Operating instructions
10004233
ECE 20
G
04.98 -
02.01
0108.GB
Foreword
The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide
sufficient instruction for the safe operation of the industrial truck. The information is
provided clearly and concisely. The chapters are arranged by letter. Each chapter
starts with page 1. The page identification consists of a chapter letter and a page
number.
For example: Page B 2 is the second page in chapter B.
The operating instructions detail different truck models. When operating and servicing
the truck, make sure that the instructions apply to your truck model.
Safety instructions and important explanations are indicated by the following
graphics:
fUsed before safety instructions which must be observed to avoid danger to
personnel.
mUsed before notices which must be observed to avoid material damage.
AUsed before notices and explanations.
tUsed to indicate standard equipment.
oUsed to indicate optional equipment.
Our trucks are subject to ongoing development. Jungheinrich reserves the right to
alter the design, equipment and technical features of the truck. No guarantee of
particular features of the truck should therefore be inferred from the present operating
instructions.
Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
Jungheinrich Aktiengesellschaft
Am Stadtrand 35
22047 Hamburg - GERMANY
Telephone: +49 (0) 40/6948-0
www.jungheinrich.com
0108.GB
Foreword
The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide
sufficient instruction for the safe operation of the industrial truck. The information is
provided clearly and concisely. The chapters are arranged by letter. Each chapter
starts with page 1. The page identification consists of a chapter letter and a page
number.
For example: Page B 2 is the second page in chapter B.
The operating instructions detail different truck models. When operating and servicing
the truck, make sure that the instructions apply to your truck model.
Safety instructions and important explanations are indicated by the following
graphics:
fUsed before safety instructions which must be observed to avoid danger to
personnel.
mUsed before notices which must be observed to avoid material damage.
AUsed before notices and explanations.
tUsed to indicate standard equipment.
oUsed to indicate optional equipment.
Our trucks are subject to ongoing development. Jungheinrich reserves the right to
alter the design, equipment and technical features of the truck. No guarantee of
particular features of the truck should therefore be inferred from the present operating
instructions.
Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
Jungheinrich Aktiengesellschaft
Am Stadtrand 35
22047 Hamburg - GERMANY
Telephone: +49 (0) 40/6948-0
www.jungheinrich.com
0108.GB
0108.GB
I 1
0201.GB
Table of contents
A Correct use and application of the truck
B Description of the truck
1 Design and application ........................................................................ B 1
2 Assemblies .......................................................................................... B 2
3 Technical data - standard version ....................................................... B 3
3.1 Performance data ................................................................................ B 3
3.2 Dimensions ......................................................................................... B 4
3.3 EN standards ...................................................................................... B 6
3.4 Conditions for application .................................................................... B 6
4 Labels .................................................................................................. B 7
4.1 Truck identification plate ..................................................................... B 8
C Transportation and commissioning
1 Transportation by crane ...................................................................... C 1
2 Commissioning .................................................................................... C 1
3 Moving the truck with the drive unit inoperative .................................. C 2
D Battery - Servicing, recharging, replacement
1 Safety regulations governing the handling of lead-acid batteries ........ D 1
2 Battery types ....................................................................................... D 2
3 Exposing the battery ........................................................................... D 2
4 Charging the battery ............................................................................ D 3
5 Removing and installing the battery .................................................... D 4
6 Combined instrument (o) ................................................................... D 5
I 1
0201.GB
Table of contents
A Correct use and application of the truck
B Description of the truck
1 Design and application ........................................................................ B 1
2 Assemblies .......................................................................................... B 2
3 Technical data - standard version ....................................................... B 3
3.1 Performance data ................................................................................ B 3
3.2 Dimensions ......................................................................................... B 4
3.3 EN standards ...................................................................................... B 6
3.4 Conditions for application .................................................................... B 6
4 Labels .................................................................................................. B 7
4.1 Truck identification plate ..................................................................... B 8
C Transportation and commissioning
1 Transportation by crane ...................................................................... C 1
2 Commissioning .................................................................................... C 1
3 Moving the truck with the drive unit inoperative .................................. C 2
D Battery - Servicing, recharging, replacement
1 Safety regulations governing the handling of lead-acid batteries ........ D 1
2 Battery types ....................................................................................... D 2
3 Exposing the battery ........................................................................... D 2
4 Charging the battery ............................................................................ D 3
5 Removing and installing the battery .................................................... D 4
6 Combined instrument (o) ................................................................... D 5
0201.GB
I 2
EOperation
1 Safety regulations governing the operation of the fork lift truck .......... E 1
2 Description of the operating controls and indicators ........................... E 2
3 Starting up the truck ............................................................................ E 4
4 Operation of the fork lift truck .............................................................. E 6
4.1 Safety regulations applicable when operating the truck ...................... E 6
4.2 Seat height adjustment (o) ................................................................. E 7
4.3 Driving, steering, braking .................................................................... E 8
4.4 Pedestrian-controlled operation (o) .................................................... E 13
4.5 Picking up and setting down loads ...................................................... E 14
4.6 Order-picking up to the second level ................................................... E 15
4.7 Safe parking of the truck ..................................................................... E 15
5 Information and service display (LISA) (o) ......................................... E 16
5.1 LED warning lamps ............................................................................. E 16
5.2 Key assignment ................................................................................... E 16
5.3 Displays ............................................................................................... E 17
5.4 Changing truck parameters ................................................................. E 18
6 Fault location ....................................................................................... E 19
F Maintenance of the fork lift truck
1 Operational safety and environmental protection ................................ F 1
2 Safety regulations applicable to truck maintenance ............................ F 1
3 Servicing and inspection ..................................................................... F 3
4 Maintenance checklist ........................................................................ F 4
5 Lubrication schedule ........................................................................... F 6
5.1 Fuels, coolants and lubricants ............................................................. F 7
6 Description of the servicing and maintenance operations ................... F 8
6.1 Preparing the truck for the performance of servicing and
maintenance operations ...................................................................... F 8
6.2 Tightening the wheel screws ............................................................... F 8
6.3 Removing the front hood ..................................................................... F 9
6.4 Checking the electric fuses ................................................................. F 10
6.5 Recommissioning the truck ................................................................. F 11
7 Decommissioning the fork lift truck ..................................................... F 11
7.1 Operations to be performed prior to decommissioning ....................... F 11
7.2 Measures to be taken during decommissioning .................................. F 11
7.3 Recommissioning the truck ................................................................. F 12
8 Safety checks to be performed at regular intervals and
following any untoward incidents (D: Accident prevention
check according to VBG 36) ............................................................... F 12
0201.GB
I 2
EOperation
1 Safety regulations governing the operation of the fork lift truck .......... E 1
2 Description of the operating controls and indicators ........................... E 2
3 Starting up the truck ............................................................................ E 4
4 Operation of the fork lift truck .............................................................. E 6
4.1 Safety regulations applicable when operating the truck ...................... E 6
4.2 Seat height adjustment (o) ................................................................. E 7
4.3 Driving, steering, braking .................................................................... E 8
4.4 Pedestrian-controlled operation (o) .................................................... E 13
4.5 Picking up and setting down loads ...................................................... E 14
4.6 Order-picking up to the second level ................................................... E 15
4.7 Safe parking of the truck ..................................................................... E 15
5 Information and service display (LISA) (o) ......................................... E 16
5.1 LED warning lamps ............................................................................. E 16
5.2 Key assignment ................................................................................... E 16
5.3 Displays ............................................................................................... E 17
5.4 Changing truck parameters ................................................................. E 18
6 Fault location ....................................................................................... E 19
F Maintenance of the fork lift truck
1 Operational safety and environmental protection ................................ F 1
2 Safety regulations applicable to truck maintenance ............................ F 1
3 Servicing and inspection ..................................................................... F 3
4 Maintenance checklist ........................................................................ F 4
5 Lubrication schedule ........................................................................... F 6
5.1 Fuels, coolants and lubricants ............................................................. F 7
6 Description of the servicing and maintenance operations ................... F 8
6.1 Preparing the truck for the performance of servicing and
maintenance operations ...................................................................... F 8
6.2 Tightening the wheel screws ............................................................... F 8
6.3 Removing the front hood ..................................................................... F 9
6.4 Checking the electric fuses ................................................................. F 10
6.5 Recommissioning the truck ................................................................. F 11
7 Decommissioning the fork lift truck ..................................................... F 11
7.1 Operations to be performed prior to decommissioning ....................... F 11
7.2 Measures to be taken during decommissioning .................................. F 11
7.3 Recommissioning the truck ................................................................. F 12
8 Safety checks to be performed at regular intervals and
following any untoward incidents (D: Accident prevention
check according to VBG 36) ............................................................... F 12
A 1
0600.GB
A Correct use and application of the truck
AThe “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are
included in the scope of delivery for this truck. The guidelines are part of these ope-
rating instructions and must always be heeded. National regulations are fully applica-
ble.
The fork lift truck described in these operating instructions is a truck that is suitable
for lifting and transporting loads.
It must be used, operated and maintained according to the information in these ope-
rating instructions. Any other uses are outside the design envelope and can lead to
injury to persons or damage to equipment and property. Above all, overloading
caused by excessively heavy or unbalanced loads must be avoided. The max. admis-
sible load to be picked up is indicated on the identification plate or load diagram label
shown on the truck. The fork lift truck must not be operated in spaces subject to fire
or explosion hazards, or in spaces where corrosive or very dusty atmospheres pre-
vail.
Duties of the user: A “user” within the meaning of these operating instructions is de-
fined as any natural or legal person who either uses the fork lift truck himself, or on
whose behalf it is used. In special cases (e.g. leasing or renting), the user is conside-
red the person, who, in accordance with existing contractual agreements between the
owner and the user of the fork lift truck, is charged with the observance of the opera-
ting duties.
The user must ensure that the truck is not abused and only used within its design li-
mits and that all danger to life and limb of the operator, or third parties, is avoided. In
addition to this, it must be ensured that the relevant accident prevention regulations
and other safety-related provisions, as well as the operating, servicing and mainte-
nance guidelines, are observed. The user must also ensure that all persons operating
the truck have read and understood these operating instructions.
mIf these operating instructions are not observed the warranty becomes void. The same app-
lies if improper works are carried out at the device by the customer and/or third parties without
permission of our Customer Service.
Mounting of attachments: The mounting or installation of any attachments which
will interfere with, or supplement, the functions of the truck is permitted only after writ-
ten approval by the manufacturer has been obtained. If necessary, the approval of
local authorities has to be obtained.
Any approval obtained from local authorities does not, however, make the approval
by the manufacturer unnecessary.
A 1
0600.GB
A Correct use and application of the truck
AThe “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are
included in the scope of delivery for this truck. The guidelines are part of these ope-
rating instructions and must always be heeded. National regulations are fully applica-
ble.
The fork lift truck described in these operating instructions is a truck that is suitable
for lifting and transporting loads.
It must be used, operated and maintained according to the information in these ope-
rating instructions. Any other uses are outside the design envelope and can lead to
injury to persons or damage to equipment and property. Above all, overloading
caused by excessively heavy or unbalanced loads must be avoided. The max. admis-
sible load to be picked up is indicated on the identification plate or load diagram label
shown on the truck. The fork lift truck must not be operated in spaces subject to fire
or explosion hazards, or in spaces where corrosive or very dusty atmospheres pre-
vail.
Duties of the user: A “user” within the meaning of these operating instructions is de-
fined as any natural or legal person who either uses the fork lift truck himself, or on
whose behalf it is used. In special cases (e.g. leasing or renting), the user is conside-
red the person, who, in accordance with existing contractual agreements between the
owner and the user of the fork lift truck, is charged with the observance of the opera-
ting duties.
The user must ensure that the truck is not abused and only used within its design li-
mits and that all danger to life and limb of the operator, or third parties, is avoided. In
addition to this, it must be ensured that the relevant accident prevention regulations
and other safety-related provisions, as well as the operating, servicing and mainte-
nance guidelines, are observed. The user must also ensure that all persons operating
the truck have read and understood these operating instructions.
mIf these operating instructions are not observed the warranty becomes void. The same app-
lies if improper works are carried out at the device by the customer and/or third parties without
permission of our Customer Service.
Mounting of attachments: The mounting or installation of any attachments which
will interfere with, or supplement, the functions of the truck is permitted only after writ-
ten approval by the manufacturer has been obtained. If necessary, the approval of
local authorities has to be obtained.
Any approval obtained from local authorities does not, however, make the approval
by the manufacturer unnecessary.
0600.GB
A 2
0600.GB
A 2
B 1
0201.GB
B Description of the truck
1 Design and application
The truck is an electric pallet truck in four-wheel version with driver stand and equip-
ped with tiller-shaft steering or by means of a steering wheel (o). The truck is desi-
gned for use on level surfaces for transporting and order-picking goods. Pallets with
open ground support or pallets fitted with lateral boards (provided that the boards are
outside the range of the load-bearing wheels) can be picked up.
The second order-picking level can be reached via a step integrated into the backrest
and by stepping onto the battery hood, or from the raisable operator platform (option).
Optionally, a fixed driver standing platform is available.
The rated capacity of the truck is shown on the identification plate or on the capacity
label Qmax.
B 1
0201.GB
B Description of the truck
1 Design and application
The truck is an electric pallet truck in four-wheel version with driver stand and equip-
ped with tiller-shaft steering or by means of a steering wheel (o). The truck is desi-
gned for use on level surfaces for transporting and order-picking goods. Pallets with
open ground support or pallets fitted with lateral boards (provided that the boards are
outside the range of the load-bearing wheels) can be picked up.
The second order-picking level can be reached via a step integrated into the backrest
and by stepping onto the battery hood, or from the raisable operator platform (option).
Optionally, a fixed driver standing platform is available.
The rated capacity of the truck is shown on the identification plate or on the capacity
label Qmax.
0201.GB
B 2
2 Assemblies
Item Designation Item Designation
1 o Master switch (emerg. stop) 9 tLifting device
2 t Key switch 10 tStep
3 oTrucks with control shaft:
Combined instrument
Trucks with steering wheel:In-
formation and servicedisplay
11 o Key “Operator walking”
12 tPlatform switch
13 oControl shaft
(electrical steering system)
4 tControl shaft
(mechanical steering system)
14 oSteering wheel
15 oDivided standing platform
5 tController 16 tSupporting wheel
6 tBrake key 17 tDrive wheel
7 oSeat 18 tMaster switch (emerg. stop)
8 tBattery hood 19 tFront hood
t= Standard equipment o= Optional equipment
0201.GB
B 2
2 Assemblies
Item Designation Item Designation
1 o Master switch (emerg. stop) 9 tLifting device
2 t Key switch 10 tStep
3 oTrucks with control shaft:
Combined instrument
Trucks with steering wheel:In-
formation and servicedisplay
11 o Key “Operator walking”
12 tPlatform switch
13 oControl shaft
(electrical steering system)
4 tControl shaft
(mechanical steering system)
14 oSteering wheel
15 oDivided standing platform
5 tController 16 tSupporting wheel
6 tBrake key 17 tDrive wheel
7 oSeat 18 tMaster switch (emerg. stop)
8 tBattery hood 19 tFront hood
t= Standard equipment o= Optional equipment
B 3
0201.GB
3 Technical data - standard version
AIndication of technical data according to VDI 2198,
subject to modification and supplementing.
3.1 Performance data
Designation Standard Rapid drive
Q Rated capacity 2000 2000 kg
C Load centre distance 600 600 mm
Travelling speed
with / without rated load
8.4 / 10.7 9.5 / 12.5 km/h
Lifting speed
with / without rated load
4.0 / 5.0 4.0 / 5.0 cm/s
Lowering speed
with / without rated load
6.5 / 4.0 6.5 / 4.0 cm/s
W
a
b1
b5
b3
b11
l1
95
30
l2
h3
137
a
2
a
2
225
h13
Ast3
x
l6
e
1370
430
990
1675
1)
1722
1)
1)
y
l
c
Q
1) Truck with permanent
driver standing platform
B 3
0201.GB
3 Technical data - standard version
AIndication of technical data according to VDI 2198,
subject to modification and supplementing.
3.1 Performance data
Designation Standard Rapid drive
Q Rated capacity 2000 2000 kg
C Load centre distance 600 600 mm
Travelling speed
with / without rated load
8.4 / 10.7 9.5 / 12.5 km/h
Lifting speed
with / without rated load
4.0 / 5.0 4.0 / 5.0 cm/s
Lowering speed
with / without rated load
6.5 / 4.0 6.5 / 4.0 cm/s
W
a
b1
b5
b3
b11
l1
95
30
l2
h3
137
a
2
a
2
225
h13
Ast3
x
l6
e
1370
430
990
1675
1)
1722
1)
1)
y
l
c
Q
1) Truck with permanent
driver standing platform
0201.GB
B 4
3.2 Dimensions
(all dimensions in mm)
Working aisle widths - standard (all dimensions in mm)
1) With the load part lifted, the values are reduced by 89mm.
2) Increased wheel base for pallets with floor boards.
Designation Standard Permanent driver
standing platform
l2Design length of front 1268 1434
h13 Height of fork when lowered 90 90
h3Lift 125 125
b1Truck width 800 800
b5Distance between forks, outside 510 / 540 / 670 510 / 540 / 660
b11 Track 340 / 370 / 500 340 / 370 / 490
b3Distance between forks, inside 170 / 200 / 330 170 / 200 / 320
e Fork width 170 170
a Safety distance 200 200
Dead weight: Refer to truck identification label
ll
1y1) x1) l6Wa1) Ast3
1000 2268 1857 814 1000 2082 2468
1150 2418 2007 964 1200 2232 2668
1400 2668 2257 1214 1400 2482 2868
1400 2668 1885 842 1400 2110 2868
1450 2718 1935 892 1450 2160 2918
1600 2868 2457 1414 1600 2682 3068
1600 2868 2085 1042 1600 2310 3068
1950 3218 2435 1392 2000 2660 3468
2180 3448 2423 1380 2180 2648 3648
2310 3578 3167 2124 2310 3392 3778
2400 3668 28852) 18422) 2400 31102) 3868
2400 3668 2643 1600 2400 2868 3868
2430 3698 2573 1530 2430 2798 3898
2550 3818 2793 1750 2550 3018 4018
2850 4118 3093 2050 2850 3318 4318
2900 4168 3143 2100 2900 3368 4368
0201.GB
B 4
3.2 Dimensions
(all dimensions in mm)
Working aisle widths - standard (all dimensions in mm)
1) With the load part lifted, the values are reduced by 89mm.
2) Increased wheel base for pallets with floor boards.
Designation Standard Permanent driver
standing platform
l2Design length of front 1268 1434
h13 Height of fork when lowered 90 90
h3Lift 125 125
b1Truck width 800 800
b5Distance between forks, outside 510 / 540 / 670 510 / 540 / 660
b11 Track 340 / 370 / 500 340 / 370 / 490
b3Distance between forks, inside 170 / 200 / 330 170 / 200 / 320
e Fork width 170 170
a Safety distance 200 200
Dead weight: Refer to truck identification label
ll
1y1) x1) l6Wa1) Ast3
1000 2268 1857 814 1000 2082 2468
1150 2418 2007 964 1200 2232 2668
1400 2668 2257 1214 1400 2482 2868
1400 2668 1885 842 1400 2110 2868
1450 2718 1935 892 1450 2160 2918
1600 2868 2457 1414 1600 2682 3068
1600 2868 2085 1042 1600 2310 3068
1950 3218 2435 1392 2000 2660 3468
2180 3448 2423 1380 2180 2648 3648
2310 3578 3167 2124 2310 3392 3778
2400 3668 28852) 18422) 2400 31102) 3868
2400 3668 2643 1600 2400 2868 3868
2430 3698 2573 1530 2430 2798 3898
2550 3818 2793 1750 2550 3018 4018
2850 4118 3093 2050 2850 3318 4318
2900 4168 3143 2100 2900 3368 4368
B 5
0201.GB
Working aisle widths with permanent driver standing platform
(all dimensions in mm)
1) With the load part lifted, the values are reduced by 89mm.
2) Increased wheel base for pallets with floor boards.
ll
1y1) x1) l6Wa1) Ast3
1000 2434 2023 814 1000 2248 2634
1150 2584 2173 964 1200 2398 2834
1400 2834 2423 1214 1400 2648 3034
1400 2834 2051 842 1400 2276 3034
1450 2884 2101 892 1450 2326 3084
1600 3034 2623 1414 1600 2448 3234
1600 3034 2251 1042 1600 2476 3234
1950 3384 2601 1392 2000 2826 3634
2180 3614 2589 1380 2180 2814 3814
2310 3744 33332) 21242) 2310 35582) 3944
2400 3834 3051 1842 2400 3276 4034
2400 3834 2809 1600 2400 3034 4034
2430 3864 2739 1530 2430 2964 4064
2550 3984 2959 1750 2550 3184 4184
2850 4284 3259 2050 2850 3484 4484
2900 4334 3309 2100 2900 3534 4534
W
a
b
1
b
5
b
3
b
11
l
1
95
30
l
2
h
3
137
a
2
a
2
225
h
13
A
st3
x
l
6
e
1370
430
990
1675
1)
1722
1)
1)
y
l
c
Q
B 5
0201.GB
Working aisle widths with permanent driver standing platform
(all dimensions in mm)
1) With the load part lifted, the values are reduced by 89mm.
2) Increased wheel base for pallets with floor boards.
ll
1y1) x1) l6Wa1) Ast3
1000 2434 2023 814 1000 2248 2634
1150 2584 2173 964 1200 2398 2834
1400 2834 2423 1214 1400 2648 3034
1400 2834 2051 842 1400 2276 3034
1450 2884 2101 892 1450 2326 3084
1600 3034 2623 1414 1600 2448 3234
1600 3034 2251 1042 1600 2476 3234
1950 3384 2601 1392 2000 2826 3634
2180 3614 2589 1380 2180 2814 3814
2310 3744 33332) 21242) 2310 35582) 3944
2400 3834 3051 1842 2400 3276 4034
2400 3834 2809 1600 2400 3034 4034
2430 3864 2739 1530 2430 2964 4064
2550 3984 2959 1750 2550 3184 4184
2850 4284 3259 2050 2850 3484 4484
2900 4334 3309 2100 2900 3534 4534
W
a
b
1
b
5
b
3
b
11
l
1
95
30
l
2
h
3
137
a
2
a
2
225
h
13
A
st3
x
l
6
e
1370
430
990
1675
1)
1722
1)
1)
y
l
c
Q
0201.GB
B 6
3.3 EN standards
Continuous sound level: 66 dB(A)
according to prEN 12053 as stipulated in ISO 4871
AThe continuous sound level is a value averaged according to standard regulations,
taking the sound pressure level into account when driving, lifting and idling. The
sound pressure level is measured at the ear.
Vibration: 0.62 m/s2
according to prEN 13059
AThe swinging acceleration acting on the body in its operating position is, according to
standard regulations, the linear integrated, weighted acceleration in the vertical pla-
ne. It is determined by driving over bumps with a constant speed.
Electromagnetic compatibility (EMC)
The manufacturer confirms compliance with the limit va-
lues for electromagnetic emission and interference im-
munity as well as testing of static electricity discharge ac-
cording to prEN 12895 and the references to other
standards contained therein.
AElectrical or electronic components and their arrangement may only be modified after
written approval by the manufacturer has been obtained.
3.4 Conditions for application
Ambient temperature:
- during operation: 5°C to 40°C
AIndustrial trucks must be specially equipped and approved for continuous use in en-
vironments with temperatures below 5°C or in cold stores respectively with extreme
temperatures or humidity changes.
0201.GB
B 6
3.3 EN standards
Continuous sound level: 66 dB(A)
according to prEN 12053 as stipulated in ISO 4871
AThe continuous sound level is a value averaged according to standard regulations,
taking the sound pressure level into account when driving, lifting and idling. The
sound pressure level is measured at the ear.
Vibration: 0.62 m/s2
according to prEN 13059
AThe swinging acceleration acting on the body in its operating position is, according to
standard regulations, the linear integrated, weighted acceleration in the vertical pla-
ne. It is determined by driving over bumps with a constant speed.
Electromagnetic compatibility (EMC)
The manufacturer confirms compliance with the limit va-
lues for electromagnetic emission and interference im-
munity as well as testing of static electricity discharge ac-
cording to prEN 12895 and the references to other
standards contained therein.
AElectrical or electronic components and their arrangement may only be modified after
written approval by the manufacturer has been obtained.
3.4 Conditions for application
Ambient temperature:
- during operation: 5°C to 40°C
AIndustrial trucks must be specially equipped and approved for continuous use in en-
vironments with temperatures below 5°C or in cold stores respectively with extreme
temperatures or humidity changes.
B 7
0201.GB
4 Labels
AThe capacity label (24) indicates the maximum capacity of the truck as Qmax. The
rated capacity as shown must not be exceeded. The load “distribution label” (20) sti-
pulates that the load on the fork is to be approximately uniform.
Item Designation
20 Load distribution
21 Label “Caution, pushbutton operation”
22 Truck identification plate
23 Accident prevention inspection label (D only)
24 Capacity Qmax
25 Attachment point of hooks for transportation by crane
26 Label “CAUTION: Low-voltage electronics”
1
2
1
1
1
0
9
8
7
6
5
4
3
2
1
2000
23
24
26 25
22
20
21
Qmax 2000kg
mV
1,5 V
kg
kg mm kg
Xxx
Xxxx
Xxxxxxx
Xxxxxxxxx
Xxxxxxxxx
Xxxxxxxxxx
Xxxxx
Xxxx
Xxxxxxx
Xxxxxx
Xxxxxx
Xxxxxx
Xxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxx
VkW
Xxxxxxxxx
Xxxxxxxxxx
xxxxxxxxxx
xxxxxxxx
Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxx
B 7
0201.GB
4 Labels
AThe capacity label (24) indicates the maximum capacity of the truck as Qmax. The
rated capacity as shown must not be exceeded. The load “distribution label” (20) sti-
pulates that the load on the fork is to be approximately uniform.
Item Designation
20 Load distribution
21 Label “Caution, pushbutton operation”
22 Truck identification plate
23 Accident prevention inspection label (D only)
24 Capacity Qmax
25 Attachment point of hooks for transportation by crane
26 Label “CAUTION: Low-voltage electronics”
1
2
1
1
1
0
9
8
7
6
5
4
3
2
1
2000
23
24
26 25
22
20
21
Qmax 2000kg
mV
1,5 V
kg
kg mm kg
Xxx
Xxxx
Xxxxxxx
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Xxxxxxxxx
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Xxxxx
Xxxx
Xxxxxxx
Xxxxxx
Xxxxxx
Xxxxxx
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VkW
Xxxxxxxxx
Xxxxxxxxxx
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xxxxxxxx
Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxx
0201.GB
B 8
4.1 Truck identification plate
AIn the event of queries relating to the truck or spare part orders, please state the serial
No. (28) of the truck.
Item Designation Item Designation
27 Type 34 Drive power in kW
28 Serial No. 35 Customer no.
29 Rated capacity in kg 36 Min./max. battery weight in kg
30 Battery: Voltage V
Ampere hours Ah
37 Empty weight without battery in kg
31 Manufacturer 38 Year of manufacture
32 Order no. 39 Manufacturer logo
33 Load centre distance in mm
kg
kg mm kg
Xxx
Xxxx
Xxxxxxx
Xxxxxxxxx
Xxxxxxxxx
Xxxxxxxxxx
Xxxxx
Xxxx
Xxxxxxx
Xxxxxx
Xxxxxx
Xxxxxx
Xxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxx
VkW
Xxxxxxxxx
Xxxxxxxxxx
xxxxxxxxxx
xxxxxxxx
Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxx
27
28
29
30
31
32
34
38
37
36
35
33
39
0201.GB
B 8
4.1 Truck identification plate
AIn the event of queries relating to the truck or spare part orders, please state the serial
No. (28) of the truck.
Item Designation Item Designation
27 Type 34 Drive power in kW
28 Serial No. 35 Customer no.
29 Rated capacity in kg 36 Min./max. battery weight in kg
30 Battery: Voltage V
Ampere hours Ah
37 Empty weight without battery in kg
31 Manufacturer 38 Year of manufacture
32 Order no. 39 Manufacturer logo
33 Load centre distance in mm
kg
kg mm kg
Xxx
Xxxx
Xxxxxxx
Xxxxxxxxx
Xxxxxxxxx
Xxxxxxxxxx
Xxxxx
Xxxx
Xxxxxxx
Xxxxxx
Xxxxxx
Xxxxxx
Xxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxx
VkW
Xxxxxxxxx
Xxxxxxxxxx
xxxxxxxxxx
xxxxxxxx
Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxx
27
28
29
30
31
32
34
38
37
36
35
33
39
C 1
0201.GB
C Transportation and commissioning
1 Transportation by crane
fOnly lifting gear of adequate ca-
pacity must be used
(for the transport weight, refer to
the truck identification label).
ALifting gear attachment points
are provided on the chassis (1)
and the fork (2) in case the truck
is to be lifted or transported by
crane.
– Park the truck and render it
safe (refer to chapter E).
– Secure the lifting gear to the
attachment points (1) and (2).
mThe lifting gear must be atta-
ched to the attachment points in
such a manner that it absolutely
cannot slip and cannot come
into contact with any attach-
ments of the truck when the
truck is lifted.
2 Commissioning
mThe truck must only be operated on battery current. Rectified alternate current will da-
mage the electronics. Cables connected to the battery (trailing cables) must be less
than 6 meters in length.
In order to prepare the truck for work following delivery or transportation, the following
operations must be performed:
– Check the truck for completeness and satisfactory condition of the equipment.
– If necessary, install the battery. Do not damage the battery cable
(refer to chapter D).
– Charge the battery (refer to chapter D).
– If necessary, check whether the setting of the combined instrument or information
and service display matches the type of battery (see chapter D).
– Commission the truck as detailed in chapter E.
AWhen the truck is parked, the running surface of the tyres will flatten. The flattening
will disappear after a short operating time of the truck.
2
1
C 1
0201.GB
C Transportation and commissioning
1 Transportation by crane
fOnly lifting gear of adequate ca-
pacity must be used
(for the transport weight, refer to
the truck identification label).
ALifting gear attachment points
are provided on the chassis (1)
and the fork (2) in case the truck
is to be lifted or transported by
crane.
– Park the truck and render it
safe (refer to chapter E).
– Secure the lifting gear to the
attachment points (1) and (2).
mThe lifting gear must be atta-
ched to the attachment points in
such a manner that it absolutely
cannot slip and cannot come
into contact with any attach-
ments of the truck when the
truck is lifted.
2 Commissioning
mThe truck must only be operated on battery current. Rectified alternate current will da-
mage the electronics. Cables connected to the battery (trailing cables) must be less
than 6 meters in length.
In order to prepare the truck for work following delivery or transportation, the following
operations must be performed:
– Check the truck for completeness and satisfactory condition of the equipment.
– If necessary, install the battery. Do not damage the battery cable
(refer to chapter D).
– Charge the battery (refer to chapter D).
– If necessary, check whether the setting of the combined instrument or information
and service display matches the type of battery (see chapter D).
– Commission the truck as detailed in chapter E.
AWhen the truck is parked, the running surface of the tyres will flatten. The flattening
will disappear after a short operating time of the truck.
2
1
0201.GB
C 2
3 Moving the truck with the drive unit inoperative
fThis operating mode is not permitted when negotiating inclines and gradients.
If the truck has to be moved after a failure has rendered it immobile, proceed as fol-
lows:
– Set the master switch to position “OFF”.
– Set the key switch to position “OFF” (“0”) and remove the key.
– Ensure that the truck cannot accidentally move.
– Unlock the cover locks (5), open and set down the front hood (6).
– Slacken the lock nuts (4) and tighten the
screws (3).
The brake has now been released and the truck
can be moved.
fAfter arriving at the repair bay, ensure that the
brake is put back to its initial state. The truck
must on no account be parked with the brake in
the released condition.
– Loosen the screws (3) by approx. 5 mm and
lock by tightening the lock nuts (4).
The brake is now applied again.
– Reinstall the front hood (6).
4
3
6
5
0201.GB
C 2
3 Moving the truck with the drive unit inoperative
fThis operating mode is not permitted when negotiating inclines and gradients.
If the truck has to be moved after a failure has rendered it immobile, proceed as fol-
lows:
– Set the master switch to position “OFF”.
– Set the key switch to position “OFF” (“0”) and remove the key.
– Ensure that the truck cannot accidentally move.
– Unlock the cover locks (5), open and set down the front hood (6).
– Slacken the lock nuts (4) and tighten the
screws (3).
The brake has now been released and the truck
can be moved.
fAfter arriving at the repair bay, ensure that the
brake is put back to its initial state. The truck
must on no account be parked with the brake in
the released condition.
– Loosen the screws (3) by approx. 5 mm and
lock by tightening the lock nuts (4).
The brake is now applied again.
– Reinstall the front hood (6).
4
3
6
5
D 1
0201.GB
D Battery - Servicing, recharging, replace-
ment
1 Safety regulations governing the handling of lead-acid batteries
The truck must be parked and rendered safe before any operations on batteries are
undertaken (refer to chapter E).
Servicing staff: Recharging, servicing and replacing of batteries must only be per-
formed by qualified personnel. The instructions contained in this operating manual,
and the instructions of the manufacturer of the battery and of the battery recharging
station, must be observed when performing the above operations.
Fire protection measures: Smoking and naked flames are not permitted when
handling batteries. No inflammable substances or spark-generating materials must
be present or stored within a distance of 2 meters of the truck parked for battery re-
charging. The location must be well ventilated and fire fighting equipment must be
kept ready.
Servicing of batteries: The battery cell screw caps must be kept dry and clean. Ter-
minals and cable shoes must be clean, lightly greased with pole grease and must be
securely tightened. Batteries with bare terminal posts must be covered using a non-
skid insulating mat.
Disposal of the battery: Batteries must only be disposed of as stipulated in the na-
tional environmental protection regulations or waste disposal provisions. The manu-
facturer’s specifications for the disposal must be heeded.
mBefore closing the battery hood, make sure that the battery cable cannot be dama-
ged.
fBatteries contain dissolved acid which is toxic and caustic. For this reason, protective
clothing and goggles must be worn whenever work is undertaken on batteries. Avoid
physical contact with battery acid.
If clothing, skin or eyes accidentally come into contact with battery acid, liberally flush
the affected parts with clean water. Consult a doctor when skin or eyes come into con-
tact with battery acid. Spilled battery acid must be immediately neutralized.
mOnly batteries with closed tray may be used.
fBattery weight and dimensions have considerable influence on operational safety of
the truck. Changing the battery equipment is not permitted without prior approval by
the manufacturer.
D 1
0201.GB
D Battery - Servicing, recharging, replace-
ment
1 Safety regulations governing the handling of lead-acid batteries
The truck must be parked and rendered safe before any operations on batteries are
undertaken (refer to chapter E).
Servicing staff: Recharging, servicing and replacing of batteries must only be per-
formed by qualified personnel. The instructions contained in this operating manual,
and the instructions of the manufacturer of the battery and of the battery recharging
station, must be observed when performing the above operations.
Fire protection measures: Smoking and naked flames are not permitted when
handling batteries. No inflammable substances or spark-generating materials must
be present or stored within a distance of 2 meters of the truck parked for battery re-
charging. The location must be well ventilated and fire fighting equipment must be
kept ready.
Servicing of batteries: The battery cell screw caps must be kept dry and clean. Ter-
minals and cable shoes must be clean, lightly greased with pole grease and must be
securely tightened. Batteries with bare terminal posts must be covered using a non-
skid insulating mat.
Disposal of the battery: Batteries must only be disposed of as stipulated in the na-
tional environmental protection regulations or waste disposal provisions. The manu-
facturer’s specifications for the disposal must be heeded.
mBefore closing the battery hood, make sure that the battery cable cannot be dama-
ged.
fBatteries contain dissolved acid which is toxic and caustic. For this reason, protective
clothing and goggles must be worn whenever work is undertaken on batteries. Avoid
physical contact with battery acid.
If clothing, skin or eyes accidentally come into contact with battery acid, liberally flush
the affected parts with clean water. Consult a doctor when skin or eyes come into con-
tact with battery acid. Spilled battery acid must be immediately neutralized.
mOnly batteries with closed tray may be used.
fBattery weight and dimensions have considerable influence on operational safety of
the truck. Changing the battery equipment is not permitted without prior approval by
the manufacturer.
0201.GB
D 2
2 Battery types
Depending on the truck version, the truck will be supplied with different battery types.
The battery weights can be seen on the battery identification plate.
Depending on the type of battery used, it is also possible to use models with enhan-
ced performance or maintenance-free batteries.
mWhen replacing or installing batteries, ensure that the battery is correctly secured in
the battery compartment of the truck.
3 Exposing the battery
fPark the truck and render it safe (refer to chapter E).
– Press the lever (1) downward and swivel up the control shaft.
– Release the lever (1) again.
– Open the battery hood by means of the handle (2).
fCarefully open/close the battery hood using only the handle.
The hood is held in this position only by its dead weight.
– Close the battery hood by means of the handle (2) and move the control shaft to
the required position.
fAll covers and connections must be restored to the normal operating condition before
the truck is started up for work.
24 V PzS battery 3 PzS 330 Ah L (with weights)
24 V PzS battery 3 PzS 420 Ah L
24 V PzS battery
performance-enhanced
3 PzS 450 Ah-HX
1
2
0201.GB
D 2
2 Battery types
Depending on the truck version, the truck will be supplied with different battery types.
The battery weights can be seen on the battery identification plate.
Depending on the type of battery used, it is also possible to use models with enhan-
ced performance or maintenance-free batteries.
mWhen replacing or installing batteries, ensure that the battery is correctly secured in
the battery compartment of the truck.
3 Exposing the battery
fPark the truck and render it safe (refer to chapter E).
– Press the lever (1) downward and swivel up the control shaft.
– Release the lever (1) again.
– Open the battery hood by means of the handle (2).
fCarefully open/close the battery hood using only the handle.
The hood is held in this position only by its dead weight.
– Close the battery hood by means of the handle (2) and move the control shaft to
the required position.
fAll covers and connections must be restored to the normal operating condition before
the truck is started up for work.
24 V PzS battery 3 PzS 330 Ah L (with weights)
24 V PzS battery 3 PzS 420 Ah L
24 V PzS battery
performance-enhanced
3 PzS 450 Ah-HX
1
2
D 3
0201.GB
4 Charging the battery
fTo charge the battery, the truck must be parked in a closed and properly ventilated
room.
– Expose the battery (refer to section 3).
mThe battery connector (4) and the charging cable (3) must only be connected or dis-
connected with the truck and the battery charger switched off. The master switch (5)
must also only be actuated with the truck and the battery charger switched off.
fDuring the recharging operation, the tops of the battery cells must be exposed to en-
sure adequate ventilation. No metal objects must be placed on the battery. Prior to
starting the recharging operation, check all cable connections and plugged connec-
tions for visible damage.
All safety instructions as provided by the battery supplier and battery charger supplier
must be strictly observed.
– Withdraw the battery connector (4).
– Remove any insulating mats from the battery.
– Connect the charging cable (3) of the battery charger to the battery connector (4)
and switch on the charger.
mRecharge the battery observing the instructions provided by the battery supplier and
by the battery charger supplier.
4 5
3
D 3
0201.GB
4 Charging the battery
fTo charge the battery, the truck must be parked in a closed and properly ventilated
room.
– Expose the battery (refer to section 3).
mThe battery connector (4) and the charging cable (3) must only be connected or dis-
connected with the truck and the battery charger switched off. The master switch (5)
must also only be actuated with the truck and the battery charger switched off.
fDuring the recharging operation, the tops of the battery cells must be exposed to en-
sure adequate ventilation. No metal objects must be placed on the battery. Prior to
starting the recharging operation, check all cable connections and plugged connec-
tions for visible damage.
All safety instructions as provided by the battery supplier and battery charger supplier
must be strictly observed.
– Withdraw the battery connector (4).
– Remove any insulating mats from the battery.
– Connect the charging cable (3) of the battery charger to the battery connector (4)
and switch on the charger.
mRecharge the battery observing the instructions provided by the battery supplier and
by the battery charger supplier.
4 5
3
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