other damage

Chassis/structure
The secure seating of the electrical connections and for damage.
Restraint system is complete and functions correctly and for damage
Connections and cables are secure and for insulation damage and other damage

Restraint system / SUN protector

Chassis/structure
Restraint system is complete and functions correctly and for damage

Lead-acid battery, international

Power supply
The secure seating of the battery, battery cables and cell connectors and for damage
The presence of safety labels are present and for damage

Lead-acid battery

Power supply
The secure seating of the battery, battery cables and cell connectors and for damage
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1.2.3 Maintenance parts
The manufacturer recommends the replacement of the following maintenance parts
at the specified intervals.

1.2.3.1 Standard equipment

maintenance part service hours months
Brake fluid 2000 24
Hydraulic oil 2000 12
Hydraulic system - breather filter 2000 12
Hydraulic oil filter 2000 12
Hydraulic oil filter, seal kit 2000 12
Transmission oil 1000 12

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