EKS 513 / 515k / 515 EKX 513 / 515k / 515: Operating Instructions

EKS 513 / 515k / 515
EKX 513 / 515k / 515 05.07 -
G
Operating Instructions
51058446
10.10
EKS 513
EKS 515k
EKS 515
EKX 513
EKX 515k
EKX 515
Declaration of Conformity
Jungheinrich AG, Am Stadtrand 35, D-22047 Hamburg

Manufacturer or authorized representative in the Community
Type Option Serial No. Year of Construction

EKS 513
EKS 515k
EKS 515
EKX 513
EKX 515k
EKX 515
Additional information
Authorised signatory
Date
G EU Declaration of Conformity
The signatories hereby certify that the specified powered industrial truck conforms to
the EU Directive 2006/42/EC (Machine Directive) and 2004/108/EEC (Electro-Magne-
tic Compatibility, EMC) including their amendments as translated into national legisla-
tion of the member countries. The signatories are individually empowered in each case
to compile the technical documentation.
1009.GB
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2
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Foreword
The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide
sufficient instruction for the safe operation of the industrial truck. The information is
provided clearly and concisely. The chapters are arranged by letter. Each chapter
starts with page 1. The page identification consists of a chapter letter and a page
number.
For example: Page B 2 is the second page in chapter B.
The operating instructions detail different truck models. When operating and servicing
the truck, make sure that the instructions apply to your truck model.
Safety instructions and important explanations are indicated by the following

graphics:
F Used before safety instructions which must be observed to avoid danger to

personnel.
M Used before notices which must be observed to avoid material damage.
Z Used before notices and explanations.
t Used to indicate standard equipment.

o Used to indicate optional equipment.
Our trucks are subject to ongoing development. Jungheinrich reserves the right 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
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Table of contents
A Correct Use and Application
1 General ............................................................................................... A 1
2 Correct application .............................................................................. A 1
3 Approved application conditions ......................................................... A 1
4 Proprietor responsibilities .................................................................... A 2
5 Adding attachments and/or accessories ............................................. A 2
B Truck Description
1 Application ........................................................................................... B 1
1.1 Travel direction definition .................................................................... B 2
2 Assemblies and Functional Description .............................................. B 3
2.1 Truck functional description ................................................................ B 6
3 Standard version specifications .......................................................... B 10
3.1 Performance data ................................................................................ B 11
3.2 Dimensions (as per data plate) ........................................................... B 12
3.3 Mast version ........................................................................................ B 16
3.4 Engine data ......................................................................................... B 18
3.5 Weights ............................................................................................... B 18
3.6 Wheels, chassis .................................................................................. B 21
3.7 EN norms ............................................................................................ B 22
3.8 Conditions of use ................................................................................ B 23
3.9 Electrical requirements ........................................................................ B 23
4 Identification points and data plates .................................................... B 24
4.1 Truck data plate .................................................................................. B 26
4.2 Truck capacity plate ............................................................................ B 27
4.3 Attachment capacity plate (o) ............................................................ B 28
5 Stability ................................................................................................ B 28
C Transport and Commissioning
1 Transport ............................................................................................. C 1
2 Lifting by Crane ................................................................................... C 2
2.1 Lifting by crane with mast assembled ................................................. C 2
2.2 Crane points / Strap points .................................................................. C 3
2.3 Lifting the battery by crane .................................................................. C 4
3 Securing the truck during transport ..................................................... C 5
3.1 Basic truck transport safety ................................................................. C 6
3.2 Mast transport retainer ........................................................................ C 8
3.3 Transport retaining mechanism for trucks with the
mast assembled .................................................................................. C 10
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4 Using the Truck for the First Time ....................................................... C 11
4.1 Moving the industrial truck without a battery ....................................... C 11
4.2 Installing and removing the mast ........................................................ C 11
5 Starting the Truck ................................................................................ C 12
5.1 Mechanical tilt safety devices (t) ....................................................... C 13
5.2 Active stabiliser (o) ............................................................................. C 14
D Battery - Servicing, Recharging, Replacement
1 Safety Regulations Governing the Handling of

Lead-Acid Batteries ............................................................................. D 1
2 Battery types ....................................................................................... D 2
2.1 Battery compartment dimensions ........................................................ D 3
3 Exposing the battery ........................................................................... D 4
4 Charging the Battery ........................................................................... D 6
5 Battery Removal and Installation ........................................................ D 10
5.1 Installing and removing a battery with a battery trolley (t) ................. D 11
5.2 Placing/removing batteries in the battery replacement trolley
using a forklift (o) ............................................................................... D 14
5.3 Battery lock sensor (t) ....................................................................... D 18
6 On-Board Charger (o) ........................................................................ D 19
6.1 Description .......................................................................................... D 19
6.2 Different current collectors .................................................................. D 20
6.3 Operating modes ................................................................................. D 21
6.4 Different Operating Modes .................................................................. D 22
6.5 Symbols and meaning ......................................................................... D 24
6.6 On board charger maintenance instructions ....................................... D 25
7 Battery Checking Condition and Acid Level ..................................... D 26
8 Battery Discharge Indicator "Bar Display" (t) ................................... D 27
8.1 Battery discharge monitor with bar display ......................................... D 28
8.2 Battery symbol fluorescent colours ..................................................... D 29
9 Battery Discharge Indicator "Percentage Display" (o) ....................... D 30
9.1 Battery symbol fluorescent colours ..................................................... D 30
E Operation
1 Safety Regulations for the Operation of Forklift Trucks ...................... E 1

2 Controls and Displays ......................................................................... E 3
2.1 Operating and display equipment on control panel ............................. E 3
2.2 Display unit controls and displays ....................................................... E 10
2.3 Lower range symbols and pushbuttons .............................................. E 16
2.4 Truck operational status symbols ........................................................ E 22
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3 Starting up the truck ............................................................................ E 23
3.1 Checks and operations to be performed before starting
daily operation ..................................................................................... E 23
3.2 Truck entry and exit ............................................................................. E 24
3.3 Removing the drivers seat .................................................................. E 25
3.4 Setting up the operator position .......................................................... E 25
3.5 Adjusting the drivers seat ................................................................... E 26
3.6 Control panel angle adjustment .......................................................... E 27
3.7 Control panel height adjustment ......................................................... E 28
3.8 To prepare the truck for operation (t) ................................................ E 28
3.9 Preparing the truck for operation with an additional
access code (o) .................................................................................. E 29
3.10 ISM Access Module (o) ...................................................................... E 30
3.11 Checks and operations to be carried out when the truck
is operational ....................................................................................... E 30
3.12 Referencing the main and auxiliary lift ................................................ E 32
3.13 Setting date and time .......................................................................... E 35
3.14 Operator specific settings (o) ............................................................. E 37
4 Industrial Truck Operation ................................................................... E 40
4.1 Safety regulations for truck operation ................................................. E 40
4.2 Emergency Disconnect, Travel, Steering, Braking .............................. E 44
4.3 Negotiating narrow aisles .................................................................... E 50
4.4 Diagonal travel .................................................................................... E 57
4.5 Lifting Lowering Reaching Traversing outside
the rack aisles ..................................................................................... E 58
4.6 Simultaneous load handler traverse and fork carriage swivel ............. E 61
4.7 Telescopic table (o) ............................................................................ E 64
4.8 Symmetrical sideshifter (o) ................................................................ E 71
4.9 Fork adjuster (o) ................................................................................. E 71
4.10 Telescopic forks (o) ............................................................................ E 72
4.11 Symmetrical sideshift with integrated fork adjuster (o) ...................... E 74
4.12 Asymmetrical sideshifter with integrated fork adjuster (o) ................. E 75
4.13 Lifting - Lowering - Traversing - Pivoting inside the rack aisles .......... E 76
4.14 Order picking and stacking .................................................................. E 77
4.15 Lifting, transporting and depositing loads ............................................ E 81
4.16 Rack Height Select with Zone Entry (o) ............................................. E 86
4.17 Horizontal positioning (o) ................................................................... E 93
4.18 Parking the truck securely ................................................................... E 107
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5 Troubleshooting .................................................................................. E 108
5.1 Emergency stop device ....................................................................... E 111
5.2 Drivers cab / Aux. Lift emergency lowering ........................................ E 112
5.3 Slack chain safety device override ...................................................... E 114
5.4 Travel cutout override (o) ................................................................... E 115
5.5 Lift cutout override (o) ........................................................................ E 116
5.6 Lower cutout override (o) ................................................................... E 117
5.7 Aisle end safety device (o) ................................................................. E 118
5.8 Wire guidance emergency mode (event messages 3670 / 3752) .......... E 119
5.9 Recovering the truck from a narrow aisle / Moving the truck
without a battery .................................................................................. E 121
6 Exiting the driver's cab with the rescue equipment ............................. E 131
6.1 Rescue equipment storage compartment in the driver's cab .............. E 132
6.2 Rescue equipment testing / servicing ................................................. E 132
6.3 Rescue equipment service life ............................................................ E 133
6.4 Rescue equipment storage and transportation ................................... E 133
6.5 Rescue equipment description / application (- 07.09) ......................... E 134
6.6 Rescue equipment description / application (07.09 -) ......................... E 149
7 Personal Protection System (o) ......................................................... E 165
7.1 Personal Protection System (PPS) ..................................................... E 165
7.2 Functional description ......................................................................... E 165
7.3 Cleaning the front panel of the scanners ............................................ E 167
7.4 Daily checks before starting the Personal Protection System ............. E 169
7.5 Personal Protection System ................................................................ E 170
8 EKS 513/515k/515 Stockpicker ........................................................... E 172
8.1 Control panel layout ............................................................................ E 172
8.2 EKS 513/515k/515 with load guard and walk-on pallet (o) ................ E 175
8.3 Display of stockpicking platform side and / or front gates
and load direction gates ...................................................................... E 183
8.4 Additional symbols in driver's display .................................................. E 185
8.5 Lifting / depositing a load .................................................................... E 185
8.6 EKS 513/515k/515 with auxiliary lift (o) ............................................. E 193
9 Optional equipment ............................................................................. E 194
9.1 Rear view mirror (o) ........................................................................... E 194
9.2 Rider mode (in the driver's cab) (o) ................................................... E 195
9.3 Weigher (o) ........................................................................................ E 197
9.4 Using a work platform (o) ................................................................... E 198
9.5 Fire extinguisher (o) ........................................................................... E 204
9.6 Closed driver's cab (o) ....................................................................... E 205
9.7 Camera system (o) ............................................................................ E 213
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F Industrial Truck Maintenance
1 Operational Safety and Environmental Protection .............................. F 1

2 Maintenance safety regulations .......................................................... F 1
3 Servicing and Inspection ..................................................................... F 7
4 Maintenance Checklist ........................................................................ F 8
4.1 Attachment service checklist (options) ................................................ F 14
5 Lubricants and Lubrication Schedule .................................................. F 18
5.1 Handling consumables safely ............................................................. F 18
5.2 Lubrication Schedule ........................................................................... F 20
5.3 Consumables ...................................................................................... F 21
6 Maintenance and Repairs ................................................................... F 22
6.1 Preparing the truck for maintenance and repairs ................................ F 22
6.2 Preventing the driver's cab from accidentally lowering ....................... F 23
6.3 Lift chain servicing ............................................................................... F 26
6.4 Lubricating the lift chains, cleaning and greasing
the contact surfaces in the mast sections ........................................... F 26
6.5 Automatic chain lubrication (o) ........................................................... F 28
6.6 Lift chain inspection ............................................................................. F 32
6.7 Hydraulic hose lines ............................................................................ F 33
6.8 Drive panel disassembly / assembly ................................................... F 34
6.9 Checking the hydraulic oil level ........................................................... F 35
6.10 Checking electrical fuses .................................................................... F 38
6.11 Recommissioning the truck after cleaning or
maintenance work ............................................................................... F 40
7 Decommissioning the industrial truck .................................................. F 42
7.1 Action to be taken before decommissioning ....................................... F 43
7.2 Action to be taken during decommissioning ........................................ F 43
7.3 Restoring the truck to service after decommissioning ......................... F 44
8 Safety tests to be performed at intervals and after
unusual incidents ................................................................................ F 45
9 Final de-commissioning, disposal ....................................................... F 45
10 Human vibration measurement ........................................................... F 45
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Appendix Appendix
JH Traction Battery Operating Instructions JH Traction Battery Operating Instructions

Z These operating instructions apply only to Jungheinrich battery models. If using
another brand, refer to the manufacturer's operating instructions.
Z These operating instructions apply only to Jungheinrich battery models. If using
another brand, refer to the manufacturer's operating instructions.
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2
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A Correct Use and Application
1 General
The industrial truck described in the present operating instructions is designed for
lifting, lowering and transporting load units.
It must be used, operated and serviced in accordance with the present instructions.
Any other type of use is beyond the scope of application and can result in damage to
personnel, the industrial truck or property.
2 Correct application
Z The maximum load and load distance are indicated on the load chart 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 rest on the back of the fork carriage and centrally between the forks.
Lifting, lowering and picking loads.

Always transport a load outside the narrow aisle as low as possible, allowing for
ground clearance.
Do not carry or lift passengers.
Do push or pull load units.
Do not negotiate slopes or inclines.
Do not negotiate docks.
Do not tow trailers.
Do not transport swinging loads.
3 Approved application conditions
F Do not exceed the permissible surface and spot load limits on the travel routes.
At blind spots get a second person to assist.
Z The industrial truck must not be used in fire or explosion endangered areas, or areas
threatened by corrosion or excessive dust. Furthermore, the truck must not be
operated in the vicinity of unprotected active components of electrical systems.
Operation in industrial and commercial environments.
Permissible temperature range +5 C to +40 C.
The truck must only be operated on level surfaces in accordance with DIN 15185
part 1.
Safety clearances between the truck and rack to EN 1726-2 item 7.3.2.
Minimum 100 mm safety clearance between rail guided truck and rack.
Minimum 125 mm safety clearance between wire guided truck and rack.
Z Special equipment and authorisation are required if the truck is to be constantly used
in extreme conditions or areas at risk from explosion.
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4 Proprietor responsibilities
For the purposes of the present operating instructions the proprietor 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 proprietor must ensure that all
users have read and understood these operating instructions.
Z Failure to comply with the operating instructions shall invalidate 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 accessories
The mounting or installation of additional equipment which affects or enhances

the performance of the forklift truck requires the written permission of
the manufacturer. Local authority approval may also need to be obtained.
Approval of the local authorities however does not constitute the manufacturers
approval.
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B Truck Description
1 Application
The EKX is an electric three-way stockpicker. The EKS is an electric stockpicker.

They are designed to transport and pick goods on level surfaces in accordance with
DIN 15185 Part 1.
It can lift open bottom or diagonal board pallets as well as roll cages beyond the area
of the load wheels. Loads can be stacked, unstacked and transported over
long distances.
The driver's cab rises together with the load handler to provide excellent visibility and
easy access to the various rack heights.
The racks must be set up for the EKX / EKS. The safety distances stipulated by
Jungheinrich (e.g. EN 1726-2 item 7.3.2) must be observed.
For rail-guided trucks a minimum safety distance of 100 mm must be maintained

between the rack and the truck.
For wire-guided trucks the safety distance between the rack and the truck must be
no less than 125 mm. The safety distance may however be increased if special
attachments are fitted.
Z The ground must comply with DIN 15185 Part 1.
Guide rails must be provided in the narrow aisles for the rail guidance system.
Vulkollan guide wheels attached to the truck chassis guide the truck between the
guide rails.
A guide wire must be routed in the ground for the wire guidance system. The signals
from the wire are received by sensors on the chassis and processed by the on-board
computer.
The capacity is shown on the data plate.
Type Capacity Load centre of gravity

EKX 513 / EKS 513 1,250 kg 600 mm
EKX 515k / EKS 515k 1,500 kg 600 mm
EKX 515 / EKS 515 1,500 kg 600 mm
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1.1 Travel direction definition
The following determinations have been made for travel direction specification:
EKX 513/515k/515
Left
Drive Load
direction direction
Right
EKS 513 / 515k / 515 Left
Drive Load
direction direction
Right
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2 Assemblies and Functional Description
24
23 2
22 3
21 4
9,10
11
12
13
20 19 18 17 16 15 14
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24
23 2
22 3
21 4
9,10
11
12
13
20 19 18 17 16 15 14
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Item Description
1 t Mast
2 t Overhead guard
3 t Auxiliary Lift1)
4 t Control panel
5 t Gates
6 t Lifting driver's cab
7 t Fork
8 t Deadman button
9 o Front sensor for wire guidance system (not shown)
10 o Front scanner for personal safety system (not shown)
11 o Rail guidance rollers in front of the load wheel
12 t Load wheel
13 t Chassis
14 o Rail guidance wheels behind the load wheel
15 t Side panel
16 o Rail guidance wheels on the drive compartment
t Tilt safety device
17
o Active stabilisers
18 t Drive wheel
19 o Rear sensor for wire guidance system
20 o Personal protection system rear scanner
21 o Battery cover
22 o Mast braces
o Automatic chain lubrication on the free lift cylinders
23
(DZ mast only)
o Automatic chain lubrication on the the top mast cross member
24
(ZT / DZ masts)
t = Standard equipment o = Optional equipment

1)
not applicable on the EKS 513 / 515k / 515
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2.1 Truck functional description
Safety mechanisms:
An enclosed truck geometry with rounded edges ensures safe handling of the truck.
The overhead guard protects the driver from falling objects.
The drive wheel and the load wheels are protected by a solid skirt. A slight danger
remains for third parties, even when a drive wheel cover is used.
The Emergency Disconnect immediately disconnects all truck movement in
hazardous situations.
Gates on either side of the cab interrupt all truck operations as soon as they are
opened.
Travelling, lifting and lowering can only be activated when the deadman button
is pressed.
Traverse and pivot operations can only be activated when the deadman button is
pressed (EKX only).
Deadman button
After preparing the truck to operation ("Preparing the truck for operation" and
"Preparing the truck for operation with an additional access code (o)" in chapter E)
and closing the gates, the deadman button in the leg well:
t=
be pressed once to allow the drive to operate the truck. When the travel control
button is released and the truck comes to a halt the parking brake applies
(prevents the truck from rolling away).
o=
be pressed and held down to allow the drive to operate the truck. Lifting and travel
are inhibited if the driver takes his foot off the foot switch. Steering and braking
remain enabled. When the deadman button is released and the truck comes to
a halt the parking brake applies (prevents the truck from rolling away).
Emergency Stop safety feature

If an error is detected the truck automatically brakes to a halt. Control indicators
on the drivers display indicate the emergency stop. Every time the truck is
switched on, the system performs a self test which only releases the parking brake
(emergency stop) if the functional test is positive.
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Drive:
Vertically mounted, heavy-duty and maintenance-free threephase motor with no

wear parts. The motor is directly attached to the single-wheel driving gear,
ensuring rapid and trouble-free maintenance.
Brake system:
Electronically controlled drive brake and wear-free electromagnetic multiplate

brake acting on the load wheels.
The operator can brake the truck gently and wear-free by pulling back the travel
control button or by changing direction. This feeds energy into the battery
(service brake).
The electromagnetic spring pressure brake acting on the drive motor serves as
a parking and handbrake.
Depending on the lift height, the load wheel brake acting on the front axle
(electro-magnetic spring pressure brake) is only activated when the Emergency
Disconnect switch is pressed or if the truck is set to emergency stop.
Steering:
Extremely smooth steering with threephase drive system (sturdy and maintenance-
free threephase motor with no wear parts).
The manageable steering wheel is integrated within the control panel. The position
of the steered drive wheel is shown in the control panel display unit. The steering
angle is +/- 90, offering maximum manoeuvrability in narrow aisles.
With the mechanical rail guidance system the drive wheel can be set to the forward
position at the press of a button (optional).
In wire guidance mode, steering is automatically assumed by the truck controller
when it detects the guidance wire, and manual steering is deactivated (optional).
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Controls and displays:
The functions are activated via ergonomic thumb movement to ensure fatigue-free
operation without stressing the wrists; sensitive application of travel and hydraulic
movements to spare and position the goods exactly.
Soft keys to control functions (Aux. lift raise / lower,...) and menus.
Integrated information display unit with colour display for all important driver
information such as steering wheel position, overall lift, truck status reports
(e. g. faults), service hours, battery capacity, time and wire guidance status etc..
Electrically adjustable control panel.
Non-switch two-handed operating principle for maximum safety and operating
comfort. Sensors record any contact made by the operator and feed this
information to the on-board computer.
Ergonomics and Comfort
Generous entry room

Large leg area, adjustable knee pads
Excellent view of the load and travel lane with extremely low swivel/traverse guides
and clearview masts.
Cushioned, adjustable and folding comfort seat.
Individual truck programs.
Limit position / transition damping for all hydraulic functions.
Hydraulic system:
All hydraulic operations are controlled by a sturdy, maintenance-free AC motor with

no wear parts and with a flanged low emission gear pump.
Oil is distributed via magnetic switch valves. The varying oil requirements are
controlled by the speed of the motor.
During a lowering operation the hydraulic pump drives the motor which then acts
as a generator (regenerative lowering). The energy produced is then fed back to
the battery.
Extremely torsion-resistant mast for high residual capacities and minimal mast sway.
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Electrical system:
Electronic system with wear-free sensors.

Service laptop connection interface:
To configure all the key truck data (end position damping, lift cutout, retardation and
acceleration patterns, reach speeds, cut-outs etc.) rapidly and reliably.
To read off the error log to analyse fault causes.
To simulate and analyse program operations.
Simple function extension by releasing code numbers.
The controller is fitted with a CAN Bus and a constantly recording sensor system.
All operations can be set using parameters. The controller provide smooth start-up
and braking of the load in all limit positions through end position and intermediate
dampers. The MOSFET threephase controller provides smooth starting for all
movements.
Highly efficient threephase technology with energy retention for the traction and lift
motors provides high travel and lift speeds and better use of energy.
Simultaneous main lift and auxiliary lift raise / lower.
Speed recording on the wheels using traction control and drive wheel wear
recognition.
Z For drive battery options refer to Battery Types in Chapter D.

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Optional equipment
Mechanical rail guidance.

Wire guidance for precise aisle guidance with no physical load of components.
A range of modular telescopic forks.
Workstation comfort package with work lights, mirror, fan.
Radio with CD player and MP3 interface.
Mechanical and electrical interfaces for material flow management systems.
Jungheinrich ISM: Information system for truck management.
Truck prepared to receive work stations.
Cutouts of the overhead guard.
Modular system of lift and travel cutouts plus speed reductions.
Faster cycles through synchronised swivel.
RFID ground control
Transponder-based truck controller system.
Permanent route measurement for precise identification of all warehouse zones.
High degree of flexibility in terms of switch and safety functions (end of aisle safety
device, lift/travel cutouts, speed reduction).
Travel speed setting optimisation through ground topology.
Integrated Jungheinrich personal safety system (PSS).
Electric active stabilisers for maximum capacities up to large lift heights (optional).
3 Standard version specifications
Z Technical data specified in accordance with VDI 2198 / EN 1726 *.

Technical modifications and additions reserved.
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3.1 Performance data
Description EKX 513 EKX 515k EKX 515

EKS 513 EKS 515k EKS 515
Q (t) Capacity (where C = 600 mm) 1250 1500 1500 kg
c / D* Load centre distance 600 600 600 mm
Travel speed without load (RG) 10.5 10.5 1) 10.5 1) km/h
Travel speed with load (RG) 10.5 10.5 1) 10.5 1) km/h
Travel speed without load (WG) 9 9 9 km/h
Travel speed with load (WG) 9 9 9 km/h
Travel speed without load
9 9 9 km/h
(free ranging)
Travel speed with load (free ranging) 9 9 9 km/h
Lift speed without load 0.42 0.47 2) 0.47 2) m/s
Lift speed with load 0.42 0.47 2) 0.47 2) m/s
Lower speed without load 0.45 0.45 0.45 m/s
Lower speed with load 0.45 0.45 0.45 m/s
Aux. lift speed without load 0.35 0.35 0.35 m/s
Aux. lift speed with load 0.30 0.30 0.30 m/s
Aux. lift lower speed without load 0.25 0.25 0.25 m/s
Aux. lift lower speed with load 0.30 0.30 0.30 m/s
Combined raising of main and
0.7 0.7 0.7 m/s
aux. lift
Traverse speed without load 3) 3)
0.2 - 0.3 0.2 - 0.3 0.2 - 0.3 3) m/s
Traverse speed with load 0.25 3) 0.25 3) 0.25 3) m/s
Rotate without load 13 13 13 s/180
Rotate with load 13 13 13 s/180
Service brake Inversion / regenerative
Parking brake Electric spring brake / multi-plates
Type of traction controller AC drive control
RG: Rail guidance

WG: Wire guidance
FR: free ranging
1)
Available in conjunction with power package up to 12 km/h
2) Available in conjunction with power package up to 0.52 m/s
3)
Available in conjunction with power package up to 0.4 m/s
(lift height-dependent 0.2 m/s to 0.4 m/s)
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3.2 Dimensions (as per data plate)
h4
h15
h1
h12
h10
h3
h6
h9
h7
s m1 m2
x y z
l1
l2
l8
r b14 I10 b9
b8 c b1 b2 b6 Ast
Wa
b7
l
l6
e
b5
b3 x
b12
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c / D Load centre of gravity 600 600 600 mm
x Load distance 440 440 440 mm
y Wheelbase 1826 1926 2222 mm
Centre drive wheel /
z counterweight 280 280 280 mm
(truck geometry)
h1 Mast height retracted 2955 2955 2955 mm
h3 Lift 3500 * 3500 * 3500 * mm
h4 Mast height extended 6050 6050 6050 mm
h6 Overhead guard height 2550 2550 2550 mm
h7 Seat height / standing height 430 430 430 mm
h9 Auxiliary Lift 1) 1780 1780 1780 mm
Overall lift EKX (h3 + h9) 5280 5280 5280 mm
h10
Overall lift EKS (h3) 3500 3500 3500 mm
h12 Truck height raised 3930 3930 3930 mm
h15 Picking height (h12+1600) 5530 5530 5530 mm
Working aisle width for
Ast 1640 1640 1640 mm
pallets 1200 x 800
b1/ b2 Overall width 1210 / 1400 1210 / 1500 1210 / 1500 mm
b3 Fork carriage width 480 480 480 mm
b5 Outside straddle 465 465 465 mm
b6 Width across guide wheels 1500 1600 1600 mm
b7 Traverse, sideways 1300 1300 1300 mm
Traverse, to the side of truck
b8 480 480 480 mm
centre
b9 Outer operator position width 1440 1440 1440 mm
b12 Pallet width 800 800 800 mm
b14 Swivel/traverse frame width 1440 1440 1440 mm
1)
not applicable on the EKS 513 / 515k / 515
Z The data listed in the table (performance data, dimensions and weights) are based
on a truck with a 350 ZT mast (*).
The data (performance data, dimensions and weights) on the particular truck supplied
can be found on the data plate.
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h4
h15
h1
h12
h10
h3
h6
h9
h7
s m1 m2
x y z
l1
l2
l8
r b14 I10 b9
b8 c b1 b2 b6 Ast
Wa
b7
l
l6
e
b5
b3 x
b12
1109.GB
B 14
l1 Overall length w.o. load 3250 3350 3646 mm
l2 Headlength 3146 3264 3560 mm
l6 Pallet length 1200 1200 1200 mm
l8Fork pivot point distance 904 904 904 mm
Fork pivot point - toothed
l8- x 464 464 464 mm
rack distance
1) 1) 1)
l10 Outrigger width 172 172 172 mm
50 x 120 x 50 x 120 x 50 x 120 x
s/e/l Fork dimensions mm
1200 1200 1200
Wa Turning radius 2106 2206 2502 mm
Ground clearance with load
m1 80 80 80 mm
below mast
Ground clearance centre
m2 80 80 80 mm
wheelbase
Fork pivot point - pivot point
r 154 154 154 mm
distance
-- "Driver's cab entry" width 420 420 420 mm
-- Drivers cab ceiling height 2100 2100 2100 mm
1)
Special build: l10 = 190 mm
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B 15
3.3 Mast version
3.3.1 Standard mast version with telescopic mast (ZT)

h1 Mast height retracted 2705 - 5055 2705 - 6155 2705 - 6405 mm
h3 Lift 3000 - 7500 3000 - 9500 3000 - 10000 mm
h4 Mast height extended 5550 - 10050 5550 - 12050 5550 - 12550 mm
h10 Overall lift EKX (h3 + h9) 4780 - 9280 4780 - 11280 4780 - 11780 mm
Overall lift EKS (h3) 3000 - 7500 3000 - 9500 3000 - 10000 mm
h12 Truck height raised 3430 - 7930 3430 - 9930 3430 - 10430 mm
h15 Picking height (h12+1600) 5030 - 9530 5030 - 11530 5030 - 12030 mm
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3.3.2 Standard mast with two stage triplex mast (DZ)

h1 Mast height retracted 2550 - 3895 2550 - 4695 2550 - 5750 mm
h3 Lift 4000 - 7500 4000 - 9500 4000 - 12500 mm
h4 Mast height extended 6550 - 10050 6550 - 12050 6550 - 15050 mm
h10 Overall lift EKX (h3 + h9) 5780 - 9280 5780 - 11280 5780 - 14280 mm
Overall lift EKS (h3) 4000 - 7500 4000 - 9500 4000 - 12500 mm
h12 Truck height raised 4430 - 7930 4430 - 9930 4430 - 12930 mm
h15 Picking height (h12+1600) 6030 - 9530 6030 - 11530 6030 - 14530 mm
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3.4 Engine data
EKX 513 EKX 515k EKX 515

Description
Drive motor, output at S2 60 min 7.6 kW 7.6 kW 7.6 kW
Lift motor, output at S3 25 % 20.0 kW 20.0 kW 20.0 kW
Steer motor, output at S2 60 min 1.0 kW 1.0 kW 1.0 kW
3.5 Weights
3.5.1 Basic truck / mast weight including driver's cab and attachment
1 13
Basic truck weight
Z The weight of the basic truck (13) can be found in the following table.
Truck Basic truck weight

EKX 513 / EKS 513 2600 kg1)
EKX 515 k / EKS 515k 2600 kg1)
EKX 515 / EKS 515 2600 kg1)
1)
including additional weights of 300 kg that may be installed depending on
the model
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B 18
Mast weight including driver's cab and attachment
Z The weight of the mast including the driver's cab and attachment (1) can be
calculated using the formulae given below. The necessary data such as net weight
(overall weight) of the truck without battery can be found on the data plate.
A Truck net weight without battery

B Mast weight including driver's cab and attachment
Formula for the EKX 513/515k/515 and EKS 513/515k/515:

B = A - 2300 kg
Example:
Required details:
(see truck data plate)
Truck type = EKX 515

Truck net weight without battery = 5722 kg
Formula:
B = A - 2300 kg = 5722 kg - 2300 kg = 3422 kg
Z The weight of the mast including the driver's cab and attachment is 3422 kg.
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3.5.2 Truck net weight / axle loads
EKX 513 EKX 515k EKX 515

Description
Net weight incl. battery, w.o. load 6350 6750 7900 kg
Battery weight 1238 1558 2178 kg
Truck net weight without battery,
5112 5192 5722 kg
see "data plate"
Axle load with load
5720 / 1880 6190 / 2060 6590 / 2810 kg
front / rear
Axle load without load
3850 / 2500 3980 / 2770 4480 / 3420 kg
front / rear
Battery type 3EPzS 465 4EPzS 620 6EPzS 930
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B 20
3.6 Wheels, chassis
F Accident risk from incorrect wheel disassembly/assembly

The load / drive wheels can only be disassembled or assembled by the
manufacturer's customer service department which has been trained to do this.
Exceptionally, this task may be performed by a customer service organisation
authorised by the manufacturer.
EKX 513 / EKS 513
Description EKX 513 / EKS 513

Tyre type Vulkollan
Wheels, front (load wheel) 380 mm x 192 mm
Wheels, rear (drive wheel) 400 mm x 160 mm
Wheels, number front (load wheel) 2
Wheels, number rear (*= driven) 1*
EKX 515k / EKS 515k
Description EKX 515k / EKS 515k

Tyre type Vulkollan
EKX 515 / EKS 515
Description EKX 515 / EKS 515

Tyre type Vulkollan
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B 21
3.7 EN norms
Noise emission level: 68 dB(A)
in accordance with EN 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: 1.14 m/s2 in accordance with EN 13059
Seat vibration: 0.70 m/s2
Z The internal accuracy of the measuring chain at 21C is 0.02 m/s.

Further deviations may occur in particular through the positioning of the sensor and
different driver weights.
Z The vibration acceleration acting on the body in the operating position is,
in accordance with standard procedures, the linearly integrated, weighted
acceleration in the vertical direction. It is calculated when travelling over bumps at
constant speed. These recordings were taken on a single occasion and must not be
confused with the human vibrations of the "2002/44/EC/Vibrations" operator directive.
The manufacturer offers a special service to measure these human vibrations,
see "Human Vibrations" in Chapter F.
Electromagnetic compatibility (EMC)

The manufacturer confirms that equipment complies with tolerance levels for
electromagnetic emissions and resistance as well as static electricity discharge
testing in accordance with EN 12895 including the normative procedures contained
therein.
Z No changes to electric or electronic components or their arrangement may be made

without the written agreement of the manufacturer.
M 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 with a doctor or the medical equipment
manufacturer to clarify whether it can be used near the industrial truck.
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B 22
3.8 Conditions of use
Ambient temperature: operating at 5 qC to 40 qC
Z Special equipment and authorisation are required if the truck is to be constantly used
in conditions of extreme temperature or air humidity fluctuations.
The truck is not authorised for use in cold stores.
The truck must only be used in an closed indoor environment. The following applies:
Ambient temperature in 24-hour mode: max. 25 C

max. air humidity (inside) 70%, non-condensing.
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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B 23
4 Identification points and data plates
F Warnings and notices such as load charts, strap points and data plates must be
legible at all times. Replace if necessary.
h3 (mm) Q (kg)
D (mm)
26 27
25
29
30
41
28
31
31
mV
1,5 V
40
32
33
39
28
38
37
36 34 35 34 25
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B 24
Item Description
25 Strap points for crane lifting
26 Truck data plate
27 Capacity decal
28 Decal: Abseil device
29 Decal: No passengers
30 Test plaque (o)
31 "Hazard warnings in narrow aisle" notice
32 Decal: Do not step onto or beneath the load, risk of trapping
33 "Control panel unlock" notice
34 Jack contact points
35 Serial number (engraved in chassis underneath the right hand side panel)
36 Decal: Emergency drain key
37 Decal: Add hydraulic oil
38 Decal: Emergency drain
39 Company and model information
40 Decal: Caution: Low voltage electronics system
41 Read operating instructions" notice
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B 25
4.1 Truck data plate
50 61
51 60
52 59
53 58
54 57
56
55
Item Description Item Description

50 Type 56 Manufacturer
51 Serial number 57 Min./max. battery weight (kg)
52 Rated capacity (kg) 58 Drive output (kW)
53 Battery voltage (V) 59 Load centre (mm)
54 Net weight w.o. battery (kg) 60 Year of manufacture
55 Manufacturers logo 61 Option
Z For truck-related queries or when ordering spare parts always quote the truck serial
number (51). The truck's serial number (51) is indicated on the data plate (26) and is
engraved on the chassis (35) (see Identification points and data plates in
chapter B).
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B 26
4.2 Truck capacity plate
M Replacing the forks can cause accidents

The capacity changes when the forks are replaced.
When replacing the forks always attach an additional capacity plate to the truck.
Trucks supplied without forks are given a capacity plate for standard forks
(length: 1150 mm)
27
h3 (mm) Q (kg)
D (mm)
The capacity plate (27) indicates the capacity (Q kg) of the truck. The maximum
capacity is shown as a table with a given load centre of gravity D (in mm) and the
required lift height h3 (in mm).
Z The capacity plate (27) of the truck indicates the truck's capacity with the forks as
originally supplied.
Example of how to calculate the maximum capacity:
4250 850 850 600

1105 1105 850
3600
1250 1250 850
2900
500 600 700
With a load centre of gravity D of 600 mm and a maximum lift height h3 of 3600 mm.
the max. capacity Q is 1105 kg.
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B 27
4.3 Attachment capacity plate (o)
The attachment capacity plate gives the trucks capacity Q [in kg] in conjunction with
the respective attachment. The serial number specified in the load chart must match
the data plate of the attachment, as the specific capacity for each truck is indicated
by the manufacturer. It is shown in the same way as the trucks capacity and can be
determined accordingly.
For loads with a centre of gravity above 500 mm upward, the capacities are reduced
by the difference of the altered centre of gravity.
5 Stability
F Loss of stability can cause accidents

The stability as indicated on the load chart can only be guaranteed with the
components (battery, mast etc.) as shown on the data plate. Only use manufacturer-
approved batteries.
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:
Battery size and weight

Wheels
Mast
Attachment
Transported load (size, weight and centre of gravity)
Ground clearance, e.g. modification of the tilt safety devices.
M Loss of stability can cause accidents

Changing the components can affect stability.
1109.GB
B 28
C Transport and Commissioning
1 Transport
Depending on the height of the mast and local conditions, the industrial truck can be
transported in different ways:
Vertically with the mast and load handler assembled

(for low heights)
Vertically with the mast and load handler disassembled
(for large truck heights)
Safety Instructions for Assembly and Commissioning
F Incorrect assembly can result in accidents

The assembly of the truck at the application site, commissioning and driver training
must only be performed by the manufacturer's customer service representatives who
have been specially trained for these tasks.
The hydraulic lines may be connected to the basic truck / mast interface and the
truck commissioned when the mast has been properly assembled.
The truck can then be started.
If several trucks have been delivered, make sure that always the serial numbers of
the load handlers, masts and basic trucks match each other.
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C1
2 Lifting by Crane
F Improper lifting by crane can result in accidents. The use of unsuitable lifting gear can
cause the truck to crash when being lifted by crane.
Prevent the truck and mast from striking other objects when they are being raised,
and avoid any uncontrolled movement. If necessary, secure the truck and mast with
guide ropes.
The truck and mast should only be laden by people who are trained in handling
lifting slings and tools.
Wear safety shoes when lifting the truck by crane.
Do not stand under a swaying load.
Do not walk into or stand in a hazardous area.
Always use lifting gear with sufficient capacity (for truck weight see truck data plate).
Always attach the crane slings to the prescribed strap points and prevent them
from slipping.
Use the lifting gear only in the prescribed load direction.
Crane slings should be fastened in such a way that they do not come into contact
with any attachments when lifting.
2.1 Lifting by crane with mast assembled

1
2
3
4
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C2
M Only use lifting gear with sufficient capacity
(for the truck weight refer to the data plate).
F The truck must only be raised by a crane without a battery, see Battery removal and
installation in Chapter D.
Park the truck securely,
see Parking the Truck Securely in Chapter E.
Secure the truck with wedges to prevent it from rolling away.
M Attach the crane slings to the strap points (1-4) so that the truck cannot slip.
Crane slings should be fastened in such a way that they do not come into contact with
any parts of the truck when it is being raised.
2.2 Crane points / Strap points
The crane points (1) are the eyes in the mast.

The crane points (2) are the eyes on the drive compartment.
The strap points (3) are the two mast attachments on the side of the chassis.
The crane points (4) are the mast's lower strap points connecting it to the chassis.
For lifting by crane, use the following crane points:
M Only use lifting gear with sufficient capacity.

Fastening / quick release belts placed over lift chains and / or sharp edges must be
protected by a suitable support material, e.g. foam.
Crane points for complete truck with mast assembled:

points (1) and (2)
Z For the truck net weight without battery see the truck data plate.
M The basic truck with the mast assembled must only be raised by crane without
a battery, see Battery removal and installation in Chapter D.
Crane points for the basic truck:

points (2) and (3) (weight approx. 2,700 kg excluding battery)
Z For the weight of the basic truck see "Weights" in Chapter B.
M The basic truck must only be raised by crane without a battery, see Battery removal
and installation in Chapter D.
F Make sure the mast attachment upper half shells Allen screws are torqued to the
required 205 Nm.
Mast crane points including drivers cab and attachment:
points (1) and (4)
Z For the weight of the mast plus driver's cab and attachment see "Weights" in Chapter B.
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C3
2.3 Lifting the battery by crane
F Batteries can be hazardous

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

see "Battery removal and installation" in Chapter D.
Z The weight to be taken into account when lifting the

battery by crane, refer to the battery's data plate.
Lifting the battery with crane slings:

Attach the lifting gear to the four eyes of the
battery tray (for weight refer to the battery data
plate).
The battery can now be raised and loaded with
a crane.
Load the battery onto a pallet:
Place the battery on a pallet.
Attach the battery to the pallet with two tie-
down straps/tension belts.
The battery can now be raised and loaded with
a forklift truck.
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C4
3 Securing the truck during transport
F Accidental movement during transport

Improper fastening of the truck and mast during transport can result in serious
accidents.
Loading must be carried out by specially trained staff in accordance with
recommendations contained in Guidelines VDI 2700 and VDI 2703. In each case
correct measurements must be made and appropriate safety measures adopted.
The truck must be securely fastened when transported on a lorry or a trailer.
The lorry / trailer must have clamp rings.
Use wedges to prevent the truck from moving.
Use only tensioning belts or tie-down straps or with sufficient strength.
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C5
3.1 Basic truck transport safety
M The mast must only be disassembled or assembled by the manufacturers authorised

service department.
To ensure secure transport of a disassembled EKX / EKS, use the prescribed

attachment points for fastening/quick release belts.
Z Only use fastening / quick release belts with a rated capacity of > 5 to. Fastening /
quick release belts placed over lift chains and / or sharp edges must be protected
by a suitable support material, e.g. foam.
M When transporting, always relieve the drive wheel (10) by placing the entire surface
of a wooden beam (11) underneath the battery compartment (minimum chassis
width) in front of the drive wheel (10). In addition, secure the load wheels (15) using
a wedge (16).
F If the truck battery is supplied in the chassis, disconnect the battery.
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C6
The fastening/quick release belts must be attached to at least six different clamp
rings (8).
5 6 7
16 15 8 14 13 12 8 11 10 9 8
To ensure secure transport of the basic truck, use the following prescribed
attachment points for fastening/quick release belts.
Guide the fastening belt / quick release belt (9) through the attachment latches (7)
on the mast bracing to the truck chassis rear, and attach to the clamp rings (8).
Guide the fastening belt / quick release belt (12) via both outriggers (14) to the truck
chassis front, and attach to the clamp rings (8).
Guide the fastening belt / quick release belt (5) via the top chassis structure (13)
through the two mast attachments (6), and attach to the clamp rings (8).
M Note the cable routing and cover sharp edges with a suitable material.
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C7
3.2 Mast transport retainer
M Use a transport retaining device (19) to prevent the driver's cab (17) from sliding.
The fork carriage (18) must also be secured to prevent it from sliding.
If the mast (27) is stored on a pallet(s) (28), the pallet(s) must be fastened to the mast
(27) with fastening belts / quick release belts (26). Ensure a positive fit by placing
a wooden beam (22) between the bottom mast (27) and the pallet (28).
In addition, guide a fastening belt / quick release belt (24) through thedrivers position
carriage (17) to guide and fasten the mast (27).
17 18
31 19
30
29
28 20 26 27 26 20 25 24 23 22 21 20
1109.GB
C8
Mast bottom strap point
Secure the fastening belts / quick release belts (21, 25) to the attachment latch (23)
of the mast (27) and the clamp rings (20).
Mast top strap point
Stow any supplied parts (forks, guide wheels, etc.) on a

pallet (31) so that they cannot slip. Place the pallet (31)
on the top of the mast (27) and secure it. To do this,
guide the fastening belt / quick release tensioning
belt (29) over the pallet (31) and around the mast (27)
and fasten it. Guide the fastening belt / quick release
fastening belt (30) over the pallet (31) and secure it to
31
the clamp rings (20).
Without the pallet (31) guide the fastening belt / quick release fastening belt (30)
over the mast (top) and secure it to the clamp rings (20).
M Fastening / quick release belts placed over lift chains and / or sharp edges must be
protected by a suitable support material, e.g. foam.
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C9
3.3 Transport retaining mechanism for trucks with the mast assembled
32 33 34 35
36 41 40 39 38 37 36
F If the truck battery is supplied in the chassis, disconnect the battery.
M When transporting, always relieve the drive wheel (37) by placing the entire surface
of a wooden beam (38) underneath the battery compartment (minimum chassis
width) in front of the drive wheel (37). In addition, secure the load wheels (39) using
a wedge (40).
Attach a minimum of four fastening belts / quick release belts, two on the left and two
on the right (33,35) to the mast (34) and secure them to the clamp rings (36).
Using wooden planks, a pallet or a rubber mat (32) from the outrigger (41) to the front
of the transporter, ensure a positive fit.
1109.GB
C 10
4 Using the Truck for the First Time
Safety Instructions for Assembly and Commissioning
F Incorrect assembly can result in accidents

The assembly of the truck at the application site, commissioning and driver training
must only be performed by the manufacturer's customer service representatives who
have been specially trained for these tasks.
The hydraulic lines may be connected to the basic truck / mast interface and the
truck commissioned when the mast has been properly assembled.
The truck can then be started.
If several trucks have been delivered, make sure that always the serial numbers of
the load handlers, masts and basic trucks match each other.
M Only operate the truck with battery current. Rectified AC current will damage the
electronic components. Cable connections to the battery (tow leads) must be less
than 6m long and have a minimum cross-section of 50 mm2.
4.1 Moving the industrial truck without a battery
M This operation must only be performed by suitably trained maintenance personnel.
F It must not be performed on slopes or inclines (no brakes).
See also Recovering the truck from a narrow aisle / Moving the truck without
a battery in chapter E.
4.2 Installing and removing the mast
M The mast can only be disassembled / assembled by the manufacturer's specialist

customer service personnel who have been trained to do this. Exceptionally, this task
may be performed by a customer service organisation authorised by the manufacturer.
There is an additional risk of trapping when reaching and traversing in the traverse/
reach section of the attachment.
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C 11
5 Starting the Truck
M Only operate the truck with battery current. Rectified AC current will damage the
electronic components. Cable connections to the battery (tow leads) must be less
than 6 m long and have a minimum cross-section of 50 mm2.
To prepare the truck after delivery or transport the following tasks must be carried out:
Undo the transport chain(s) (42).

If necessary install and charge the battery,
see Battery removal and installation and
Charging the battery in Chapter D.
Remove the load wheel brake transport retainers
The transport retainers release the load wheel
brakes when they are de-energised.
Procedure:
Disassemble the wheel guard by removing the
42a
three Allen screws from the load wheels.
Remove the transport retainers from the load
wheel brakes by removing three setscrews (42b)
from the load wheel brakes (42c).
Z The load wheel brakes (42c) are now applied without

power.
Store the setscrews (42b) in the plastic bag

supplied. Seal the plastic bag with a tape or similar. 42b
Fit the wheel guard. 42c
Loosen the twist grip screws (42e) under the
driver's seat (42d) and carefully move the seat
forward.
Store the plastic bag in the compartment under
the driver's seat (42d).
Move the driver's seat back (42d) and secure it to
the driver's cab by tightening the two twist grip
screws (42e).
Make sure all safety mechanisms are present and
test them (e.g. tilt safety devices, gates etc.).
Start up the truck as indicated, see Starting up the 42d
Truck in chapter E.
42e
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C 12
5.1 Mechanical tilt safety devices (t)
43
44
Z On the EKX 513/515k/515 and EKS 513 / 515k / 515 a tilt safety device (44) can be
mounted on the left or right of the truck chassis, depending on the tilt test. If a tilt
safety device (44) is used, an X is engraved on the chassis (43) on the right hand side
of the battery compartment (see Identification Points and Data Plates in chapter B).
M Before commissioning, check the trucks to ensure the tilt safety devices (44)
are present.
Z For a new drive wheel, the distance from the tilt safety device (44) to the ground
should be 10 mm - 12 mm.
M Check that all safety devices are present and operational.

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C 13
5.2 Active stabiliser (o)
45
Z With industrial trucks the residual capacity can be increased by 200 kg by using
active stabilisers (45). Nevertheless, the maximum capacity must not be exceeded.
The active stabiliser (45) has a maximum setting range of 40 mm and moves to
compensate for uneven ground.
Operation:
The active stabiliser is referenced (extend R

retract) when the truck is switched on. The 46
"Active stabiliser referencing" display (46)
lights up red in the display unit.
After referencing the active stabiliser moves
to a distance of 10 mm to 12 mm from
the ground.
When the truck is idle and the attachment
has moved from its home position, the active 47
stabiliser moves to a distance of up to 5 mm
from the ground, depending on the lift
height. The "Active stabiliser extended"
display (47) lights up yellow in the display
unit.
x Attachment extends left
-> left active stabiliser extends
x Attachment extends right
-> right active stabiliser extends
Z An adjustment run with a maximum speed of 2.5 km/h can be carried out.
When the attachment is back in the home position the active stabiliser moves to a
distance of 10 mm to 12 mm from the ground and the "Active stabiliser extended"
display (47) goes out.
M Check that all safety devices are present and operational.

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C 14
D Battery - Servicing, Recharging,
Replacement
1 Safety Regulations Governing the Handling of Lead-Acid Batteries
Park the industrial truck securely before carrying out any work on the batteries
(see Chapter E).
Maintenance personnel: Recharging, servicing and replacing of batteries must only

be performed by qualified personnel. These operating instructions and the
manufacturers instructions concerning batteries and charging stations must be
observed when carrying out the work.
Fire protection: Smoking and open flames are not permitted when handling
batteries. Wherever an industrial truck is parked for charging there shall be no
inflammable material or lubricants capable of creating sparks within 2 metres around
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.
M Before closing the battery cover make sure that the battery cable cannot be
damaged. There is a risk of short circuits with damaged cables.
Battery disposal: Batteries may only be disposed of in accordance with national

environmental protection regulations or disposal laws. The manufacturers disposal
instructions must be followed.
1109.GB
D1
General notes on handling batteries

with battery acid.
F Using unsuitable batteries can cause accidents

The weight and dimensions of the battery have a considerable effect on the stability
and capacity of the industrial truck. Changing the battery equipment requires the
manufacturers approval, as compensating weights are required if smaller batteries
are fitted. When replacing/installing the battery make sure the battery is securely
located in the battery compartment of the truck.
2 Battery types
The EKX / EKS can be fitted with a variety of battery types. All battery types comply
with DIN 43531-A. The following table shows which combinations can be included
as standard:
Voltage Capacity Battery type Battery type Weight Truck model

80 V 465 Ah 3 E PzS 465 Single part 1,238 kg
EKX 513 /
80 V EKS 513
465 Ah 3 E PzS 465 Two part 1,250 kg
( 2 x 40 V )
EKX 515k /
80 V EKS 515k
( 2 x 40 V )
EKX 515 /
80 V EKS 515
( 2 x 40 V )
Z The battery weights can be taken from the battery data plate.
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D2
2.1 Battery compartment dimensions
Truck model Length (L) Width (W) Height (H)

EKX 513 1,060 mm 616.5 mm 925 mm
EKS 513 Maximum battery height = 880 mm
EKX 515k 1,060 mm 716.5 mm 925 mm
EKS 515k Maximum battery height = 880 mm
EKX 515 1,060 mm 1,012.5 mm 925 mm
EKS 515 Maximum battery height = 880 mm
F When replacing the battery equipment make sure that the dimensions, types and
weights of the replacement batteries are identical to the ones previously used.
Changing the battery equipment requires the manufacturers approval,
as compensating weights are required if smaller batteries are fitted.
When replacing/installing the battery make sure the battery is securely located in
the battery compartment of the truck.
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D3
3 Exposing the battery
M Trapping hazard
There is a risk of trapping when you close the battery cover.
Make sure there is nothing between the battery cover and the truck when you close
the battery cover.
F An unsecured truck can cause accidents

Parking the truck on an incline or with a raised load / load handler is dangerous and
is strictly prohibited.
Always park the truck on a level surface. In special cases the truck may need to be
secured with wedges.
Always fully lower the mast and forks.
Select a place to park where no other people are at risk of injury from
lowering forks.
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D4
1
Park the truck securely

(see Parking the Truck Securely in Chapter E).
Lower the load handler to the ground.
Turn key switch (2) to "0" (zero).
Press the Emergency Disconnect switch (1) down.
Lift up the battery panel (3) (see arrow direction).
M Open covers can cause injury and accidents

The covers (battery cover, side panels, drive compartment cover etc.) must be closed
during operation.
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D5
4 Charging the Battery
F The gases produced during charging can cause explosions

The battery gives off 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.
Switch the charging station and truck off first before connecting/disconnecting the
charging cable of the battery charging station to/from the battery connector.
The charger must be adapted to the battery in terms of voltage and charge capacity.
Before charging, check all cables and plug connections for visible signs of damage.
Ventilate the room in which the truck is being charged.
The battery cover must be open and the battery cell surfaces must be exposed
during charging to ensure adequate ventilation.
Do not smoke and avoid naked flames when handling batteries.
Wherever an industrial truck is parked for charging there shall be no inflammable
material or lubricants capable of creating sparks within 2 metres around the truck.
Fire protection equipment must be on hand.
Do not lay any metallic objects on battery.
It is essential to follow the safety regulations of the battery and charger station
manufacturers.
Expose the battery (see Exposing the battery in this chapter).
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D6
1
Park the truck securely, see Parking the Truck Securely in Chapter E.
Expose the battery, see Exposing the battery in this chapter.
Switch off the charger.
Set the correct charging program on the charger.
Remove the battery connector (4).
F When charging, the tops of the battery cells must be exposed to provide sufficient
ventilation. Do not place any metal objects on the battery. Before charging, check all
cables and plug connections for visible signs of damage.
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D7
1
Z The charger must be adapted to the battery in terms of voltage and charge capacity.
Connect the charger lead of the battery charger station with the battery connector (4).
Switch on the charger.
Charge the battery in accordance with the battery and charging station
manufacturers' instructions.
F It is essential to follow the safety regulations of the battery and charger station
manufacturers. 1109.GB
D8
F The gases produced during charging can cause explosions
Switch the charging station and truck off first before connecting/disconnecting the
charging cable of the battery charging station to/from the battery connector.
M Trapping hazard
There is a risk of trapping when you close the battery cover.
the battery cover.
Switch off the truck once the battery is fully charged.

Disconnect the battery charging station cable from the battery connector (4).
Check all cables and plug connections for visible signs of damage.
M There is a risk of short circuits with damaged cables.

Report any defects immediately to your supervisor.
Tag out and decommission a faulty lift truck.
Only return the truck to service when you have identified and rectified the fault.
Attach the battery connector (4) to the truck.
M Open covers can cause injury and accidents

The covers (battery cover, side panels, drive compartment cover etc.) must be closed
during operation.
Close the battery cover (3).
After the battery charge the truck is ready for operation.

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D9
5 Battery Removal and Installation
M 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.
Note the "Safety regulations for handling acid batteries" section in this chapter.
Wear safety shoes when removing and installing the battery.
Use only batteries with insulated cells and terminal connectors.
When replacing a battery always install the same battery type in the
battery compartment. Extra weights must not be removed and must remain in the
same position.
Park the truck on a level surface to prevent the battery from sliding out.
Make sure the crane slings have sufficient capacity to replace the battery.
Use only approved battery replacement devices (battery roller stand, replacement
trolley etc.).
Make sure the battery is securely located in the truck's battery compartment.
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D 10
5.1 Installing and removing a battery with a battery trolley (t)
1 9 8
5 4 6 7
Battery removal:

Turn the key switch (2) to "0" (zero) and press the Emergency Disconnect switch (1).
Pull the battery panels (5) up and lift them off.
Remove the battery connector (4).
Undo the battery retainer (9) by moving the lever (8) and remove the retainer.
Position the battery roller stand in front of the battery compartment in such a way
that the battery (7) can be safely pushed onto the roller stand.
Pull the battery (7) onto the side of the prepared battery transporter.
F Make sure the battery trolley is properly secured.

Secure the battery (7) on the roller stand against accidental movement.
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D 11
1 9 8
5 4 6 7
Battery installation:
F A non-installed battery can result in accidents

and capacity of the industrial truck. Do not work on the truck without a battery installed
in the battery compartment. In exceptional cases short shunting journeys are
permitted, e.g. to replace the battery.
The following conditions must apply:
The tow leads must be less than 6 m long and have a minimum cross-section of
50 mm2.
The mast fully lowered.
No load units lifted.
Only carry out short shunting operations at slow speed.
This requires added concentration on the part of the operator.
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D 12
M There is a risk of trapping when you close the battery cover and fit the side panels,
battery retainers, battery latches and battery.
When you fit the battery, retainers and side panels make sure there is nothing
between these components and the truck.
the battery cover.
Z The battery retainers (6, 9) can swap positions. This means that they can both be
fitted in either the left or right side of the trucks chassis.
M To avoid pushing the battery (7) through on assembly, the battery retainer (6) must
first be plugged in on the opposite side.
Position the battery roller stand with the battery (7) in front of the battery
compartment in such a way that the battery (7) can be safely pushed into the truck's
battery compartment.
Insert the battery retainer (6) opposite the side of entry and lock it so that the
battery (7) cannot be pushed through the battery compartment when inserted.
Undo the battery latch on the battery roller stand.
Push the battery (7) off the roller stand as far as the stop in the truck's battery
compartment (see arrow direction).
Insert the battery retainer (9) in the chassis and lock it by flipping the lever (8) over.
F After replacing / fitting the battery (7), make sure that the battery (7) is well secured
in the battery compartment.
Fit the side panels (5).

Attach the battery connector (4) to the truck.

F After installing again, check all cables and connectors for signs of visible damage and
before using the truck again check that:
the battery retainers (6, 9) are fitted and the battery retainer (9) is pulled tight by the
lever (8), see "Battery lock sensor" in chapter D.
the side panels (5) are inserted safely and the battery panel (3) is closed.
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D 13
5.2 Placing/removing batteries in the battery replacement trolley using a forklift (o)
1 12
5 4 10 11 7
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D 14
Battery removal:

Turn the key switch (2) to "0" (zero) and press the Emergency Disconnect switch (1).
Pull the battery panels (5) up and lift them off.
Remove the battery connector (4) (2 off).
Remove the battery retainers (10, 12) on the left and right-hand sides of the chassis.
Carefully pull out the batteries (7) on the left or right hand side using a forklift truck.
To do this, insert the forks of the truck into the fork shoes (11) of the battery
roller stand. Raise the batteries (7) carefully until they are clear of the ground.
Pull the batteries (7) carefully out of the chassis.
M When replacing batteries (7) avoid damaging the truck chassis, the batteries and
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D 15
1 12
5 4 10 11 7
Battery installation:
F A non-installed battery can result in accidents

and capacity of the industrial truck. Do not work on the truck without a battery installed
in the battery compartment. In exceptional cases short shunting journeys are
permitted, e.g. to replace the battery.
The following conditions must apply:
The tow leads must be less than 6 m long and have a minimum cross-section of
50 mm2.
The mast fully lowered.
No load units lifted.
Only carry out short shunting operations at slow speed.
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D 16
M There is a risk of trapping when you close the battery cover and fit the side panels,
battery retainers, battery latches and battery.
When you fit the battery, retainers and side panels make sure there is nothing
between these components and the truck.
the battery cover.
Z The battery retainers (10, 12) can swap positions. This means that they can both be
fitted in either the left or right side of the trucks chassis.
M When installing the batteries (7) make sure that the forks of the truck used for
assembly are located in the fork shoes (11) of the battery roller stand. In addition,
the fork tips of the truck used must not project beyond the battery roller stand.
Bring the battery (7) in front of the battery compartment.

Raise the battery (7) so that it can be moved into the battery compartment without
striking any objects.
M When replacing the batteries (7) avoid damaging the truck chassis, batteries and
Move the battery (7) into the battery compartment.

Lower the battery (7) pull the forks of the truck used for assembly carefully out of
the fork shoes (11) of the battery roller stand.
Insert the battery retainers (10, 12) on the left and right-hand sides of the chassis.
F After replacing / fitting the battery (7), make sure that the battery (7) is well secured
in the battery compartment.
Fit the side panels (5).

Attach the battery connectors (4) to the truck (2 off).

F After installing again, check all cables and connectors for signs of visible damage and
before using the truck again check that:
the battery retainers (10, 12) are inserted and are secure,
see "Battery lock sensor" in chapter D.
the side panels (5) are inserted safely and the battery panel (3) is closed.
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D 17
5.3 Battery lock sensor (t)
13a 13b 14
15a 15b
M An unsecured battery can result in accidents

If the battery lock is not applied in the chassis, the battery may slide out of the battery
compartment due to truck movement.
Apply the battery latch in the chassis.
Only carry out short shunting operations.
During operation the battery lock sensors monitor if the battery retainers in the
chassis have been applied.
If the battery retainer(s) is (are) not installed, the truck cannot be operated.
The display unit shows the "Travel Cutout Override" (13b) and the "Battery lock not
installed" (13a) symbols.
Press the Release unlock pushbutton (15b) while simultaneously applying the travel
control knob (14) to operate the truck at inching speed (2.5 km/h).
Turn right = Travel in load direction

Turn left = Travel in drive direction
When the battery retainer(s) has (have) been inserted in the chassis, press the
pushbutton (15a) under the "Battery lock not installed" symbol (13a) to remove the
truck's speed restriction. At the same time the "Travel cutout override" (13b) and
"Battery lock not installed" (13a) symbols go out. The truck can now travel again at
the required speed.
The hydraulic functions are not restricted or altered if the battery retainer(s) is/are
not applied.
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D 18
6 On-Board Charger (o)
Z On board chargers are used to ensure longer operational times without having to
change the battery.
6.1 Description
Structure
16 17
22 23
21 18
20
19a
19b
Item Meaning
16 Reed contact
17 Current collector (different versions)
18 Charger On switch
19a Charger mains connector
19b Collector connector
20 Status indicator
21 Isolator
22 Controller (SPS)
23 Charger
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D 19
6.2 Different current collectors
Example 1
Closed version current collector
Example 2
Open version current collector
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D 20
6.3 Operating modes
Z The on board charger allows two different operating modes to be selected.

1. Compensation charging mode
This charging method can be carried out either at a charging station or in the
narrow aisle. It requires the truck to be switched off.
Z See item 1 "Normal charging (possible switch LED arrangements)" in "Different

Operating Modes" in chapter D.
This charging mode should be performed weekly to preserve the life of the battery.
With this type of charge the battery is charged according to the IUIU0IU characteristic
curve. This means that when the charger is switched on the battery is charged with
the full rated current until the charging characteristics change to the constant voltage
part at 2.4 volts/cell. If the value falls below the recharge value, the system switches
to recharge current at 2.7 volts/cell constant voltage part. When the battery is fully
charged the charger switches to compensation charge at 2.23 volts/cell.
2. Charging during travel (trickle charge)
Z See item 2 "Charging during travel via current collector" in "Different Operating
Modes" in chapter D.
This form of charging is used to capture peak currents which occur during stacking
and to keep the battery at a constant supply voltage.
With this form of charging the battery is charged to IU characteristic curve at a

constant voltage of 2.35 volts/cell.
Z Changing characteristics during travel
After the system has switched from normal charging (charging with compensation
charge) to travel mode, the charger remains off for 10 minutes (via SPS). This is
followed by charging at 2.23 volts/cell. If more than 100 Ah has been taken from the
battery, the system switches to 2.35 volts/cell. It switches back to 2.23 volts/cell when
the voltage exceeds 2.35 volts/cell.
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D 21
6.4 Different Operating Modes
1. Normal charging (possible switch LED arrangements)
24 25 24 25 26
For charging within a conductor rail For charging at a charging station via
stationary network
Switch off the truck. Take the truck out of the aisle /
Open the battery cover to ventilate conductor rail to the mains connection /
the battery. charging station.
Press switch (24) to start charging. Switch off the truck.
The charger on (25) and charging Remove the collector's connector.
on (26) indicators light up. Plug in the main circuit connector and
The charger now charges until the connect it to the stationary mains.
battery is fully charged and then Open the battery cover to ventilate the
switches to compensation charging. battery.
Press switch (24) to start charging.
The charger on (25) and charging
on (26) indicators light up.
The charger now charges until the
battery is fully charged and then
switches to compensation charging.
Z Travel release is not authorised during normal charging.

After charging, complete the charging session by pressing the switch (24).
Close the battery cover. If the battery has been charged via the stationary
network disconnect from the mains and re-connect the collectorto the charger.
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D 22
2. Charging during travel via a current collector
16 17
Make sure the current collector is connected.

Make sure the isolator of the respective bus bar and the charger are switched on.
Drive the truck into the aisle / bus bar with extreme caution.
When the current collector (17) has been aligned and the truck passes over the
ground sensor system, maximum travel speed is enabled again.
If adjustable current collectors (17) are fitted, the trucks electronic system checks
that the current collector is correctly positioned (active current collector light) and
releases travel once this has been verified.
When the current collector (17) has been aligned with the bus bar, the reed
contact (16) is closed via a permanent magnet attached to the bus bar / rack.
The charger now switches on (Charger On and Travel On indicators) and charges
at a constant rate of 2.35 volts per cell and a pre-determined rated current.
If energy is recovered from the drive controllers, e.g. during regenerative lowering,
braking or reversing, the charger cuts out.
When the truck leaves the narrow aisle, the reed contact (16) opens via the
permanent magnet and the charger cuts out.
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D 23
6.5 Symbols and meaning
Charger On switch
White background
Option:
Active collector indicator lamp
(for two collector version)
Yellow background
Charger On indicator lamp

Yellow background
Charger fault indicator lamp

Red background
Charging On indicator lamp

Green background
Travel mode On indicator lamp

Green background
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D 24
6.6 On board charger maintenance instructions
Z Maintenance intervals are listed in the operating instructions under Maintenance

checklist - On board chargers (o) in chapter F.
F Electric currents can cause accidents

Maintenance and repair work to on board chargers and the live attachments
(collectors etc.) can only be performed by trained specialists or electrical engineers.
Maintenance and repair work to on board chargers and the live attachments
(collectors etc.) can only be performed when the system is de-energised.
For normal charging disconnect the mains plug, or for conductor rail operation
repairs disconnect the power supply to the conductor rail.
Z The owner or authorised personnel must perform a daily inspection of the condition
of the on board charger and the live attachments such as the collector, including
mechanically operating components, cables and mains connectors.
F A faulty on-board charger and live attachments can cause accidents

If the on-board charger and the live attachments are not in a satisfactory condition,
withdraw the truck from service.
Z The operator / owner must check each day that the conductor rail is safe to operate.
Particular attention must be paid to overhanging components which could damage
the current collector or tear it out of the bus bar. The conductor rail and its feed funnel
must not be physically damaged or twisted.
F Bus bar defects can result in accidents

If the bus bar or feed funnel are damaged, block the lane and de-energise the bus
bar. Inform the customer service department.
Tag out and decommission the faulty lane.
Only return the lane to service when you have identified and rectified the fault.
If the red indicator lamp is activated during charging (charger fault), notify the
customer service department.
Battery maintenance and servicing is subject to the conditions listed in the operator
manual under Item D.
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D 25
7 Battery Checking Condition and Acid Level

with battery acid.
The battery manufacturers maintenance instructions apply.
Check the battery housing for cracks and any spilled acid.
Remove any oxidation remains from the battery terminals and apply an acid-free
grease to the battery terminals.
Open the plugs and check the acid level.
The acid level should be at least 10-15 mm above the top of the plates. Now close
the plugs.
If necessary, re-charge the battery.
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D 26
8 Battery Discharge Indicator "Bar Display" (t)
When you turn the Emergency Disconnect switch to

activate it and turn the key in the key switch clockwise,
the battery discharge indicator / discharge monitor will
show the residual capacity available. The lower section
of the battery symbol is empty. It indicates the residual
capacity of the battery which is protected and cannot
be used to avoid damaging the battery.
Z The standard setting for the battery discharge

indicator / discharge monitor is based on standard batteries. When using
maintenance-free or special batteries the display and cutout points of the battery
discharge monitor must be set by authorised specialist personnel. If this adjustment
is not made the battery may become damaged through excessive depletion.
M Excessive depletion shortens the useful life of the battery.

Charge the battery in good time, see Charging the Battery in this chapter.
1109.GB
D 27
8.1 Battery discharge monitor with bar display
When a battery is discharged to the permissible level (residual capacity) the battery
symbol in the driver's display is empty and flashes red. A display appears. Main Lift
and Auxiliary Lift raising are inhibited.
Lifting is only enabled again when the connected battery:
is at least 40% charged for a wet-cell battery.

is at least 50% charged for a gel battery.
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D 28
8.2 Battery symbol fluorescent colours
Z The fluorescent colours of the battery symbol represent the following conditions:
Battery symbol colour Meaning

Battery is charged.
White
Z The more bars the battery discharge indicator
shows, the greater the battery's residual capacity.
Battery charge recommended.
Yellow Z Depending on the battery type, the battery

discharge indicator symbol flashes when there
are one or two remaining bars.
Battery charge required
(charge is below residual capacity level).
Flashing red The battery discharge indicator symbols does not
show any bars.
Z Main Lift and Auxiliary Lift raising is inhibited.

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D 29
9 Battery Discharge Indicator "Percentage Display" (o)
When you turn the Emergency Disconnect switch

to activate it and turn the key in the key switch
- +
clockwise, the battery discharge indicator /
discharge monitor will show the residual capacity
available as a percentage.
75%
Z The standard setting for the battery discharge
indicator / discharge monitor is based on standard batteries. When using
maintenance-free or special batteries the display and cutout points of the battery
discharge monitor must be set by authorised specialist personnel. If this adjustment
is not made the battery may become damaged through excessive depletion.
M Excessive depletion shortens the useful life of the battery.

Charge the battery in good time, see Charging the Battery in this chapter.
9.1 Battery symbol fluorescent colours
If a battery is discharged to less than 31% for wet-cell batteries or 41% for gel
batteries (residual capacity), the battery symbol flashes. Main Lift and Auxiliary Lift
raising are disabled below 21% for wet-cell batteries and 31% for gel batteries.
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D 30
The fluorescent colours of the battery symbol represent the following conditions:
for wet-cell batteries (PB):

Battery is charged.
Black 100 % - 31 %
Z The higher the percentage, the greater the
battery residual capacity.
Yellow 30 % - 21 % Battery charge recommended.
Flashing red 20 % - 0 %
Z Main Lift and Auxiliary Lift raising is
inhibited.
Z Lifting is only enabled again when the battery connected is at least 40% charged.
for gel batteries:

Battery is charged.
Black 100 % - 41 %
Z The higher the percentage, the greater the
battery residual capacity.
Yellow 40 % - 31 % Battery charge recommended.
Flashing red 30 % - 0 %
Z Main Lift and Auxiliary Lift raising is
inhibited.
Z Lifting is only enabled again when the battery connected is at least 50% charged.
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D 31
D 32
1109.GB
E Operation
1 Safety Regulations for the Operation of Forklift Trucks
Driver authorisation: The forklift 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.
Drivers rights, obligations and responsibilities: The driver must be informed of

his duties and responsibilities and be instructed in the operation of the truck and shall
be familiar with the operator manual. The driver shall be afforded all due rights.
Unauthorised use of truck: The driver is responsible for the truck during the time it
is in use. The driver 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 immediately informed 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 driver must not carry out any repairs or alterations to the industrial truck
without the necessary training and authorisation to do so. The driver must never
disable or adjust safety mechanisms or switches.
1010.GB
E1
Hazardous area: The hazardous area is defined as the area in which a person is at
risk due to truck movement, lifting operations, the load handler (e.g. forks or
attachments) or the load itself. This also includes areas which can be reached by
falling loads or lowering operating equipment.
F Unauthorised persons must be kept away from the hazardous area. Where there is
danger to personnel, a warning must be sounded with sufficient notice.
If unauthorised personnel are still within the hazardous area the truck shall be
brought to a halt immediately.
Safety devices and warning signs: Safety devices, warning signs and warning
instructions in the present operating instructions shall be strictly observed.
Z Warnings and notices such as load charts, strap points and data plates must be
legible at all times. Replace if necessary.
F Removing or disabling safety devices can cause accidents

Removing or disabling safety devices such as the Emergency Disconnect switch,
deadman button, horn, warning lights, safety gates, mast guards, panels etc. can
result in accidents and injury.
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E2
2 Controls and Displays
2.1 Operating and display equipment on control panel
1 2 3 4 5 6 7 8 9 10 11 12
13
14
14 21 22 23 24 25 26
15
16
17
20 19 18
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E3
1 2 3 4 5 6 7 8 9 10 11 12
13
14
14 21 22 23 24 25 26
15
16
17
20 19 18
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E4
Item Control / display Function
Controls hydraulic functions, such as Main
1 Hydraulic control button t and Aux. Lift raise and lower, fork traverse
and rotate
2 Horn pushbutton t Activates the horn, releases an audible warning.
Activates wire guidance in the narrow aisle
Rail guidance:
Switch guidance on/off Sets the drive wheel to the forward position
3 o
pushbutton Wire guidance:
Activates the alignment process (and frequency
selection for multi-frequencies)
Allows the control panel to be tilted between
Control panel 130 and 180. To do this, press down on the
4 t
adjustment pushbutton "Control panel adjustment" pushbutton and tilt it
in the required direction.
Displays function, operating information and
5 Display unit t
warning messages
6 Indicator lamp t
7 Indicator lamp t For manufacturer's service department only.
8 Indicator lamp t
Fork carriage rotate Changes the hydraulic control button to the
9 t
pushbutton Fork carriage swivel function
Attachment traverse Changes the hydraulic control button to the
10 t
pushbutton Attachment Reach function
Switches the hydraulic control button to lift and
11 Aux. Lift pushbutton t
lower the fork carriage without the drivers cab
Controls the travel direction and speed of
12 Travel control knob t
the truck
Main and Aux. Lift raise / Enables simultaneous lowering/raising of
13 t
lower pushbutton Main and Aux. Lift.
Two-hand operation in narrow aisle
Hand rest and
14 t (via the contacts in the traction controller and
contact point
hydraulic controller handle).
The truck functions can be controlled via the
15 Control panel t
control panel.
16 Gate t Prevents the driver from falling out
To adjust the driver's seat, see "Adjusting the
17 Driver's seat t
driver's seat" in Chapter E.
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E5
1 2 3 4 5 6 7 8 9 10 11 12
13
14
14 21 22 23 24 25 26
15
16
17
20 19 18
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E6
Not pressed ("Deadman button not pressed"
lit in the display unit, see Display unit controls
and displays in Chapter E):
Travel functions are inhibited.
Hydraulic functions are inhibited.
t Steering, driver's display and horn are
released.
pressed ("Deadman button not pressed"
disappears, see Display unit controls and
displays in Chapter E):
Deadman button
18 Travel and hydraulic functions are released.
(foot switch)
The deadman button must be applied
permanently while the truck is in operation
(lifting/lowering/travelling).
When the deadman button is released the
truck brakes regeneratively to a halt
o
(parking brake applied). The truck coasts to
a stop according to the coasting brake
parameter setting.
For functional description see standard
versions.
Control panel height The control panel height can be adjusted by
19 t
adjuster 85 mm.
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E7
1 2 3 4 5 6 7 8 9 10 11 12
13
14
14 21 22 23 24 25 26
15
16
17
20 19 18
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E8
Switches the control current on and off.
Key switch t Removing the key prevents the truck from being
switched on by unauthorised personnel.
Replaces the key switch.
20 Releases the truck response with card or
transponder.
ISM access module o
Time out monitoring
Records the truck's operators (shifts)
Operational data acquisition
Emergency Disconnect Interrupts the main supply, all truck movement
21 t
switch is disabled
22 Steering wheel t Steers the truck in the required direction.
Changes menu: When you press the "Cancel
Quit sub-menu sub-menu" button the menu currently shown in
23 t
pushbutton the driver's display changes to the higher-level
menu.
Activates or confirms the function shown in
the display unit (as a symbol) via the pushbutton
24 Pushbutton t
below it. The symbol will be given a dark
background.
25 Numerical keypad t Controls and settings for standard functions
Cursor keys for special (e.g. setting the time) and additional functions
26 t (e.g. Rack Height Select)
hydraulic functions

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2.2 Display unit controls and displays
30 31 32 33 34 35 36 37 38
48 0h 07:48 EKX 5XX 39

P 40
xx kg
47
46
41
42
45
43
44
23 24
Upper range symbols
Item Symbol Control / display Function

Service hours Displays the number of service hours
30 t
display since the truck was commissioned
31 Time display t Shows the time
Indicates the current steer angle with
32 Steer angle display t
reference to the centre position
Rail guidance: Steer angle display is replaced by the following symbols:
Symbol lights up as soon as the truck is
"Truck guided
automatically guided and has received
(with aisle detection)"
an aisle signal
Symbol lights up as soon as the truck
is automatically guided and has not
32 received an aisle signal.
o
"Truck guided Continue travelling in the narrow aisle.
(without aisle As soon as the truck receives an aisle
detection)" signal the "Truck guided (without aisle
recognition)" symbol is replaced by the
"Truck guided (with aisle recognition)"
symbol.
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Wire guidance: Steer angle display is replaced by the following symbols:
Acquisition in Symbol lights up as soon as the truck has
progress acquired the guide wire
"Truck guided
automatically guided on the wire and has
(with aisle detection)"
received an aisle signal
automatically guided on the wire and has
not received an aisle signal
"Truck guided Continue travelling in the narrow aisle.
(without aisle As soon as the truck receives an aisle
detection)" signal the "Truck guided (without aisle
recognition)" symbol is replaced by the
32 symbol.
o
Symbol lights up as soon as the truck on
the guide wire is switched off and on with
the key switch.
Continue travelling in the narrow aisle.
The "Truck not guided" symbol is
"Truck not guided" replaced by the "Wire acquisition in
progress" symbol.
As soon as the truck has acquired the
wire and received an aisle signal, the
symbol lights up.
The symbol lights up as soon as the truck
Deviation from guide
moves away from the guide wire and
wire
therefore from automatic guidance
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30 31 32 33 34 35 36 37 38
48 0h 07:48 EKX 5XX 39

P 40
xx kg
47
46
41
42
45
43
44
23 24

33 Truck model t Indicates the truck model
Overall lift" and "Referencing Shows the lift height of the forks after
required displays: referencing
Main Lift - raise Requests the Main Lift to raise
34 Main Lift - lower t Requests the Main lift to lower
Aux. lift - lift Requests Aux. Lift to lift
Aux. lift - lower Requests Aux. Lift to lower
35 kg
Weighing system o Shows the weight of the raised load in kg
Shows the battery charge status

t
Battery Discharge (bar display)
36
Indicator Displays the battery charge status
- +
50% o
(residual capacity as a percentage)
The current display receives a dark
37 Level display t
background
Indicates that the permissible water
content level in the hydraulic oil has been
exceeded. The hydraulic oil must be
"Replace hydraulic oil"
38 o replaced. Contact the manufacturer's
display
service department. The manufacturer
has a service department specially
trained for these tasks.
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E 12
Indicates that the cycle test must be
performed. During this time the travel
Perform cycle test
39 o speed is restricted to 2.5 km/h. Refer to
display
the "Personal protection system (o)"
section in chapter E.
Indicates that the active stabiliser has
been extended to a distance of 5 mm
"Active stabiliser from the ground when the truck is idle
o
extended" display and the sideshifter applied.
40 An adjustment run with a maximum
speed of 2.5 km/h can be carried out.
R "Active stabiliser Indicates the active stabiliser is being
o
referencing" display referenced while the truck is idle.
Attachment in home See Attachment in Home Position in
t
position chapter E
41
Horizontal positioning
o See "Horizontal positioning" in chapter E.
function stacking display
Guide wire detection Wire guidance sensors that have
42 o
display identified the guide wire illuminate
The rack height select and horizontal
Rack height select and positioning displays and function are
43 horizontal positioning o described in Rack Height Select with
function display Zone Entry and Horizontal Positioning
in chapter E.
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30 31 32 33 34 35 36 37 38
48 0h 07:48 EKX 5XX 39

P 40
xx kg
47
46
41
42
45
43
44
23 24

For details see Lower range symbols
44 Functions t
and Pushbuttons in chapter E
Service mode active Event and / or information messages are
t
(wrench) shown in the display unit
A wire guidance antenna on the truck has
45 left the prescribed range of the guide
wire. The truck immediately undergoes
Wire guidance fault o
an Emergency Stop (see "Wire guidance
emergency mode (event message I 3670
/ I 3752)" in chapter E).
Rabbit:
Displays possible Max. travel speed
46 t
travel speeds:
Turtle:
Inching speed 1010.GB
E 14
Deadman button not Truck is ready for operation.
t
pressed Deadman button not pressed
Truck is ready for operation.
Gates not closed t
Gates not closed
Emergency
Disconnect switch Truck is ready for operation.
STOP t
indicator lamp Emergency Disconnect switch pressed
pressed
Travel and hydraulic functions are
inhibited.
47
Do not touch the travel / hydraulic
control handles
Do not press the deadman button
Release two-handed The "Release two-handed operation"
o symbol fades out
operation
Press deadman button
Touch the travel / hydraulic control
handles again
Z Travel and hydraulic functions are

enabled again
Indicates the truck has come to a halt
Parking brake
P (drive wheel brake and load wheel brake
engaged
engaged)
48 t
Indicates the truck has come to a halt
Drive wheel brake
R and the drive wheel brake has been
referencing
referenced
RG = Rail guidance WG = Wire guidance
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E 15
2.3 Lower range symbols and pushbuttons
Activate pushbutton (24) under the respective symbols (44) displayed or confirms the
related function. The symbol will be given a dark background.
Symbol Control / Display Function

Warnings
Slack chain safety t Displayed when the slack chain safety
device display device engages
Slack chain safety device Bypasses the slack chain safety device to lift
override pushbutton the driver's position freely
Fwd./Rev. travel only t Displayed when the lift cutout device is
display activated due to low battery capacity and
only forward or reverse travel is possible.
Acknowledge lift cutout Confirms lift cutout for low battery capacity
due to battery discharge and releases travel
pushbutton
Lift height dependent lift o Displayed when the lift limit is activated
cutout display
Lift limit override Overrides the lift limit. Note the maximum
pushbutton overhead clearance heights.
Lower limit display o Indicates that the automatic lowering limit
has been activated.
Lower limit override Overrides the lowering limit, controlled by
pushbutton hydraulic control button
Travel cutout display o Indicates that automatic, height dependent
travel cutout has been activated
Travel cutout override Overrides the automatic, height dependent
pushbutton travel cutout
Aisle endsafety device o Indicates that the aisle end safety device has
display (option) been activated. The truck brakes.
Select Warning sub- o Indicates that several warnings (e.g. slack

menu display chain safety device, lift cutout, set date /
time, operator specific settings,) have
run out.
Select Warning sub- Individual warnings can be seen
menu button
Quit warnings sub- o Indicates that the sub-menu can be quit.
menu.
Quit warnings sub-menu Resets the sub-menu to the standard menu
pushbutton
"Battery lock not applied" t Appears when the truck has been switched
display on but the battery lock has not been applied.
The truck can only be operated at crawl
speed (2.5 km/h).
"Battery lock applied Acknowledges the message when the
confirmation" pushbutton battery lock has been applied
1010.GB
E 16
Personal Protection System (PPS)
Acknowledge cycle test o Indicates that the cycle test must be
display performed (every 24 hours).
The truck brakes and can only be operated
at crawl speed (2.5 km/h).
Refer to the "Personal protection
system (o)" section in chapter E.
Acknowledge cycle test Launches the automatic performance of
pushbutton cycle test
Warning field o Indicates that the warning field of the
infringement display Personal Protection System has been
infringed by persons / objects in the narrow
aisle. The truck brakes and can only be
operated at crawl speed (2.5 km/h).
Refer to the "Personal Protection System (o)"
Protection field o Indicates that the protection field of the
infringement display Personal Protection System has been
infringed by persons / objects in the narrow
aisle. The truck brakes to a halt.
Protective field Bypasses the protective function and
infringement pushbutton enables crawl speed (2.5 km/h) if there is
sufficient distance from the obstacle.
Refer to the "Personal protection system (o)"
Guidance systems
Displays Select o Indicates that wire guidance is available with
Frequency 1 frequency 1 (similar to other frequencies,
(Guidance on sub-menu) maximum 5 frequencies).
Select Frequency 1 Activates wire guidance via frequency 1
pushbutton (similar to (sub-menu is quit automatically when
other frequencies) pressed for 1 sec.).
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E 17
Attachment fork operation
Synchronised rotate t Changes the menu to synchronised rotate
menu change display functions
Synchronised rotate Activates synchronised rotate menu change
menu change pushbutton
Fork synchronised left t Indicates that the fork synchronised left
rotate display rotate right traverse is available
Fork synchronised left Activates fork left rotate, simultaneous
rotate pushbutton control of load handler right traverse via the
hydraulic control button
Automatic fork o Indicates that the automatic fork
synchronised left rotate synchronised left rotate right traverse
display is available
Automatic fork Activates fork left rotate with simultaneous
synchronised left rotate load handler right traverse
pushbutton
Fork synchronised right t Indicates that the fork synchronised right
rotate display rotate left traverse is available
Fork synchronised right Activates fork right rotate, simultaneous
rotate pushbutton control of load handler left traverse via the
Automatic fork o Indicates that automatic fork synchronised
synchronised right rotate right rotate left traverse is available
display
Automatic fork Activates fork right rotate with simultaneous
synchronised right rotate automatic load handler left traverse
pushbutton
Automatic fork o Indicates that the forks can be
synchronised rotate to automatically set to the centre position
centre position display (forks facing forwards)
Automatic fork Activates swivelling with automatic fork stop
synchronised rotate to in centre position, simultaneous automatic
centre position load handler traversing with stop at centre
pushbutton position
Telescopic table fork Indicates that the telescopic table forks can
adjuster display be adjusted
Telescopic table fork Activates the telescopic table fork
adjuster pushbutton adjustment, controlled via the hydraulic
control button
Single telescopic fork o Indicates that the single telescopic forks can
display be operated
Single telescopic fork Activates the single telescopic fork,
pushbutton controlled via the hydraulic control button
Telescopic table display o Indicates that the telescopic table can be
operated
Telescopic fork Activates the telescopic fork, controlled via
pushbutton the hydraulic control button
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E 18
Telescopic fork - o Indicates that Telescopic fork -
synchronised movement synchronised movement is available,
display controlled via the hydraulic control button
Telescopic fork - Activates synchronised movement of the
synchronised movement telescopic forks
pushbutton
asynchronous movement asynchronous movement (top) is available,
(top) display controlled via the hydraulic control button
Telescopic fork - Activates asynchronous movement
asynchronous movement (top fork) of the telescopic forks
(top) pushbutton
asynchronous movement asynchronous movement (bottom) is
(bottom) display available, controlled via the hydraulic
control button
Telescopic fork - Activates asynchronous movement
asynchronous movement (bottom fork) of the telescopic forks
(bottom) pushbutton
2nd stacking depth o Indicates that the 2nd stacking depth is
display possible
2nd stacking depth Activates the 2nd stacking depth, controlled
pushbutton via the hydraulic control button
Fork tilt display o Indicates that fork tilt is possible
Fork tilt pushbutton Activates the fork tilt, controlled via the
Special attachment o Indicates that the special attachment can be
display controlled
Special attachment Activates control of the special attachment,
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E 19
Fork adjuster / sideshift
Fork adjuster / sideshift o Changes the display unit menu to
menu change display fork adjuster / sideshift functions
Fork adjuster / sideshift Activates fork adjuster / sideshift menu
menu change pushbutton change
Symmetrical fork o Indicates that fork adjustment can be
adjuster display operated
Symmetrical fork Activates the fork adjuster when hydraulic
adjuster pushbutton control button is simultaneously applied
Asymmetrical fork o Indicates that the Asymmetrical fork
adjuster menu change adjuster menu can be changed
display
Asymmetrical fork Changes the display unit menu to
adjuster menu change asymmetrical fork adjuster functions
pushbutton
Fork adjuster, left only o Indicates that left only fork adjustment
display is possible
Fork adjuster, left only Activates left only fork adjustment,
Fork adjuster, right only o Indicates that right only fork adjustment
display is available
Fork adjuster, right only Activates right only fork adjustment,
Fork sideshift display o Indicates that fork sideshift is possible
Fork sideshift Activates the fork sideshift, controlled via the
pushbutton hydraulic control button
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E 20
Optional equipment
Work lights / fan menu o Changes the display unit menu to work
change display lights / fan functions
Work lights / fan menu Activates the work lights / fan menu change
change pushbutton
Overhead guard work o Indicates that the overhead guard work

lights display lights can be switched on / off.
Overhead guard work Activates the overhead guard work lights
lights pushbutton
Load handler work lights o Indicates that the load handler work lights
display can be switched on / off.
Load handler work lights Activates the load handler work lights
pushbutton
Fan display o Indicates that the fan can be switched on / off.
Fan pushbutton Activates the fan
"Weigher display zero o Indicates that the weight measurement

0 setting" display
"Weigher display zero
display can be set (tared) to zero
This pushbutton sets the weight
setting" pushbutton measurement to zero
"Warehouse or o Warehouse mode = Symbol has a dark
stockpicking mode" background
display Stockpicking mode = Symbol has a light
background
Z See "Horizontal positioning"

chapter E.
in
"Warehouse or This pushbutton toggles between

stockpicking mode warehouse and stockpicking mode
toggle" pushbutton
RG = Rail guidance WG = Wire guidance
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E 21
2.4 Truck operational status symbols
The operational status of the truck on power up is indicated by symbols in the

display unit.
Gates open
Deadman button not pressed
Attachment in home position, see section of the same

name in chapter E.
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E 22
3 Starting up the truck
F Before the truck can be started, operated or a load lifted, the driver must ensure that
there is nobody within the hazardous area.
3.1 Checks and operations to be performed before starting daily operation
F Damage and other truck or attachment (special equipment) defects can result
in accidents.
If damage or other truck or attachment (special equipment) defects are discovered,
the truck must be taken out of service until it has been repaired.
Check the whole of the outside of the truck for signs of damage and leaks.
Check the battery attachment and wire connections for damage, make sure they
are secure.
Check the battery connector is secure.
Check the battery retainers are present and test them.
Ensure the battery is securely fixed in the battery compartment.
Check battery cover and side panels are secure and look for damage.
Check the overhead guard for damage.
Check the load handler for visible signs of damage such as cracks, bent or severely
worn forks.
Check the drive wheel and load wheels for damage.
Make sure the load chains are evenly tensioned.
Make sure all safety mechanisms are correct and functional.
Test the service and parking brakes.
For rail guidance systems check the guide wheels are smooth and not damaged.
Check static charge eliminator is present.
Test the instruments, displays and control switches.
Check the Personal Protection System laser scanner front panels and clean
if necessary (o).
Carry out a cycle test on the Personal Protection System, see Daily Checks before
starting the Personal Protection System in chapter E (o).
Check that the load chart and warning labels are legible.
Check the rescue equipment is present.
F It is prohibited for more than one person to enter the drivers cab at a time.
1010.GB
E 23
3.2 Truck entry and exit
50
M Safety gate trapping hazard

There is a risk of trapping when the gates are opened and closed.
Make sure there is nothing between the cab chassis / foot compartment and the
gates when the gates are opened and closed.
F Fall hazard
When the gates are opened and the driver's cab raised, the operator risks falling out
of the cab.
Do not open the gate when the driver's cab is raised.
Fully lower the mast / driver's cab.

Lift up the gates.
To enter and exit the cab, hold onto the cab chassis (50).
Close the gates.
M No more than one person may operate the truck in the driver's cab at a time.
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E 24
3.3 Removing the drivers seat
M Do not loosen the twist grip screws (52) while travelling.

To remove the drivers seat (51), loosen
the two twist grip screws (52) underneath
the driver's seat (51).
The drivers seat (51) can now be lifted up
complete with the adjusting unit.
Z The driver's seat (51) with the adjusting unit

weighs approx. 45 kg.
M If the drivers seat has seat heating, the seat

heating plug connection must first be
removed before lifting out the seat.
3.4 Setting up the operator position 51
M Accident risk 52
Do not adjust the drivers seat and control
panel during operation.
Before operating, adjust the drivers seat and control panel 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.
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3.5 Adjusting the drivers seat
M The drivers seat setting must not be changed during travel.
Z The drivers seat has a high backrest (53)

and a sculpted seating area (60) providing 53
fatigue-free operation in a seated position.
The padded underside of the seat is used
to lean against when the operator is 54
standing.
Pull up the adjusting lever (61) and apply 55

or remove weight to obtain the correct
seat (60) height. The setting range is
56
120 mm.
Loosen the setscrew (62) to adjust the
height of the armrest (55). 57
The armrest (55) swivel can be adjusted
via the wheel (56).
58
Push the seat swivel adjustment
lever (58) to swivel the seat (60) 40 mm
up or down.
Apply the seat adjustment lever (59) to
push the seat (60) 50 mm forward or 52 62 61 60 59
back.
To unlock the seat (60) apply the lever (57).
The rotary button (54) for adjusting the back support is on the left hand side of
the seat.
The drivers seat can optionally be equipped with seat heating. To switch the seat
heating on, the seat heating switch must be turned on (position l).
1010.GB
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3.6 Control panel angle adjustment
M Do not adjust the inclination of the control panel (15) during operation.
Make sure the control panel is locked in position after any adjustment.
Z The control panel (15) incline can be

infinitely adjusted by up to 50 4
(tilt range: 130 to 180).
21
Turn the Emergency Disconnect (21) to
release it. 15
Put the key in the key switch (20) and
switch the truck on.
20
Press and hold down on the control panel
adjustment button (4).
Set the control panel (15) to the required
position.
Control panel adjustment pushbutton (4).
Make sure the control panel is locked in
position.
F In the event of malfunctions the release

pin (4a) must be kept pressed in order to
adjust the tilt angle of the control panel (15).
4a
1010.GB
E 27
3.7 Control panel height adjustment
M Do not adjust the height of the control panel (15) during operation.
Make sure the control panel is locked in position after any height adjustment.
Z The height of the control panel (15) can be

adjusted by 85 mm.
Release the lever (19).

Pull the control panel in the desired
position (up or down).
Tighten the lever (19).
15
19
3.8 To prepare the truck for operation (t)
Close the gates.

2
Turn the Emergency Disconnect (21) to
release it.
Put the key in the key switch (20) and
turn it clockwise.
Test the horn by pressing the horn 21
pushbutton (2).
Carry out a test run on the mast
(Main Lift and Auxiliary Lift) to adjust the 20
height display,
see Referencing the Main and Auxiliary
Lift in Chapter E.
F Press the Emergency Disconnect switch (21) immediately if the truck starts to move
or lift as soon as it is switched on.
Z Brief steering movements caused by steering referencing are permissible.

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E 28
3.9 Preparing the truck for operation with an additional access code (o)
Z Optionally, the truck can be prepared for operation with an additional 5 digit access
code. In addition to the access code the key switch is still used to switch on the truck.
77 75
*****
2 21 5 25 78 20
Close the gates.

Turn the Emergency Disconnect (21) to release it.
Put the key in the key switch (20) and turn it clockwise.
Z In the display unit (5) you will be prompted to enter your 5 digit access code.
Press the "Select" button (78) in the cursor field.

Enter your 5 digit access code via the numerical keypad (25) and press "OK".
The cursor keys (75, 77) can be used to enter each digit of the 5-digit access code:
Move the cursor key (75) one place forward or cursor key (77) one place back.
Press the "CE" key to cancel entering the 5 digit access code.
Z The truck will not operate at all unless the correct access code is entered. Up to
99 different access codes can be set. The individual codes can be assigned to pre-
defined travel programs, steer programs and hydraulic programs (see Operator
specific settings in chapter E). If no travel, steer or hydraulic operations are
performed within a factory-set interval, the display unit (5) will again ask you to enter
the 5-digit code with the numerical keypad (25).
Test the horn by pressing the horn pushbutton (2).

Carry out a mast reference operation (main and auxiliary lift) to adjust the height
display, see Referencing Main and Auxiliary Lift in chapter E.
F Press the Emergency Disconnect switch (21) immediately if the truck starts to move
or lift as soon as it is switched on.
Z Brief steering movements caused by steering referencing are permissible.

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E 29
3.10 ISM Access Module (o)
Z If the truck is equipped with an ISM access module refer to the ISM Access Module
operator manual.
3.11 Checks and operations to be carried out when the truck is operational
F Truck defects can result in accidents

Do not use the truck if the brake system, steering and/or hydraulic system
are defective.
If any damage or other truck or attachment (special equipment) defects are
discovered, the truck must be taken out of service until it has been repaired.
1010.GB
E 30
Procedure
Test warning indicators and safety devices:

Test the Emergency Disconnect by pressing the Emergency Disconnect switch.
The main circuit is disconnected and no truck operations can be performed.
Now turn the Emergency Disconnect to unlock it.
Test the horn by pressing the "horn" button.
Test the deadman button.
Test the side / safety gates.
Test the service and parking brakes, see "Brakes" in Chapter E.
Test the steering, see "Steering" in Chapter E.
Test the hydraulic system.
Test the lift cutouts (o), see "Lift cutout override (o)" in Chapter E.
Test the travel functions, see "Travel" and "Negotiating narrow aisles" in
Chapter E.
Test the end of aisle safety device and aisle recognition functions (o),
see "End of aisle safety device (o)" in Chapter E.
Test the travel cutouts (o), see "Travel cutout override (o)" in Chapter E.
Test the lighting (o).
Test the Personal Protection System (o), see "Personal Protection System
(o)" in Chapter E.
Test the front screens of the Personal Protection System laser scanners for
dirt (o), and clean if necessary, see "Cleaning the laser scanner front screen"
in Chapter E.
Test the controls and displays, see "Displays and controls" in Chapter E.
Check the hand rests (14) and handles are secure and check for damage,
see "Displays and controls" in Chapter E.
Carry out a mast reference operation to adjust the height display, see Referencing
the Main and Auxiliary Lift in Chapter E.
Test the two-handed operation system in the narrow aisle, see "Negotiating narrow
aisle with rail-guided trucks (o)" and "Negotiating narrow aisles with wire-guided
trucks (o)" in Chapter E.
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E 31
3.12 Referencing the main and auxiliary lift
65 1 21 5 11 12
Z When the following symbols are displayed you must carry out a reference/test run in
accordance with the display (5), i.e. primary lift and aux. lift must be raised approx.
10 cm and then lowered again. This is the only way for the controller to release all the
truck movements at full speed.
Procedure:
Close the safety gates securely on both sides.

Put the key in the key switch and switch the truck on.
Press deadman switch (65).
Referencing: Main Lift - raise

Raise the Main Lift approx. 10 cm via the hydraulic
control button (1).
Left turn = lift
Z The main lift automatically stops at the top limit.
Referencing: Main Lift - lower
Fully lower the Main Lift with the hydraulic control

button (1).
Right turn = Lower.
1010.GB
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65 1 21 5 11 12
Referencing: Aux. lift - lift
Raise the auxiliary lift approx. 10 cm via the hydraulic

control button (1) while simultaneously pressing the
Aux. Lift pushbutton (11).
Left turn = lift
Z The Aux. Lift automatically stops at the top limit.
Referencing: Aux. lift - lower
Fully lower the auxiliary lift via the hydraulic control

button (1) while simultaneously pressing the aux. lift
pushbutton (11).
Right turn = Lower.
Lift cutout with referencing
F An extended mast can cause accidents

The lift cutout is an auxiliary function designed to support
the operator which however does not release him from
his responsibility to stop hydraulic operations e.g. when
confronted with an obstacle.
Pressing the lift cutout override pushbutton disables the

lift cutout.
1010.GB
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Load handler referencing (fork carriage / sideshift)
If the sideshift and / or rotation of the load handler are adjusted when the truck has
been switched off, the "rotate reference operation" or "traverse reference operation"
symbols will be shown in the display unit the next time the truck is switched on.
Rotation or traverse must be referenced.
Rotating reference operation Traversing reference
operation
Sideshifting is referenced by moving the sideshifter over the "attachment centre"

position, see "Traverse (load handler attachment)" in Chapter E.
The rotary sensor system of the attachment is referenced by performing at least one
complete rotation with the load handler, see "position, see "Swivel / Rotate
(Fork Carriage)" in Chapter E.
Referencing is successful if the appropriate symbol goes out after referencing.
Z If one of the two symbols does not go out after referencing, contact the
manufacturers service department.
1010.GB
E 34
3.13 Setting date and time
Selecting the Set Date/Time menu:

Press the "Quit sub-menu"
pushbutton (23). The set date/time
menu now opens. The display unit
shows the date and the time.
Z Truck movement is inhibited in this

truck menu. 23
01 . 0 5 . 2 0 07
12 : 0 0 : 0 0
Date and time formats:
Format Date Time

Standard setting dd.mm.yyyy hh:mm:ss
US setting mm.dd.yyyy hh:mm:ss am/pm
Abbreviations d = day h = Hour
m = month m = minute
y = Year s = second
1010.GB
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Setting the date / time:
Press the Select pushbutton (78) in

the cursor field. The first digit in the
date display appears against a blue
background. 01 . 0 5 . 2 0 07
The operator can use the cursor
keys (76, 79) to choose the required
setting in the selected field:
12 : 0 0 : 0 0
Cursor key (76): decrease number
Cursor key (79): increase number.
Z The required number can also be

entered directly via the number field of
the numerical keypad (25).
Use the cursor keys (75, 77) in the 23 66

cursor field to select the next /
previous field: 25 78 79
Cursor key (75): next field
Cursor key (77): previous field.
75
Z The selected field appears with a "blue"
background.
77
When the date and time have been

entered, the entry must be confirmed 76
by pressing OK in the numerical
keypad (25).
Quitting the Set Time menu:
Press pushbutton (71) below the

truck functions symbol. The display
unit changes to the "truck functions"
menu.
75
71
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3.14 Operator specific settings (o)
Selecting the Operator Specific Settings menu:

Press the quit sub-menu
pushbutton (23); the display unit 72
shows the sub-menu warnings menu
item (72).
Z Truck movement is inhibited in this truck

menu.
Now press the pushbutton (66) below

the sub-menu warnings symbol (72).
The display unit now shows the
operator specific settings menu
item (80).
23 66 80
Press the pushbutton (67) below
the operator specific settings v,a
symbol (80). The operator specific
settings menu now opens.
67
1010.GB
E 37
Settings in the Operator Specific
Settings menu:
Z Truck operations are inhibited in this

menu.
the cursor field. The symbol for the
Travel acceleration user-defined
setting appears in the display unit 78 79
(see table). 25
The operator can toggle between func-
75
tions using the cursor keys (75, 77):
Cursor key (75): go one function 77
forward
Cursor key (77): go one function
back. 76
Function order:
Functions Display
Travel Acceleration a
Apron speed v
Aisle Speed v
Main lift- raise speed V
Main lift lower speed V
Sideshift speed V
Steering wheel transmission v

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The operator can use the cursor
8
keys (76, 79) to set the functions from
1 (weak) to 8 (strong):
Cursor key (76):
weaken the setting.
Cursor key (79):
1
strengthen the setting.
Z This allows individual settings to be

made within a pre-defined area in the
program.
When the driver-specific settings

have been entered, the entries must
be confirmed by pressing OK in the
numerical keypad (25).
25 78 79
M Altering travel parameters can cause

accidents 75
Increasing the settings for acceleration,
77
steering, travel, lifting and lowering can
result in accidents.
Carry out a test run in a secure
environment. 76
This requires greater attention on the
part of the operator.
Quitting the Driver-specific settings menu:
Press pushbutton (71) below the

truck functions symbol. The display
unit changes to the "truck functions"
menu.
75
71
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4 Industrial Truck Operation
4.1 Safety regulations for truck operation
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.
F Do not exceed the permissible surface and spot load limits on the travel routes.
At blind spots get a second person to assist.
Z 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.
Driving conduct:
The driver 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, at blind spots and when entering and leaving the narrow aisle.
The driver 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.
F Truck tipover procedure

If the truck is in danger of tipping over, the driver should not jump out of the truck.
He must keep the whole of his body inside the driver's cab.
The driver must:
Crouch down,
Hold onto the operator position with both hands,
Lean against the direction of fall.
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Visibility when travelling outside the narrow aisle:
The driver must look in the direction of travel and must always have a clear view of
the route ahead.
Loads that affect visibility must be positioned at the rear of the truck. If this is not
possible, a second person must walk in front of the truck as a lookout. In this case
proceed only at walking pace and pay particular attention. Stop the truck immediately
if visual contact is lost between the lookout and the operator.
Use the mirror only to observe the traffic behind you. Should you need visibility aids
(mirrors, monitors etc.) to ensure adequate visibility, practice working with them
beforehand.
Procedure and visibility when operating with a raised driver's cab and load
handler
F Accident risk when operating with a raised driver's cab and load handler
Operating the truck with a raised driver's cab and load handler can impair the driver's
visibility. 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.
When carrying out hydraulic or travel operations, make sure that nobody is present
in the hazardous area.
Instruct 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.
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Crash protection
The driver must not leave the operator position in a raised position. Do not climb onto
parts of the building or other trucks and do not climb over safety devices such as
railings or gates. If Euro pallets are stored lengthways it may not be possible to reach
items from the operator platform without the use of aids. The proprietor must provide
the operators with suitable tools to pick the items without putting them at risk.
Load aids may only be walked on if suitable safety devices such as pallet guard and
pallet tipover safety mechanisms are in place.
F Improper use of controls and components can cause the driver to fall
Climbing onto the gates, control panel, driver's cab safety guard, driver's seat etc. can
cause the operator to fall out of the cab.
The operator must not climb on the gates, control panel, driver's cab guard, driver's
seat etc.
Operating with a walk-on pallet (o):
If the truck is equipped for operation with a walk-on pallet without side gates or railing,
the operator must wear a restraint belt in accordance with EN 361 and a
harness (2.0 m) in accordance with EN 355
(see chapter 3.1).
F It is prohibited to stop and operate racks without a base even on just one side of the
rack aisle. Keep a maximum distance of 0.2 m to the rack.
M Negotiating slopes and inclines:

Do not negotiate slopes and inclines.
M Travelling on docks:
Do not travel on docks.
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Entering lifts:
Lifts may only be entered 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.
Work platforms
F The use of work platforms is governed by national law. In some member states the
use of work platforms is prohibited on industrial trucks. Observe the applicable law.
Work platforms can only be used in the country of application if the law permits it.
-Contact the national authorities before using a work platform
Nature 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.
M Accident risk when transporting fluid loads

The following hazards can arise from transporting fluid loads:
Fluid sloshing out.
Change of load centre of gravity due to sudden lift and travel movements and possible
crashing of load.
Truck stability can be affected by sliding or unstable loads.
Note the instructions in the "Transporting loads" section.
M Do not transport swinging loads.
M Towing trailers: The truck must not be used to tow a trailer.

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4.2 Emergency Disconnect, Travel, Steering, Braking
4.2.1 Emergency Disconnect switch
21
F Accident risk
Applying the Emergency Disconnect switch during travel will cause the truck to
decelerate to a halt at maximum force. This may cause the load to slide off the forks.
There is an increased risk of accidents and injury!
The operation of the Emergency Disconnect switch must not be affected by any
objects placed in its way.
Pressing the Emergency Disconnect switch
Press the Emergency Disconnect switch (21) down.
Z All truck operations are disabled. The truck brakes to a halt. Do not use the
Emergency Disconnect (21) as a service brake.
Releasing the Emergency Disconnect switch

Turn the Emergency Disconnect switch (21) to unlock it.
Z All electrical functions are enabled and the truck is operational again (assuming the
truck was not operational before the Emergency Disconnect was pressed).
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4.2.2 Travel
M Do not drive the truck unless the

panels and covers are closed and
properly locked.
65
The truck can be operated in 3 modes:
Free ranging in the apron field (FR)

Wire guided
Rail guided (RG)
Z The operating mode used depends

on the guidance system of the
racking system in question.
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Travelling in the apron field
65 1 21 22 11 12
Close the gates.

Put the key in the key switch and switch the truck on.
Press deadman switch (65).
Carry out a mast reference operation (main and auxiliary lift) to adjust the
height display, see Referencing Main and Auxiliary Lift in chapter E.
Fully lower the auxiliary lift via the hydraulic control button (1) while simultaneously
pressing the aux. lift pushbutton (11).
Right turn = Lower.
Lift the Main lift with the hydraulic control button (1) until the forks are clear of
the ground.
Left turn = lift
Slowly turn the travel control knob (12) with your right thumb.
Right turn = Travel in load direction (V)
Turn left = Travel in drive direction (R)
You can control the travel speed by continuing to turn or by retracting the travel
control knob (12)
Use the steering wheel (22) to steer the truck in the required direction.
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4.2.3 Steering
Steering outside narrow aisles:

Use the steering wheel (22) to steer
outside narrow aisles. 82 5
The position of the drive wheel (82) is
shown in the display unit (5).
Steering inside narrow aisles:
Z The truck is automatically guided and

the steering wheel (22) operation is
deactivated.
22
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4.2.4 Brakes
65 21 12
Z The trucks brake pattern depends largely on the ground conditions. The driver must
take this into consideration when handling the truck. Brake with care to prevent the
load from slipping.
The truck can brake in three different ways:
with the service brake (t)

with the deadman button (65) (o)
with the Emergency Disconnect (21) (t).
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Braking with the service brake (t)
While travelling, set the travel direction switch (12) to the zero position or the opposite
travel direction; the traction controller will cause the truck to brake.
Z The truck brakes regeneratively via the traction controller until it starts to move in the
opposite direction. This method reduces energy consumption. Energy is recovered,
which is controlled by the traction current controller.
Braking with the deadman button (o)
Releasing the deadman button (65) causes the truck to brake.
Z This method of braking only acts as a parking brake and not as a service brake.
Braking with the Emergency Disconnect switch (t)
Applying the Emergency Disconnect switch (21) will cause the truck to brake to a halt.
M The Emergency Disconnect switch (21) should only be used in hazardous situations.
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4.3 Negotiating narrow aisles
F Unauthorised entry of narrow aisles by other trucks or people can cause

accidents
Unauthorised personnel must not enter narrow aisles (truck lanes in racking systems
with safety distances < 500 mm), nor must any personnel cross through them.
These work areas must be marked and identified accordingly.
Carry out a daily inspection of the safety mechanisms on the truck or the racking
system to avoid hazards and to protect personnel.
These must not be rendered ineffective, misused, adjusted or removed.
Report any defects to your supervisor immediately.
Tag out faulty racking systems and block them for entry.
Note DIN 15185 Part 2.
Narrow aisles must only be entered by trucks which are designated for
this purpose.
Before entering a narrow aisle, the driver must look for people or other trucks in
the aisle. Never enter an aisle where there are people or other trucks. If there are
people or trucks in the aisle, stop the truck immediately.
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M A non-guided truck can cause accidents
If an automatically guided truck is switched off and on again, the wire guidance is no
longer active when it is switched on again. The same applies if the guide system is
faulty or switched off and on again. If you continue to travel a warning sounds and the
speed is reduced.
When starting or continuing the truck after the wire guidance has been deactivated,
note the position of the drive wheel as manual steering is now activated again.
Re-activate the wire guidance and re-align the truck. During alignment, the rear
section of the truck may veer out when it reaches the guide wire.
If the guide system is faulty or switched off the truck can only exit the narrow aisle
at crawl speed.
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4.3.1 Rail guided trucks
Z Rail-guided trucks are fitted with sensors or RFID readers. Narrow aisles must have
guide rails. These sensors activate aisle detection when the truck enters an aisle.
Approach the aisle at reduced speed so that the truck is aligned with the narrow
aisle and is within the demarcation.
Z Note the markings attached along the route (e.g. aisle centre).
Travel and hydraulic operations can only be activated in the narrow aisle with two-
handed control.
Enter the narrow aisle slowly.
Ensure that the truck guide wheels enter the narrow aisle guidance rails.
Press the Switch guidance on/off 3 82
pushbutton (3).
The drive wheel is automatically
set forward. The steering angle
display (82) changes to Truck
guided (92). Manual steering is
disabled.
92
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Grab the hand rest (14) in the traction
and control handle (two-handed 1 10 11 12
operation).
Z Travel and hydraulic operations can

only be activated in the narrow aisle with
two-handed operation.
The main lift can be raised or lowered

via the hydraulic control button (1),
see "Lift Lower (Main Lift)" in
chapter E. 3 14 82 9 14
The auxiliary lift can be raised or low-
ered via the hydraulic control
button (1) while simultaneously press-
ing the "Auxiliary lift" pushbutton (11),
see "Lift Lower (Auxiliary Lift)" in
chapter E.
The attachment can be rotated to the
left or right via the hydraulic control
button (1) and simultaneously
pressing the Fork carriage rotate
pushbutton (9), see "Traverse
(load handler attachment)" in chapter E.
The attachment can be traversed to the left or right via the hydraulic control
button (1) and simultaneously pressing the Attachment traverse pushbutton (10),
see "Swivel / rotate (fork carriage)" in chapter E.
Turn the travel control knob (12) to change travel speed and direction:
Right turn = Travel in load direction,
Left turn = Travel in drive direction.
Continue travelling along the narrow aisle at your required speed.
Leaving the narrow aisle
F You can only change from automatic to manual steering once the truck has
completely left the narrow aisle.
To quit rail guidance:
The truck must be removed fully from the narrow aisle.

The truck must have come to a halt.
the Switch guidance on/off pushbutton (3) must be pressed.
Z The truck guided display (92) changes to the steer angle display (82). The truck is
now free to move again. The steer angle display (82) shows the current position of
the drive wheel.
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4.3.2 Wire guided trucks
F When starting or continuing the truck after the wire guidance has been deactivated,
note the position of the drive wheel as manual steering is now activated again.
If an automatically guided truck is switched off, the wire guidance is no longer active
when it is switched on again. Accident risk If you continue to travel a warning sounds
and the speed is reduced. Re-active the wire guidance by pressing the
Switch guidance on/off pushbutton (3) and re-align the truck. During alignment,
the rear part may veer out when it reaches the guidance wire.
Approach the guidance wire (93) at an angle

and at reduced speed.
Z When acquiring the wire, the truck (94) should not

be parallel to the guidance wire (93). 93
The optimum approachment angle is between
10 and 50.
M Accident risk during wire acquisition process

If the attachment is not in the home position as the 94
truck acquires the wire, it can collide with the
racking system. The travelspeedremains limited
to reduced speed.
Z The truck should preferably acquire the wire in the

load direction, as this involves less time and
distance.
When the truck is close to the

guidance wire, switch on the wire 3 82
guidance with the Switch guidance
on/off pushbutton (3).
The wire acquisition signal sounds.
When the guidance wire (93) has
been reached the truck is
automatically guided.
When the guidance wire (93) is
reached, acquisition ensues at
reduced speed. The steer angle
display (82) changes to Acquisition in
progress (95). The acquisition signal 95
sounds.
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Inductive automatic steering takes
over and applies the truck to the 92
guidance wire (93).
Acquisition is complete once the truck
has been guided precisely onto the
guidance wire (93). Acquisition in
progress (95) changes to Truck
guided (92).
The acquisition signal no longer
sounds.
The track is now automatically guided.
Z Travel and hydraulic operations can only be activated in the narrow aisle with two-
handed operation.
Grab the hand rest (14) in the traction

and control handle 1 10 11 12
(two-handed operation).
The main lift can be raised or lowered
via the hydraulic control button (1), see
"Lift Lower (Main Lift)" in chapter E.
The auxiliary lift can be raised or low-
ered via the hydraulic control
button (1) while simultaneously press-
ing the "Auxiliary lift" pushbutton (11),
see "Lift Lower (Auxiliary Lift)" in 14 9 14
chapter E.
The attachment can be rotated to the
left or right via the hydraulic control button (1) and simultaneously pressing the
Fork carriage rotate pushbutton (9), see "Traverse (load handler attachment)" in
chapter E.
The attachment can be traversed to the left or right via the hydraulic control
button (1) and simultaneously pressing the Attachment traverse pushbutton (10),
see "Swivel / rotate (fork carriage)" in chapter E.
Turn the travel control knob (12) to change travel speed and direction:
Right turn = Travel in load direction,
Left turn = Travel in drive direction.
Continue travelling along the narrow aisle at your required speed.
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Leaving the narrow aisle
F You can only change from automatic to

manual steering once the truck has 92
completely left the narrow aisle.
To quit rail guidance:
The truck must be removed fully from

the narrow aisle.
The truck must have come to a halt.
The Switch guidance on/off pushbut-
ton (3) must be pressed.
Z The truck guided display (92) changes

to the steer angle display (82). The truck 3 82
is now free to move again. The steer
angle display (82) shows the current
position of the drive wheel.
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4.4 Diagonal travel
Z Diagonal travel is only possible if the

truck is wire or rail guided. 1 12
Diagonal travel is possible (simultaneous

travelling and lifting / lowering) when both
the hydraulic (1) and travel (12) control
buttons are pressed.
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4.5 Lifting Lowering Reaching Traversing outside the rack aisles
F Risk of accidents during lifting and lowering

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.
Instruct 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.
The truck must be prevented from being used by unauthorised people if people do
not leave the hazardous area despite the warning.
Only carry loads that have been secured and positioned in accordance with
regulations. Use suitable precautions to prevent parts of the load from tipping or
falling down.
Never exceed the maximum loads specified in the capacity chart.
Never stand underneath a raised load handler / driver's cab.
Do not stand on the load handler.
Do not lift other people on the load handler.
Never reach or climb into moving truck parts.
The driver must not leave the operator position when it is raised do not climb onto
building constructions or other trucks.
F Risk of trapping when swivelling or moving the forks.

Make sure there is nobody present in the danger zone when carrying out swivel,
traverse or synchronised rotate movements with the load handler. Stop the truck if
people do not leave the hazardous area. If people do not leave the hazardous area
despite the warning, prevent the truck from being used by unauthorised people.
F Fall hazard
of the cab.
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4.5.1 Lift Lower (Main Lift)
Press the deadman button.

Turn the hydraulic control switch (1) 1
Right turn = Main Lift lower.
Left turn = Main Lift raise.
Z The lift and lower speeds are in

proportion to how far the hydraulic
control button (1) is turned.
The maximum lift speed is achieved

when the attachment is in the home
position (see Attachment in Home Position in chapter E).
Z If the line break safety devices applies for an unauthorised

lowering speed (> 0.6 m/s), determine the cause and if there no leakage in the
hydraulic system, briefly raise the Main Lift and then lower it again slowly.
Spilled fluids must be removed immediately with an appropriate bonding agent.
The bonding agent / consumable mixture must be disposed of in accordance with
regulations.
4.5.2 Lift Lower (Aux. Lift)

Press the Aux. lift pushbutton (11) 1 11
and simultaneously turn the hydraulic
control button (1):
Left turn = Auxiliary Lift raise.
Right turn = Auxiliary Lift lower.
Z The lift and lower speeds are in

proportion to how far the hydraulic
control button (1) is turned.
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4.5.3 Traverse (LAM attachment)

Press the Attachment traverse 1 10
pushbutton (10) and simultaneously
turn the hydraulic control button (1):
Right turn = Traverse right.
Left turn = Traverse left.
Z The traverse speed is in proportion to

how far the hydraulic control button (1)
is turned.
4.5.4 Swivel / rotate (fork carriage)

Press the Fork carriage rotate 1
Right turn = Swivel right.
Left turn = Swivel left.
Z The swivel speed is in proportion to

how far the hydraulic control button (1) is
turned.
9
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4.5.5 Simultaneous lifting / lowering of Main and Aux. Lift

Press the Main and Aux. Lift 1 13
raise / lower pushbutton (13) on
the bottom of the travel control
handle while simultaneously
turning the
hydraulic control button (1):
Turn right = simultaneously lower
the Main and Aux. Lift.
Turn left = simultaneously raise
the Main and Aux. Lift.
Z You can stop the raising / lowering of the Auxiliary Lift by releasing the "Main and Aux.
Lift raise / lower" pushbutton (13). Pressing the "Main and Aux. Lift raise / lower"
pushbutton (13)" has no affect on Main Lift or diagonal travel.
Z The lift and lower speeds are in proportion to how far the hydraulic control button (1)
is turned.
4.6 Simultaneous load handler traverse and fork carriage swivel
F Risk of trapping when swivelling or moving the forks.

traverse or synchronised rotate movements with the load handler. Stop the truck if
people do not leave the hazardous area. If people do not leave the hazardous area
despite the warning, prevent the truck from being used by unauthorised people.
Z If you move the attachment the fork carriage will swivel simultaneously. The rotate
speed cannot be changed. The traverse speed is in proportion to how far the
hydraulic control button (1) is turned.
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4.6.1 Manual rotate / traverse (t)
Press the pushbutton (24) below the

96
synchronised rotate menu change
symbol (96). The display changes
from the menu item Synchronised
rotate menu change (96) to Fork
synchronised right/left rotate (97, 98).
Fork synchronised right rotate
symbol (97) while simultaneously
turning the hydraulic control button (1).
Rotate left = swivel fork carriage to the
right and traverse load handler to 1 98 24 97
the left.
Fork synchronised left rotate
symbol (98) while simultaneously
turning the hydraulic control button (1):
Rotate right = swivel fork carriage to
the left and traverse load handler to
the right.
4.6.2 Automatic rotate/traverse (o)

14 24
symbol (96). The display changes from the menu item Synchronised rotate menu
change (96) to Fork synchronised right/left rotate (97, 98).
Touch the control panel hand rest (14) with your left hand.
Press the pushbutton (24) below the Synchronised fork right rotate symbol (97):
Swivel the fork carriage right swivel and load handler left traverse.
Press the pushbutton (24) below the Synchronised fork left rotate symbol (98):
Automatic fork carriage left swivel and load handler right traverse.
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4.6.3 Synchronised rotate until forks are in centre position (o)

96
symbol (96). The display changes
from the menu item Synchronised
rotate menu change (96) to
Synchronised rotate until forks in
centre position (99).
Touch the control panel hand rest (14)
with your left hand.
Synchronised rotate until forks in
centre position symbol (99) = swivel 1 24 99
fork carriage and traverse load
handler in centre position.
14 24
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4.7 Telescopic table (o)
4.7.1 Telescopic table attachment traverse (o)
Z The extended limit position of the telescopic forks is limited both electrically and
mechanically.
M No loads may be pushed or pressed with the telescopic forks.

Raise and transport loads which are evenly distributed with both telescopic forks.

checklist Telescopic table (o) in chapter F.

Press the Telescopic forks attach- 1 10
ment traverse pushbutton (10) and
simultaneously turn the hydraulic con-
trol button (1):
Z The telescopic table automatically stops

in the centre position. If you release the
hydraulic control button (1) and press it
again, the telescopic table can then be moved either left or right.
If the telescopic forks are not in the centre position, you can only travel, lift and lower
at reduced speed.
Z The traverse speed is in proportion to how far the hydraulic control button (1)
is turned.
M The driver must check the condition and test the operation of the telescopic table
every day.
If the telescopic table is not in a proper condition, take the truck out of service and
notify the relevant customer service department.
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4.7.2 Telescopic table attachment fork adjuster (o)
M The fork spread must only be adjusted without load.

No loads may be pushed or pressed with the telescopic forks.


1 100
Telescopic fork adjuster symbol (100)
while simultaneously turning the
Left turn = Traverse forks in drive
direction.
Right turn = Traverse forks in load
direction.
Z If the telescopic forks are not in the

centre position, you can only travel, lift
and lower at reduced speed. 24
is turned.
every day.
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4.7.3 Rotary telescopic table (o)


Z The rotation of the rotary table is limited both electrically and mechanically.

Press the Fork carriage rotate 1
turn the hydraulic control button (1) to
turn the rotary table in or out of the
stockpicking position:
Right turn = Turn telescopic table right.
Left turn = Turn telescopic table left.
Z If the telescopic forks are not in the

centre position, you can only travel, lift
9
and lower at reduced speed.
Z The rotation speed is in proportion to how far the hydraulic control button (1) is turned.
every day.
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Pallet lifting from the left
If a pallet is lifted from the left hand rack

side, to enable stockpicking the rotary
table must be rotated 90 clockwise and
extended in the direction of the cabin
(stockpicking position)..
800
*
* Note the fork marking. The fork must
be rotated in the corresponding direction
before discharging a pallet.
*
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Pallet lifting from the right
If a pallet is lifted from the right hand rack

side, to enable stockpicking the rotary
table must be rotated 90 anti-clockwise
and extended in the direction of the
cabin (stockpicking position).
800
* Note the fork marking. The fork must *
be rotated in the corresponding direction
before discharging a pallet.
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Re-positioning (180)
If a pallet is taken from one side of a rack, it can be repositioned by rotating the rotary
table 180.
* Note the fork marking. The fork must be rotated in the appropriate direction before
discharging a pallet.
Example: removing a pallet from the right.
*
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4.7.4 Telescopic table forks individually moving (o)


Press the Telescopic forks attach- 1 101 102 103 10
ment traverse pushbutton (10) and
simultaneously turn the hydraulic con-
trol button (1):
Use the pushbuttons (24) to decide
which forks can be traversed.
A different telescopic fork can be se-
lected by pressing the pushbutton (24)
below the symbols (101, 102, 103).
The choice of telescopic forks can 24
only be made if both telescopic forks
are in the centre position. The display unit shows which telescopic forks can be se-
lected and hence traversed.
F Always take into account the charge on the telescopic table when choosing the
telescopic forks.
An individual telescopic fork must not be chosen when the load on the two telescopic
forks is overlapping, i.e. when laden with a wire box.
Z The telescopic table automatically stops in the centre position. If you release the
hydraulic control button (1) and press it again, the telescopic table can then be moved
either left or right.
If the telescopic forks are not in the centre position, you can only travel, lift and lower
at reduced speed.
is turned.
every day.
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4.8 Symmetrical sideshifter (o)

1 104
Fork sideshift symbol (104) while
simultaneously turning the hydraulic
control button (1):
direction.
direction.
Z The speed of movement is proportional

to the turn of hydraulic control button (1).
24
4.9 Fork adjuster (o)

checklist Fork adjuster (o) in chapter F.

1 105
Fork adjuster symbol (105) while
control button (1).
Turn left =
increase the range.
Turn right =
reduce the range.
Z The forks cannot be adjusted individually.
M The fork spread can only be adjusted

without load.
24
Z The speed of movement is proportional to the turn of hydraulic control button (1).
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4.10 Telescopic forks (o)
Z Telescopic forks are used to achieve a greater stacking depth (single telescopic forks)
or double-deep storage (double telescopic forks on narrow aisle trucks).
4.10.1 Single telescopic forks (o)

checklist Telescopic forks (o) in chapter F.

1 106
Press the Attachment traverse
If the attachment has been extended
as far as the limit position, the forks
can be extended further by pressing
the pushbutton (24) below the single
telescopic fork symbol (106) and
control button (1). 24 10
Right turn = Extend further to the right.
Left turn = Extend further to the left.
The forks can be retracted to the home position by pressing the pushbutton (24)
below the single telescopic fork symbol (106) and simultaneously turning the
hydraulic control button (1). When the forks have been retracted, the attachment
can be retracted to the home position by pressing the Traverse attachment
pushbutton (10) and simultaneously turning the hydraulic control button (1).
is turned.
4.10.2 Double telescopic forks (o)

checklist Telescopic forks (o) in chapter F.

Press the Attachment traverse pushbutton (10) and simultaneously turn the
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After traversing to the limit position
press the pushbutton (24) under the 1 107
2nd stacking depth symbol (107)
(changes to the active mode).
Press the Attachment traverse
Right turn = Extend further to the right.
Left turn = Extend further to the left.
Version A Retract forks, then move

the attachment back to the home
position:
24 10
Press 2nd stacking depth
pushbutton (107) (changes to the active mode).
Press the Attachment traverse pushbutton (10) and simultaneously turn the
When the forks have been retracted press the pushbutton (24) under the 2nd
stacking depth symbol (107) (changes to the non active mode).
The attachment can now be retracted to the home position by pressing the
Traverse attachment pushbutton (10) and simultaneously turning the hydraulic
control button (1).
is turned.
Version B Move back the attachment, then retract the forks to the
home position:
Press the pushbutton (24) below the 2nd stacking depth symbol (107).
(changes to active mode).
Press the Attachment traverse pushbutton (10) and by simultaneously turning the
hydraulic control button (1) first retract the attachment and then the forks:
Now press the pushbutton (24) below the 2nd stacking depth symbol (107)
(changes to the non-active mode).
is turned.
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4.11 Symmetrical sideshift with integrated fork adjuster (o)
M The fork adjuster is used to extend the forks beyond the geometry of the
sideshift frame.
F Due to the special design of the sideshifter with integrated fork adjuster, the operator
must ensure that the forks and sideshifter do not extend into the area of the operator
position.
To avoid injury to personnel and damage to the truck and load, trained operators must
handle the attachment with particular care.

checklist Symmetrical/Asymetrical sideshift with integrated fork adjuster (o) in
chapter F.
Function
1 108
Fork adjuster / sideshifter menu
change symbol (108). The display
changes from the menu item Fork
adjuster / sideshifter (108) to the
Fork sideshift (104) and Fork
adjuster, symmetrical (105) functions.
simultaneously turning the hydraulic 1 104 24 105
control button (1).
direction.
direction.
control button (1):
Turn left = increase the fork spread.
Turn right = decrease the fork spread.
Z The forks cannot be adjusted individually. 24
M The fork spread can only be adjusted

without load.
Z The speed of movement is proportional to how far the hydraulic control button (1)
is turned.
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4.12 Asymmetrical sideshifter with integrated fork adjuster (o)

checklist Symmetrical / Asymetrical sideshifter with integrated fork adjuster (o) in
chapter F.
Home position right, forks swivelled to the left
Z The asymmetrical arrangement of the attachment enables the forks to be adjusted in

this position as far as the drivers cab, for stockpicking.
F In this position the attachment / raised load can damage the operator position.
Be careful when adjusting the sideshifter and fork adjuster.
Home position left, forks swivelled to the right
Z For transporting pallets up to 3.3 m long. The sideshifter and forks cannot be adjusted
as far as the cab for stockpicking purposes.
Function
1 108
Fork adjuster / sideshift menu
change symbol (108). The display
changes from the menu item Fork
adjuster / sideshifter (108) to the
Fork sideshift (104) and Fork
adjuster, symmetrical (105) functions.
simultaneously turning the hydraulic 1 104 24 105
control button (1).
direction.
direction.
control button (1):
Turn left =
increase the fork spread.
Turn right = decrease the fork spread. 24
Z The forks cannot be adjusted individually.
M The fork spread can only be adjusted without load.
Z The speed of movement is proportional to how far the hydraulic control button (1)
is turned.
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4.13 Lifting - Lowering - Traversing - Pivoting inside the rack aisles
F Risk of trapping when traversing or rotating with the forks.

traverse or synchronised rotate movements with the load handler.
F Risk of accidents during lifting and lowering

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.
The truck must be prevented from being used by unauthorised people if people do
not leave the hazardous area despite the warning.
Only carry loads that have been secured and positioned in accordance with
regulations. Use suitable precautions to prevent parts of the load from tipping or
falling down.
The driver must not leave the operator position when it is raised do not climb onto
building constructions or other trucks.
F Fall hazard
of the cab.
Z Lifting and lowering inside narrow aisles requires two-handed operation.

Otherwise, operation is the same as for outside the aisles.
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4.14 Order picking and stacking
F Unsecured and incorrectly positioned loads can cause accidents

Before lifting a load unit the driver must make sure that it has been correctly palletised
and does not exceed the trucks capacity.
Only carry loads that have been correctly secured and positioned. Use suitable
precautions to prevent parts of the load from tipping or falling down.
Damaged loads must not be transported.
Check the fork spread before lifting the load and adjust if necessary.
Insert the forks as far as possible underneath the load.
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4.14.1 Adjusting the forks
F Incorrect fork adjustment can

cause accidents
To lift the load securely, the forks
must be spread as far apart as
possible and positioned centrally
with respect to the fork carriage. 110
The load centre of gravity must be
centrally aligned between the forks.
F Unsecured forks can cause

accidents
111
Check the stop retainer (113) is 112

present. Do not operate the truck if
the stop retainer is missing (113). 113
Lift up the locking lever (110).
Push the forks (111) into the correct position on the fork carriage (112).
Apply the locking lever (110) down and move the forks (111) until the locking pin
engages in a notch.
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4.14.2 Replacing the forks
F Faulty forks can cause accidents

Faulty forks can cause the load to crash.
Do not operate the truck with faulty forks.
If one fork tine is damaged, both fork tines must be replaced.
Tag out faulty forks and withdraw them from use.
M Injury risk when replacing forks

You can injure your legs when replacing the forks.
Wear safety shoes when replacing the forks.
Always push the forks away from your body, never towards it.
Secure heavy forks with lifting slings and a crane before pushing them down from
the fork carriage.
After replacing the forks fit the stop retainer and make sure it is seated correctly.
F Using two different forks can cause accidents

Assembling forks of different types will affect the stability of the truck.
Use only the same type of fork that has been approved by the manufacturer.
Always replace forks in pairs.
The fork tine dimensions must match.
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Disassembling the forks
Park the truck securely.

Lower the mast.
Raise the auxiliary lift slightly so that the
forks are no longer touching the ground. 110
Disassemble the stop retainer (113).
Lift up the locking lever (110).
Carefully push the forks (111) off the fork
111
carriage (112).
The forks (111) are now dismantled from
112
the fork carriage (112) and can be
replaced.
113
Assembling the forks
Park the truck securely.

Lower the mast.
Raise the fork carriage so that the fork tine can be pushed onto the fork carriage.
Disassemble the stop retainer (113).
Carefully push the forks (111) onto the fork carriage (112).
Adjust the forks (111), see "Adjusting the forks" in Chapter E.
Apply the locking lever (110) down and move the forks (111) until the locking pin
engages in a notch.
F Unsecured forks can cause accidents

Check the stop retainer (113) is present. Do not operate the truck if the stop retainer
is missing (113).
Fit the stop retainer (113) and make sure it is secure.
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4.15 Lifting, transporting and depositing loads
F Unsecured and incorrectly positioned loads can cause accidents

Before lifting a load unit the driver must make sure that it has been correctly palletised
and does not exceed the trucks capacity.
Only carry loads that have been correctly secured and positioned. Use suitable
precautions to prevent parts of the load from tipping or falling down.
Do not transport loads other than on the authorised load handler.
Damaged loads must not be transported.
If the stacked load obscures forward visibility, you must travel in reverse.
Make sure you have enough visibility when reversing.
Never stand underneath a raised load handler.
Do not reach through the mast.
Check the fork spread before lifting the load and adjust if necessary.
Insert the forks as far as possible underneath the load.
F Ensure there are no other people standing underneath the raised load and
driver's cab.
Never stand underneath a raised and unsecured load handler / driver's cab.
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4.15.1 Lifting a load from the side (EKX only)
Check the fork spread for the pallet

and adjust if necessary.
Drive the truck carefully up to the
storage location
M The forks should be evenly laden.

The weight of the load unit should not
exceed the truck's capacity.
Slowly insert the forks into the pallet

until the fork back touches the load or
the pallet.
Z The load unit must not extend by more

than 50 mm beyond the fork tips.
Raise the load slightly until it rests

freely on the forks.
Retract the forks.
M The ground surface must be in good

condition to ensure this works correctly.
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4.15.2 Lifting a load from the front
Check the fork spread for the pallet

and adjust if necessary.
Set the attachment to the centre
position and position the forks at right
angles (90) to the truck.
Raise or lower the load handler so that 90
the forks can enter the pallet without
striking it.
M The forks should be evenly laden.

The weight of the load unit should not
exceed the truck's capacity.
Slowly insert the forks into the pallet

until the fork shank touches the load or
the pallet.
Z The load unit must not extend by more

than 50 mm beyond the fork tips.
Raise the load slightly until it rests

freely on the forks.
Make sure you can see behind you
and that you have sufficient space to
move. Now reverse the truck slowly
until the load is clear (e.g. out of
the rack).
Bring the load to the home position,
(see Attachment in Home position
section in Chapter E.)
M The ground surface must be in good

condition to ensure this works correctly.
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4.15.3 Transporting loads

Raise the load slightly.
Z Always transport a load outside the rack

aisle as low as possible, allowing for
ground clearance.
Always transport loads with both forks.

When transporting heavy loads
always ensure that both forks carry
the same weight.
Accelerate gradually.
Travel at a constant speed. Adapt
your travel speed to the conditions of
the route and the load you are
transporting.
Always be prepared to brake. Brake
gently in normal circumstances. Only
stop suddenly in dangerous situations.
Reduce speed accordingly on narrow
bends.
Watch out for other traffic at crossings
and passageways.
Always travel with a lookout at blind
spots.
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4.15.4 Depositing loads

Drive carefully up to the storage
location.
M Before depositing a load, the driver must

ensure that the storage location is
suitable for storing the load (size and
capacity).
Z 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.
Raise the load handler so that the load

can enter the storage location without
striking any objects.
Carefully push / insert the load in its
storage location.
Carefully lower the load handler so
that the forks are clear of the load.
M Avoid placing the load down suddenly

to avoid damaging the load and the
load aid.
Make sure you can see behind you

and that you have sufficient space
to move.
Carefully remove the load handler
from the load.
Fully lower the load handler.
If required, set the attachment to the
home (standard) position.
90
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4.16 Rack Height Select with Zone Entry (o)
To lift or deposit loads in pre-selected warehouse locations, the truck must be

adapted to the warehouse setup. The work required to do this must only be performed
by trained field engineers from the manufacturer's service department.
In addition to the current lift height, the following symbols are displayed:
Symbol
Function
Telescopic
Attachment
table
Attachment or telescopic table in home position
without load
Attachment or telescopic table in home position

with load
Lower / raise attachment or telescopic table

without load
Lower / raise attachment or telescopic table

with load
Traverse attachment or telescopic table without

load to the left / right
Traverse attachment or telescopic table with load

to the left / right
Zone selection / area selection
Z A load sensor between the forks identifies if there is a load on the forks
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4.16.1 Entering area recognition (zones)

the cursor field.
The zones are entered via the
If an incorrect entry is made it can be
deleted by pressing the CE push-
button in the numerical keypad (25).
After the zone has been entered,
it must be stored by pressing the OK 25 78 79
pushbutton in the numerical
keypad (25).
75
Z The selected zone is now shown in the

display unit above the zone selection
77
symbol.
76
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4.16.2 Rack number entry (lift height)
The zones are entered via the numerical keypad (25).

After the rack number has been entered, it must be stored by pressing the OK
pushbutton in the numerical keypad (25).
Z The rack number can be entered as a single digit (0 - 9) or a 2-digit number (00-64).
For a 2-digit entry, the first number entered is used as a multiple of ten, the second
as a unit position.
If an incorrect entry is made it can be deleted by pressing the CE pushbutton in

the numerical keypad (25).
Z The entered rack number is now shown in the display unit. Depending on the current
lift height, the nominal direction (Raise or Lower) is indicated with an arrow.
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4.16.3 Raising or depositing a load in pre-selected warehouse locations with Rack
Height Select:
Grab the hand rests (14) on the control panel (two-handed operation).
Enter the respective narrow aisle.
Enter the zone with the numerical keypad (25).
see Entering zone recognition in chapter E.
Enter the rack number with the numerical keypad (25),
see Rack number entry (lift height) in chapter E.
When the required rack number has been entered it can approached by turning the
hydraulic control button (1) in the displayed direction.
Right turn = lower.
Left turn = lift.
To approach the nominal height manually (t):
The hydraulic control button (1) must be pressed and held down until the
required height has been reached (automatic stop).
Z The lift and lower speeds are in proportion to how far the hydraulic control button (1)
is turned.
If the rack number entered is not reached with Main Lift, use the Auxiliary Lift to
reach the remaining height.
To approach the nominal height automatically (o):
Grab the hand rests (14) on the control panel (two-handed operation).
Turn the travel control knob (12) to the left or right and hold it in position.
The nominal height is then approached automatically in the optimum manner,
depending on how far away the warehouse location is.
Z The truck movements can be stopped by releasing the travel control knob (12) or the
hand rests (14) on the control panel, or by pressing the Emergency Disconnect switch.
Z The rack height entered is approached with the Main Lift.

If the entered lift height cannot be positioned with the Main Lift extended or
fully lowered, Auxiliary Lift is used to reach the remaining height.
Stacking operation:
1 11
General procedure:
Retrieval:
Extend - Raise - Retract
Stacking:
Extend - Rest - Lower - Retract
14 21 25 14
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The following variants are possible depending on the design:
11
1 25 10
Stacking Grab the hand rests in the control panel (two-handed operation).
procedure not Press the deadman button.
active When the selected height is reached, the Rack Height Select
command disappears from the display unit.
The operator can now start manual stacking and retrieval,
see Lifting Lowering Traversing Swivelling outside rack aisles,
in Chapter E.
Stacking Grab the hand rests in the control panel (two-handed operation).
operation not Press the deadman button.
active with Stacking / retrieval can be performed when the selected nominal
feedback to height has been reached.
radio data
transmission see Lifting Lowering Traversing Swivelling outside rack aisles,
terminal in Chapter E.
Z The message "Order processed" to the radio data transmission

terminal is only issued when the attachment has abandoned and
returned to the home position.
Manual stacking Grab the hand rests in the control panel (two-handed operation).
operation Press the deadman button.
Stacking / retrieval can be performed when the selected nominal
height has been reached.
Stacking and unstacking are prescribed to the driver in the display unit
via the load sensor.
see Lifting Lowering Traversing Swivelling outside rack aisles,
in Chapter E.
On reaching the respective limit position (traverse / lift height reached),
the next stage can follow if the hydraulic control button (1) is in neutral.
Z All hydraulic speeds can be determined by the operator via the

hydraulic control button (1).
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Automatic Grab the hand rests in the control panel (two-handed operation).
stacking Press the deadman button.
operation with When the selected nominal height has been reached, throughout the
the hydraulic entire stacking operation the direction must be applied and maintained
control button (1) by the hydraulic control button (1) as follows:
(version A) "Left" stacking operation = turn the hydraulic control button (1) to
the left.
"Right" stacking operation = turn the hydraulic control button (1) to
the right.
Z All functions can be stopped by releasing the hydraulic control

button (1). The stacking operation continues when the hydraulic
control button (1) is pressed again.
Automatic Grab the hand rests in the control panel (two-handed operation).
stacking Press the deadman button.
operation with When the selected nominal height has been reached, throughout the
the hydraulic entire stacking operation the direction must be applied and maintained
control button (1) by the hydraulic control button (1) as follows:
(version B) "Left" stacking operation = turn the hydraulic control button (1) to
the left.
"Right" stacking operation = turn the hydraulic control button (1) to
the right.
Z All functions can be stopped by releasing the hydraulic control

button (1). The stacking operation continues when the hydraulic
control button (1) is pressed again.
Pressing one of the "Auxiliary Lift" (11), "Attachment traverse" (10) or

"Fork carriage rotate" (9) pushbuttons cancels the automatic stacking
operation.
Z The driver is notified of this via an audible signal.

After the cancellation the operator must carry out traversing, lifting and
lowering manually, see "Manual stacking operation".
If during positioning another rack is selected, this is displayed for approx. 1 second
and stored in an intermediate log. At the end of the stacking operation the rack is
automatically taken from the intermediate log (this does not apply to the Stacking not
active variant).
Z Stacking can be cancelled by pressing the CE key in the numerical keypad (25).
No "Order processed" message is sent to the radio data transmission terminal.
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The following symbols appear in the
display unit for left stacking operation:
1 21 25 10
Symbol
Manual stacking operation
Stacking Retrieval
Grab the hand rests in the control panel (two-
handed operation).
Press the Attachment traverse pushbutton (10)
and simultaneously turn the hydraulic control
button (1) to the left.
Rest time active.
Grab the hand rests in the control panel

Turn the hydraulic control button (1):
- left = lift (retrieve)
- right = lower (stack)
Grab the hand rests in the control panel
Press the Attachment traverse pushbutton (10)
and simultaneously turn the hydraulic control
button (1) to the right.
Z When stacking, after the attachment has been extended there is an interval to reduce
mast vibration.
All automatic stacking operations can be interrupted by releasing the two-handed
operation system.
F In an emergency, press the Emergency Disconnect (21).

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4.17 Horizontal positioning (o)
The truck is equipped with the Horizontal Positioning (HozPos) function.

This function supports the owner in positioning (automatic, direct targeted positioning
of the pallet location) the truck in the rack and at the transfer station. In conjunction
with the integrated rack height select with programmable fork cycles, this provides
consistent depositing and lifting of the load in the rack and at transfer stations with
very few monitored deviations.
The degree of positioning is:
for marker detection (vertically) r 5 mm and (horizontally) r 12 mm.

for warehouse navigation (vertically) r 5 mm and (horizontally) r 100 mm.
"Horizontal Positioning (HozPos)" offers programmable warehouse conditions.
To achieve constant insertion widths over the entire lift height, ten height-dependent
traverse adjustment values can be programmed as an option.
The aisle and fork positions are checked on entry to the aisle.
Options
Manual targeted entry via cursor keys and via the numerical keypad.
Targeted entry via barcode scanner on the control panel or load handler.
Targeted entry via radio connection.
Adjustable fork cycle (manual, function-related or automatic).
Extension locking during travel without target or incorrect target.

checklist Horizontal positioning (o) in chapter F.
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4.17.1 Warehouse and stockpicking mode (o)
Z Optionally it is possible to toggle between warehouse and stockpicking mode.

Warehouse mode:
In warehouse mode pallets can be stacked and retrieved, see "Lifting Lowering
Traversing Swivelling outside rack aisles, in chapter E.
The vertical position of the warehouse location entered is the height of the forks.
This ensures that the required pallet is stacked or retrieved.
The horizontal position of the warehouse location entered is the centre of the load
handler. This ensures that the required pallet is stacked or retrieved.
Stockpicking mode:
In stockpicking mode articles can be gathered together.

The vertical position of the warehouse location entered is the picking height
(raised operator height +1600 mm). This ensures that the required articles can
be picked.
The horizontal position of the warehouse location entered is the centre of the
driver's cab. This ensures that the required articles can be picked.
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Changing between warehouse and picking mode

the cursor field. 114
Z The display unit shows the "Warehouse

or stockpicking mode" symbol (114).
To change between warehouse and

stockpicking mode press the
pushbutton (24) below the
"Warehouse or stockpicking mode"
symbol (114). 78 79
Warehouse mode = "Warehouse 24
or stockpicking mode" 75
symbol (114) has a dark
77
background
Stockpicking mode = "Warehouse
or stockpicking mode"
symbol (114) has a light 76
background
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4.17.2 Horizontal positioning symbols in the display unit
The following symbols are displayed along with the lift height:
130
0h 07:48 EKX 5XX

125, 126,
127, 132a
P
xx kg
115
116
117
118 - 124
128, 129
131, 132b
Z The position of the symbols (118-124, 128, 129, 131, 132b) can be adapted to
customer requirements. In this case the positions must then be entered so as to
match the symbol display
Item Symbol Function / Description
115 Travel in drive direction symbol
116 Travel in load direction symbol
117 Truck horizontally positioned symbol
Lightning symbol,
118
see Horizontal positioning error description
Warning symbol,
119 ! see Horizontal positioning error description
Question mark symbol,
120
? see Horizontal positioning error description
121 Rack row display, only single digit entry allowed

Zone selection / area selection
122 Zone display = different lift heights,
only single digit entry allowed
Position (mark) display, horizontal position in
123 narrow aisle; single, double or three digit entries
allowed
Rack (height), rack display = lift height vertical
124 position in aisle; single or double digit entries
allowed
Fork warning symbol, see Horizontal positioning
125 ! ! error description
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Item Symbol Function / Description
126 ! Turn fork right warning symbol
127 ! Turn fork left warning symbol
0 8
128 to Area display from 0 to 8
A H
129 to Area display from A to H
130 Truck in narrow aisle / transponder recognised
Light button on reflector symbol, indicates

131
whether the position entered has been reached
132 The lower or lift symbols indicate that vertical
a adjustment runs are required
The "Order in memory" symbol indicates that in
132
addition to the current order there is another
b
order in the truck's memory
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Horizontal positioning error description
Correction measure /
Item Error
Display
115 / Truck has entered the Drive out of the aisle.
116 wrong aisle. Travel direction symbol flashing.
Reflex marker reached:
Wrong position in aisle
Aisle start, end or centre transponder must be
(marker identified without
118 / passed over.
having read the corresponding
123 Pallet location / marker and lightning symbol
transponder)
flash alternately.
Reflex marker not recognised,
tolerance level exceeded
Stacking operation carried out as far as home
119 No load when unstacking
position. Warning symbol lit.
Order cannot be performed, re-enter data or
amend order.
119 Incorrect checksum on data entry Total symbol / warning symbol flash alternately
until total key is pressed again or the order is
cancelled.
Check entry.
120 / Incorrect rack row entered
Question mark / rack row symbols flash
121 with order
alternately.
Check entry.
120 / Incorrect location details entered
Question mark and location (marker) symbols
123 with order
flash alternately.
Check entry.
120 / Incorrect rack details entered
Question mark / rack (height) symbols flash
124 with order
alternately.
Set the attachment / forks to the home position
Forks are not in home position shown.
for the order entry Load handler symbol / warning symbol flash
125 alternately every 5 seconds
Apply the required direction.
Wrong direction pressed for
The load handler symbol flashes as long as the
stacking
wrong direction is indicated.
Forks are not in the correct
125 / Turn forks in the direction displayed. Load
position for the stacking
126 / handler symbol / rotation symbol flash until the
operation requested (error in
127 correct position is reached.
stacking operation)
Orders cannot be entered as
-- there is already an order in Entry blocked.
the memory.
-- Faulty data transmission
Data transmission not repeated Order not accepted. The error number is issued.
--
despite error recognition (NAK)
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4.17.3 Horizontal positioning destination input
(manual / via barcode scanner / via data radio transmission)
Z The destination input selection can be

adapted to customer requirements.
Manual destination input:
the required target is manually
entered and confirmed.
Destination input with barcode
scanner:
the target position is scanned in with
a barcode scanner. 25 78 79
Destination input via radio:
the target is transmitted to the truck 75
via radio transmission. 77
Z A maximum of two orders can be stored

in the trucks memory.
76
When the current order has been
processed it is deleted from the
display unit and the order stored in the memory is moved into the display.
A displayed order can be deleted by pressing the CE pushbutton twice in the
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Manual target entry (default setting):
Z The position of the symbols can be adapted to customer requirements. In this case
the positions must then be entered so as to match the symbol display!

the cursor field. 121 123 124 122
The rack row field (121) has a BLUE
background.
Using the numerical keypad (25)
enter the rack row.
Z Only single digit entries are allowed in

the rack row field (121).
Press the cursor key (75).
Z The operator can toggle between

the input fields using the cursor
25 78 79
keys (75, 77):
Cursor key (75): One input field forward
Cursor key (77): One input field back. 75
77
The position (marker) field (123) has
a BLUE background.
Enter the required location (marker)
via the numerical keypad (25). 76
Z The entry in the position (marker) field (123) can be one, two or three-digit.

The rack (height) field (124) has a BLUE background.
Enter the required compartment (height) via the numerical keypad (25).
Z The entry in the rack (height) field (124) can be one or two-digit.

The zone selection / area selection field (122) has a BLUE background.
Enter the required zone / area via the numerical keypad (25).
Z Only single digit entries are allowed in the zone selection / area selection field (122).
Confirm the entry of all required locations with the OK pushbutton in the numerical
keypad (25).
Z A maximum of 2 orders can be stored in the trucks memory.

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Destination input with barcode scanner
Scan in the label with the barcode scanner.

The target stored on the label is directly transmitted to the display unit and
displayed.
Z A maximum of two orders can be stored

in the trucks memory. 132b
The destination entered first is shown
on the driver's display as the current
order. The second destination scanned
in is stored in the trucks memory.
The "order in memory" symbol (132b) is
displayed.
When the current order has been
processed it is deleted from the
display unit and the order stored in
the memory is moved into the display.
A second target can then be accepted via the barcode scanner.
Z Destinations can be inputted manually if the barcode scanner fails.
Destination input via data radio transmission
The destination transmitted via data radio from the data terminal is received by the
truck and transmitted directly to the display unit and displayed.
Destination input via the radio terminal is now complete. The destination can now
be approached.
When the current order has been performed this order is deleted from the
display unit.
The truck sends a message back to the data terminal.
Another destination can then be transmitted via the data terminal and displayed.
Another destination can then be transmitted via radio and accepted.
A displayed order can be deleted by pressing the CE key twice in the numerical
keypad.
Z Destinations can be inputted manually if the data radio fails.

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4.17.4 Stacking / retrieval after target entry
Z When the destination has been inputted, the destination can be approached.
See "Negotiating narrow aisles" and "Diagonal travel" in chapter E)
Automatic horizontal and manual

117 131
vertical destination approach (t)
1 11
Grab the hand rests (14) on the
control panel (two-handed operation).
Drive the truck into the chosen aisle.
Z An incorrect aisle will be displayed and

entry will be prohibited.
The attachment must be in the correct

position. Check the display. If neces-
sary push / turn the attachment to the 14 11 14
correct home position.
Slowly turn the travel control knob (12) with your right thumb.
Turn right = Travel in load direction
Turn left = Travel in drive direction
You can control the travel speed by continuing to turn or by retracting the travel
control knob (12)
When you have reached the horizontal destination position the "Truck horizontally
positioned" symbol (117) is shown in the display unit and the truck stops.
Z For marker detection the display unit also shows the "Light button on reflector"
symbol (131).
Turn the hydraulic control button (1):

Right = Main Lift lower
Left = Main Lift raise
Press the Auxiliary lift pushbutton and simultaneously turn the hydraulic control
button (1):
Right = Auxiliary Lift lower
Left = Auxiliary Lift raise
Z Horizontal adjustment runs are shown in the display unit

through the travel in drive direction (115) and travel in load 115
direction (116) symbols. Vertical adjustment runs (height in
rack) are shown through the lower and lift (132a) symbols.
116
When the horizontal and vertical positions have been
reached, stacking/retrieval can begin, see also Raising or
depositing a load in pre-selected warehouse locations with 132a
Rack Height Select in chapter E.
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Automatic horizontal and vertical
117 131
destination approach (o)
1 11
Grab the hand rests (14) on the
control panel (two-handed operation).
Drive the truck into the chosen aisle.
Z An incorrect aisle will be displayed and

entry will be prohibited.
The attachment must be in the correct

position. Check the display. If neces-
sary push / turn the attachment to the 14 11 14
correct home position.
Turn the travel control knob (12) to the left or right and hold it in position.
The truck starts its automatic horizontal and vertical destination approach.
Z The truck movements can be stopped by releasing the travel control knob (12) or
the hand rests (14) on the control panel, or by pressing the Emergency Disconnect
switch.
On reaching the warehouse location:

the "Truck horizontally positioned" symbol (269) is shown in the display unit.
the truck stops.
lifting / lowering stop automatically.
the "Lift" or "Lower" symbols (132a) fade out.
Z For marker detection the display unit also shows the "Light button on reflector"
symbol (131).
When the horizontal and vertical positions have been reached, stacking/retrieval
can begin, see also Raising or depositing a load in pre-selected warehouse
locations with Rack Height Select in chapter E.
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4.17.5 Warehouse or stockpicking mode symbols
The following symbols (41) are shown in the display unit:

0h 07:48 EKX 5XX
P
xx kg
41
Symbols in warehouse mode with attachment
Z A load sensor between the forks detects whether there is a load on the forks.
Symbol Function
Attachment in home position without load / with load
Without load, lower / lift to reach the warehouse location
With load, lower / lift to reach the warehouse location
Without load, traverse the attachment to the left / right
With load, traverse the attachment to the left / right
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Symbols in warehouse mode with telescopic table
Z A load sensor between the forks detects whether there is a load on the forks.
Symbol Function
Telescopic table in home position without load / with load
Without load, lower / lift to reach the warehouse location
With load, lower / lift to reach the warehouse location
Without load, traverse the telescopic table to the left / right
With load, traverse the telescopic table to the left / right
Rest time without / with load
Telescopic table in home position without load / with load

The telescopic table can be extended to the left / right
Without load, traverse the telescopic table to the left / right into the
second stacking depth, see "Double telescopic forks (o)" in chapter E
With load, traverse the telescopic table to the left / right into the
second stacking depth, see "Double telescopic forks (o)" in chapter E
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Symbols in stockpicking mode
Symbol Function
Stockpicking mode active
Lower / lift to reach the warehouse location
Remove articles from the left / right warehouse location
Adjustment run display to reach the warehouse location
4.17.6 Picking direction position lamp (o)
On reaching the warehouse location the position lamps on the driver's cab illuminate
the warehouse location. The operator can start to pick goods in the illuminated area.
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4.18 Parking the truck securely
When you exit the truck it must be securely parked even if you only intend to leave it
for a short time.
F Do not park the truck on an incline. In special cases the truck may need to be secured
with wedges.
Select a parking place where nobody will get caught on the lowered forks.
Always park the truck with the mast (Main and Aux. Lift) fully lowered.
Lower the forks to the ground.
Set the attachment to the home (standard) position.
Turn the truck off with the key switch (20) and remove the key.
4.18.1 Set the attachment to the home position (EKX only)

Traverse the attachment (133) to the right or left limit position of the sideshift
frame (136).
Turn the forks (135) parallel to the sideshift frame (136).
The display unit now shows the symbol for Attachment in home position (134).
133
134
20
135
136
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5 Troubleshooting
This chapter enables the user to identify and rectify basic faults and the effects of
incorrect operation. When trying to locate a fault, proceed in the order shown in
the table.
Fault Possible Cause Action

Truck does Battery connector not Check battery connector and insert
not start plugged in if necessary.
Gates open Close the gates
Emergency Unlock the Emergency Disconnect
Disconnect pressed.
Key switch in 0 Set key switch to I
position
Battery charge too low Check battery charge, charge battery
if necessary
Deadman button not Press deadman button
pressed
Faulty fuse Check fuses
Travel cutout Press travel cutout override pushbutton
activated (charge battery)
Travel cutout Set the travel control knob to neutral and
activated via end of press it again.
aisle safety device
Chains slack See Slack Chain Safety Device Override
section in chapter E
Load cannot Truck not operational Carry out all measures listed under
be lifted Truck does not start.
Battery charge too low, Check battery charge, charge battery
lift cutout if necessary
Insufficient hydraulic Check hydraulic oil, top up if necessary
oil
Chains slack See Slack Chain Safety Device Override
section in chapter E
Faulty fuse Check fuses
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Rapid travel Load handler not in Push load handler into home position
disabled home position
Main Lift / Aux. Lift Lower Main Lift / Aux. Lift below 0.5 m
raised above 0.5 m
WG search mode Align truck or turn off WG mode
activated Perform lifting and lowering
No reference run
performed
Truck cannot Truck not operational Carry out all measures listed under Truck
be steered does not start.
Narrow aisle mode Switch off narrow aisle travel function
switch pressed
I 1901 Travel control button Do not apply travel control button,
pressed during power- switch truck on and off again
up test
I 2902 Hydraulic control Do not apply travel control button,
button applied during switch truck on and off again
power-up test
I 3670 Truck has abandoned Restore wire guidance
the guide wire (see "Wire guidance emergency mode
(event message I 3670 / I 3752)" in
chapter E).
I 3752 Truck has abandoned Restore wire guidance
the guide wire (see "Wire guidance emergency mode
(event message I 3670 / I 3752)" in
chapter E).
I 4916 A pushbutton below Do not press pushbutton, switch truck on
the display unit and / and off again
or a pushbutton on
the numerical keypad
pressed during the
power up test
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I 4917 A pushbutton / function Do not press the pushbutton / function
pre-select button pre-select button (switch guidance on/off,
(switch guidance on/ Aux. Lift raise / lower, fork carriage rotate,
off, Aux. Lift raise / traverse attachment), switch the truck off
lower, fork carriage and on again.
rotate, traverse
attachment) pressed
during power up test
I 4918 Deadman button Do not press the deadman button, switch
pressed during power- truck off and on again
up test
E 9963 Front screen of Front screen of Personal Protection
Personal Protection System (PPS) laser scanner dirty, clean
System (PPS) laser
scanner dirty
E 9901 The Personal Carry out a cycle test on the Personal
Protection System Protection System, see Daily Checks
cycle test does not before starting the Personal Protection
have to be performed. System in chapter E
Z If, after carrying out the remedial action, the truck cannot be restored to operation or
if a fault in the electronics system is displayed with an error code, contact the
manufacturers service department.
Further remedial work should only be carried out by the manufacturers trained
service personnel. The manufacturer has a customer service department specially
trained for these tasks.
In order for customer services to respond quickly and specifically to the fault,
the following information is essential:
- Truck serial number
- Error number on the display unit (if applicable)
- Error description
- Current location of truck.
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5.1 Emergency stop device
When the automatic emergency stop device applies (e.g. if the wire guidance is lost,
electrical steering fails) the truck brakes to a halt. Before starting again, the cause of
the error must be identified and corrected. Start the truck again in accordance with
manufacturers instructions contained in these operating instructions (see Starting
up the Truck in Chapter E).
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5.2 Drivers cab / Aux. Lift emergency lowering
F Automatic lowering can cause accidents

If the load handler is in the rack emergency lowering must not be performed. Due to
leakage from the hydraulic system there is also the risk that the rack could be
damaged by the load handler lowering.
Prevent the load handler from lowering further, e.g. with strong chains.
Arrange for trained personnel to recover the truck as soon as possible.
F Accident risk during emergency lowering

When using emergency lowering, make sure that there is no one present in the
danger zone. If a second person is used to lower the load handler via the emergency
lowering device, this person must consult with the driver. Both people must be in a
safe area to avoid danger. Emergency lowering of the drivers cab is prohibited when
the load handler is in the rack.
Set the attachment to the home position, see Attachment in Home Position in
chapter E.
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E 112
If necessary, a second person can be deployed to lower the cabin from the ground.
Remove the Allen key (138) from the bracket in the centre below the strobe.
Insert the Allen key (138) into the hole to the left below the strobe.
F Trapping risk during emergency lowering

When an emergency lowering of the driver's cab is being performed, there is
a trapping risk to the driver in the cab.
Keep the whole of your body inside the cab.
Using the Allen key (138):

Turn the drain valve (137) slowly anti-clockwise:
The mast / driver's cab lower.
Turn the drain valve clockwise as far as it will go:
Lowering is stopped.
137
138
F The truck may only be started again once the error has been localised and rectified.
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5.3 Slack chain safety device override
Z The slack chain safety device applies when a chain is not tensioned, or slack.
For example, a chain can become slack when the load handler or the cab are
attached, when the chain is loosened and/or breaks.
Raising the Main Lift when the slack
chain device device is activated 1 145
Z Main Lift lower is disabled when the

slack chain safety device is activated.

Press and hold down on the
pushbutton (24) below the "slack
chain safety device override"
symbol (145).
Turn the hydraulic control button (1) to
the left.
24
Raise the Main Lift slightly
(approx. 0.25 m) until the "slack chain safety device override" symbol (145) is no
longer displayed.
If necessary set the attachment to the home position (see Attachment in Home
position section in Chapter E).
F If the "slack chain safety device override" symbol does not disappear after the
Main Lift has been raised approx. 0.25m, the truck can only be started again when
the fault has been identified and rectified.
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5.4 Travel cutout override (o)
Z The travel cutout override symbol (146) is illuminated in the driver's display
whenever further travel is inhibited beyond a certain lift height or area. If however the
position of the truck needs to be adjusted with respect to the rack in order to stack or
retrieve a load, proceed as follows:
F The truck can cause accidents

Travel cutout is an additional function designed to support the operator, but which
does not release him from any responsibility, e.g. to monitor braking at the aisle end
and if necessary to apply the brakes.
Operating the truck in the event of a

travel cutout 146 12

pushbutton (24) below the "travel
cutout override" symbol (146).
Turn the travel control knob (12)
slowly to the right:
Travel in load direction.
Turn the travel control knob (12)
slowly to the left:
Travel in drive direction. 24
The truck can now move at crawl
speed.
Z When you have pressed the pushbutton (24) below the override symbol, various
travel / hydraulic speeds and directions can be released. The override functions can
be adjusted by the manufacturer's customer service department.
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5.5 Lift cutout override (o)
Z If local conditions require, an automatic lift cutout can be installed to be activated from
a given lift height. The automatic lift cutout, which is active from a fixed height,
prevents the Main and Auxiliary Lifts from raising. The driver's display shows the
"lift cutout override" symbol (149).
M An extended mast can cause accidents

The lift cutout is an auxiliary function designed to support the operator which however
does not release him from his responsibility to stop hydraulic operations e.g. when
confronted with an obstacle.
Z The lift cutout only takes effect when referencing has been carried out
(see Referencing the Main and Auxiliary Lift in chapter E). When referencing has
been completed, the height actual value is shown in the driver's display.
F Accident risk
If the lift cutout is deactivated, the driver must pay particular attention to obstacles
when the mast is extended.
Lift cutout override

1 147
pushbutton (24) below the "lift cutout
override" symbol (147).
the left.
The Main or auxiliary lift is raised. Lift
cutout is deactivated.
Z The lift cutout is re-activated each time

the mast falls below the lift limit height. 24
Z When you have pressed the

pushbutton (24) below the override symbol, various travel / hydraulic speeds and
directions can be released. The override functions can be adjusted by the
manufacturer's customer service department.
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5.6 Lower cutout override (o)
If local conditions require, an automatic lower cutout can be installed to be activated

from a given height. The automatic lower cutout, which is active from a fixed height,
prevents the Main and Auxiliary Lifts from lowering. The driver's display shows the
"lower cutout override" symbol (148).
M Risk of injury when the drivers cab or load handler are lowered
The lower cutout is an auxiliary function designed to support the operator which
however does not release him from his responsibility to stop hydraulic operations
e.g. when confronted with an obstacle.
Z The lower cutout only takes effect when referencing has been carried out
(see Referencing the Main and Auxiliary Lift in chapter E). When referencing has
been completed, the height actual value is shown in the driver's display.
F Accident risk
If the lower cutout is deactivated, the driver must pay particular attention to obstacles
when the driver's cab or load handler are lowered.
Lower cutout override

1 148
Press and hold down on the pushbut-
ton (24) below the "lower cutout over-
ride" symbol (148).
the right.
The Main or auxiliary lift is lowered.
The lower cutout is deactivated.
Z The lower cutout is re-activated each

time the mast is raised above the lower 24
cutout height.
Z When you have pressed the pushbutton (24) below the override symbol, various
travel / hydraulic speeds and directions can be released. The override functions can
be adjusted by the manufacturer's customer service department.
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5.7 Aisle end safety device (o)
Trucks with the end of aisle safety device brake before the aisle exit or in the transfer
aisle. There are two basic versions for this:
1. Braking to a halt
2. Braking to 2.5 km/h
Other variants (affecting the subsequent travel speed, lift height etc.) are available.
F A truck without brakes can cause accidents

End of aisle safety braking is an additional function designed to support the operator,
but which does not release him from his responsibilities such as to monitor braking at
the aisle end and if necessary to apply the brakes.
1. Braking to a halt:
When the truck passes over the aisle end safety devices (RFID, magnets,
reflex markers) in the direction of the end of the aisle, it comes to a halt.
M The stopping distance depends on the travel speed.
To continue travelling:
Briefly release the travel control knob and then apply it again.
The truck can be driven out of the narrow aisle at max. 2.5 km/h.
2. Braking to 2.5 km/h

When the truck passes over the aisle end safety devices (RFID, magnets,
reflex markers) in the direction of the end of the aisle, it brakes to 2.5 km/h and can
be driven out of the narrow aisle at this speed.
M The stopping distance depends on the travel speed.
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5.8 Wire guidance emergency mode (event messages I 3670 / I 3752)
In a wire guidance system if the truck's antenna extends beyond the pre-
determined range of the guide wire, an emergency stop is immediately
induced. The display flashes the "wire guidance fault" symbol and displays
the event messages "I 3670" and "I 3752".
Z If in addition to the "wire guidance fault" symbol the "screwdriver" symbol is also lit,
this indicates that other faults have occurred apart from the wire guidance fault.
The resulting event messages and / or information messages are shown on the
driver's display.
If the truck is travelling parallel to the guide wire, travel is not disabled.
The Acquisition in progress display and the audible alignment signal however
remain permanently on, warning the driver.
Automatic Emergency Stop
If during operation one of the monitors for steering control, steering system,
wire guidance, the safety cutout for the traction electronic system or the power
electronic system applies, the truck safety devices will cause the truck to stop.
To enable the truck to travel again after an Emergency Stop, carry out the following:
Z The display flashes the "wire guidance fault" symbol and displays the event
messages "I 3670" and "I 3752".
Determine the possible cause of the Emergency Stop and rectify it.
Turn the Emergency Disconnect to unlock it.
Z In the driver's display the "wire guidance fault" symbol and event messages "I 3670"
and "I 3752" disappear.
Switch the automatic guidance system back on, see "Negotiating narrow aisles with
wire-guided trucks (o)" in chapter E.
Press the switch guidance on/off button.
Apply the travel control knob and carefully align the truck with the guide wire.
Z The truck is now operational and aligned with the guide wire.
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Z If you cannot start the truck again after an automatic Emergency Stop, despite having
rectified the problem, turn the key switch off and on again.
Carry out a mast reference operation (see Referencing the Main and Auxiliary Lift
in Chapter E) and perform the above points.
The truck is now operational again.
Z When the truck is operational again, test it with both manual steering (outside the
aisle) and automatic guided steering.
Manual Emergency Stop
A manual Emergency Stop is induced when the Emergency Stop button is pressed.
The truck is operational again when the Emergency Stop has been released.
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5.9 Recovering the truck from a narrow aisle / Moving the truck without a battery
F This operation must only be performed by suitably trained maintenance personnel.

When the brakes are de-activated the truck must be parked on a level surface,
since the brakes are no longer effective.
M If the brakes are not working, place wedges underneath the wheels of the truck to
prevent it from moving.

See Attachment in Home Position in Chapter E.
Fully lower the mast (Main and auxiliary lift).
F Before recovering the truck from a narrow aisle, disconnect the battery.
Z Obtain assistance from another person. The other person must be trained and
familiar with recovery operations.
To recover the truck from the narrow aisle, the drive wheel brake and the load wheel
brake must first be released.
M When using the truck again, check its deceleration rate.

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5.9.1 Releasing and applying the drive wheel brake
150
151
150
153
154
F Uncontrolled truck movement

Do not release the brake on slopes or inclines.
Apply the brake again when you reach your destination.
Do not park the truck with the brake released.
Releasing the drive wheel brake
Switch off the truck with the key switch.

Press the Emergency Disconnect.
Disconnect the battery.
Remove the drive compartment panel, see "Drive panel disassembly / assembly"
in chapter F.
Disassemble the setscrews (150) from the bracket (151) above the magnetic
brake (153).
Insert the setscrews (150) into the magnetic brake (153) above the drive
motor (154) and tighten them with the hex. nut to release the magnetic brake (153).
The magnetic brake (153) is now released.
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Activating the drive wheel brake

lowering forks.

Remove the setscrews (150) from the magnetic brake (153).
Attach the setscrews (150) to the bracket (151) above the magnetic brake (153).
in chapter F.
The drive wheel brake can now be applied without current.

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5.9.2 Releasing and applying the load wheel brake
51
155
52
156
159 158 157 156
F Uncontrolled truck movement

Do not release the brake on slopes or inclines.
Apply the brake again when you reach your destination.
Do not park the truck with the brake released.
Releasing the load wheel brake

Disassemble the wheel cover (159) by unscrewing three hex. bolts per load
wheel (158).
Z The load wheel (158) has five notches (157) which are arranged so that for each
position of the load wheel (158) at least three out of nine possible thread holes (156)
can be accessed by the load wheel brake.
Loosen the twist grip screws (52) below the driver's seat (51).
Tilt the drivers seat (51) forward carefully.
Remove the setscrews from the storage compartment (155) behind the driver's
seat (51).
Z For each load wheel (158), screw in three setscrews with an angle offset of 120
loosely into the thread holes (156) of the load wheel brake.
Insert the setscrews loosely into the thread holes (156) of the load wheel brake and
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tighten them by no more than half a turn.

The load wheel brake is now released.
E 124
Applying the load wheel brake

lowering forks.

Remove the setscrews from the thread holes (156) of the load wheel brake.
Store the setscrews in the storage compartment (155) behind the driver's seat (51).
Tilt the driver's seat (51) back and attach it to the driver's cab with the twist grip
screws (52).
Fit the wheel guard (159).
The load wheel brake can now be applied without current.

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5.9.3 Steering the truck without its own drive system
M The truck may not be able to be

steered if the steering system is
damaged.
F The battery must be disconnected

when adjusting the steering angle.
Remove the drive compartment

panel, see "Drive panel disas-
sembly / assembly" in chapter F. 160
Using an Allen key set the
steered wheel to the required
direction via the screw in the
steer motor (160).
Z When setting an angle greater

than 4 degrees it is advisable to
discharge the wheel by raising /
jacking up the truck.
F The truck may only be started

again once the error has been
localised and rectified.
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5.9.4 EKX - Recovery in load direction
Load direction
Drive direction
164 163 162 139 161

Switch off the truck via the key switch and disconnect the battery.
Release the drive brake and load wheel brake, see Releasing and activating the
drive wheel brake and Releasing and activating the load wheel brake in
chapter E.
Guide the tow rope (161), tow force > 5 tonnes, around the Aux. Lift mast (139).
F The tow rope (161), tow force > 5 tonnes, must be guided around the lowest point of
the auxiliary mast (139).
Recover the truck carefully and slowly.
F The truck can only be steered without its own drive system when it is idle
(see Steering the Truck without its own Drive System). Do not stand between the
tow truck and the truck to be recovered during a recovery operation.
After recovery, prevent the truck from accidentally moving.
To do this unscrew the setscrews from the drive brake and load wheel brake and
attach them to their bracket or store them in their compartments, see Releasing and
activating the drive wheel brake and Releasing and activating the load wheel brake
in chapter E. If the brake is not working, secure the truck to prevent it from moving
accidentally by placing wedges against the wheels.
The truck may only be started again once the error has been localised and rectified.
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5.9.5 EKX - Recovery in drive direction
Load direction
Drive direction
164 163 162 139 161

in chapter F.
chapter E.
Guide the tow rope (164), tow force > 5 tonnes, around the recess in the truck
chassis (163) (see illustration).
M Risk of damage from the tow rope

Do not route the tow rope (164) over the tailgate (162) as the tailgate (162) is not
designed for recovery operations and will get damaged.
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5.9.6 EKS - Recovery in load direction
161a
Load direction
Drive direction
164 163 162 162b 162a 161b

chapter E.
M Risk of damage from tow ropes

During recovery route the tow ropes to the front in such a way as to avoid damaging
the hydraulic lines, the mast cable, the mast and the driver's cab.
Sling the tow ropes (161a,161b), tow force > 5 to, around both sides of the mast
cross member (162b) (see illustration).
Route the tow ropes (161a, 161b) around the outside of the mast (162a) and past
the driver's cab to the front (see illustration).
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5.9.7 EKS - Recovery in drive direction
161a
Load direction
Drive direction
164 163 162 162b 162a 161b

in chapter F.
chapter E.
Guide the tow rope (164), tow force > 5 tonnes, around the recess in the truck
chassis (163) (see illustration).
M Risk of damage from the tow rope

Do not route the tow rope (164) over the tailgate (162) as the tailgate (162) is not
designed for recovery operations and will get damaged.
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6 Exiting the driver's cab with the rescue equipment
Industrial trucks with a driver's cab which can be raised more than 3 m off the ground
have an emergency lowering mechanism and a rescue equipment (rescue harness /
abseil device / rescue rope) for the driver which can be used to reach the ground
should the operator position be blocked.
Z If the drivers cab cannot be lowered due to a fault, not even with the emergency
lowering (see Drivers Cab Emergency Lowering in chapter E), the operator must
exit the driver's cab via the emergency abseil device.
F Untrained personnel and non-serviced rescue equipment can result in

accidents and injury
The rescue equipment (rescue harness / abseil device with rescue rope) should only
be used by people who are physically capable, trained to use the equipment safely
and who have the required expertise.
The user must have a rescue plan listing all necessary action to be taken in
emergencies.
The driver must undergo annual training in how to handle the rescue equipment.
For the operation and service intervals of the rescue harness and the emergency
abseil device, refer to the accompanying operating instructions.
Follow the maintenance intervals stated in rescue harness and emergency abseil
device operating instructions.
Z The Jungheinrich AG customer service department is specially trained for these

operations.
1010.GB
E 131
6.1 Rescue equipment storage compartment in the driver's cab
Z The rescue equipment is located in the

storage compartment behind the driver's
seat.
Loosen the twist grip screws (52) on the left
and right below the driver's seat (51).
Tilt the drivers seat (51) forward
(arrow direction).
Remove the rescue equipment from the
open storage compartment.
51
52
6.2 Rescue equipment testing / servicing
F Unchecked rescue equipment can result in accidents

The rescue equipment (rescue harness / abseil device and rescue rope) must be
inspected by the manufacturer or an authorised person (specialist) after every
rescue operation (not practice).
The rescue equipment (rescue harness / abseil device) must be checked at least
annually by the manufacturer or an authorised person (specialist).
More regular inspections may be required if the rescue equipment is used frequently
or is subject to heavy duty usage (e.g. environmental or industrial factors affecting
the material).

operations.
F No modifications or additions may be made to the rescue harness and abseil device.
1010.GB
E 132
6.3 Rescue equipment service life
6.3.1 Rescue equipment useful life
Rescue harnesses have a service life of 8 years under normal operating conditions
or if the harness is not used.
6.3.2 Rescue device service life
Rescue ropes have a useful life of 6 years under normal operating conditions or if they
are not used.
Z The exact service life of the abseil device, karabiner hook and screw lock karabiner
depend on the application and ambient conditions.
6.4 Rescue equipment storage and transportation
F Incorrectly stored rescue equipment can cause accidents

The storage of the rescue equipment has a considerable effect on its service life.
Store the rescue equipment in the truck's storage compartment. This is will ensure
that the equipment is protected from damp, heat and UV radiation and can be
reached in emergencies.
Avoid contact with acid, corrosive fluids and oils.
Protect the rescue equipment from contact with sharp objects.
M Damp harness straps and/or damp rescue rope should always dry off naturally, e.g. in
a well-ventilated, shady location. Do not dry wet items of equipment in tumble dryers,
near fires or other heat sources.
To transport the rescue equipment always use a secure equipment bag or case to
prevent damage caused by external influences.
1010.GB
E 133
6.5 Rescue equipment description / application (- 07.09)
The rescue equipment consists of an RG 16-E rescue harness, an AG 10 S abseil

device and a pre-assembled rescue rope with karabiner hooks and a secured
end knot.
F Improper use of the rescue equipment can cause accidents

The rescue equipment must not be used as a fall protection restraint harness.
The rescue equipment must not be used for collecting purposes and is authorised for
a pay load of up to 150 kg or 1 person.
The rescue harness consists of two leg loops, a back belt and a breast belt with
a clevis type eyelet. The back belt has two shoulder straps made of elastic material
which prevent the operator from sliding down when used. The supporting rubber
harness consist of a 45 mm wide, non-elastic harness material. The rescue harness
has an adjustable breast belt which allows it to be adapted to suit the user. The length
is adjusted via a body friction lock.
Z It can be used in ambient temperatures of -25C to 80C.

The abseil equipment can be used in temperatures between -30C and 60C. If the
device is used in temperatures below 0C it must be protected against humidity to
prevent freezing for example inside the equipment (brake).
1010.GB
E 134
6.5.1 RG 16-E rescue harness
200
200 201 201
202 202
201
204
205
205
Item Description
200 Clevis type eyelet
201 Shoulder strap
202 Longitudinally adjustable breast belt with body friction lock
203 Data plate
204 Posterior and leg belt
6.5.2 RG 16-E rescue harness specifications
Type: RG 16-E
Net weight: 0.6 kg
Capacity: 150 kg
1010.GB
E 135
6.5.3 RG 16-E rescue harness data plate
206 207
XXX
XXXXXXXXXXX XXXXXX 208
209
XXXXXXXXXXX
EN 1497 0158 210
XXXX
XXXX
211 212 213 214 215
Item Description
Indicates that the rescue harness should be used "for rescue
206
purposes only"
207 Type
208 Next inspection
209 Manufacturer
210 Test plaque with details of month and year when next service is due
211 Prototype tested to EN
212 Year of manufacture
213 Factory number (manufacturer's serial number)
214 Reference number of notified test centre
215 Instruction to follow the operating instructions
1010.GB
E 136
6.5.4 AG 10 S abseil device
Item Description
Karabiner hook and union nut (attaching the
216
abseil device to the rescue harness)
216
217 Test plaque
Abseil device (with centrifugal force 217
218
automatic braking for smooth abseiling)
218
219 Data plate
Brake lever 219
220 The brake lever is used by the operator to 220
interrupt / start abseiling.
Rescue rope (static core cladded rope) 221
221
Diameter = 9 mm.
Karabiner hook and union nut (attaching the 222

222
rescue rope to the driver's cab)
6.5.5 AG 10 S abseil device specifications
Type: AG 10 S
Equipment class: A
Permissible abseil height: max: 400 m
Permissible abseil load: 150 kg (one person)
Abseil speed: 0,7 m/s
Net weight: 1,4 kg without rescue rope
1010.GB
E 137
6.5.6 AG 10 S abseil device data plate
223 224
225
XXXXXXXXXXXXXXXX
226
XXX XXXXXXXXXXXXXXXX
EN 341 / EN 1496 227
XXXXXXXX 0158 228
XXXXXXXX
229
XXXXXXXX
230
XXXXXXXXXX
XXXXXXXXX
231
XXXXXXXXXX
232 233 234
Item Description
224 Type
225 Company logo / name
226 Manufacturer's address
227 Reference number of notified test centre
228 Factory number (manufacturer's serial number) / year of manufacture
229 Instruction to follow the operating instructions
230 Abseil height (rescue rope length details)
231 Abseil speed (approx. 0.7 m/s)
232 Equipment class
2 people (max. 225 kg / max. 100 m)
233 Specification of maximum abseil height with 2 people with maximum
overall abseil load of 225 kg
Abseil load (max. 150 kg / max. 400 m)
234 Specification of maximum abseil height with maximum overall abseil load
of 150 kg
1010.GB
E 138
6.5.7 Visual Inspection of the Rescue Equipment
The user must carry out a visual inspection of the rescue equipment (rescue harness /
rescue rope / screw lock karabiner) before each operation. This will ensure that the
rescue equipment is operational and fit for purpose.
F Withdraw the rescue equipment from use if you find any damage or if you are in doubt
as to its functionality. Return the equipment to the manufacturer or a specialist
appointed by the manufacturer for inspection.

operations.
6.5.8 Visually inspecting the RG 16-E rescue harness
The user must carry out a visual inspection of the RG 16-E rescue harness before
each operation. This will ensure that the RG 16-E rescue harness is operational and
fit for purpose.
When carrying out a visual inspection make sure that:
the belt material does not show any signs of damage such as chafing, cracks or
loose thread ends on the seams.
there is no damage to the locks.
the elastic shoulder pads are not worn.
the body friction lock is not damaged.
the eyelet is not corroded, deformed and/or suffering from any other mechanical
damage.
F Withdraw the RG 16-E rescue harness from use if you find any damage or if you are
in doubt as to the functionality of the harness. Return the RG 16-E rescue harness to
the manufacturer or a specialist appointed by the manufacturer for inspection.

operations.
1010.GB
E 139
6.5.9 Visually inspecting the AG 10 S abseil device
The user must carry out a visual inspection of the AG 10 S abseil device before each
operation. This will ensure that the AG 10 S abseil device is operational and fit
for purpose.
The data plate is present and legible.

the abseil device is not corroded, deformed and/or suffering from any other
mechanical damage.
The abseil device does not have excessive traces of wear.
All cheese head screws are present and tight.
The integrated length of the screws shows if one of the screws is loose. If a loose
screw is found during the inspection it must be tightened with an appropriate
wrench (accessories set). If not all the screws are present, withdraw the abseil
device from service.
the abseil device does not have excessive traces of wear.
There is no wear / abrasion on the rope inlet and outlet points.
The rope inlet and outlet points should have no more than 2 mm abrasion
(detected by finger), otherwise the abseil device must be withdrawn from use.
Z Worn material has a frayed, smooth and shiny surface. Abrasion causes a clear
trough formation in the material.
F Withdraw the AG 10 S abseil device from use if you find any damage or if you are in
doubt as to the functionality of the abseil device. Return the AG 10 S abseil device to

operations.
1010.GB
E 140
6.5.10 Testing the brake lever
The brake lever must always be tested and its condition checked before it is used.
This will ensure that the abseil device is operational and fit for purpose.
When carrying out the visual inspection make sure the brake lever is not corroded,
physically damaged, deformed and/or cracked.
In addition, test the brake lever:
Do not apply the brake lever.

Pull the end of the rope with the karabiner hook away from the abseil device.
The rescue rope should not slip through the abseil device. If it does, withdraw the
abseil device from service immediately and return it to the manufacturer or
manufacturer's authorised specialist for examination.
F Withdraw the abseil device from use if you find any damage to the brake lever or if
you are in doubt as to the functionality of the brake lever. Return the abseil device to

operations.
1010.GB
E 141
6.5.11 Test the centrifugal brake
The centrifugal brake must always be tested before it is used. This will ensure that
the abseil device is operational and fit for purpose.
Press the brake lever down and hold it in this position.

Pull the end of the rope with the karabiner hook approx. 1.0 m away from the abseil
device. You should feel a resistance due to the centrifugal brake.
Release the brake lever.
Pull the end of the rope with the karabiner hook further away from the abseil device.
The brake lever should automatically revert to the default "Stop" position.
F A non-functional centrifugal brake can cause accidents

If the rescue rope can be pulled through the abseil device without any resistance or
if the brake lever is not pushed up to the "Stop" default position, withdraw the abseil
device immediately from service and return it to the manufacturer or manufacturer's
authorised specialist for examination.
If the abseil device jams and the rescue rope cannot be pulled through the abseil
device (despite pressing the brake lever down and holding it in this position),
you must also withdraw the abseil device immediately from service and return it to the
manufacturer or manufacturer's authorised specialist for examination.

operations.
1010.GB
E 142
6.5.12 Visual inspection of rescue rope with karabiner hook
The user must carry out a visual inspection of the rescue rope and karabiner hook
before each operation. This will ensure that the rescue rope is operational and fit
for purpose.
F Withdraw the rescue rope or karabiner hook from use if you find any damage or if you
are in doubt as to their functionality. Return the rescue rope and karabiner hook to the
manufacturer or a specialist appointed by the manufacturer for inspection.

operations.
Visual inspection of the karabiner hook
When carrying out the visual inspection make sure the karabiner hook is
not corroded, physically damaged, deformed and/or cracked.
Also check the functionality of the lock (catch) and the rivet on the karabiner hook.
The union nut must open and close easily.
The lock (catch) on the karabiner hook must be restored to its original position after
manual opening.
1010.GB
E 143
Visual inspection of the rescue rope
Check that the end knot is present and secured to the end of the rope by the cable tie.
There must be a knot at the end of the rope so that the rescue rope does not run out
of the abseil device during abseiling.
The stitching on the rope end with the karabiner hook must be in good condition.
When carrying out the visual inspection make sure that the rescue rope does not
show any of the following signs of physical damage, defects or heat/chemical
damage etc.:
Interfaces,
Fibre damage,
Swelling,
Twisting,
Excessive wear suchas fluff,
Sheath displacement,
Open, loose end connections,
Loops,
Knots,
Burnt parts,
Decayed parts.
Z Check the rescue rope for the above features before dropping it. Do this by letting the
rescue rope drop through your hands.
Z Brake dust produced from work performed on the brakes is conducted away from the
abseil device via the rescue rope inlet and outlet points due to the open position of
the brake unit in the equipment housing. In addition, material abrasion on the
equipment housing (aluminium dust) caused by the equipment operation is
conducted away in the same manner. This can cause the rescue rope to turn black.
However, this colouration has no negative effect on the rope's properties.
1010.GB
E 144
6.5.13 Putting on the RG 16-E rescue harness
Remove all objects from your trouser pockets.

Remove the lead seal.
Remove the rescue equipment from the equipment bag or case.
Carry out a visual inspection of the rescue equipment, see previous section:
"Visual Inspection of the Rescue Equipment".
The back belt must be facing the back and the leg
straps facing the front.
Hold the rescue harness in front of your body with
one hand on the clevis type eyelet.
To facilitate handling, place the rescue harness
gently on the ground and using your free hand pull
the back belt gently backwards.
Put both legs in the leg straps, one after the other.
Meanwhile keep holding onto the clevis type eyelet
on the breast belt.
Pull up the clevis type eyelets on the breast belt to

position the leg straps directly under your bottom.
Now put on the two elastic shoulder straps. These
prevent the operator from slipping out when using
the belt.
The back belt is automatically positioned when the
two shoulder straps are in place.
Adjusting the breast belt enables the rescue

harness to be adapted to the operator's body size.
The harness material can be pulled tighter at the
loose end through the body friction lock.
Make sure the rescue harness is comfortable and
not fitted too tight against the body.
1010.GB
E 145
6.5.14 Exiting the driver's cab with the rescue equipment
139 20 21
216 218 220 221 222
Switch off the truck with the key switch (20).

Take the abseil device (218) and rescue harness from out of the storage
compartment, see "Rescue equipment storage compartment in the driver's cab" in
Chapter E.
Z The assembled rescue equipment is ready for use on breaking the seal, removal from
the equipment bag or case and after carrying out a visual inspection of the belt, abseil
device and rescue rope.
Carry out a visual inspection of the rescue harness, abseil device, rescue rope and
screw lock karabiner, see "Visual Inspection of the Rescue Equipment" in
chapter E.
Put on the rescue harness, see "Putting on the RG 16-E rescue harness" in
Chapter E.
Insert the karabiner hook (222) of the rescue rope (221) into the eyelet (to EN 795)
on the overhead guard (139) and secure it with the union nut.
Insert the karabiner hook (216) of the abseil device (218) into the eyelet on the
rescue harness and secure it with the union nut. Make sure that the descending
person can operate the abseil device (218) while abseiling.
1010.GB
E 146
216
218
220
221
222
F Insufficient rescue rope can result in accidents

The rope must reach the ground, otherwise you must not abseil down it.
F Rescue rope can tear, resulting in accidents

The rope must pass over fixed objects. It must not pass over sharp edges.
Use a border guard for abseiling over sharp edges.
Store the rescue equipment in the truck's storage compartment. This will ensure
that the rescue rope is protected from damp, heat and UV radiation.
Avoid contact with acid, corrosive fluids and oils.
Protect the rescue equipment from contact with sharp objects.
1010.GB
E 147
Abseiling
216
218
220
221
222
Throw the rescue rope (221) down to the ground so that it is free of knots
(except for the end knot).
Pull the rescue rope (221) taut. The rescue rope (221) should be free to run in and
out of the rope inlet and outlet points on the abseil device.
M Risk of accidents from abseiling

Always use the rescue harness to abseil.
Avoid slack rope to keep the fall distance as short as possible.
Do not fall into loose rescue rope or jump from the operator position into the
rescue rope.
Watch out for obstacles when abseiling.
Z Make sure that the person exiting the driver's cab does so slowly to avoid swinging
on the rescue rope.
Exit with both feet firmly on the edge and facing towards the truck.
Z The default position of the brake lever (220) on the abseil device (218) is Stop,
which indicates that the device is not ready to descend.
To abseil, press the brake lever (220) on the abseil device (218) down.
Z The abseil speed is automatically governed by a centrifugal brake.
To stop abseiling, release the brake lever (220). The brake lever (220)
automatically reverts to the default "Stop" position. Abseiling is interrupted.
M When abseiling take care to avoid obstacles.

inspected by the manufacturer or an authorised person (specialist) after every rescue
operation (not practice).
1010.GB
E 148
6.6 Rescue equipment description / application (07.09 -)
The rescue equipment consists of an ARG 30 rescue harness, a MARK 1 abseil

device, a connector (OVALINK 8 screw lock karabiner ) and a pre-assembled rescue
rope with karabiner hooks and a secured end knot.
The rescue equipment must not be used for collecting purposes and is authorised for
a pay load of 30 - 150 kg or 1 person.
F Improper use of the rescue equipment can cause accidents

The rescue equipment must not be used as a fall protection restraint harness.
6.6.1 ARG 30 rescue harness
If the driver's cab cannot be lowered due to a fault, the ARG 30 rescue harness in
conjunction with the abseil kit (abseil device and rescue rope) can be used to rescue
individual people from the faulty truck.
The ARG 30 rescue harness consists of two adjustable leg and should straps, a chest
strap with a D ring and a back strap with a D ring. The supporting rubber harness
consist of a 45 mm wide harness material.
Adjust the chest and leg straps to achieve optimum adjustment of the ARG 30 rescue
harness. The length of the chest strap / leg straps can be adjusted with clip-on
buckles.
Z The temperature-dependent application area of the ARG 30 rescue harness ranges

from ambient temperatures of -23 C to +60 C.
1010.GB
E 149
250
251
252
253
254
255
Item Description
250 Adjustable shoulder straps
251 D ring on chest strap
252 D ring on back strap
253 Data plate, see "RG 30-E rescue harness data plate" in Chapter E.
254 Clip-on buckles
255 Adjustable leg straps
6.6.2 ARG 30 rescue harness specifications
Type: ARG 30
Net weight: 1.2 kg
Capacity: One person
Size: UNISIZE
Norm: EN 361 1010.GB
E 150
6.6.3 ARG 30 rescue harness data plate
256 257
258
259 260
261
262
263
264
Item Description
256 Serial number
257 Note: Read operating instructions
258 Type
261 Manufacturer
262 CE mark
263 Next inspection
264 Manufacturers part number
1010.GB
E 151
6.6.4 Service life of the MARK 1 abseil device with rescue rope and OVALINK 8 screw
lock karabiner
If the driver's cab cannot be lowered due to a fault, the MARK 1 abseil device and
rescue rope can be used in conjunction with the ARG 30 rescue harness to rescue
individual people from the faulty truck. The MARK 1 abseil device and rescue rope
must not be used for collecting purposes.
The MARK 1 abseil device consists of a main body to which the controls and brake
unit are attached. The bottom area of the body contains a D-ring to which a fastener
(OVALINK 8 screw lock karabiner) can be attached in accordance with EN 362.
The MARK 1 abseil device is authorised for a pay load of 30 - 150 kg, i.e. 1 person.
One end of the rescue rope has a karabiner hook while the other has an end knot.
The end knot is secured by a cable tie and prevents the rescue rope from running out
of the abseil device. The rescue rope data plate is located below a transparent
protective hose on the rope end of the karabiner hook.
The OVALINK 8 screw lock karabiner (in accordance with EN 362) is used to connect
the "MARK 1" abseil device to the ARG 30 rescue harness. The lock is secured with
a threadlocker to prevent it from releasing accidentally during operation.
Z The temperature-dependent application range for the MARK 1 abseil device,

rescue rope and OVALINK 8 screw lock karabiner varies from -35 C to +60 C.
1010.GB
E 152
Item Description
Rescue rope with karabiner hook (to attach 265
265 the MARK 1 abseil device to the truck) and
266
secured end knot
267
266 Brake cam
267 MARK 1 abseil device

268
268 Control handle
D ring for fastener (karabiner / screw lock 269
269
karabiner)
OVALINK 8 screw lock karabiner to attach 265
270 the MARK 1 abseil device to the ARG 30 270
rescue harness
271 End knot 271
272 Cable tie 272
6.6.5 MARK 1 abseil device specifications
Type: MARK 1
Net weight: 0.35 kg (excl. rope)
Capacity: One person (30 kg - 150 kg)
Max. abseil height: 200 m
in accordance with EN 341: 11 mm
Rope diameter: in accordance with EN 12841: 10 to
12 mm
Static rope in accordance with EN 1891
Authorised rope type:
type A
EN 341 category A
Norm:
EN 12841 Type C
1010.GB
E 153
6.6.6 Specifications of rescue rope and karabiner hook
Type: PARALOC Static 12.0

Net weight: approx. 1.5 kg
Material: Polyamine (PA)
Length: 17.5 m
Rope diameter: 12 mm
Rope type: Semi-static rope
Norm: EN 1891 type A
6.6.7 OVALINK 8 screw lock karabiner specifications
Type: OVALINK 8
Net weight: approx. 0.04 kg
Dimensions: 74 x 39 mm
EN 362 / Q
Norm:
EN 12275
6.6.8 MARK 1 abseil device housing specifications
Item Description
273
01
23
274 273 CE mark
DSD 30+25
30-150kg
max. 200m
274 Abseil device type
275
EN 341 CLASS A
ROPE 11mm
EN 12841 Type C
10 12mm
275 Rope diameter / max. abseil height
276
276 Pictogram (insert rope)
277
1010.GB
E 154
6.6.9 Rescue rope data plate
278
279
280
281
282
283
284 285
Item Description
278 Serial number
279 Type
282 CE mark
283 Manufacturer
284 Manufacturers part number
285 Note: Read operating instructions
1010.GB
E 155
6.6.10 Visual Inspection of the Rescue Equipment
The user must carry out a visual inspection of the rescue equipment (rescue harness /
rescue rope / screw lock karabiner) before each operation. This will ensure that the
rescue equipment is operational and fit for purpose.
F Withdraw the rescue equipment from use if you find any damage or if you are in doubt
as to its functionality. Return the equipment to the manufacturer or a specialist
appointed by the manufacturer for inspection.

operations.
6.6.11 Visual inspection of the ARG 30 rescue harness
The user must carry out a visual inspection of the ARG 30 rescue harness before
each operation. This will ensure that the ARG 30 rescue harness is operational and
fit for purpose.
the load-bearing harness material does not show any signs of damage such
as chafing, cracks or loose thread ends on the seams.
the clip-on buckles are not corroded, physically damaged, deformed and/or cracked.
the D rings on the chest strap and the back strap are not corroded, damaged,
deformed and/or cracked.
the data plate is present and legible.
F Withdraw the ARG 30 rescue harness from use if you find any damage or if you are
in doubt as to the functionality of the harness. Return the ARG 30 rescue harness to

operations.
1010.GB
E 156
6.6.12 Visual inspection of the MARK 1 abseil device
The user must carry out a visual inspection of the MARK 1 abseil device before each
operation. This will ensure that the MARK 1 abseil device is operational and fit
for purpose.

the abseil device is not corroded, deformed and/or suffering from any other
mechanical damage.
the abseil device does not have excessive traces of wear.
the details on the abseil device are clearly legible.
the control handle is not corroded, deformed and/or suffering from any other
mechanical damage.
Also carry out a test on the control handle by pulling the rescue rope, both when the
control handle is not applied and pushed through. The rescue rope should not slip
through the device.
F Withdraw the MARK 1 abseil device from use if you find any damage or if you are in
doubt as to the functionality of the abseil device. Return the MARK 1 abseil device to

operations.
1010.GB
E 157
6.6.13 Visual inspection of rescue rope with karabiner hook
The user must carry out a visual inspection of the rescue rope and karabiner hook
before each operation. This will ensure that the rescue rope is operational and fit
for purpose.
F Withdraw the rescue rope or karabiner hook from use if you find any damage or if you
are in doubt as to their functionality. Return the rescue rope and karabiner hook to the
manufacturer or a specialist appointed by the manufacturer for inspection.

operations.
Visual inspection of the rescue rope
Check that the end knot is present and secured to the end of the rope by the cable
tie. There must be a knot at the end of the rope so that the rescue rope does not run
out of the abseil device during abseiling.
The stitching on the rope end with the karabiner hook must be in good condition.
When carrying out the visual inspection make sure that the rescue rope does not
show any of the following signs of physical damage, defects or heat/chemical
damage etc.:
Interfaces,
Fibre damage,
Swelling,
Twisting,
excessive wear suchas fluff,
Sheath displacement,
Open, loose end connections,
Loops,
Knots,
Burnt parts,
Decayed parts.
Z Check the rescue rope for the above features before dropping it. Do this by letting the
rescue rope drop through your hands.
1010.GB
E 158
Visual inspection of the karabiner hook
When carrying out the visual inspection make sure the karabiner hook is not
corroded, physically damaged, deformed and/or cracked.
Also check the functionality of the lock (catch) and the rivet on the karabiner hook.
The union nut must open and close easily.

The lock (catch) on the karabiner hook must be restored to its original position after
manual opening.
6.6.14 Visual inspection of the OVALINK 8 screw lock karabiner
The user must carry out a visual inspection of the OVALINK 8 screw lock karabiner
before each operation. This will ensure that the screw lock karabiner is operational
and fit for purpose.

the screw lock karabiner is not corroded, deformed and/or suffering from any other
mechanical damage.
the threadlocker on the lock is not broken or damaged.
F Withdraw the OVALINK 8 screw lock karabiner from use if you find any damage or if
you are in doubt as to the functionality of the screw lock karabiner. Return the
OVALINK 8 screw lock karabiner to the manufacturer or a specialist appointed by the
manufacturer for inspection.

operations.
1010.GB
E 159
6.6.15 Putting on the rescue harness
Preparation:
Remove all objects from your trouser pockets.

Remove the lead seal.
Remove the rescue equipment from the
equipment bag or case.
Carry out a visual inspection of the rescue
equipment, see "Visual Inspection of the
Rescue Equipment" in Chapter E. 3x
Hold the rescue harness in front of your body
with one hand on the D ring.
Open the clip-on buckles (3 off).
Put on the rescue harness:

Put on the rescue harness like a jacket.
Pull the leg straps forward between your legs
and then up.
1010.GB
E 160
Adjust the rescue harness to match the size
of the operator's body:
Close the clip-on buckles (2 off) on the

leg straps.
Guide the clip-on buckle on the chest strap
through the front D ring.
Close the clip-on buckle of the chest strap.
Adjust the rescue harness to fit your individual
3x
size and tighten the straps.
Make sure the leg straps are adjusted so that

you can push your hand flat between the leg
strap and thigh. After adjusting the D ring on
the back strap you be exactly between your
shoulder blades.
Undo the Velcro strip and hence the abseil 4x
device from the rescue harness.

1010.GB
E 161
6.6.16 Exiting the driver's cab with the rescue equipment
Switch off the truck with the key switch (20).

Take the abseil device and rescue harness out of the storage compartment in the
driver's cab, see "Rescue equipment storage compartment in the driver's cab" in
Chapter E.
Z The assembled rescue equipment is ready for use on breaking the seal, removal from
the equipment bag or case and after carrying out a visual inspection.
chapter E.
Put on the rescue harness, see "Putting on the rescue harness" in Chapter E.
Insert the karabiner hook of the rescue rope
into the D ring (in accordance with EN 795) on
the overhead guard and secure it with the
union nut.
1010.GB
E 162
Throw the rescue rope down to the ground
so that it is free of knots (except for the end
knot).
F Insufficient rescue rope can result in

accidents
The rope must reach the ground, otherwise
you must not abseil down it.
F Rescue rope can tear, resulting in

accidents
The rope must pass over fixed objects.
It must not pass over sharp edges.
Use a border guard for abseiling over
sharp edges.
Store the rescue equipment in the truck's
storage compartment. This will ensure
that the rescue rope is protected from
damp, heat and UV radiation.
Avoid contact with acid, corrosive fluids
and oils.
Protect the rescue equipment from
contact with sharp objects.
Abseiling
Pull the rescue rope taut between the
overhead guard and abseil device.
The free rescue rope must be free to run
in and out over the rope inlet and outlet
points on the abseil device.
M Risk of accidents from abseiling

Always use the rescue harness to abseil.
Avoid slack rope to keep the fall distance
as short as possible.
Do not fall into loose rescue rope or
jump from the operator position into the
rescue rope.
Watch out for obstacles when abseiling.
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Z Make sure that the person exiting the driver's cab
does so slowly to avoid swinging on the
rescue rope.
Exit with both feet firmly on the edge and facing
towards the truck.
Z The default position of the control lever on the

abseil device is Stop which indicates that the
device is not ready to descend (see position "A").
To abseil, push the control lever slightly towards

the abseil device (see position"B").
Z The lowering speed depends on the weight of the

user and position of the control lever.
A B C
The maximum descent speed is between 0.4m/sec. and 0.7m/sec.
To stop abseiling, release the control lever (see position"A") or push fully in the
direction of the abseil device (see position"C").
M When abseiling take care to avoid obstacles.

inspected by the manufacturer or an authorised person (specialist) after every rescue
operation (not practice).
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7 Personal Protection System (o)
7.1 Personal Protection System (PPS)
The truck's integrated personal protection system (PSS)

is designed to protect persons. The personal protection
system is used with industrial trucks in warehouse
systems where pedestrians are not permitted to be in
narrow aisles at the same time as industrial trucks
Z The PPS satisfies the requirements of BGV D 27, 28

Section 2, DIN 15 185, part 2 item 3.13. The PPS
corresponds to ISO 13849 PXF Level D for identifying
persons and obstacles. The safety laser scanner
corresponds to laser protection class 1. No other
measures for screening the laser beam are required
(eye protection).
The laser scanner complies with the following norms:
CDRH 21 CFR 1030.10 and DIN EN 60825:2001, where
the following notice is made: Caution Hazardous ray
exposure can result if the operating or adjusting devices used or procedures
performed differ from those contained herein.
National / international regulations apply to the assembly and use of the safety laser
scanner both for commissioning and recurrent technical inspections, in particular:
Machinery Directive 2006 / 42 / EC

Use of Work Equipment Directive 89 / 655 / EEC
Accident prevention / health and safety regulations
other relevant safety regulations
The manufacturer and operators of the machine on which the safety laser scanner is
being used are responsible for agreeing and complying with all valid safety
regulations issued by the relevant authorities.
7.2 Functional description
Mobile personal protection system with laser scanner based obstacle detection.
Apron field protection / collision protection:
Optimum integration in the truck.
Easy adjustment / settings to match warehouse environment.
Automatic speed reduction / stopping in front of obstacles / personnel / other
industrial trucks.
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7.2.1 Standard functions
Crawl speed released when scanner covered (load handler lowered).

Crawl speed released when approaching the last pallet location at a closed narrow
aisle end.
Automatic reduction of maximum speed to 2.5 km/h before exiting the aisle.
Additional stop at aisle end; option of temporary, confirmed, or absolute.
Short range apron field protection
(directly in front of and behind the truck depending on travel direction).
M The personal protection system is not a collision guard in the sense of DIN 15185
part 2 section 3.7.
7.2.2 Special functions depending on the ground conditions
Aisle type identification within a warehouse.

Speed reductions for escape routes within the lane.
Stopping for escape routes within the lane.
Zone change within a lane with short range recognition.
Twin lane width recognition. Protection field change wider monitoring field on
one side.
Option of attaching additional sensors for operator position carriage control with
lower cutout on detection of persons.
7.2.3 Environmental awareness
The safety laser scanner is designed to keep environmental damage to a minimum.

It uses minimal energy and resources. Always act with regard to the environment at
your place of work. Please note the following disposal information.
Disposal:
Always dispose of unusable or irreparable equipment in accordance with your
countrys waste disposal regulations.
Remove plastic parts and send the aluminium housing of the safety laser scanner
for recycling.
Dispose of all electronic components as special waste.
Electronic components are easy to disassemble.
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7.3 Cleaning the front panel of the scanners
7.3.1 Preparation
Scanner under the load axle
Secure the operator position, see Securing the operator position in chapter F.
7.3.2 Cleaning the front panel
Damp clean the front panel.

Additionally, damp clean the connecting lug at the
bottom of the front panel.
Z Dry cleaning carries the risk of static charge. More dust

will be attracted to the front screen. There is also the risk
of scratching the front screen.
Wipe the panel dry using a clean, soft woollen cloth /

micro fibre cloth or a new soft paper towel.
M Do not use dirty or large fibre cleaning cloths as these

can scratch the front screen. This could result in errors
and would require replacing.
After cleaning, hold a light / torch against the front

panel. Check for any contamination / scratching on the front panel, if necessary
clean again.
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7.3.3 Error displays on the seven segment display and indicator light (LED)
Z The seven segment display and the indicator light (LED) on the scanner act as the
display for the operator and the customer service engineer.
Display LED signal Description

Off Protection field clear,
no object in protection field
Lit Object in protection field
Off Warning field clear,

no object in warning field
Lit Object in warning field
Off Front panel clean

Lit Front screen contaminated,
operation inhibited.
clean front panel (see Cleaning the front
panel of scanners in chapter E)
Flashes at one Hz Front screen contaminated,
(one second off, Operation still enabled,
one second on) clean front panel (see Cleaning the front
panel of scanners in chapter E)
Z Other seven segment and indicator light (LED) error displays are relevant only to the
manufacturers service department. Troubleshooting must only be performed by the
manufacturers specialist service engineers. The manufacturer has a customer
service department specially trained for these tasks.
In order for customer services to respond quickly and specifically to the fault,
the following information is essential:
- Truck serial number
- Error number on the seven segment display (if applicable)
- Indicator light (LED) display.
- Error description
- Current location of truck.
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7.4 Daily checks before starting the Personal Protection System
Check the front screens of the personal protection system laser scanners for
contamination and clean as required.
7.4.1 Cycle test
Z To ensure the correct operation of the personal protection system a cycle test must
be carried out every day (24 hour timer). The information message "I 9901" and the
"Perform cycle test" symbol (165b) prompt you to perform the cycle test. During this
time the travel speed is restricted to 2.5 km/h . The speed restriction is only removed
when the cycle test has been performed. In addition, each time the truck is switched
off and on again it automatically performs the cycle test.
Cycle test:
Switch off the truck.
Switch on the truck.
Z When the truck has been switched

on the display unit shows the 165a 165b
Acknowledge cycle test
symbol (165a).
Press the pushbutton (24) below

the Acknowledge cycle test
symbol (165a).
The truck automatically performs
the cycle test.
When the cycle test has been
successfully performed:
the "Perform cycle test" 24
symbol (165b) disappears.
the speed restriction is removed.
the 24 hour timer is reset and starts afresh.
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7.5 Personal Protection System
7.5.1 No obstacles / persons identified
Z If there are no persons and / or obstacles in the PPS warning or protection fields,
the truck can travel at the maximum enabled speed.
7.5.2 Obstacles / persons in warning field
The display unit shows the warning field

infringement symbol (167). The travel 166 167 12
speed is restricted to 2.5 km/h.
Z When the obstacle is removed or the

person has left the warning field, the
truck can travel again at the maximum
speed. The warning field infringement
symbol (167) also disappears.
24
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7.5.3 Obstacles / persons in the protection field
The truck stops. You can only continue travelling by pressing the protective field
infringement symbol (166) and simultaneously turning the travel control button (12)
in the required direction.
The travel speed is restricted to 2.5 km/h.
F Risk of accidents and injury from the truck

Travel cutout override is an additional function to ensure the position of the truck can
be adjusted despite a protection field infringement. However, it does not release the
operator from his responsibility to bring the truck to a halt in good time before it
reaches any obstacles and / or persons.
Z When the obstacle is removed or the person has left the warning field, press the
pushbutton (24) below the protective field infringement symbol (166) to continue at
maximum speed. The protective field infringement symbol (166) also disappears.
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8 EKS 513/515k/515 Stockpicker
The following functions described in chapter E do not apply to the EKS 513/515k/515:
"Traverse (load hander attachment)",
"Swivel / rotate (fork carriage)" and
"Simultaneous load handler traverse and fork carriage swivel".
8.1 Control panel layout
Z The illustrations shown are examples and do not represent the equipment supplied.
Control panel in load direction
Z To operate the truck see "Displays and

controls" in Chapter E.
Control panel in drive direction

Control panel in drive direction with side-stance

Split control panel in load direction
Z The truck is operated in exactly the

same way as detailed in "Controls and
Displays".
The truck is controlled via two control panels.

The controls are described in "Split control
panel controls" and the tilt / height adjustment in
"Split control panel height and tilt adjustment".
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8.1.1 Divided control panel controls
291
290
292 292
293 293
293
293
Item Description
Left control panel
290
Z The left control panel contains the steering wheel,
Emergency Disconnect switch and the hydraulic control button.
Right control panel
291
Z The right control panel contains the travel control button, display unit,
key switch and the keypads (e.g. numerical keypad, cursor keys,...).
292 Infinite tilt adjustment screw
Control panel height adjusting lever (max. 170 mm)
293
Control panel height adjusting button (max. 170 mm)
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8.1.2 Split control panel height and tilt adjustment
Split control panel tilt adjustment
M Do not adjust the inclination of the control panels (290.291) during operation.
Make sure the screw (292) is locked in position after any adjustment.
Undo the screw (292).
M Do not remove the screw (292) fully as it is also used to fasten the control panel.
Set the control panel to the required angle.

Tighten the screw (292).
Split control panel height adjustment
M Do not adjust the height of the control panels (290, 291) during operation.
Make sure the control panel is locked in position after any height adjustment.
Each control panel can be individually height adjusted by pressing the button (293)
or by pulling the lever (293).
Z The height of each control panel can be adjusted by up to 170 mm.
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8.2 EKS 513/515k/515 with load guard and walk-on pallet (o)
F Risk of accidents / crashing when using walk-on pallets

When the gates are opened, the driver's cab can be raised to a fixed height up to a
maximum of 1200 mm. When the gates are closed, the operator position can be
raised to the maximum lift height.
Only walk on pallets with a pallet guard (o).
Beyond lift heights > 1200 mm the gates must be closed to enable travel, lifting and
lowering (Main Lift).
One-way pallets cannot be used as a surface to walk on.
Good ground conditions.
Only use pallets of a suitable size to fit a pallet guard.
8.2.1 Truck equipment - stockpicking platform without pallet lift option
Version A
The stockpicking platform has a closed guard.
The stockpicking platform can only be accessed from the truck.
Version B
295
Z The illustrations shown are examples and do not
represent the equipment supplied.
The stockpicking platform has a guard with side

gates (295).
The stockpicking platform can:
be accessed from truck.
be accessed via the side gates (295) when the
stockpicking platform is lowered.
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Version C
295
295
The stockpicking platform has a guard with

side (295) and front gates (296).
be accessed via the side gates (295) when the
be accessed via the front gates (296) when the
296
Version D

The stockpicking platform has a guard with front

gates (296).
be accessed via the front gates (296) when the
296
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8.2.2 Stockpicking platform with pallet lift option (not monitored, not locked)
Version E
298
297
299
The raised pallet can be accessed from the truck via the gates (298) in the
load direction.
The raised pallet has a side guard (297) but is open at the front.
Version F
297
299
The raised pallet can be accessed from the truck. The truck does not have any
gates in the load direction.
The raised pallet has a side guard (297) but is open at the front.
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Version G
298
297
300
299
load direction.
The raised pallet has a side (297) and a front guard (300).
Version H
301
299 301
The pallet has side gates (301) but is open at the front.
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Version I
298
301
299 301
load direction.
The pallet has side gates (301) but is open at the front.
Version J
301
302
299 301
The pallet has side gates (301).
There is an option for a front guard through the gates (302).
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Version K
301 298
302
299 301
load direction.
The pallet has side gates (301).
There is an option for a front guard through the gates (302).
Version L
303
The raised pallet:

cannot be accessed from truck.
can be reached through the driver's cab extension (303).
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8.2.3 Stockpicking platform with pallet lift option including pallet monitoring
and fixing
Z When pallets, pick boxes or load containers specially designed for the task are raised,
they can be monitored and also fixed. The illustrations shown are examples and do
not represent the equipment supplied.
Raised pallet load sensing version
Raised pallet load sensing via switches or

non-contact sensors. 305
Example:
The "load sensing" switch (305) is located
on the load handler between the forks.
When the load sensing switch (305) is
pressed, the controller is notified that a
pallet has been lifted.
Raised pallet mechanical stop with load

sensing version
Raised pallet load sensing via non-contact 307

sensors.
Requirements:
The pallet must have a pallet stop

bolt (306). 306
The pallet fixing / pallet stop locating
eye (307) must be located on the truck's
load handler.
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Claw with load sensing version
Raised pallet load sensing via switches or 305

non-contact sensors.
The "load sensing" switches or non-contact
sensors (305) are located on the left and
right sides of the load handler.
308
Z The claw (308) is used to fix the pallets.
Clamp with load sensing version

305
Raised pallet load sensing via a switch or
non-contact sensors. The "load sensing"
switch or non-contact sensors (305) are
located on the load handler.
Z The clamp (309) is used to fix the pallets. 309
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8.3 Display of stockpicking platform side and / or front gates and load direction gates
Z The monitored side and / or front gates of the stockpicking platform as

well as the load direction gates are shown on the driver's display,
depending on the use of the load handler (see "Display and Controls" in
chapter E).
Stockpicking platform without

The fitted gates are displayed as a single gate.
pallet lift option
The fitted gates are shown like a side gate,
Stockpicking Platform with
irrespective of whether the pallet or picking box
Pallet Lift Option
has been lifted and locked.
Without a picking box raised and locked, the pallet
Stockpicking platform with lift panel is displayed as a single gate.
panel and pallet lift option With a picking box raised and locked, the pallet lift
panel is not displayed.
Z See also "Control Panel Controls and Displays" in chapter E.

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8.3.1 Example: Monitored and non-monitored gates in load direction (o)
Closed Open
gates gates
311 310
310
311
Access in the load direction is via:
two foldaway, non-monitored gates (310)

two monitored gates (311).
Z The gates (311) are displayed depending on whether the load handler is being used.
Example:
Without a picking box raised and locked, the gates (311) are displayed
as a side gate.
With a picking box raised and locked, the gates (311) are not displayed.
Description and operation of the gates
Without a raised and locked picking box:
with the gate open (311) the operator position can be raised up to 1.2 m
(fixed operator position height).
When the gates (311) are closed, the operator position can be raised to the
maximum lift height.
Z When the picking box is lifted and closed, the operator position can be raised to the
maximum lifting height. The gates (311) are not monitored in this case.
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8.4 Additional symbols in driver's display
The following symbols are displayed depending on the truck's equipment:
Symbol Meaning
Clamp open
Clamp closed, no load clamped
Clamp closed, load clamped
Pallet / picking box raised and / or locked
Claw open
Claw closed
Z When the pallet or picking box is raised and locked by the clamp / claw, Main Lift -
Auxiliary Lift lowering can only be performed using the override button at heights
below 10 cm. This is to avoid damaging the clamp / claw.
8.5 Lifting / depositing a load
driver's cab.
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F Risk of accidents / falling when using walk-on pallets
When the gates are opened, the driver's cab can be raised to a fixed height up to a
maximum of 1200 mm. When the gates are closed, the operator position can be
raised to the maximum lift height.
Only walk on pallets with a pallet guard (o).
Beyond lift heights > 1200 mm the gates must be closed to enable travel, lifting and
lowering (Main Lift).
One-way pallets cannot be used as a surface to walk on.
Only use pallets of a suitable size to fit a pallet guard.
F Risk of accidents / falling when using picking boxes

Without a raised and locked picking box, the driver's cab can be raised with open side
gates up to a maximum of 1200 mm (fixed driver's cab height).
Without a raised and locked picking box, the driver's cab can be raised with closed
gates for pallet lifting to the maximum lift height.
When the picking box is lifted and closed, the operator position can be raised to the
maximum lifting height. The gates for pallet lifting are not monitored in this case.
driver's cab.
M Before a load can be deposited, the driver must ensure that the storage location is
suitable for storing the load (size and capacity).
Z Loads must not be deposited on travel or escape routes, in front of safety

mechanisms or plant equipment that must be accessible at all times.
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8.5.1 Lifting / depositing a load with a mechanical lock on the forks (with or without
load-sensing)
Lifting a load with a mechanical lock on the forks (with or without load-sensing)
Requirements
Truck prepared for operation.

Load unit weight matches the truck's capacity.
Forks evenly loaded.
Procedure

Drive the truck carefully up to the load.
Lower/raise the load handler so that the
load can be lifted. 305
M Risk of injury and accidents

The pallet / picking box must rest fully on the
forks behind the anti-slip mechanisms (299).
Insert the forks slowly into the pallet /
picking box until:
The fork shank is touching the load
(pallet / picking box).
The load is touching the load-sensing
switch (305) (o).
Raise the load slightly until it rests freely 299
on the forks.
Make sure you can see behind you and
that you have sufficient space to move. Now reverse the truck slowly until the load
is clear (e.g. out of the rack).
Z The load has been lifted correctly.

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Depositing a load with a mechanical lock on the forks
(with or without load-sensing)
Requirements
Load unit correctly lifted.
Storage location suitable for the load (size and capacity).
Procedure

Preparing to deposit the load in the rack:
Raise or lower the load handler so that the load can be placed in the storage
location without striking any objects.
Carefully place the load in its storage location.
Z Avoid depositing the load suddenly to avoid damaging the load, load handler and
the rack.
Carefully lower the load handler so that the forks are clear of the load.
Z When reversing make sure the goods are not damaged by the front guard or brought
crashing down.
Carefully remove the load handler from the load.

Z The load has been deposited correctly.
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8.5.2 Lifting / depositing a load with a mechanical lock on the load handler
Lifting a load with a mechanical lock on the load handler

Requirements
Procedure
Z The pallet / picking box must have a pallet stop bolt (306). The pallet retaining /
pallet stop recess (307) must be located on the truck's load handler.

load can be lifted. 307

The stop bolt (306) should enter the recess
in the load handler (307).
306
picking box until:
The fork shank is touching the load
(pallet / picking box).
The stop bolt (306) is in the recess of the load handler (307).
The stop bolt (306) is touching the load-sensing sensor (o).
Raise the load slightly until it rests freely on the forks.
Make sure you can see behind you and that you have sufficient space to move.
Now reverse the truck slowly until the load is clear (e.g. out of the rack).
Z The load has been correctly lifted and is mechanically (306, 307) protected against
slipping.
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Lifting a load with a mechanical lock on the load handler
Requirements
Procedure

Carefully bring the load to its storage location.
the rack.
Lower the load handler sensitively until:

The forks are clear of the load.
The stop bolt (306) can be removed from the recess of the load handler (307).
crashing down.

Z The load has been deposited correctly.
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8.5.3 Lifting / depositing a load with load sensing and a clamp / claw for locking
Lifting a load with load sensing and a clamp / claw for locking
Requirements

Procedure
Press the deadman button. 1 315 316

Open the clamp / claw.
clamp / claw symbol (315/316) while
control button (1) to the left.
load can be lifted.
picking box until: 24
The fork shank is touching the load (pallet / picking box).
The load is touching the load-sensing switch (o).
Slowly raise the load until it is clear of the ground.

Lock the pallet / picking box with the clamp / claw to prevent it from slipping / crashing.
Close the clamp / claw.

Press the pushbutton (24) below the clamp / claw symbol (315/316) while
simultaneously turning the hydraulic control button (1) to the right.
Z When the pallet / picking box is locked, the load cannot be lowered down to
the ground.
Make sure you can see behind you and that you have sufficient space to move.
Now reverse the truck slowly until the load is clear (e.g. out of the rack).
The load has been lifted correctly.

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Depositing a load with load-sensing and a clamp / claw for locking
Requirements

Procedure

Carefully bring the load to its storage location.
Carefully lower the load handler to a height of approx. 10cm above the ground /
rack surface.
Open the clamp / claw.
Press the pushbutton (24) below the clamp / claw symbol (315/316) while
simultaneously turning the hydraulic control button (1) to the left.
the rack.
Carefully lower the load handler so that the forks are clear of the load.
crashing down.

The load has been deposited correctly.
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8.6 EKS 513/515k/515 with auxiliary lift (o)
Z The auxiliary lift is operated as described in "Lift - Lower (Aux. Lift") in chapter E.
Without a raised picking box the load handler can be raised approx. 450 mm with
the auxiliary lift.
With a raised and lock picking box, raising of the auxiliary lift is inhibited when it
reaches the seamless transition from the driver's cab to the pallet / picking box.
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9 Optional equipment
9.1 Rear view mirror (o)
168
Z Use the mirror only to observe the traffic behind you. Should you need visibility aids
(mirrors, monitors etc.) to ensure adequate visibility, practice working with them
beforehand.
The rear view mirror (168) is fitted with a swivel joint. This allows the operator to set
the rear view mirror (168) to suit his individual requirements.
M An incorrectly set rear view mirror can cause accidents

Incorrectly set rear view mirrors can collide with the rack or goods during operation in
the narrow aisle.
Adjust the rear view mirror so that the safety clearances between the truck and rack
are in accordance with EN 1726-2 item 7.3.2.
Minimum 100 mm safety clearance between rail guided truck and rack.
Minimum 125 mm safety clearance between wire guided truck and rack.
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9.2 Rider mode (in the driver's cab) (o)
In chapter E of the operating instructions: Safety Regulations for the Operation of

Forklift Trucks the section Unauthorised use of truck strictly prohibits the carrying
of passengers in the driver's cab and on the load handler.
M If the truck is equipped for passenger mode with an additional control panel
(two-hand operation), a second person may be allowed in the driver's cab in
exceptional circumstances.
The driver must instruct the passenger how to operate in passenger mode and
inform him of potential hazards.
Example:
Do not lean out of the driver's cab while travelling or lifting / lowering.
F A second person can only be transported if there is an additional control panel for the
passenger in the driver's cab. This control panel monitors the "two-handed operation"
of the passenger.
The additional control panel should only be added to activate passenger mode on
the truck.
If unused, the control panel must be kept safe by an appointed person.
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9.2.1 Operation
Z The driver must check the passenger mode safety mechanisms before starting to
travel. If one of the safety mechanisms is not functional, passenger mode must not
be activated. Notify the manufacturer's customer service department.
F The two-hand control switches on the additional control panel must be operational at
all times.
If in exceptional circumstances, a second person is allowed to ride in the drivers cab

with the owners permission, proceed as follows.

Attach the additional control panel to the side panel in the driver's cab.
Establish an electrical connection between the truck and the additional control panel.
Switch on the truck with the key switch.
During operation (travel / lifting / lowering) the passenger must depress the
switches on the additional control panel with both hands (two-hand control).
Z If at any time while travelling or carrying out a hydraulic operation the two-hand
operation switches installed for passenger mode are not pressed, travel and/or
hydraulic operations are deactivated.
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9.3 Weigher (o)
Z The truck can be fitted optionally with a

weighing system. When the load has
been lifted, the weight [in kg] (187) is
187 XX kg
shown on the display unit.
M The weighing system is not a substitute

for a calibrated weigher.
9.3.1 Tare function (o)
Z The weighing system can optionally be

equipped with tare function. The tare
1 72 189 190 11
function sets the weigher display to zero.
Display zero setting: 0

Without load raise the Main Lift
approx. 10 cm:
Turn the hydraulic control button (1)
to the left.
Without load raise the Aux. Lift
approx. 10 cm: 23 24 187 71
Press the Aux. Lift
pushbutton (11) and simultane- 0 kg
ously turn the hydraulic control

button (1) to the left.
Press the "Quit sub-menu"
pushbutton (23).
Z Truck movement is inhibited in this

truck menu.
The display unit shows the "Weigher display zero setting" symbol (189).
Press the pushbutton (24) next to the "Weigher display zero setting" symbol (189).
Press the pushbutton (71) below the truck functions symbol (190). The display
unit changes to the "truck functions" menu.
The weight measurement in the driver's display unit is zero (187).
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9.4 Using a work platform (o)
The truck's operating instructions, chapter E Safety Regulations for the Operation of
Forklift Trucks, item Unauthorised use of truck strictly prohibit the carrying of
passengers (travel and lifting) in the operator position and on the load handler.
If the truck is equipped for use with a detachable, authorised work platform, in
exceptional circumstances a person who has been authorised by the proprietor
may be carried in the work platform.
The driver must instruct the passenger how to operate the work platform and point
out the hazards.
Example: do not lean out of the work platform while travelling or lifting / lowering.
Z Operate the work platform only at reduced travel / hydraulic speeds!
83
84
85a
83
85a 84
86
85b
86 87
87
91
89
90 88
M The work platform authorised for this truck must be connected mechanically and
electrically to the truck during operation.
To do this, the work platform has a locking mechanism (86, 87) attached to the truck's
load handler and a connection cable (84) leading to the truck.
Z The work platform is equipped with an additional control panel (83) to enable two-
hand operation for the passenger. The connection of the work platform (86) and the
closed gate (85a) are constantly monitored.

checklist Work platform (o) in chapter F.
1010.GB
E 198
9.4.1 Operation
Z The work platform is authorised for one person only. If a second person is to be
carried in the work platform, it must be fitted with an additional two-hand control
system.
The operators must be instructed by the driver in how to operate the system and the
risks involved.
Example: do not lean out of the work platform while travelling or lifting / lowering.
If in exceptional circumstances, approved by the proprietor, the work platform is to be

lifted and an operator carried in it, proceed as follows:
9.4.2 Lifting the work platform
83
84
85a
83
85a 84
86
85b
86 87
87
91
89
90 88
F The work platform must be lifted in such a way that at all times during travel, lifting or
lowering, eye contact is maintained between the driver and the operator of the
work platform.
M The work platform for the telescopic table can only be lifted from the left hand side
(viewed in the load direction).
1010.GB
E 199
Insert the forks fully in the fork guide (88, 90) of the work platform.
Raise the work platform slightly until it is clear of the ground.
Attachment:
Now make sure that the lock (87) of the work platform is properly engaged in the
stop (86) on the load handler.
Push back the attachment to the standard position.
Telescopic table:
Push back the telescopic forks with the work platform to the standard position.
Now make sure that the lock (87) of the work platform is properly engaged in the
stop (86) on the truck.
Using a bolt (86) prevent the work platform lock (87) from loosening.
Z The display unit shows the "work platform / stockpicking box raised and
secured" symbol. The raised and locked work platform is monitored by non-
contact sensors.
Connect the cable (84) of the work platform to the truck. Travel and hydraulic
operations are now only possible when the two-hand operation system (83) is
pressed and the access gate (85a) is closed.
Z "Traversing" and / or "rotating" of the attachment are inhibited when the work platform
has been lifted and connected electrically. If the cable (84) is not connected to the
truck after the work platform has been lifted, all travel, lifting and lowering functions
are disabled.
1010.GB
E 200
9.4.3 Operating the work platform
83
84
85a
83
85a 84
86
85b
86 87
87
91
89
90 88
F The driver must check the work platform safety mechanisms before starting to travel.
Do not use the work platform if one of the safety mechanisms is not working.
Notify the manufacturers customer service department.
Only return the work platform to service when you have identified and rectified
the fault.
F The access gate to the work platform must be kept closed at all times while the truck
is in operation. The passenger in the work platform must press the control panel
switches with both hands (two-handed operation) while travel, lifting or lowering.
Z If at any time while travelling or carrying out a hydraulic operation the two-hand
operation switches installed in the work platform are not pressed, travel and/or
hydraulic operations are deactivated.
If at any time while travelling or carrying out a hydraulic operation the access
gate (85a) is opened, travel and hydraulic operations are disabled.
The access gate (85a) can be opened via the switch in the work platform. In the
event of a fault the access gate (85a) can be opened with the key (85b) supplied.
1010.GB
E 201
M The driver must never leave the truck while there are people in the raised work
platform.
F Never disable the "work platform raised" switch, the "two-handed operation" switch or
the gate switch.
No additional climbing aids (such as ladders, stools etc.) may be used in the
work platform.
Before starting (travel / lifting / lowering) the operator(s) must ensure that no objects
are protruding out of the work platform and that any objects they have taken with them
are securely fixed.
The work platform must not be accessed or left while in a raised position.
Do not exceed the maximum load for the work platform. This can be found on the
data plate.
1010.GB
E 202
9.4.4 Lowering the work platform
83
84
85a
83
85a 84
86
85b
86 87
87
91
89
90 88
Disconnect the cable (84) of the work platform from the truck.
Attachment:
Extend the attachment and lower the work platform.
Disconnect the locking mechanism (86, 87) between the work platform and
the truck.
Telescopic table:
Disconnect the locking mechanism (86, 87) between the work platform and
the truck. Extend the telescopic forks and lower the working platform.
Retract the attachment / telescopic forks.
1010.GB
E 203
9.5 Fire extinguisher (o)
Z The fire extinguisher (171) can be attached

to the operator position or overhead guard.
Open the lock (170). 169

Pull the fire extinguisher (171) out of its
bracket (169) - see arrow direction.
Z To operate, refer to the illustrations on the

fire extinguisher (171).
170
171
1010.GB
E 204
9.6 Closed driver's cab (o)
The truck can be fitted optionally with a closed driver's cab. In an emergency you can
leave the driver's cab via the egress system.
9.6.1 Entering / exiting the driver's cab
175
176
177
172 173
174
Z On trucks fitted with a closed driver's cab, both doors can be closed.
1010.GB
E 205
Opening and locking the cab door
Procedure
To open the cab door (174):

insert the key in the door lock (172).
turn the key anti-clockwise as far as the stop.
To lock the cab door (174):

insert the key in the door lock (172).
Turn the key clockwise as far as it will go:
Opening the door from the outside and the inside
Procedure
To open the cab door (174) from the outside:

lock the cab door (174).
push the door lock (172) in and open the cab door (174) inwards.
To open the cab door (174) from the inside:

Push the handle (177) as far as the stop in the arrow direction.
open the cab door (174) inwards.
Z The monitored cab doors are shown in the driver's display like a gate
(see "Displays and controls" in Chapter E).
Entering / exiting the driver's cab
F Fall hazard
When the cab door is open and the driver's cab raised, the operator risks falling out
of the cab.
Do not open the cab door when the driver's cab is raised.
Fully lower the mast / driver's cab.

Open the cab door.
To enter and exit the cab, hold onto the cab chassis.
Close the cab door from the inside.
M No more than one person may operate the truck in the driver's cab at a time.
1010.GB
E 206
9.6.2 Roof hatch
175
176
177
172 173
174
Opening / closing the roof hatch
Procedure
Turn the lever (176) to:
close and lock the roof hatch (175).
open the roof hatch (175) by approx. 10. This position allows the driver's cab
to be ventilated
open the roof hatch (175) fully by approx. 85.
M Accident risk when the roof hatch is full opened

When the roof hatch is fully opened the operator is not protected from falling objects.
Do not open the roof hatch fully during operation.
Do not perform any travel or hydraulic operations when the roof hatch is open.
1010.GB
E 207
9.6.3 Exiting a closed driver's cab
Industrial trucks with a driver's cab which can be raised more than 3 m off the ground
have an emergency lowering mechanism and a rescue equipment (rescue harness /
abseil device / rescue rope) for the driver which can be used to reach the ground
should the operator position be blocked.
Z See "Exiting the driver's cab with the rescue equipment" in chapter E.
Z If the drivers cab cannot be lowered due to a fault, not even with the emergency
lowering (see Drivers Cab Emergency Lowering in chapter E), the operator must
exit the driver's cab via the emergency abseil device.
F Untrained personnel and non-serviced rescue equipment can result in

accidents and injury
The rescue equipment (rescue harness / abseil device with rescue rope) should only
be used by people who are physically capable, trained to use the equipment safely
and who have the required expertise.
The user must have a rescue plan listing all necessary action to be taken in
emergencies.
The driver must undergo annual training in how to handle the rescue equipment.
For the operation and service intervals of the rescue harness and the emergency
abseil device, refer to the accompanying operating instructions.
Follow the maintenance intervals stated in rescue harness and emergency abseil
device operating instructions.

operations.
1010.GB
E 208
Exiting the driver's cab via the cab doors
Requirement
Sufficient space between the driver's cab

and rack.
Procedure 180

Press the Emergency Disconnect. 180 181
Take the abseil device and rescue
harness out of the storage compartment
in the driver's cab, see "Rescue
equipment storage compartment in the
driver's cab" in Chapter E.
172 173
Z The assembled rescue equipment is ready
for use on breaking the seal, removal from 174
the equipment bag or case and after
carrying out a visual inspection.
chapter E.
Open the cab door (174).
F Risk of falling after opening the cab door.

When the cab door is open and the driver's cab raised, the operator risks falling out
of the cab.
When attaching the karabiner hook of the rescue rope make sure you are standing
securely in the driver's cab.
Insert the karabiner hook (181) of the rescue rope into the D ring (in accordance
with EN 795) on the overhead guard (180) and secure it with the union nut.
Z Abseiling is detailed in "Exiting the driver's cab with the rescue equipment" in
chapter E.
1010.GB
E 209
Exiting the driver's cab via the roof hatch
Requirement
180
Sufficient space to open and exit the
driver's cab via the roof hatch.
176
Procedure 175

180
Take the abseil device and rescue 181

for use on breaking the seal, removal from
Carry out a visual inspection of the

rescue harness, abseil device, rescue rope and screw lock karabiner, see "Visual
Inspection of the Rescue Equipment" in chapter E.
Turn the lever (176) anti-clockwise as far as the stop to open the roof hatch (175).
F Fall risk
The operator may only exit via the roof hatch once he has secured himself to the
driver's cab with the karabiner hook.
Exiting the driver's cab via the roof hatch. The seat and backrest can be used to
help climb out of the cab.
chapter E. 1010.GB
E 210
9.6.4 Exiting the driver's cab via the front window
Z Only exit the driver's cab via the front

window if you cannot exit via the roof hatch
181
180
or cab door.
180
Procedure

Take the abseil device and rescue

for use on breaking the seal, removal from
182
Carry out a visual inspection of the 183
rescue harness, abseil device, rescue
rope and screw lock karabiner, see
"Visual Inspection of the Rescue Equipment" in chapter E.
Remove the emergency hammer (182) from its bracket in the driver's cab.
1010.GB
E 211
M Risk of injury when striking the front window
Turn your face away and close your eyes when you strike the front window.
Strike the front window (183) with the emergency hammer (182).
Strike out the fragmented sections of the front window (183).
M Risk of injury from broken front windows

Carefully remove any fragments / glass splinters from the front window. If they are not
removed you may cut and injure yourself when leaving the driver's cab.
Use hand protection to remove the fragments. You can use for example the rescue
harness storage container as hand protection.
F Fall risk
If there is no front window and the driver's cab raised, the operator risks falling out of
the cab.
When attaching the karabiner hook of the rescue rope make sure you are standing
securely in the driver's cab.
chapter E.
1010.GB
E 212
9.7 Camera system (o)
M Accident risk from hidden work areas

The camera system acts as an aid to assist safe operation.
Practice travelling and working with the camera system.
Align 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.
195 196 197 198 199
Using the camera system
Press the button (199) on the monitor to switch the camera system on or off.
Press the button (198) to lighten or darken the screen (day / night settings).
Press the button (195). The screen menu opens up.
Z Pressing the button (195) 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 (197) to go one step forward.
Press the button (196) to go one step back.
Z Clean a dirty screen or vent slots with a soft cloth or brush.

1010.GB
E 213
E 214
1010.GB
F Industrial Truck Maintenance
1 Operational Safety and Environmental Protection
The servicing and inspection duties contained in this chapter must be performed in
accordance with the intervals indicated in the maintenance checklists.
F Risk of accidents and damage to components

Any modification to the truck, in particular the safety mechanisms, is prohibited.
The operating speeds of the truck must not be increased under any circumstances.
F Only original spare parts have been passed by our quality assurance service.
To ensure safe and reliable operation of the truck, use only the manufacturer's
spare parts.
For safety reasons, only components which have been specially agreed by the
manufacturer for this truck may be installed near the computer, controllers and wire
guidance antennae. These components (computers, controllers, wire guidance
antennae) must therefore not be replaced either by similar components from other
trucks of the same series.
F Old parts, oils and fuels must be disposed of in accordance with the applicable
environmental protection regulations. For oil changes, contact the manufacturers oil
service department.
On completion of inspection and service work, carry out the activities listed in the
Recommissioning the truck after cleaning or maintenance work section
(see chapter F).
2 Maintenance safety regulations
Maintenance personnel: Industrial trucks must only be serviced and maintained by

the manufacturers trained personnel. The manufacturers service department has
field technicians specially trained for these tasks. We therefore recommend that you
enter into a maintenance contract with the manufacturers local service centre.
0210.GB
F1
Lifting and jacking up
M Lifting and jacking up the truck safely

When an industrial truck is to be lifted, the lifting gear must only be secured to the
points specially provided for this purpose.
You may only work under a raised load handler / raised cab if they have been secured
with a sufficiently strong chain or the fastening bolt.
In order to raise and jack up the truck safely, proceed as follows:
Jack up the truck only on a level surface and prevent it from moving accidentally.
Always use a jack with sufficient capacity. When jacking up the truck, take
appropriate measures to prevent it from slipping or tipping over (e.g. wedges,
wooden blocks).
In order to raise the truck, the lifting gear must only be secured to the points
specially provided for this purpose, see "Identification points and data plates" in
chapter B.
When jacking up the truck, take appropriate measures to prevent it from slipping or
tipping over (e.g. wedges, wooden blocks).
Z Prevent the driver's cab from accidentally lowering (see "Preventing the driver's cab
from accidentally lowering" in Chapter F) and jack lifting points (see "Identification
points and data plates" in Chapter B).
0210.GB
F2
Cleaning
M Fire hazard
Do not use flammable liquids to clean the industrial truck.
Always disconnect the battery before starting cleaning work.
Carry out all necessary safety measures to prevent sparking before cleaning
(e.g. by short-circuiting).
M Risk of electrical system damage

The electrical system can be damaged if it is cleaned with water. Do not wet-clean
the electrical system.
Do not clean the electrical system with water.
Clean the electrical system with weak suction or compressed air (use a compressor
with a water trap) and not a conductive, anti-static brush.
M Risk of component damage when cleaning the truck

If the truck is to be cleaned with a water jet or a high-pressure cleaner, all electrical
and electronic components must be carefully covered beforehand as moisture can
cause malfunctions. Do not clean with pressurised water.
Z After cleaning, carry out the activities detailed in Recommissioning the truck after
cleaning or maintenance work (see chapter F).
0210.GB
F3
Electrical system
M Accident risk
Only suitably trained electricians may operate on the truck's electrical system.
Before working on the electrical system, take all precautionary measures to avoid
electric shocks.
Always disconnect the battery before starting cleaning operations.

Make sure the electrical system is voltage-free before starting work on it.
The capacitors in the controller must be fully discharged. The capacitors are fully
discharged after approx. 10 minutes. Before starting maintenance on the electrical
system:
Remove any rings or metal bracelets etc. before working on electrical components.
0210.GB
F4
Consumables and used parts
M 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.
Note the safety regulations when handling these materials.
Welding: To avoid damaging electric or electronic components, remove these from

the truck before performing welding operations.
F Load bearing parts of the truck may only be welded after consultation with the
manufacturer.
Settings: When repairing or replacing hydraulic, electric or electronic components

or assemblies, always note the truck-specific settings.
0210.GB
F5
Wheels
F The use of wheels that do not comply with the manufacturer's specifications
can result in accidents.
The quality of wheels affects the stability and performance of the truck.
Uneven wear affects the truck's stability and increases the stopping distance.
When replacing wheels make sure the truck is not skewed.
Always replace wheels in pairs, i.e. left and right at the same time.
Z When replacing wheels fitted at the factory, only use the manufacturers original
spare parts. Otherwise the truck's rated performance cannot be ensured.
0210.GB
F6
3 Servicing and Inspection
Thorough and expert servicing is one of the most important requirements for the safe
operation of the industrial truck. Failure to perform regular servicing can lead to truck
failure and poses a potential hazard to personnel and equipment.
M The application conditions of an industrial truck have a considerable impact on the

wear of the service components.
We recommend that a Jungheinrich customer service adviser carries out an
application analysis on site to work out specific service intervals to prevent damage
due to wear.
The service intervals stated are based on single shift operation under normal
operating conditions. They must be reduced accordingly if the truck is to be used in
conditions of extreme dust, temperature fluctuations or multiple shifts.
The following maintenance checklist states the tasks and intervals after which they
should be carried out. Maintenance intervals are defined as:
W = Every 50 service hours, or at least weekly

A = Every 500 service hours
B = Every 1000 service hours, or at least annually
C = Every 2000 service hours, or at least annually
Z W maintenance interval operations are performed by the proprietor.

0210.GB
F7
4 Maintenance Checklist
Maintenance intervals
Standard= t W A B C
Brake 1.1 Test operation t

1.2 Check effectiveness of operating and parking brakes, t
adjust where necessary and measure braking distance
1.3 Check brake lining wear on drive brake t
1.4 Check electrical connections t
1.5 Make sure the sensors are secured, not damaged, t
clean and operational
1.6 Test micro switch setting t
Electrical 2.1 Check static charge eliminator is present t

system 2.2 Test instruments, displays and control switches t
2.3 Test electric system t
2.4 Check electrical system for frame leakage t
2.5 Test lighting t
2.6 Test warning and safety devices and cutouts t
2.7 Check fuse ratings t
2.8 Make sure wire connections are secure and check t
for damage
2.9 Test the operation of the cable guides and check t
for damage
2.10 Make sure sensors are secured, not damaged, t
2.11 Test micro switch setting t
2.12 Check contactors, replace any worn parts. t
2.13 Check relays, replace any worn parts. t
0210.GB
F8
Standard= t W A B C
Power supply 3.1 Battery visual inspection t

3.2 Check battery cable connections are secure, t
grease terminals if necessary.
3.3 Make sure battery plug connections, battery cables and t
cell connectors are secure and check for damage;
replace and clean if necessary
3.4 Check acid density, acid level and cell voltage t
3.5 Visually inspect Aquamatik lines and connections t
Travel 4.1 Test travel function t

4.2 Test travel switch. t
4.3 Test travel speeds t
4.4 Check motor attachment t
4.5 Make sure motor lines are secure and check for damage t
4.7 Check transmission for noise and leakage t
4.8 Check transmission oil level, top up if necessary t
4.9 Change the gear oil t
4.10 Check drive wheel / load wheel for wear and damage t
4.11 Check drive wheel / load wheel bedding and attachment t
4.12 Check rail guide rollers for wear and damage t
4.13 Check rail guide roller bedding and attachment t
4.14 Check the distance between the guide roller and the rail t
guidance over the entire length of the rails
0210.GB
F9
Standard= t W A B C
Truck setup 5.1 Check all load bearing components for damage t
5.2 Check screw connections t
5.3 Check mast attachments (bearings and retaining screws) t
5.4 Check mast anchoring for damage (option) t
5.5 Check the truck chassis for damage. t
5.6 Make sure tilt safety devices are present and check t
the setting (option)
5.7 Check active stabilisers are present; test settings and t
operation (option)
5.8 Check the overhead guard for damage t
5.9 Test the operator platform and check for damage t
5.10 Check the cabin for damage. t
5.11 Check the mast guard for damage t
5.12 Test the gates and gas pressure dampers and check t
for damage
5.13 Test the folding seat and check for damage t
5.14 Check the step mat for damage. t
5.15 Check the indication points and labels are legible and t
replace if necessary
5.16 Check the battery rollers are present and test them. t
5.17 Check the battery retainers are present and test them. t
5.18 Make sure battery sensors are secured, not damaged, t
5.19 Check the battery panel and sides are secure t
5.20 Test the battery cover gas pressure springs and check t
for damage
Hydraulic 6.1 Test hydraulic operations t

operation 6.2 Test Main Lift lower / raise controls t
6.3 Test Aux. Lift lower / raise controls t
6.4 Test traverse / rotate controls t
0210.GB
F 10
Standard= t W A B C
Hydraulic 6.5 Test lift and lowering speeds t

operation 6.6 Test rotate and traverse speeds t
6.7 Test emergency lowering valve t
6.11 Check the mast for damage. t
6.12 Clean rollers, guide rollers and contact surfaces in the t
mast sections and apply grease
M Danger of crashing!
6.13 Check setting of slide pieces and stops, and adjust t

if necessary
6.14 Visually inspect mast rollers and check contact surface t
wear level
6.15 Visually inspect rollers, slide pieces and stops t
6.16 Check lift chains and guides for wear, adjust and t
lubricate.
6.17 Lubricate lift chains t
6.18 Test automatic chain lubrication (option) t
6.19 Check chain bolts for damage and make sure the t
lockwashers / pins are present
6.20 Test slack chain switch t
6.21 Check valves for leaks and damage t
6.22 Test operation of pressure relief valves t
6.23 Check hydraulic cylinder and piston rods for t
damage and leaks and make sure they are secure
6.24 Check that hose and pipe lines and their t
connections are secure, check for leaks
and damage, and tighten unions if necessary p)
6.25 Test hose guide and check for damage t
p) Replace hydraulic hoses after 6 years' operation

0210.GB
F 11
Standard= t W A B C
Hydraulic 6.26 Test attachment, check settings and check for damage t
operation 6.27 Check the attachment is properly secured to the truck t
and the supporting member
6.28 Attachment: t
Visually inspect bearing points, guides and stops for
wear and damage, lubricate these components
6.29 Attachment: t
Check the eccentric bolt setting on swivel traverse frame
and adjust if necessary
6.30 Clean and grease toothed racks t
6.31 Lubricate rollers, guide rollers and swivel bearings on t
the swivel traverse fork.
6.32 Check the rotary / traverse hydraulic motor for leaks t
and damage
6.33 Check hydraulic oil level and top up if necessary t
6.34 Replace hydraulic oil t
6.35 Replace filter cartridge t
6.36 Replace ventilation and discharge filter on hydraulic t
reservoir
6.37 Check the fork tines and fork carriage for wear and t
damage
Steering 8.1 Test steering t

8.2 Test operation and setting of wheel setting display t
clean and operational 0210.GB
F 12
Standard= t W A B C
System 9.1 Test the wire guidance and cutout limits, t

components adjust if necessary e)
9.2 Measure the current in the guide wire, t
adjust if necessary e)
9.3 Check travel on the guide wire, check maximum t
deviation and adjust if necessary e)
9.4 Check the guide wire acquisition for aisle tracking e) t
9.5 Check wire guidance Emergency Stop operation e) t
9.6 Check the laser scanner attachment on the t
Personal Protection System f)
9.7 Clean the front screens of the Personal Protection t
System laser scanners f)
9.8 Test the Personal Protection System f) t
9.9 Test the warning and protective field areas of the t
Personal Protection System f)
Sign off/Dem- 10.1 Lubricate the truck according to the lubrication schedule t
onstration 10.2 Carry out a test run with / without rated load t
10.3 Demonstration after servicing t
e) WG: wire guidance trucks

f) For trucks with a Personal Protection System (PPS)
0210.GB
F 13
4.1 Attachment service checklist (options)
M Check the attachment daily for external signs of damage or defects. If necessary
(for major damage such as breakage) the truck may have to be taken out of service.
4.1.1 Symmetrical/asymmetrical sideshift with integrated fork adjuster checklist (o)
Z In addition to the items described in chapter F of the operating instructions,

the following service items must be carried out.
Standard= t W A B C
Fork adjuster 1 Clean and lubricate the fork adjuster contact surfaces t
with sideshift 2 Clean and lubricate the sideshift plate contact surfaces t
3 Check the hydraulic unions for leaks. t
4.1.2 Maintenance checklist telescopic table (o)

Standard= t W A B C
Telescopic 1 Check anti-slip lining for damage and wear, t

table replace if necessary.
2 Check chain tension, adjust if necessary t
3 Clean and lubricate chains t
4 Check rollers and telescopic shuttle table gear unit for t
wear and lubricate.
5 Clean and lubricate wear strips t
6 Lubricate all lubrication points t
7 Check switch contacts and magnetic coupling t
0210.GB
F 14
4.1.3 Maintenance checklist telescopic forks (o)

Standard= t W A B C
Telescopic 1 Check chain tension, adjust if necessary t

forks 2 Clean and lubricate chains t
3 Clean and lubricate wear strips t
4 Check outer shoe wear (a) t
5 Check contact surface on inner fork tip t
6 Replace dowel pins t
4.1.4 Maintenance checklist fork adjuster (o)

Standard= t W A B C
Fork 1 Check chain tension, adjust if necessary t

positioner 2 Clean and lubricate the fork positioner contact surfaces t
3 Check mechanical limit stops. t
0210.GB
F 15
4.1.5 Maintenance checklist work platform (o)

Standard= t W A B C
Work platform 1 Test the operation of the work platform and check t
for damage
2 Check the locks / stops on the truck and work platform t
for damage
3 Check the wires, connectors and switches for damage. t
4.1.6 Maintenance checklist - on-board charger (o)

Standard= t W A B C
On board 1 Check current collector for damage and wear, t

charger and test operation
2 Check collector contacts for wear t
3 Test operation t
4 Check cable and plug connections for damage and wear t
0210.GB
F 16
4.1.7 Maintenance checklist horizontal positioning (o)

Standard= t W A B C
Horizontal 1 Clean barcode scanner with an appropriate solvent t

positioning 2 Check the horizontal position reflection light barrier is t
secure and clean
3 Test operation t
4 Check cable and plug connections for damage and wear t
0210.GB
F 17
5 Lubricants and Lubrication Schedule
5.1 Handling consumables safely
Handling consumables
Consumables must always be handled correctly. Follow the manufacturers instructions.
F Improper handling is hazardous to health, life and the environment

Consumables can be flammable.
Keep consumables away from hot components and naked flames.
Always keep consumables in prescribed containers.
Always fill consumables in clean containers.
Do not mix different grades of consumable. The only exception to this is when
mixing is expressly stipulated in the Operating Instructions.
M Spilled liquids can cause slipping and endanger the environment

Risk of slipping from spilled liquids. The risk is greater when combined with water.
Do not spill fluids.
The bonding agent / consumable mixture must be disposed of in accordance
with regulations.
0210.GB
F 18
F Oils (chain spray / hydraulic oil) are flammable and poisonous.
Dispose of used oils in accordance with regulations. Store used oil safely until it can
be disposed of in accordance with regulations.
Do not spill oil.
regulations.
Observe national regulations when handling oils.
Wear safety gloves when handling oils.
Prevent oil from coming into contact with hot motor parts.
Do not smoke when handling oil.
Avoid contact and digestion. If you swallow oil do not induce vomiting but call for
Seek fresh air after breathing in oil fumes or vapours.
If oil has come into contact with your skin, rinse your skin with water.
If oil has come into contact with your eyes, rinse them with water and call for
Replace oil-soaked clothing and shoes immediately.
Consumables and used parts
M 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.
Note the safety regulations when handling these materials.
0210.GB
F 19
5.2 Lubrication Schedule
E C
E
C C
g Contact surfaces a Transmission oil drain plug

s Grease nipple c Hydraulic oil drain plug
Hydraulic oil filler neck
0210.GB
F 20
5.3 Consumables
Quantity
Code Order no. Capacity Description Application
supplied
HLP D22 including
51 037 497 5l
2% share of additive
51 037 494 1l approx.
A 68 ID Hydraulic system
105 l
Plantohyd 22 S
51 085 361* 5l
(BIO hydraulic oil)
approx. British Petrolium (BP)
B 51 179 177 1l Transmission
6.6 l Enersyn EP-XF150
400 g Grease - General,
14 038 650
C (cartridge) --- Lithium KP2K-30 Toothed racks
29 201 430 1 kg (DIN 51825) Mast
Chain spray
29 201 280 400 ml ---
Tunfluid LT 220
D Automatic chain Lift chains
51 079 513 120 ml --- lubrication cartridge
with battery pack
E 50 002 004 400 ml --- Contact spray / grease Running surfaces
51 085 365 500 ml --- All purpose cleaner Laser scanner of
F personal safety
51 085 537 1 piece --- Cleaning cloth system (PSS)
* Plus 2% additive 68 ID (order no. 50 307 735)
F The trucks are supplied from the factory with HLP D22 hydraulic oil or the
Plantohyd 22 S + 2% 68 ID additive BIO hydraulic oil.
You cannot change from the Plantohyd 22 S BIO hydraulic oil to HLP D22. The same
applies to changing from HLP D22 hydraulic oil to Plantohyd 22 S BIOhydraulic oil.
Furthermore, you cannot mix HLP D22 hydraulic oil Plantohyd 22 SBIO hydraulic oil.
0210.GB
F 21
6 Maintenance and Repairs
6.1 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:
Switch off the truck via the key switch (key switch in 0 position).
Disconnect the battery to prevent the truck from being switched on accidentally
When working under a raised lift truck, secure it to prevent it from lowering, tipping
or sliding away.
in chapter F.
F When working under a raised load handler / driver's cab or a raised truck, secure
them to prevent the truck from from lowering, tipping or sliding away. When raising
the truck, follow the instructions in chapter C, Transport and Commissioning.
When working on the parking brake, always secure the truck to prevent it from
accidentally rolling away.
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6.2 Preventing the driver's cab from accidentally lowering
Z When carrying out maintenance and repair work

under the driver's cab or load handler, the raised cab
must be prevented from accidentally lowering. The
cab must not be secured with a load on the load
handler, to prevent people below the cab from being
injured by falling loads. Do not perform any work
underneath the driver's cab without a cab locking
device in place.
Place a step ladder next to the truck so that the 1

raised driver's cab can be safely vacated via the
step ladder. 2
Raise the operator position carriage above the
first or second mast cross-member.
Z The first mast cross-member is located approx. 450 mm and the second approx.
1800 mm above the ground. Any number of attachment heights are possible between
the DZ and ZT masts.
Loosen the twist grip screws (2) under the driver's seat (1) and carefully move the
seat forward.
0210.GB
F 23
3
B D
3 A E
C 4
6
4 5
7 7
1 1
9 8
Loosen the lever (7) by turning it anti-clockwise.

Raise the pin retainer (6) slightly and flip it over to the left.
(see arrow directions A and B).
Push the fastening bolt (4) through as far as the second groove (9) (see arrow
direction C).
Engage the pin retainer (6) in the second groove (9) (see arrow directions D and E).
Secure the pin retainer (6) by pulling on the lever (7) (turn the lever (7) anti-clockwise).
Slowly lower the driver's cab until the fastening bolt (4) is resting on the mast cross-
member (3).
Open the gate.
M Falling hazard when vacating the driver's cab

Move carefully and slowly from the driver's cab onto the step ladder. The stability of
the step ladder must be ensured at all times.
Use only sufficiently long step ladders (at least 2m).
Carefully exit the driver's cab via the step ladder.
Open the battery panel.
Disconnect the battery to prevent the truck from being switched on accidentally.
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After carrying out maintenance / repairs
Re-connect the battery.

Close the battery cover.
3
B D
3 A E
C 4
6
4 5
7 7
1 1
9 8
M Falling hazard when entering the driver's cab

Move carefully and slowly from the step ladder into the driver's cab. The stability of
the step ladder must be ensured at all times.
Use only sufficiently long step ladders (at least 2 m).
Enter the driver's cab securely via the step ladder.

Close the gate.
Raise the driver's cab so that the fastening bolt (4) is no longer resting on the mast
cross member (3).
Loosen the lever (7) by turning it anti-clockwise.
Raise the pin retainer (6) and flip it over to the left (see arrow directions E and D).
Push the fastening bolt (4) through as far as the first groove (8) (see arrow
direction C).
Engage the pin retainer (6) in the first groove (8) (see arrow directions B and A).
Secure the pin retainer (6) by pulling on the lever (7) (turn the lever (7) anti-clockwise).
Carefully fold the driver's seat back (1) and fasten it by tightening the two twist
grip screws (2).
Lower the driver's cab.
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6.3 Lift chain servicing
F Non-lubricated and incorrectly cleaned lift chains can cause accidents

Lift chains are safety-critical parts. They must not contain any serious contamination.
Lift chains and pivot pins must always be clean and well lubricated.
Lift chains should only be cleaned with paraffin derivatives e.g. petroleum or
diesel fuels.
Never clean chains with steam jet high pressure cleaners, cold or chemical
cleaning agents.
Immediately after cleaning, dry the lift chain with compressed air and apply a
chain spray.
Always lubricate a chain when it is discharged.
Lubricate a lift chain with particular care around the pulleys.
Z The intervals stated in the service checklist apply to normal duty use.
More demanding conditions (dust, temperature) require more regular lift chain lubri-
cation. The prescribed chain spray must be used in accordance with the instructions.
Applying grease externally will not provide sufficient lubrication for the lift chains.
6.4 Lubricating the lift chains, cleaning and greasing the contact surfaces in the
mast sections
F Accident risk when carrying out maintenance at height

Risk of crashing and trapping when carrying out maintenance at height
(e.g. lubricating the mast).
Wear personal protective equipment.
Use a work platform, lifting platform or safety ladder.
Do not use a step ladder.
Do not stand under the driver's cab and / or the attachment.
Requirements:
Park the truck on a level surface.

Instruct a second person to operate the truck.
Required tools and materials

Use a work platform, lifting platform or safety ladder
Procedure
0210.GB
F 26
F Accident risk
Be aware of the ceiling height when lifting the attachment and / or the driver's cab.
Get the second person to fully raise the attachment and / or driver's cab.
F Do not place the work platform, lifting platform or safety ladder under an unsecured
attachment and / or driver's cab.
Never stand underneath a raised attachment / driver's cab.
Position the work platform, lifting platform or safety ladder directly next to the truck.
From the work platform, lifting platform or safety ladder:
Lubricate the lift chains.
Clean the stop faces in the mast sections and apply grease.
Z For the lubricant refer to "Consumables" in Chapter F.
Remove the work platform, lifting platform or safety ladder.

Connect the battery to the truck.
Get the second person to fully lower the attachment and / or driver's cab.
0210.GB
F 27
6.5 Automatic chain lubrication (o)
10
The trucks can optionally be fitted with an automatic chain lubrication system.
The lubrication unit (10) used in automatic chain lubrication consists of a drive
unit (11) and a lubrication cartridge (12). The lubrication unit (10) lubricates the lift
chains over a period of one, three, six or twelve months. This interval can be set via
the drive unit (11) (see Setting the Lubrication Interval in this chapter). The lubricant
cartridge (12) must be replaced after the set lubrication interval (see "Replacing the
lubricant cartridge" in this chapter).
Z The number of lubrication units (10) used depends on the mast:

ZT mast:
two lubrication units on the top mast cross member.
DZ mast:
two lubrication units on the top mast cross member,
two lubrication units on the free lift cylinders.
6.5.1 Lubricant cartridge replacement
F Accident risk when carrying out maintenance at height

Risk of falling and trapping when carrying out maintenance at height (e.g. lubricating
the mast).
Use a work platform, lifting platform or safety ladder.
Do not use a step ladder.
Do not stand under the driver's cab and / or the attachment.
0210.GB
F 28
Requirements:

Required tools and materials
Use a work platform, lifting platform or safety ladder

Procedure:
Fully lower the main and auxiliary lift.

Disconnect the battery. 11
Position the work platform, lifting platform or safety ladder directly
next to the truck so that the lubrication unit (10) can be safely 12
reached.
F Danger of falling!
Unscrew the lubrication unit (10) from its bracket.

Screw the drive unit (11) and lubrication cartridge (12) apart.
Insert the new battery pack in the drive unit (11).
Z When replacing the lubricant cartridge (12) a new battery pack must be inserted in
the drive unit (11) to ensure sufficient power supply during operation.
Screw the drive unit (11) and lubrication cartridge (12) back together.
Set the lubrication interval, see "Setting the Lubrication Interval" in this chapter.
Remove the drain plug from the lubricant cartridge.
Unscrew the lubrication unit (10) from its bracket.
Turn the rotary switch from OFF to ON.
Z A permanently lit red light for 25 seconds indicates that the automatic chain
lubrication is working correctly.
Remove the work platform, lifting platform or safety ladder.

Connect the battery to the truck.
0210.GB
F 29
6.5.2 Setting the lubrication interval
The lubrication intervals can be set via the two switches on the drive unit (11).
Switch setting Lubrication Interval
One month
Three months
Six months
Twelve months
Z After setting the interval, place the supplied stickers with the lubrication intervals on
the drive unit (11) and the installation date on the lubricant cartridge (12).
0210.GB
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6.5.3 Automatic chain lubrication indicator
Display Function Duration

Red permanent signal Start up 25 secs
Green flashing signal Unit working correctly 15 secs
Red flashing signal Error / fault 8 secs
Green / red flashing signal Lubricant cartridge is empty 3 secs
Red signal Lubrication 1 - 5 sec.
0210.GB
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6.6 Lift chain inspection
Unauthorised wear and external damage:
In accordance with official regulations, a chain is considered to be worn if it has

extended in length by 3% in the section which passes over the deflection pulley.
For safety reasons, Jungheinrich advises replacing chains when they have elongated
by 2%.
Replace a chain immediately if it shows external signs of damage. This type of
damage will result in permanent breakage.
F If the truck is fitted with two lift chains, both chains must always be replaced. This is
the only way to ensure even load distribution over the two chains.
When replacing chains the connecting bolts between the chain anchor and the
chain must be replaced.
Always use new original parts.

operations.
0210.GB
F 32
6.7 Hydraulic hose lines
F Brittle hydraulic hose lines can cause accidents

The hoses must be replaced every six years. The manufacturer's customer service
department is specially trained to carry out these operations.
Comply with the safety regulations for hydraulic hose lines in accordance with
BGR 237.

operations.
F Hydraulic line leaks can cause accidents

Hydraulic oil can escape from leaky and faulty hydraulic lines.
regulations.
F Hairline cracks in the hydraulic lines can cause injury and infection
Pressurised hydraulic oil can penetrate the skin through fine holes or hairline cracks
in the hydraulic lines, causing severe injury.
Call for a doctor immediately if you are injured.
Do not touch pressurised hydraulic lines.
regulations.
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6.8 Drive panel disassembly / assembly
Drive panel disassembly
Remove the Allen key (18) from the

bracket in the centre below the strobe.
Remove the two Allen screws (15, 16)
using the Allen key (18).
Tilt the drive panel (11) back and lift it
15
out from the top (see arrow direction).
Drive panel assembly
M Trapping hazard
There is a risk of trapping when you fit
the drive compartment cover. 16
Make sure there is nothing between
the battery cover and the truck when 17
you fit the battery cover.
Insert the drive panel (17) at an angle

into the chassis and tilt it forward.
Attach the drive panel (17) to the truck
with the Allen screws (15, 16).
Tighten the Allen screws (15, 16) using 18
the Allen key (18).
Fit the Allen key (18) in the bracket in the centre below the strobe.
After cleaning or repairs restore the truck to service, see "Recommissioning the
truck after cleaning or maintenance work" in chapter F.
0210.GB
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6.9 Checking the hydraulic oil level
M The hydraulic oil is pressurised during operation and is a hazard to health and to
the environment.
Do not touch pressurised hydraulic lines.
Dispose of used oil in accordance with regulations. Store used oil safely until it can
be disposed of in accordance with regulations.
Do not spill hydraulic oil.
The bonding agent / consumable mixture must be disposed of in accordance
with regulations.
Observe national regulations when handling hydraulic oil.
Wear safety gloves when handling hydraulic oil.
Prevent hydraulic oil from coming into contact with hot motor parts.
Do not smoke when handling hydraulic oil.
Avoid contact and digestion. If you swallow oil do not induce vomiting but call for
Seek fresh air after breathing in oil fumes or vapours.
If oil has come into contact with your skin, rinse your skin with water.
If oil has come into contact with your eyes, rinse them with water and call for
Replace oil-soaked clothing and shoes immediately.
F Hydraulic line leaks can cause accidents

Hydraulic oil can escape from leaky and faulty hydraulic lines.
regulations.
0210.GB
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6.9.1 Checking the hydraulic oil level and replenishing if necessary
Requirements

Fully lower the main and auxiliary lift. 21
Prepare the truck for maintenance
and repairs (see "Preparing the truck
for maintenance and repairs" in this
chapter).
Remove the drive compartment panel,
see "Drive panel disassembly /
assembly" in chapter F.
Procedure
19
Turn the breather (19) and dipstick (21)
anti-clockwise out of the hydraulic 22
reservoir (22).
The hydraulic oil should level between
the "MIN" and "MAX" marks on the dipstick (21).
0210.GB
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M Overfilling the hydraulic reservoir can result in damage
The hydraulic oil should not be above the "MAX" mark on the dipstick, as any
escaping oil can damage the hydraulic system.
If the hydraulic oil level is below the "MIN" mark on the dipstick (21), add approx.
3.75 litres of new hydraulic oil in accordance with the consumables table to reach
the upper "MAX" mark on the dipstick (21). The hydraulic reservoir (22) is now full.
Trucks with bio hydraulic oil have a warning notice on the hydraulic
reservoir: Add bio hydraulic oil only. In this case you may only use
Plantohyd 22 S bio hydraulic oil to replenish the hydraulic reservoir.
Trucks with normal hydraulic oil have a warning notice on the hydraulic
reservoir: Add hydraulic oil. In this case use only the "HLP D22
including 2% content additive 68 ID" hydraulic oil to fill the hydraulic
reservoir.
F You cannot change from Plantohyd 22 S BIO hydraulic oil to HLP D22. The same
applies to changing from HLP D22 hydraulic oil to Plantohyd 22 S BIO hydraulic oil.
Furthermore, you cannot mix HLP D22 hydraulic oil with Plantohyd 22 S BIO
hydraulic oil.
Turn the breather (19) and dipstick (21) clockwise into the hydraulic reservoir (22).
Fit the drive compartment panel, see "Drive panel disassembly / assembly" in
chapter F.
After cleaning or repairs restore the truck to service, see "Recommissioning the
truck after cleaning or maintenance work" in chapter F.
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6.10 Checking electrical fuses
F Electric fuses must only be checked and replaced by authorized personnel.

discharged after approx. 10 minutes. Before starting maintenance on the electrical
system:
M 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.
Use only fuses with the prescribed rated current, see "Fuse Ratings" in chapter F.
Prepare the truck for maintenance and repairs

(see section of the same name in chapter F).
in chapter F.
Loosen connector XS7 (35) from the fuse holder (25) and remove it.
Disassemble the fuse holder (25) by unscrewing the six hex. socket screws. The fuse
holder (25) can now be removed from the drive compartment computer (34).
Check all the fuses in accordance with the table; replace if necessary.
F Only use the rating indicated on the controller/fuse.
Z Assembly of the fuse holder (25) is the reverse order of disassembly.
0210.GB
F 38
6.10.1 Fuse ratings
25 26 27 28 29 30
D1 D2 D3 D4 D5 D6
R1
R2
R7
V1
R3 R4 R5 R6
R8 F_5F1 F_7F3 F_7F7 F_6F6
X3
V2
R9 F_F2.1 F_1F3 F_F1.2
R10 R11
38 R12
33 32 31
37
36
35
34
Item Description To protect: Rating

26 5F1 Control fuse 80 V 10 A
27 7F3 DC/DC converter control fuse 10 A
28 7F7 PSS scanner control fuse 10 A
29 6F6 ISM data recorder control fuse 10 A
31 F1.2 Control fuse 80 V 10 A
32 1F3 Combi controller control fuse 10 A
33 F2.1 Control fuse 80 V 10 A
Travel threephase controller
36 1F11 250 A
(AC-3 Power Control U8)
Steering threephase controller
37 3F10 35 A
Hydraulic system threephase
38 2F15 controller 325 A
M Torque the locknuts on the fuses 1F11 (36), 3F10 (37) and 2F15 (38) to 10 Nm.
0210.GB
F 39
6.10.2 LED fuse indicators on the fuse holder
Z During operation the LED fuse indicator lamps are green (marked grey).
If an LED indicator is not lit, replace the respective fuse. The other LED indicators
reflect truck-specific operating conditions.
D1 D2 D3 D4 D5 D6
1
2
3
D1 D2 D3 D4 D5 D6
24 V
Charge 24 V Heartbeat
1 circuit out
7F7 7F3 DC / DC 1
DC / DC Controller A
internal
24 V
24 V Heartbeat
2 1F3 F1.2 5F1 DC / DC 1
DC / DC Controller B
external
From key 24 V 24 V Not used
3 switch
6F6 F2.1
DC / DC 2 DC / DC
6.11 Recommissioning the truck after cleaning or maintenance work
The truck can only be re-commissioned after cleaning or maintenance once the
following procedures have been carried out:
Re-connect the battery.

Switch on the truck by inserting the key in the key switch and turning it as far right
as it will go.
F After cleaning or maintenance work test all the safety mechanisms to ensure they are
working correctly.
0210.GB
F 40
Test the safety mechanisms:
Test the Emergency Disconnect by pressing the Emergency Disconnect switch.

The main circuit is disconnected and no truck operations can be performed.
Now turn the Emergency Disconnect to unlock it.
Test the controls and displays.
Test the horn by pressing the "horn" button.
Test the deadman button.
Test the steering.
Test the gates.
Test the front screens of the Personal Protection System laser scanners for dirt (o),
and clean if necessary, see "Cleaning the laser scanner front screen" in Chapter E.
F Faulty brakes can cause accidents

As soon as the truck has been started, test the brakes several times.
Lubricate the truck in accordance with the lubrication schedule, see Lubrication
Schedule in chapter F.
Z If there are switching problems in the electrical system, apply contact spray to the
exposed contacts and remove any oxide layers on the contacts of the controls by
applying them repeatedly.
F Electric currents from working with contact spray can cause accidents
discharged after approx. 10 minutes. Before starting maintenance work:
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7 Decommissioning the industrial truck
If the industrial truck is to be decommissioned for more than two months, e.g. for
operational reasons, it must be parked in a frost-free and dry location and all
necessary measures must be taken before, during and after decommissioning as
described.
F Lifting and jacking up the truck safely

When an industrial truck is to be lifted, the lifting gear must only be secured to the
points specially provided for this purpose.
You may only work under a raised load handler / raised cab if they have been secured
with a sufficiently strong chain or the fastening bolt.
In order to raise and jack up the truck safely, proceed as follows:
Jack up the truck only on a level surface and prevent it from moving accidentally.
Always use a jack with sufficient capacity. When jacking up the truck, take
appropriate measures to prevent it from slipping or tipping over (e.g. wedges,
wooden blocks).
In order to raise the truck, the lifting gear must only be secured to the points
specially provided for this purpose, see "Identification points and data plates" in
chapter B.
When jacking up the truck, take appropriate measures to prevent it from slipping or
tipping over (e.g. wedges, wooden blocks).
M 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 If the truck is to be out of service for more than 6 months, agree further measures with
the manufacturer's customer service department.
0210.GB
F 42
7.1 Action to be taken before decommissioning
Throroughly clean the truck.

Test the brakes.
Check the hydraulic oil level and replenish if necessary, see Checking the
Hydraulic Oil Level in chapter F.
Apply a thin coating of oil or lubrication to all non-painted mechanical parts.
Lubricate the truck in accordance with the lubrication schedule, see Lubrication
Schedule in chapter F.
Charge up the battery (see Charging the Battery in chapter D.)
Disconnect the battery and clean it. Apply dielectric grease to the battery terminals.
Z In addition, observe all the instructions of the battery manufacturer.
Spray all exposed electrical contacts with a suitable contact spray.
7.2 Action to be taken during decommissioning
Every 2 months:
Charge up the battery, see Charging the Battery in chapter D.
M Battery powered trucks:

It is important to regularly charge the battery as otherwise automatic discharge will
result in battery depletion. This will destroy the battery as a result of sulphurisation.
0210.GB
F 43
7.3 Restoring the truck to service after decommissioning
Thoroughly clean the truck.

Lubricate the truck in accordance with the lubrication schedule,
see "Lubrication Schedule" in chapter F.
Clean the battery. Grease the terminal screws with delectric grease and re-connect
the battery.
Charge up the battery, see Charging the Battery in chapter D.
Check if the transmission oil contains condensate water and replace if necessary.
Check if the hydraulic oil contains condensate water and replace if necessary.
Z The manufacturer's customer service department is specially trained to carry out

these operations.
Start up the truck,

see Starting up the truck in chapter E.
Z If there are switching problems in the electrical system, apply contact spray to the
exposed contacts and remove any oxide layers on the contacts of the controls by
applying them repeatedly.
F Electric currents from working with contact spray can cause accidents
discharged after approx. 10 minutes. Before starting maintenance work:
F Faulty brakes can cause accidents

As soon as the truck has been started, test the brakes several times.
0210.GB
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8 Safety tests to be performed at intervals and after unusual incidents
Z Perform a safety check in accordance with the national regulations. Jungheinrich

recommends the truck be checked to FEM guideline 4.004. Jungheinrich has a safety
department with trained personnel, able to carry out inspections.
The truck must be inspected at least annually or after any unusual event by a qualified
inspector (be sure to comply with national regulations). The inspector shall assess the
condition of the truck from purely a safety viewpoint, without regard to operational or
economic circumstances. The inspector shall be sufficiently instructed and
experienced to be able to assess the condition of the truck and the effectiveness of
the safety mechanisms based on the technical regulations and principles governing
the inspection of forklift trucks.
A thorough test of the truck must be undertaken with regard to its technical condition
from a safety aspect. The truck must also be examined for damage caused by
possible improper use. A test report shall be provided. The test results must be kept
for at least the next 2 inspections.
The owner is responsible for ensuring that faults are immediately rectified.
Z A test plate is attached to the truck as proof that it has passed the safety inspection.
This plate indicates the due date for the next inspection.
9 Final de-commissioning, disposal
Z Final, correct de-commissioning or disposal of the truck must be performed in

accordance with the regulations of the country of use. In particular, regulations
governing the disposal of batteries, fuels and electronic and electrical systems must
be observed.
10 Human vibration measurement
Z Vibrations that affect the driver during operation over the course of the day are known
as human vibrations. Excessive human vibrations will cause the driver long term
health problems. The European "2002/44/EC/Vibration" operator directive has
therefore been established to protect drivers.
To help operators to assess the application situation, the manufacturer offers a
service of measuring these human vibrations.
0210.GB
F 45
F 46
0210.GB
A Traction Battery Appendix
Contents
A Traction Battery Appendix....................................................... 1

1 Correct Use and Application.................................................................... 2
2 Data plate ................................................................................................ 2
3 Safety Instructions, Warning Indications and other Notes ....................... 3
4 Lead acid batteries with armour plated cells and liquid electrolyte.......... 4
4.1 Description............................................................................................... 4
4.2 Operation................................................................................................. 5
4.3 Servicing lead-acid batteries with armour plated cells............................. 8
5 PzV and PzV-BS lead-acid batteries with sealed armour plated cells..... 9
5.1 Description............................................................................................... 9
5.2 Operation................................................................................................. 10
5.3 Servicing PzV and PzV-BS lead-acid batteries with sealed armour plated
cells ......................................................................................................... 13
6 Aquamatik water replenishment system.................................................. 14
6.1 Water replenishment system design ....................................................... 14
6.2 Functional Description ............................................................................. 15
6.3 Adding water............................................................................................ 15
6.4 Water pressure ........................................................................................ 15
6.5 Filling time ............................................................................................... 16
6.6 Water quality............................................................................................ 16
6.7 Battery tubing .......................................................................................... 16
6.8 Operating temperature ............................................................................ 16
6.9 Cleaning measures.................................................................................. 17
6.10 Service mobile vehicle............................................................................. 17
7 Electrolyte circulation............................................................................... 18
7.1 Functional Description ............................................................................. 18
8 Cleaning batteries.................................................................................... 20
9 Storing the battery ................................................................................... 22
10 Troubleshooting....................................................................................... 22
11 Disposal................................................................................................... 22
03.13 EN
1
1 Correct Use and Application
Failure to observe the operating instructions, carrying out repairs with non-original
spare parts, tampering with the battery or using electrolyte additives will invalidate the
warranty.
Observe the instructions for maintaining the safety rating during operation for
batteries in accordance with Ex I and Ex II (see relevant certification).
2 Data plate
1,2 3
4 5
6 7
8 9
10 15
11
13
12
14
1 Battery name
2 Battery type
3 Production week/year manf.
4 Serial number
5 Supplier number
6 Rated voltage
7 Rated capacity
9 Battery weight in kg
8 Number of cells
15 Electrolyte volume in litres
10 Battery number
11 Manufacturer
13 Manufacturer's logo
12 CE mark only for batteries beyond 75 volts
14 Safety instructions and warning information
03.13 EN
2
3 Safety Instructions, Warning Indications and other Notes
Used batteries must be treated as hazardous waste.
These batteries are marked with the recycling symbol and the sign
showing a crossed-out rubbish bin, and should not be disposed of
with ordinary household waste.
waste.
Buy-back terms and type of recycling are to be agreed with the

manufacturer as described in 8 of the battery legislation.
Do not smoke!
No naked flames, glowing embers or sparks near the battery - fire

and explosion hazard!
Avoid fire and explosion hazards and short circuits due to

overheating!
Keep away from naked flames and strong heat sources.
Always wear protective clothing (e.g. safety goggles and safety

gloves) when working on cells and batteries.
batteries.
Always wash your hands after completing the work. Use insulated
tools only. Do not physically
alter the battery, strike, crush, compress, notch, dent or modify it in
any way.
Hazardous electric voltage! The metal parts of the battery cells are
permanently live. Therefore do not place any foreign objects or tools
on the battery.
Observe national health and safety regulations.
If the materials leak, do not inhale the fumes. Wear safety gloves.
Follow the user instructions and keep them in a visible position in the
charging area.
Work on the batteries should be performed only as instructed by
specialist personnel.
03.13 EN
3
4 Lead acid batteries with armour plated cells and liquid
electrolyte
4.1 Description
Jungheinrich traction batteries are lead acid batteries with armour plated cells and
liquid electrolyte. The names of the traction batteries are PzS, PzB, PzS Lib and PzM.
Electrolyte
The rated density of the electrolyte assumes a temperature of 30C and the rated
electrolyte level is fully charged. Higher temperatures will reduce, lower temperatures
will increase the electrolyte density. The adjustment factor is 0.0007 kg/l per K, e.g.
electrolyte density 1.28 kg/l at 45C corresponds to a density of 1.29 kg/l at 30C.
The electrolyte must conform to DIN 43530 Part 2 purity regulations.
4.1.1 Battery nominal data
1. Product Traction battery

2. Nominal voltage 2.0 V x no. of cells
3. Rated capacity C5 See data plate
4. Discharge current C5/5h
5. Nominal electrolyte density1 1.29 kg/l
6. Nominal temperature2 30 C
7. System rated electrolyte level up to "Max" electrolyte level marking
Limit temperature3 55C
1. Reached within the first 10 cycles.
2. Higher temperatures shorten the useful life, lower temperatures reduce
the available capacity.
3. Not permissible as operating temperature.
03.13 EN
4
4.2 Operation
4.2.1 Commissioning unfilled batteries

Z The operations required must be carried out by the manufacturer's customer
service department or a customer service organisation authorised by the
manufacturer.
4.2.2 Commissioning filled and charged batteries

Checks and operations to be performed before starting daily work
Procedure
Make sure the battery is in physically good condition.
Make sure the terminals are correct (positive to positive and negative to negative)
and check that contacts on the battery terminal conducting system are secure.
Check the terminal screw torques (M10 = 23 1 Nm) of the terminal conductors and
connectors.
Charge up the battery.
Check the electrolyte level.
Z The electrolyte level must be above the cell baffle or the top of the separator.
Add electrolyte with distilled water up to the nominal level.
Checks completed.
4.2.3 Discharging the battery

Z To achieve an optimum useful life avoid operational discharge of more than 80% of
nominal capacity (full discharge). This corresponds to a minimum electrolyte
density of 1.13 kg/l at the end of the discharge. Recharge a discharged battery
immediately.
03.13 EN
5
4.2.4 Charging the battery
WARNING!
The gases produced during charging can cause explosions
Always disconnect the charger and truck before connecting or disconnecting the
charger and battery.
The charger must be adapted to the battery in terms of voltage, charge capacity
and battery technology.
Battery cell surfaces must remain exposed during charging in order to ensure
sufficient ventilation, see truck operating instructions, chapter D, Charging the
Battery.
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 m from the truck.
Fire protection equipment must be available.
Do not place any metallic objects on the battery.
Always follow the safety regulations of the battery and charger station
manufacturers.
NOTE
The battery must only be charged with DC current. All charging processes in
accordance with DIN 41773 and DIN 41774 are permissible.
03.13 EN
6
Z The electrolyte temperature rises by approx. 10 K during charging. Charging should
therefore only begin when the electrolyte temperature is below 45C. The
electrolyte temperature of batteries must be at least +10C before charging.
Otherwise the battery will not charge correctly. Below 10C the battery is
insufficiently charged with standard charging systems.
Charging the battery
Requirements
Electrolyte temperature min. 10C to max. 45C
Procedure
Open or take off the tray lid or covers from the battery compartment.
Z Deviations are outlined in the truck's operating instructions. The plugs remain on
the cells or remain closed.
Connect the battery to the switched off charger, ensuring the terminals are connect
(positive to positive and negative to negative).
Battery charged
Z Charging is considered to be complete when the electrolyte density and battery
voltage remain constant for more than 2 hours.
Compensation charging
Compensation charging is used to ensure the useful life and maintain capacity after
full discharge and repeated insufficient charging. The maximum compensation
charge current is 5 A/100 Ah rated capacity.
Z Compensation charging should be carried out weekly.
Trickle charging
Battery trickle charging is partial charging that extends the daily application time.
Higher average temperatures occur during trickle charging which reduce the useful
life of the batteries.
Z Trickle charges should only be performed when the charge level is below 60 %. Use
replacement batteries instead of regular trickle charging.
03.13 EN
7
4.3 Servicing lead-acid batteries with armour plated cells
Water quality
Z The quality of the water used to fill up electrolyte must correspond to purified or
distilled water. Purified water can be produced through distillation or ion
exchangers and is then suitable for the production of electrolyte.
4.3.1 Daily
Charge the battery after each discharge.
After charging, check the electrolyte level.
If necessary, add purified water up to the rated level after charging.
Z The height of the electrolyte level should not be below the cell baffle or above the
top of the separator, or the "Min" and "Max" electrolyte markings respectively.
4.3.2 Weekly
After re-charging, carry out a visual inspection for dirt and physical damage.
If the battery is charged regularly according to the IU characteristic, carry out a
compensation charge.
4.3.3 Monthly
Towards the end of the charging process measure and record the voltages of all
the cells with the charger switched on.
After charging measure and record the electrolyte density and the electrolyte
temperature in all the cells.
Compare the results with the previous ones.
Z If you find significant differences compared with the previous measurements or
differences between the cells, contact the manufacturer's customer service
department.
4.3.4 Annually
Measure the truck insulation resistance in accordance with EN 1175-1.
Measure the battery insulation resistance in accordance with EN 1987-1.
Z In accordance with DIN EN 50272-3 the battery insulation resistance should not be
less than 50 per volt of rated voltage.
03.13 EN
8
5 PzV and PzV-BS lead-acid batteries with sealed armour
plated cells
5.1 Description
PzV batteries are sealed batteries with fixed electrolytes, to which no water can be
added over the entire lifespan of the battery. Relief valves are used as plugs which
are destroyed when opened. During operation the same safety requirements apply to
the sealed batteries as for batteries with liquid electrolyte. This is to avoid electric
shock, explosion of the electrolyte charging gases or hazardous electrolyte burns if
the cell vessels are destroyed.
Z PzV batteries are low gassing, but not gassing-free.
Electrolyte
The electrolyte is sulphuric acid which is fixed in gel. The density of the electrolyte
cannot be measured.
5.1.1 Battery nominal data
1. Product Traction battery

2. Nominal voltage 2.0 V x no. of cells
3. Rated capacity C5 See data plate
4. Discharge current C5/5h
5. Rated temperature 30 C
Limit temperature1 45C, not permissible as operating
temperature.
6. Rated density of the electrolyte Cannot be measured
7. System rated electrolyte level Cannot be measured
1. Higher temperatures shorten the useful life, lower temperatures reduce
the available capacity.
03.13 EN
9
5.2 Operation
5.2.1 Commissioning
Checks and operations to be performed before starting daily work
Procedure
Make sure the battery is in physically good condition.
Make sure the terminals are correct (positive to positive and negative to negative)
and check that contacts on the battery terminal conducting system are secure.
Check the terminal screw torques (M10 = 23 1 Nm) of the terminal conductors and
connectors.
Re-charge the battery.
Charge the battery.
Check completed.
5.2.2 Discharging the battery

Z To achieve an optimum useful life avoid operational discharges of more than 60%
of nominal capacity.
Z If the battery is discharged during operation by more than 80% of rated capacity the
useful life of the battery will reduce significantly. Fully or partially discharged
batteries must be re-charged immediately and not left unattended.
5.2.3 Charging the battery
WARNING!
The gases produced during charging can cause explosions

Always disconnect the charger and truck before connecting or disconnecting the
charger and battery.
The charger must be adapted to the battery in terms of voltage, charge capacity
and battery technology.
Battery cell surfaces must remain exposed during charging in order to ensure
sufficient ventilation, see truck operating instructions, chapter D, Charging the
Battery.
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 m from the truck.
Fire protection equipment must be available.
Do not place any metallic objects on the battery.
Always follow the safety regulations of the battery and charger station
03.13 EN
manufacturers.
10
NOTE
Charging the battery incorrectly can result in material damage.

Incorrect battery charging can result in overloading of the electric wires and contacts,
hazardous gas formation and electrolyte leakage from the cells.
Always charge the battery with DC current.
All DIN 41773 charging procedures are permitted in the format approved by the
manufacturer.
Always connect the battery to a charger that is appropriate to the size and type of
the battery.
If necessary have the charger checked by the manufacturer's customer service
department for suitability.
Do not exceed limit currents in the gassing area in accordance with DIN EN 50272-
3.
03.13 EN
11
Charging the battery
Requirements
Electrolyte temperature between +15C and 35C
Procedure
Open or take off the tray lid or covers from the battery compartment.
Connect the battery to the switched off charger, ensuring the terminals are connect
(positive to positive and negative to negative).
Z The electrolyte temperature rises by approx. 10 K during charging. If the
temperatures are permanently higher than 40C or lower than 15C, a temperature-
dependent constant voltage control of the charger is required. The adjustment
factor must be applied with -0.004 V/C per K.
Battery charged
Z Charging is considered to be complete when the electrolyte density and battery

voltage remain constant for more than 2 hours.
Compensation charging
Compensation charging is used to ensure the useful life and maintain capacity after
full discharge and repeated insufficient charging.
Z Compensation charging should be carried out weekly.
Trickle charging
Battery trickle charging is partial charging that extends the daily application time.
Higher average temperatures occur during trickle charging which can reduce the
useful life of the batteries.
Z Trickle charges should only be performed when the charge level is below 50%. Use
replacement batteries instead of regular trickle charging.
Z Avoid trickle charging with PzV batteries.
03.13 EN
12
5.3 Servicing PzV and PzV-BS lead-acid batteries with sealed armour
plated cells
Z Do not add water!
5.3.1 Daily
Charge the battery after each discharge.
5.3.2 Weekly
Visually inspect for dirt and physical damage.
5.3.3 Every three months

Measure and record the overall voltage.
Measure and record the individual voltages.
Compare the results with the previous ones.
Z Carry out the measurements after full charging and subsequent resting for at least
5 hours.
Z If you find significant differences compared with the previous measurements or
differences between the cells, contact the manufacturer's customer service
department.
5.3.4 Annually
Measure the truck insulation resistance in accordance with EN 1175-1.
Measure the battery insulation resistance in accordance with EN 1987-1.
Z In accordance with DIN EN 50272-3 the battery insulation resistance should not be
less than 50 per volt of rated voltage.
03.13 EN
13
6 Aquamatik water replenishment system
6.1 Water replenishment system design
15
16
17
>3m 18
19
20
+ -
15 Water container
16 Tap connection with ball cock
17 Flow indicator
18 Shut-off cock
19 Locking coupling
20 Battery lock connector 03.13 EN
14
6.2 Functional Description
The Aquamatik water replenishment system is used to adjust the rated electrolyte
level automatically on traction batteries for industrial trucks.
The battery cells are interconnected through hoses and are attached to the water
supply (e.g. water container) through a plug connection. When the shut-off cock is
opened all the cells are filled with water. The Aquamatik plug controls the amount of
water required and, at the relevant water pressures, ensures the water supply is shut
off and the valve is closed securely.
The plug systems have an optical level indicator, a diagnostic port to measure the
temperature and electrolyte density and a degassing port.
6.3 Adding water

Water should be added to the batteries just before the battery is fully charged. This
ensures that the amount of water added is mixed with the electrolyte.
6.4 Water pressure

The water replenishment system must be operated with a water pressure in the water
line of 0.3 bar - 1.8 bar. Any deviations from the permissible pressure ranges will
affect the operation of the systems.
Water drop
Assembly height above battery surface is between 3 - 18 m. 1 m corresponds to 0.1

bar
Pressure water
The pressure regulating valve is adjusted to suit the system and must lie between 0.3
- 1.8 bar.
03.13 EN
15
6.5 Filling time
The filling time for a battery depends on the electrolyte level, the ambient temperature
and the filling pressure. Filling ends automatically. The water supply line must be
disconnected from the battery when the water has been filled.
6.6 Water quality

Z The quality of the water used to fill up electrolyte must correspond to purified or
distilled water. Purified water can be produced through distillation or ion
exchangers and is then suitable for the production of electrolyte.
6.7 Battery tubing

The tubing of the individual plugs is in accordance with the existing electric circuit. No
changes should be made.
6.8 Operating temperature

Batteries with automatic water replenishment systems should only be stored in rooms
with temperatures > 0C, as otherwise the systems could freeze.
03.13 EN
16
6.9 Cleaning measures
The plug systems must only be cleaned with purified water in accordance with DIN
43530-4. No parts of the plugs must come into contact with solvent-based materials
or soap.
6.10 Service mobile vehicle

Mobile water filling vehicle with pump and filling gun to fill individual cells. The
immersion pump in the container generates the necessary filling pressure. The
service mobile must be at exactly the same height as the battery base.
03.13 EN
17
7 Electrolyte circulation
7.1 Functional Description
Electrolyte circulation ensures the supply of air during charging to mix the electrolyte,
thereby preventing any acid layer, shortening the charge time (charge factor approx.
1.07) and reducing the formation of gas during charging. The charger must be
suitable for the battery and electrolyte circulation.
A pump in the charger produces the necessary compressed air which is introduced
to the battery cells via a hose system. The electrolyte is circulated via the inlet air and
the electrolyte density level is constant over the entire length of the electrode.
Pump
In the event of a fault, e.g. if the pressure control system responds for an unknown
reason, the filters must be checked and replaced if necessary.
Battery connection
A hose is attached to the pump module which together with the charge leads is routed
from the charger to the charging connector. The air is passed on to the battery via the
electrolyte circulation coupling ducts in the connector. When routing make sure the
hose is not bent.
Pressure monitoring module
The electrolyte circulation pump is activated when charging begins. The pressure
monitoring module monitors the build up of pressure during charging. This ensures
that the required air pressure is provided for electrolyte circulation charging.
In the event of malfunctions such as:

Battery air coupling not connected to circulation module (if coupling is separate) or
faulty.
Leaky or faulty hose connections on battery or
Intake filter contaminated
a visual error message appears on the charger.
03.13 EN
18
NOTE
If an installed electrolyte circulation system is seldom used or not used at all,
or if the battery is subjected to severe temperature fluctuations, the electrolyte
may flow back into the hose system.
Attach a separate coupling system to the air inlet line, such as: locking coupling on
the battery side and through-coupling on the air supply side.
Schematic illustration
Electrolyte circulation on the battery and air supply via the charger.
03.13 EN
19
8 Cleaning batteries
Batteries and trays must be cleaned in order to
maintain cell insulation and protect cells from ground or external conductive parts.
Avoid damage from corrosion and stray currents.
Avoid excessive and varying automatic discharge of the individual cells or block
batteries due to stray currents.
Avoid electric sparking due to stray currents.
When cleaning the batteries make sure that:
The assembly site chosen for cleaning is close to a drainage system for processing
the electrolytic rinsing water.
All health and safety as well as water and waste disposal regulations are observed
when disposing of used electrolyte or rinsing water.
Protective goggles and clothing are worn.
Cell plugs are not removed or opened.
Clean the plastic components of the battery, in particular the cell containers, only
with water or water-based cloths without any additives.
After cleaning, the top of the battery is dried with suitable equipment, e.g.
compressed air or cloths.
Any fluid that has entered the battery box must be suctioned off and disposed of in
accordance with the above-mentioned regulations.
03.13 EN
20
Cleaning the battery with a high pressure cleaner
Requirements
Cell connectors tight, plugged in securely
Cell plugs closed
Procedure
Follow the high pressure cleaner's user instructions.
Do not use any cleaning additives.
Observe the permissible cleaning device temperature setting of 140C.
Z This generally ensures that the temperature does not exceed 60C at a distance of
30cm behind the outlet nozzle.
Observe the maximum operating pressure of 50 bar.
Observe a minimum distance of 30 cm from the top of the battery.
The battery should be sprayed over its entire surface to avoid localised
overheating.
Z Do not clean one spot for more than 3 seconds with the jet to avoid exceeding the
maximum battery surface temperature of 60C.
After cleaning dry the battery surface with suitable materials e.g. compressed air or
cleaning cloths.
Battery cleaned.
03.13 EN
21
9 Storing the battery
NOTE
The battery should not be stored for longer than 3 months without charging as
otherwise it will no longer be functional.
If the battery is to be taken out of service for a long period, it should be stored fully
charged in a dry room protected from frost. To ensure the availability of the battery
the following charges can be selected:
Monthly compensation charge for PzS and PzB batteries or 3-monthly full charge
for PzV batteries.
Trickle charge for a charge voltage of 2.23 volts x no. of cells for PzS, PzM and PzB
batteries or 2.25 volts x no. of cells for PzV batteries.
If the battery is to be taken out of service for a long period ( > 3 months), it should, as
far as possible, be charged to 50% of its charge level and stored in a dry room
protected from frost.
10 Troubleshooting
If any faults are found on the battery or charger, contact the manufacturer's customer
service department immediately.
Z The operations required must be carried out by the manufacturer's customer

service department or a customer service organisation authorised by the
manufacturer.
11 Disposal
Batteries marked with the recycling symbol and the sign showing a
crossed-out rubbish bin should not be disposed of with ordinary
household waste.
Buy-back terms and type of recycling are to be agreed with the
manufacturer as described in 8 of the battery legislation.
03.13 EN
22

EKS 513 / 515k / 515 EKX 513 / 515k / 515: Operating Instructions

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EKS 513 / 515k / 515 EKX 513 / 515k / 515: Operating Instructions

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EKS 513 / 515k / 515

EKX 513 / 515k / 515 05.07 -

Jungheinrich AG, Am Stadtrand 35, D-22047 Hamburg

Type Option Serial No. Year of Construction

Safety instructions and important explanations are indicated by the following

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

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

Z Used before notices and explanations.

t Used to indicate standard equipment.

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

C Transport and Commissioning

D Battery - Servicing, Recharging, Replacement

1 Safety Regulations Governing the Handling of

1 Safety Regulations for the Operation of Forklift Trucks ...................... E 1

1 Operational Safety and Environmental Protection .............................. F 1

JH Traction Battery Operating Instructions JH Traction Battery Operating Instructions

Lifting, lowering and picking loads.

3 Approved application conditions

5 Adding attachments and/or accessories

The mounting or installation of additional equipment which affects or enhances

The EKX is an electric three-way stockpicker. The EKS is an electric stockpicker.

For rail-guided trucks a minimum safety distance of 100 mm must be maintained

Z The ground must comply with DIN 15185 Part 1.

The capacity is shown on the data plate.

Type Capacity Load centre of gravity

EKS 513 / 515k / 515 Left

t = Standard equipment o = Optional equipment

Emergency Stop safety feature

Vertically mounted, heavy-duty and maintenance-free threephase motor with no

Electronically controlled drive brake and wear-free electromagnetic multiplate

Generous entry room

All hydraulic operations are controlled by a sturdy, maintenance-free AC motor with

Electronic system with wear-free sensors.

Z For drive battery options refer to Battery Types in Chapter D.

Mechanical rail guidance.

Z Technical data specified in accordance with VDI 2198 / EN 1726 *.

Description EKX 513 EKX 515k EKX 515

RG: Rail guidance

3.3.1 Standard mast version with telescopic mast (ZT)

Description EKX 513 EKX 515k EKX 515

Description EKX 513 EKX 515k EKX 515

EKX 513 EKX 515k EKX 515

Basic truck weight

Truck Basic truck weight

A Truck net weight without battery

Formula for the EKX 513/515k/515 and EKS 513/515k/515:

Truck type = EKX 515

EKX 513 EKX 515k EKX 515

F Accident risk from incorrect wheel disassembly/assembly

EKX 513 / EKS 513

Description EKX 513 / EKS 513

EKX 515k / EKS 515k

Description EKX 515k / EKS 515k

EKX 515 / EKS 515

Description EKX 515 / EKS 515

Noise emission level: 68 dB(A)

in accordance with EN 12053 as harmonised with

Vibration: 1.14 m/s2 in accordance with EN 13059

Seat vibration: 0.70 m/s2

Z The internal accuracy of the measuring chain at 21C is 0.02 m/s.

Electromagnetic compatibility (EMC)

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

Ambient temperature: operating at 5 qC to 40 qC