115-03 Operator Manual 1158071001EN 03-2009 PDF

Operating Instructions
Electric reach truck
R14, R14HD, R14N, R16,

R16HD, R16N, R20, R20N
115 807 10 01 EN – 03/2009
Preface
g
Linde - Your Partner
With over 100,000 fork lift trucks and ware- ranging from expert advice on all aspects
house machines sold annually, Linde is one of of sales and service through, of course, to
the world’s leading manufacturers of material appropriate finance options. Our leasing, hire
handling equipment. There are many reasons or lease-purchase agreements provide you
for this success: Linde products are renowned with the flexibility to tailor decision-making to
not only for their innovative, cutting-edge tech- your individual business requirements.
nology, but also for their low energy and oper-
Linde Material Handling (UK) Ltd
ating costs, which are up to 40 per cent lower
Kingsclere Road
than those of their competitors.
Basingstoke
The high quality of Linde products is also Hants RG21 6XJ
matched by the quality of our service. With ten Telephone 01256 342000
production plants worldwide and an extensive Fax 01256 342923
network of sales partners, we are at your Web www.linde-mh.co.uk
service round the clock and around the world.
Your local Linde partner can offer you a
complete package from a single source;
Operating Instructions – 115 807 10 01 EN – 03/2009 I

Table of contents
g
1 Introduction and general description

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Safety
Operator safety guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Noise emission levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Frequency characteristic for human body vibrations . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3 Getting to know the truck

Location of identification plates and labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Truck type/capacity plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
General view of truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Operating controls and indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Operator’s display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Lift height indicator (LHI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Definition of direction of travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4 Operation
Running-in instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Pre-shift checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
The battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Operator adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Braking – twin pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Braking – single pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Driving – twin pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Driving – single pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Starting on an incline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Operating the mast and attachments (with two joystick control) . . . . . . . . . . . . . . . . . . 58
Operating the mast and attachments (with four joystick control) . . . . . . . . . . . . . . . . . . 61
Handling loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Before leaving the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Cold store cabin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Operating Instructions – 115 807 10 01 EN – 03/2009 III

Table of contents
g
360° Steering (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Opposite direction steering (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Height pre-selector - LPS (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Operator code entry (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Data Logger (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Truck data management – LFM (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Side guidance for drive-in racking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Closed circuit television . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5 Maintenance
Maintenance safety guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Report of Thorough Examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Covers and cowlings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Emergency lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Emergency steering and parking brake release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Slinging the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Securing for transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Jacking the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Towing procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Mast unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Recommended lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Inspection and maintenance data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Inspection and maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Routine inspection and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Pre-shift checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Inspection and maintenance after the first 50 hours of operation . . . . . . . . . . . . . . . . . . 121
Inspection and maintenance as required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Inspection and maintenance every 1000 hours (250 hours cold store version) . . . . . . . 121
Inspection and maintenance every 2000 hours (1000 hours cold store version) . . . . . . 122
Inspection and maintenance every 5000 hours (2500 hours cold store version) . . . . . . 122
Inspection and maintenance every 10000 hours or 5 years, whichever is earlier (5000
hour or 30 months cold store version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Inspection and maintenance as required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Clean the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Check the battery electrolyte level and specific gravity . . . . . . . . . . . . . . . . . . . . . . . . . 124
IV Operating Instructions – 115 807 10 01 EN – 03/2009

Table of contents
g
Lubricate the lift chains and mast channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Adjust the lift chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Replace the hydraulic hoses and pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Check the drive wheel nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Replace the battery trolley slides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
1000 hr Inspection and maintenance (250 hr cold store) . . . . . . . . . . . . . . . . . . . . . . . 128
Check the condition and security of the wheels and tyres . . . . . . . . . . . . . . . . . . . . . . . 128
Check the condition of the battery and battery cables . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Check the condition and security of electrical connections and cables . . . . . . . . . . . . . 130
Check the parking brake gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Check the hydraulic hoses and pipes for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Check the lift chains for condition and security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Lubricate the mast, mast rollers, lift chains and chain pulleys . . . . . . . . . . . . . . . . . . . . 132
Lubricate the mast hose pulley assemblies (cold store only) . . . . . . . . . . . . . . . . . . . . . 133
Lubricate the reach channels and rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Check and lubricate the battery trolley slides and associated mechanism . . . . . . . . . . . 134
Check the hydraulic oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Lubricate the fork carriage and sideshift slider pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Check condition of side guide rollers (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Lubricate cold store cab hinges and door latch (option) . . . . . . . . . . . . . . . . . . . . . . . . 136
Check the brake fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Check the load wheel brake shoes for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Replace the hydraulic tank breather filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Check the reach carriage rollers, adjust if required . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Grease the load wheel bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Check condition of brake pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Change the hydraulic oil and suction filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
10000 hr Inspection and maintenance (5000 hr cold store) . . . . . . . . . . . . . . . . . . . . . . 142
Change the brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Operating Instructions – 115 807 10 01 EN – 03/2009 V

Table of contents
g
Taking the truck out of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

Decommissioning the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
6 Technical data
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Technical data – 1.4 tonne capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Technical data – 1.4 tonne capacity (heavy duty) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Technical data – 1.4 tonne capacity (narrow chassis) . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Technical data – 1.6 tonne capacity (heavy duty) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Mast variations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Annex
7 Circuit diagrams
Circuit Diagram (1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Circuit diagram (Standard) - keycode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Circuit Diagram - variable electric brake (1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Circuit diagram (Variable electric brake) - keycode . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Hydraulic circuit - keycode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
VI Operating Instructions – 115 807 10 01 EN – 03/2009

1
Introduction and general description

Introduction
Introduction
Using this manual prescribed in the Inspection and Maintenance
Schedule regularly and on time.
In order to reduce the risk of personal injury,
injury to others, and to prevent possible To keep your warranty valid, and to ensure
damage to the truck, the comments below safety, all maintenance should only be carried
used in this manual indicate specific dangers out by qualified persons authorised by your
or unusual information that requires special local distributor.
attention:
DANGER Referenced standards
Indicates hazards that may result in bodily injury or This truck complies with the standard
death and/or severe product damage. EN1726-1, (Safety of industrial trucks —
Self-propelled trucks up to and including
10 000 kg capacity and industrial tractors with
WARNING a drawbar pull up to and including 20 000 N —
Indicates hazards that may result in bodily injury Part 1: General requirements), which meets
and/or severe product damage. with the specific essential requirements of the
EU Directive 98/37/CE for Safety of machinery
It also complies with the standard EN 12895
CAUTION
for Electromagnetic Compatibility and sub-
Indicates hazards that may result in damage to, or sequent amendments for materials handling
destruction of the product. trucks, which meets with the specific essential
requirements of Directive 89/336/CEE.
ENVIRONMENT NOTE Sound level tests are performed in accordance
with standard EN 12053
Indicates hazards that may be harmful to the
environment. Vibration level tests are performed in ac-
cordance with standards EN 13059 and EN
NOTE 12096
Identifies technical information requiring
special attention because the connection may Approved applications
not be obvious even to skilled personnel. Your truck is designed for transporting and
lifting stable loads as stated on the load
Your lift truck capacity plate within a temperature range
of −10 °C to +40 °C (−30 °C to +40 °C cold
Your truck offers the best in economy, safety store version).
and driving convenience. However, preserv-
ing the qualities of the truck for a long and In particular, we draw your attention to the
profitable service life, and making full use of accompanying booklet (VDMA or BITA for
it’s benefits in operation relies mainly on the UK market) concerning the safe operation
operator. and accident prevention for fork lift trucks, to
the safety guidelines for gas vehicles and the
This User Manual describes all you must regulations for use of the truck on public roads.
know about starting, running, servicing and
maintaining your truck. The booklet for users of industrial and rough
terrain trucks (VDMA or BITA for UK market)
Follow the instructions for operating the truck must be followed under all circumstances by
and carry out the maintenance and care the operator and service personnel.
2 Operating Instructions – 115 807 10 01 EN – 03/2009

Introduction and general description 1
Introduction
The user, and not the manufacturer, is re- as a result of technological progress by the
sponsible for any injury or damage arising as manufacturer.
a result of misuse, neglect, abuse, alterations,
We are therefore unable to consider any
incorrect maintenance or repairs and applica-
claims based on the specification, illustrations,
tions not authorised by the manufacturer.
and descriptions contained in this User
Should you want to use the truck for applica- Manual.
tions not covered in these instructions, please
Please submit all enquiries concerning orders
contact your local distributor. No modifica-
for spare parts to your local distributor, making
tions or conversions may be made, or addi-
sure to give the correct delivery address.
tional equipment fitted to your truck, without
prior permission of the manufacturer. For repairs use only genuine spare parts. Only
in this way can it be guaranteed that your truck
For attachments, the operating instructions
maintains its original technical standard.
supplied by the attachment manufacturer are
applicable. When ordering spare parts, please specify the
part number and state the following truck data.
NOTE
Truck type:
If fitting an attachment, then an additional
capacity plate is required.
CAUTION Manufacturer’s serial No./year built:
Operating on gradients over 10% is not permitted
due to the truck stability characteristics.
The climbing ability rates given in the data sheet
are based on the tractive force of the truck and they Delivery date:
apply only to relatively short slope lengths. Please
contact your local distributor before driving on long
slopes.
Please also specify the production number of
the mast, when ordering mast parts.
DANGER
Mast Number:
Never use a standard truck in areas where there is a
risk of explosion from gases, vapors, or flammable
and explosive powders.
Trucks that are required to operate in such environ-
ments must be specially protected. They must be Mast lift height [mm] :
accompanied by a specific EC statement of confor-
mity and the appropriate User Manual.
When taking over the fork lift truck, transfer

Technical note the data from the type plates into this User
This User Manual or excerpts thereof may Manual. This information can be found on
only be copied, translated or transmitted to the type plate attached to the operator’s
third parties after prior written approval by the console. We recommend that you transfer this
manufacturer. information to this manual for ease of future
reference.
We pursue a policy of continuous improve-
ment in design and manufacture of our prod-
ucts. The illustrations and technical details Truck takeover
referring to design, fittings, and engineering of Every truck undergoes careful inspection
lift trucks are subject to change or modification before leaving the factory in order to make
Operating Instructions – 115 807 10 01 EN – 03/2009 3

Introduction
sure that it will be in good condition and fully In order to avoid later complaints and incon-
equipped as ordered when delivered. venience to customers, you are requested to
ascertain that the truck is in satisfactory condi-
Your local distributor is under obligation to
tion and fully equipped at the time of delivery
recheck the following before delivery and to
and to acknowledge the correct installation of
hand the truck over in full working order.
the truck in the manufacturer’s certificate of
Check the security of the drive wheel nuts conformity.
Check the battery electrolyte level and
The following technical documents belong to
specific gravity
each fork lift truck:
Check the hydraulic oil level
Check the braking systems for correct and • User Manual
safe operation • EC Certificate of Conformity (The manu-
Check the steering system for correct and facturer certifies that the industrial truck
safe operation conforms to all relevant EC directives.)
Check the traction system for correct and • Spare Parts Catalogue (On CD)
safe operation
Check the mast and any attachments for • Booklet for users of industrial and rough
correct and safe operation terrain trucks (VDMA or BITA for UK market)

Introduction and general description 1
General description
General description
Introduction Electrical system
Your truck, which complies with all relevant EC These trucks are fitted with an advanced high
directives, has been developed to meet the frequency digital control system for traction,
most arduous application requirements. The steering and load handling. This system,
main design features result from a thorough which incorporates automatic regenerative
analysis of today’s warehouse logistics to electric braking, reacts progressively to
achieve maximum productivity. The overall operator demand and provides extremely
design concept ensures excellent operator smooth movements. This technology ensures
comfort contributing significantly to high work maximum efficiency from the truck and a
throughput with minimum fatigue. high number of work cycles from the battery.
Parameter adjustment allows the trucks to be
Operator’s compartment and controls tailored to suit a particular requirement and
integrated diagnostics ensure rapid servicing
The operator’s compartment has been de- and maximum uptime.
signed totally with the operator in mind. Every
aspect of form and function to maximise the
Steering
combined efficiency of man and machine for
increased productivity has been evaluated. Electrical ’fly by wire’ steering reduces opera-
The advanced, ergonomic layout of all oper- tor fatigue, ensures excellent manoeuvrability
ating controls ensures optimum comfort and and generally improves work handling. The
efficiency. The purpose-built suspension seat steering system provides feedback to the
supports every operational body movement steering wheel, ensuring full operator confi-
and its full lateral, lumbar and weight adjust- dence. 360° Steering is available as an option.
ments suit all operations. Finger light joysticks
provide precise control of all load handling Mast, hydraulics and reach system
functions.
The low deflection triplex clearview fixed mast
with tilting carriage gives a completely free
Chassis
view through the mast at all stages of lift for
The chassis has been designed to achieve faster, safer load handling. The unique design
maximum strength and rigidity. The rear lower uses only two hydraulic cylinders mounted
chassis consists of a steel casting giving a behind the mast uprights.
low centre of gravity for stability and excellent
The tilting carriage, fitted with an integral
residual capacities at high lift. The operator’s
sideshift, reduces forward load movement
compartment, motors, and electronics, are
to a minimum to provide excellent residual
protected within the rugged structure, with
capacities at all lift heights.
easy accessibility for maintenance.
Through-the-mast reeving for up to four
Drive and transmission hydraulic functions eliminates the need for
hose reels. Sealed for life angled rollers
A powerful 6.5 kW fixed AC drive motor is ensure smooth, rapid, lift/lower movements.
mounted above a turntable gearbox assem-
bly. Power is transmitted to the drive wheel via Integral outer mast and reach frame allows
a spur and bevel transmission. Reduced trac- excellent forward visibility of the forks and load
tion performance is available with the parking at low levels.
brake applied to enable safe starting on gradi- A powerful 14.0 kW AC pump motor with
ents without overloading the transmission or automatic slowdown at full lift, gives rapid lift
parking brake. movement, whilst automatic slowdown at both

General description
ends of the reach movement ensures smooth, • Hydraulic footbrake operating on the load
fast, safe and accurate load handling cycles. wheels
Comprehensive mast dampening measures • Parking brake operating on drive motor
means seamless mast function under all con- • Regenerative electric braking occurs
ditions since the control system automatically automatically when either accelerator
smooths out any sharp joystick movements demand is reduced or the opposite direction
the operator might make. of travel is selected
Brakes
The trucks have three independent braking
systems:

2
Safety
2 Safety
Operator safety guidelines

NOTE DANGER
One of the major causes of accidents involving lift
The safety rules within this manual must be trucks is the operator ignoring, or being unaware of
observed at all times. These rules are part of, basic safe operating practices.
and do not replace the rules described in the In order to ensure the safety of the operator and
booklet supplied with this truck for users of others, a few basic safe operating practices outlined
industrial and rough terrain trucks (VDMA or below must be followed.
BITA for UK markets).
Personal factors
Prior to any work with or on the truck all re-
sponsible staff, particularly the truck operators ¾ Only operators with the correct certification,
and servicing personnel, must be instructed by issued by qualified instructors should
qualified instructors in the normal and proper operate the truck.
use of the truck, and with the safety guidelines
¾ Operators must adopt a sense of respon-
supplied with this User Manual.
sibility. They must understand that they
The employer must ensure that the operator are operating valuable equipment, moving
has understood all safety information. goods in a confined area, probably where
other people work.
Please observe the operating guidelines and
safety rules in this User Manual, in particular: ¾ Before starting work, the pre-shift checks
described in this manual MUST be carried
• Information on the operation of industrial
out by the operator.
trucks
• Rules for roadways and work areas ¾ If the truck shows signs of damage or
develops a fault and it cannot be used
• Rights, duties and safety rules for the
safely, park it in a safe position, switch off,
operator
remove the key and inform supervision. Do
• Operation in special areas not operate a faulty truck.
• Information related to starting, driving and
braking ¾ Always maintain the truck in good condition,
this will ensure any potential risks are kept
• Service and repair information
to a minimum.
• Recurrent inspections, accident prevention
check ¾ Keep any warning labels or plates attached
to the truck in good condition. Replace any
• Disposal of greases, oil and batteries
illegible labels or plates.
The operator (owner) or responsible person
¾ Always handle, charge and maintain
must ensure that the above operating guide-
batteries according to the manufacturer’s
lines and safety rules are observed at all times.
instructions supplied with the battery.
During training the operator must fully ac-
¾ Protective equipment i.e. goggles and
quaint themselves with:
gloves must be worn at all times when
• special features of the lift truck working on batteries.
• additional attachments ¾ Do not install additional equipment on
• special operating conditions the truck unless it has been supplied, or
Practice driving, control and steering opera- approved by your local distributor.
tions with truck unladen until they are com-
pletely understood. Only then can stacking
and de-stacking operations commence.

Safety 2
Operating procedures ¾ If possible cross rail tracks, door thresholds

etc. at an angle.
¾ Always adapt your driving style to the
conditions of the roadway, particularly ¾ Do not operate the truck on loose or greasy
hazardous work areas and the load being surfaces.
transported.
¾ Do not travel on uneven or obstructed
¾ Prior to, and whilst travelling, ALWAYS look ground.
in the direction of travel.
¾ When raising the mast, ensure there is
¾ Be aware of pedestrians, and avoid situ- adequate headroom.
ations where they could become trapped
¾ When working near overhead electric ca-
between the truck and a fixed object.
bles, observe the safe distance established
¾ Before moving an unladen truck raise the by the responsible authorities.
forks clear of the ground, but never more
¾ Make sure the surface on which you are
than 150 mm.
travelling is capable of supporting the
¾ Never place limbs outside the operator’s combined weight of the truck and load.
compartment.
¾ Never drive into a lift unless instructed to do
¾ Never carry passengers. so by a supervisor.
¾ When approaching blind corners, doorways ¾ Never alight from a moving truck.
etc., always sound the horn.
¾ Only use the mast and any attachments for Racking
authorised applications. ¾ NEVER exceed the safe working load of the
¾ Do not overload the truck beyond it’s rated racking.
capacity as stated on the capacity plate. ¾ Before placing a load ensure the lateral
¾ When transporting a load, travel with the beams are secure.
forks fully retracted and tilted back, with the ¾ Distribute the weight evenly over the section
load against the fork carriage or backrest of racking.
so that the centre of gravity is as close as
possible to the fork carriage. ¾ Ensure loads are placed accurately onto
the racking.
¾ Do not carry off centre loads. Position the
load so that it’s load centre of gravity falls on ¾ Do not allow the forks to rest on the racking.
the centre line between the forks.
¾ Do not climb racking.
¾ Never lift a load using only one fork.
¾ Always carry loads as close to the floor as Stacking goods
possible. ¾ Do not create a hazard by building stacks
¾ On a ramp or incline: in gangways, or where they would obstruct
doorways, stairways, emergency exits, fire
• Ensure the truck has adequate ground points etc.
clearance to clear the camber
¾ When building a bulk or free standing stack,
• Raise the forks sufficiently to clear the
before placing the first pallet ensure the floor
camber
is clear of obstructions, and that subsequent
• Travel uphill with the load leading loads are secure and levelled off before
• Travel downhill with the load trailing being stacked.
¾ Do not turn or stack loads on a slope.

2 Safety
Noise emission levels
¾ Be aware of protruding forks which could Parking

foul the stack behind the load being han-
¾ Do not park the truck in front of fire extin-
dled.
guishers, emergency exits or gangways
¾ Ensure that the bottom layer of the stack will where it can cause an obstruction.
support the weight of the complete stack.
¾ Before leaving the operator’s driving posi-
¾ Before leaving a stack, ensure that it is safe. tion, always turn the keyswitch off.
¾ Do not exceed the safe working load of box ¾ Never leave the truck unattended with a
or corner post pallets. raised load.
¾ When building a stack, remember that the
goods will have to be de-stacked, so leave Summary
sufficient room for trucks to manoeuvre A safe, competent operator is one who takes
safely. pride in the way they operate their lift truck,
respects the goods they handle, and follows
the correct operating procedures. NEVER
TAKE CHANCES
Noise emission levels

Determined in a test cycle in accordance with 1.4 to 2.0 tonne LPAZ = 63 dB (A)
EN 12053 from the weighted values in the all models
operating modes DRIVING, LIFTING and (without cabin)
IDLING. 1.4 to 2.0 tonne LPAZ = 66 dB (A)
The A-weighted averaged emission sound all models (with
pressure level at the operator’s position is as cabin)
follows: Uncertainty KPA = 4 dB (A)
NOTE
Due to environmental conditions, variations in
the above figures can exist during operation of
the truck.

Safety 2
Frequency characteristic for human body vibrations

The values are determined in conformance
NOTE
with the Vibration Test Code EN 13059 and
EN12096 on trucks with standard equipment The frequency characteristic for the human
according to the technical data sheet (driving body cannot be used to determine the actual
over test course with obstacles). frequency load during operation. This load
depends on the operating environment
The r.m.s weighted acceleration of the whole-
(condition of floor, type of operation, etc.) and
body vertical vibration on the truck seat
must therefore, if necessary, be determined at
(aW,ZS) is as follows:
the site.
1.4 to 2.0 tonne all aW,ZS = 0.2 m/s2
models
Uncertainty K = 0.1 m/s2

2 Safety

3
Getting to know the truck

Location of identification plates and labels
Location of identification plates and labels
1 Truck type/capacity plate 4 Serial number (Stamped)

2 Cold store label 5 Cold store hydraulic oil label
3 Standing under raised load warning label 6 Attachment capacity plate
NOTE
The operator must verify that all identifica-
tion plates and labels are present and legible.
Pease contact your local distributor if any
identification plates or labels are damaged or
missing.

Getting to know the truck 3
Truck type/capacity plate
Truck type/capacity plate

1 2 3 4 5
6
10
1 Manufacturer 7 CE symbol (The symbol certifies that all

2 Truck type/serial number/year of manufac- relevant EC directives and applicable
ture guidelines are fulfilled)
3 Unladen mass 8 Rated drive power
4 Battery mass 9 Battery voltage
5 Ballast weight 10 Rated capacity
6 Capacity diagram

General view of truck
General view of truck
1 Mast unit 13 Gearbox

2 Lift cylinders 14 Reach cylinder
3 Protection screen 15 Traction motor
4 Control panel cover 16 Horn
5 Battery connector 17 Brake fluid reservoir
6 Battery 18 Seat mounting/motor cover
7 Lift motor and pump unit 19 Traction motor brake
8 Hydraulic tank 20 Power steering motor/gearbox/controller
9 Load wheels 21 Seat
10 Hydraulic control valve 22 Steering wheel
11 Reach rollers 23 Lift chains
12 Drive wheel

Operating controls and indicators
Operating controls and indica-

tors
Twin pedal controls
1 Steering wheel 11 Emergency isolator

2 Parking brake switch 12 Battery trolley release
3 Optional accessory switches 13 Reverse pedal
4 Keypad (Option) 14 Brake pedal
5 Keyswitch 15 Forward pedal
6 Operator’s display 16 Lift control lever (Option)
7 Lift and reach control joystick 17 Reach control lever (Option)
8 Tilt and sideshift control joystick 18 Tilt control lever (Option)
9 Attachment control joystick (Option) 19 Sideshift control lever (Option)
10 Horn push

Single pedal controls
1 Steering wheel 12 Direction selection switch

2 Parking brake switch 13 Battery trolley release
3 Optional accessory switches 14 Accelerator pedal
4 Keypad (Option) 15 Brake pedal
5 Keyswitch 16 Left foot interlock pedal (not fitted on cabin
6 Operator’s display version)
7 Lift and reach control joystick 17 Lift control lever (Option)
8 Tilt and sideshift control joystick 18 Reach control lever (Option)
9 Attachment control joystick (Option) 19 Tilt control lever (Option)
10 Horn push 20 Sideshift control lever (Option)
11 Emergency isolator

Emergency isolator
The red knob (1) isolates all electrical power
when depressed.
CAUTION
Only use the emergency isolator in an emergency
or to isolate electrical power when the truck is left
unattended.
Do not use the emergency isolator as a means of
stopping the truck under normal driving conditions.
¾ Pull the red knob (1) up to restore electrical

power.
NOTE
If the emergency isolator has been depressed,
then the correct start up procedure should be
followed in order for the truck to operate.
Steering the truck

The electric steering system provides effort-
less manoeuvring and is invaluable when
working in narrow aisles.
A steering knob (1) is provided and should be
held at all times the truck is in motion.

DANGER
When turning while travelling with the forks leading,
the chassis will swing wide in the opposite direction.
Allow adequate clearance and be aware of pe-
destrians within the area.
Take particular care when manoeuvring on loading
bays, raised platforms etc.
Operating the horn

Use the horn to warn others of your presence
when approaching blind corners, doorways
etc.
¾ Press the push button (1). The horn oper-
ates for as long the push button is pressed.
NOTE
The horn will operate without the keyswitch
being turned on, but will not operate when the
emergency isolator is pressed.

Operator’s display
1 2 3 4 5 6 7
8
A MPH
Km/h
P
Ft / in
22 mm
lb
kg 9
- +
%
Hr
21
-
+
10
20 V
Hr
Km PM
miles AM
11
19 18 17 16 15 14 13 12
1 Height pre-selector Auto indicator 13 Cabin intercom volume (Option)
2 Sideshift centre indicator 14 Clock
3 Interlock warning indicator 15 Data Logger communication indicator
4 Slow speed indicator (Option)
5 Fork height command indicators 16 Battery change indicators
6 Fork height display 17 Temperature warning indicators
7 Battery discharge indicator 18 Service interval elapsed indicator
8 Parking brake indicator 19 Hour meter
9 Brake fluid warning indicator 20 Message panel
10 Battery lock warning indicator 21 Fork tilt indicator
11 Service indicator 22 Steering Indicator
12 Cabin heater indicators (Option)
NOTE
Depending on truck model and specification
some display functions may not be available.
Operators should fully acquaint themselves
with all available display functions and indica-
tors before taking the truck into service.

Steering indicator
NOTE 1
The appearance of the steering indicator dis-
play can be changed to suit customer pre-
ferences using diagnostic software. Please 2
contact your local distributor.
When the truck is switched on, the drive wheel
orientation is displayed by opposing arrow
heads (1), which will rotate as the steering
wheel is operated.
When a direction is selected, a single arrow
(2) indicates the direction of travel.
116-596
Message panel
The twenty character message panel (1).
conveys various information to the operator
including operator help prompts and diagnos-
tic codes.
1
116-602
MESSAGE EXPLANATION ACTION REQUIRED

Attempting to drive with the
No SEAT Sit on the seat
operator’s seat unoccupied
Low battery Battery voltage is very low Recharge the battery immediately
Could Indicate a potential fault.
Switch the truck off and on again.
The traction system has not
Trac Boot Err If the message is still displayed,
powered up correctly
then please contact your local
distributor.
Close the side door (NOTE: This
Attempting to drive with the side
door open message will be displayed during
door open
battery changing procedure).


Attempting to drive with the
Release Handbrake Release the handbrake
handbrake applied
Attempting to drive without first
Select Direction Select a direction of travel
selecting a direction
Attempting to drive without
Depress the left foot interlock
Left foot depressing the left foot interlock
pedal
pedal
Ensure the battery is located
The battery securing latches are correctly (NOTE: This message
Latches dropped
not engaged will be displayed during battery
changing procedure).
External battery connected during
External Battery No action required
battery changing procedure
The lift system has not powered
Lift Boot Err If the message is still displayed,
up correctly
distributor.
Check the joysticks are in neutral
position then switch the truck off
Joystick Err Joystick is operated at power up
and on again. If the message
is still displayed, then please
A controller is reducing the
Slow Only performance of the requested No action required
function
Please contact your local
Lift Calibrate Lift is in calibration mode
distributor.
The operated head function is in Please contact your local
Pot Calibrate
“potentiometer calibrate” mode distributor.
No VALVE detected No Valve is detected If the message is still displayed,
distributor.
The reach is in a mode where oil is
Reach Purging continuously pumped to remove
distributor.
any air from the system.
The display is not tested and will Please contact your local
Not Tested
not function properly distributor.
The hour meters are being
Getting Hours collected from the truck (when
distributor.
fitting a new display)


The clock has been updated due
Clock Changed No action required
to a change in winter/summer time
The Clock is in “setting mode”
Clock Setting (requested by the operator via the No action required
keypad)
There are no signals being
No CANbus If the message is still displayed,
received on the CANbus
distributor.
A warehouse zone is being
Zone displayed or changed via the No action required
keypad
Request entry of a PIN (Personal
PIN Identification Number) to access Enter your PIN
the truck
No action required
NOTE: if the temperature of
the display is below 2°C, then
The temperature of the operator’s
some icons including the steering
Display Warming Up display is below 2°C and is being
indicator are not displayed.
warmed up.
Proceed with caution until the
display has warmed up and all
icons are displayed.
Fork tilt indicator

The fork tilt indicator displays the tilt angle of
1
the forks.
The animated fork icon (1) indicates whether 2
for forks of tilted back, forward or level.
NOTE
The display will indicate that the forks are level
when the forks are at 0° ± 0.5°
The numerical display (2) displays the precise
angle of the forks.
116-591

Sideshift centre indicator

The sideshift centre icon will be displayed
when the forks are in the central position.
116-592
Interlock warning indicator

If an attempt is made to operate a function
which has been interlocked out or inhibited,
then the interlock warning icon (1) will be dis- 1
played. This may be accompanied by a help
prompt on the message panel (2).
116-593

Slow speed indicator

The slow speed icon will be displayed when a
controller is reducing the performance of the
selected function.
116-594
Battery discharge indicator

The battery discharge indicator comprises a
bar graph of 10 segments (2) and a numerical
display (1).
The bar graph (2) gives a visual representation
of the battery state of charge. At full charge all
10 segments will be filled
The numerical display shows the remaining
charge as a percentage of the rated capacity.
NOTE
To prevent damage to the battery, the display
will indicate zero percent when the battery has
been discharged to twenty percent of it’s rated
capacity. Truck performance will be reduced
and the slow speed icon (3) will be displayed
when the lift lever is operated.
When the battery discharge indicator begins
to flash, then the battery must be recharged or
replaced.
CAUTION
Batteries that are discharged to under twenty per-
cent of the rated capacity are over discharged.
Over discharging batteries will shorten their service
life and could nullify the battery warranty.
Always recharge batteries as soon as possible.
Never leave batteries in a discharged state.

Clock
The clock displays the current time of day.
To set the clock on trucks fitted with a keypad :
¾ Log on using your personal PIN.
¾ Within ten seconds of logging on, press and
hold the 1 key for more than five seconds.
NOTE AM
On trucks not fitted with a keypad the clock is
set using diagnostic software, please contact
your local distributor.
NOTE
116-597
The clock can be turned off, and the mode

of operation set using diagnostic software,
please contact your local distributor.
Battery change indicators

The battery change indicators are displayed
during battery changing procedure.
Icon (1) will be displayed when the side door is
open.
Icon (2) will be displayed when the truck is
connected to an external power supply.
NOTE
The battery lock warning indicator will also
illuminate during some stages of the battery
changing procedure.

Over temperature indicators

Should prolonged overload conditions exist,
then the motors or controller may become too
hot. The display utilises a combination of two
icons to notify the operator of this condition.
Icons (1) will flash should the traction motor
or controller become to hot.
Icons (2) will flash should the hydraulic mo-
tor or controller become to hot.
Icons (3) will flash should the steering motor
become to hot.
NOTE
If a motor or the controller becomes too hot,
then it’s performance will be reduced until it
has cooled to normal operating temperature.
The slow speed icon (4) will be displayed to
notify the operator of reduced performance.
CAUTION
Overheating motors or controller could be caused
by a fault.
Report to supervision if the display indicates that a
motors or controller has overheated during the shift.
Service interval elapsed indicator

When a service is overdue, the animated
service interval elapsed icon will flash for 10
seconds when the keyswitch is turned on. The
icon will be displayed until the routine service
work is carried out. Please contact your local
distributor.

Hour meter
Hr
As standard, the hour meter displays opera- 1
tional time (keyswitch on and seat occupied)
of the truck in hours (1). The animated hour-
glass icon will flash to indicate that the hour 2
Hr
meter is running.
NOTE 3 Hr
Using diagnostic software, the hour meter

can be configured to display alternative meter
Hr
readings for a brief period when the truck is 4
switched on. Please contact your local distri-
butor.
Hr
5
(2) Time to next service
(3) Traction motor operational time 116-600
(4) Hydraulic motor operational time

(5) Combined traction and hydraulic motor
operational time
Please contact your local distributor.
Parking brake warning

The red LED indicator illuminates whilst the
parking brake is applied.
DANGER
P
If the red indicator flashes, then brake wear is ex-
cessive and the truck should not be operated.
Please contact your local distributor. Never operate
a truck with defective braking.
116-603

Brake fluid level warning

The red LED indicator illuminates if the brake
fluid level is low.
DANGER
Never operate the truck if the brake fluid level is low.
Immediately fill the brake fluid reservoir and check
for leaks.
116-604
Battery lock warning

The red LED indicator illuminates if the battery
is not locked firmly in place.
NOTE
-
If using a battery changing station, the battery
lock warning will illuminate during some sta-
+
ges of battery changing procedure.
116-605

Service warning
If the red LED indicator illuminates, then a fault
condition exists. Please contact your local
distributor.
116-606

Lift height indicator (LHI)

The lift height indicator display comprises a
two part numeric display (1 and 2), a stack/de-
stack icon (3), and two direction icons (4 and
5).
The lift height indicator offers two display
modes.
mm
• Actual height mode displays the height of
the forks.
• Shelf height mode displays shelf and dis-
tance information, and a stack/de-stack
icon to indicate when the forks are in the
stack or de-stack position.
NOTE
Mode of operation cannot be changed by the
operator. Please contact you local distributor.
NOTE
On trucks fitted with a keypad, an additional
zone selection function is available.
NOTE
The lift height indicator is purely a height indi-
cator, it does not slow or stop lift. It remains
the responsibility of the operator to verify that
the forks are in the correct position before sta-
cking or de-stacking a load.
Operation - actual height mode

With the forks below the free lift height, the
display will show five horizontal bars. When
the forks are raised above the free lift height, mm
the display will show the height of the forks.
NOTE
If the truck is switched on with the forks above Ft / in
the free lift height, then only slow speed lift/lo-
wer and traction will be available. To initialise
the system, lower the forks to below the free
lift height.
The system can be configured to display Ft / in
height information in either mm, inches, or
feet and inches.

NOTE
Units of measurement cannot be altered by
the operator. Please contact your local distri-
butor.
Operation - shelf mode

With the forks below the free lift height, the
display will show five horizontal bars. When
the forks are raised above the free lift height
mm
the display will show shelf and distance infor-
mation.
NOTE
If the truck is switched on with the forks above
the free lift height, then only slow speed lift/lo-
wer and traction will be available. To initialise
the system, lower the forks to below the free Ft / in
lift height.
¾ With the forks above the free lift height,
operate the lift/lower joystick.
Depending on the function selected, one of
the direction indicators (3 or 4) will illuminate.
The two left hand digits (1) display the next
shelf level in the direction operated.
The three right hand digits (2) indicate the
distance to the next shelf level (1).
NOTE
If the next shelf is further than 1000 mm (39 in)
away, then the display will show the shelf level
followed by three horizontal bars.

Stacking a load - shelf mode

¾ Raise the load until the display indicates that
the desired shelf level has been reached.
¾ Continue to raise the load until the stack mm
icon (2) is displayed.
NOTE
The de-stack icon (1) will be displayed briefly
as the load is raised past the de-stacking level.
The load is now at the correct height and can Ft / in
be placed in the racking.
De-stacking a load - shelf mode

¾ Raise the load until the display indicates that
the desired shelf level has been reached,
and the de-stack icon (1) is displayed.
mm
The forks are now at the correct height and the
load can be removed from the racking.
Warehouse zones
On trucks fitted with a keypad, it is possible to
select different zones within a warehouse.
Ft / in
Either a maximum of twenty-five shelf levels in
four zones, or ten shelf levels in ten zones can
be programmed into the system.
NOTE
A zone can only be selected if there are shelf
levels programmed into it. Please contact your
local distributor.

Displaying the current selected zone

¾ Press the ENT key on the keypad.
The message panel will briefly show the cur-
rent selected zone.
NOTE
Zone selection is preserved when the truck is
switched off, or if the battery is disconnected.
116-613
Selecting a new zone

¾ Press the ENT key followed by the desired
zone number.
The message panel briefly shows the current
zone, then once entered, shows the newly
selected zone.
NOTE
To select zone 10, press ENT , followed by 0 .
NOTE
The keys must be pressed within ½ second.
116-614

Definition of direction of travel
Definition of direction of travel

This manual defines the direction of travel as
follows:
(A) = Travel with forks trailing
(B) = Travel with forks leading
The preferred direction of travel on level
ground is with the forks trailing (A).
NOTE
When travelling on slopes the load must al-
ways face uphill.

4
Operation
4 Operation
Pre-shift checks
Running-in instructions
The truck requires no running in, and can be
operated with a full load and maximum speed
upon delivery.
Check the drive wheel nuts

¾ After taking delivery of the truck, or after
removing the drive wheel, the security of the
nuts MUST be checked within 50 hours of
operation.
For effective wheel fixing, tighten the wheel
nuts to 195 Nm in accordance with the se-
quence shown.
NOTE
If it is found necessary to tighten the wheel
nuts to the correct torque, then they must be
checked again after 50 hours. Repeat the
tightening procedure every 50 hours until the
correct torque is consistently obtained.
Pre-shift checks
Check the battery state of charge
¾ Lift the emergency isolator (1).
¾ Turn the keyswitch (3) on.
¾ Check the battery state of charge on the
operator’s display (2).
CAUTION
Batteries that are discharged to under 20% of the
rated capacity are over discharged. Over dischar-
ging batteries will shorten their service life and could
nullify the battery warranty.

Operation 4
Pre-shift checks
Check all controls and their operation

Before the start of each shift, or when taking
the truck over from someone else, check all
truck controls for correct and safe operation.
¾ Check function of braking system.
¾ Check function of steering system.
¾ Check function of traction and hydraulic
systems.
¾ Check function of operator’s display.
NOTE
When the keyswitch is turned on, all indicators
on the operator’s display should illuminate
briefly.
Report any defects to supervision.
Check all Interlock switches

DANGER
For your own safety, and the safety of others, the
truck is fitted with various interlocks.
Under no circumstances should the operation of
these interlocks be interfered with.

the truck over from someone else, check all
truck interlock switches for correct and safe
operation.
¾ Check the function of the keyswitch.
¾ Check the function of the emergency isola-
tor.
¾ Check the function of the parking brake
switch.
¾ Check the function of the seat switch.
¾ Check the function of the battery lock switch
¾ Check the function of the left foot interlock
pedal (if fitted)
¾ Check the function of the 8.5 m interlock
switch (if fitted)
¾ Check the function of the cabin door switch
(if fitted)

4 Operation
Pre-shift checks
NOTE
For any attachments, additional interlocks
may be fitted. These should be checked for
correct and safe operation.
Should any of the interlock switches fail to
operate correctly, then report to supervision.
Check general condition of truck

the truck over from someone else:
¾ Check the forks for cracks, distortion or
wear.
All forks should be withdrawn from service
when the blade near the heel has worn to 90%
of its original thickness.
NOTE
The vertical ’shank’ section of the fork is a
guide to the blade’s original thickness.
¾ Check the mast for damage and foreign
bodies.
¾ Check the overhead guard for damage.
¾ Check for any loose panels and covers.
¾ Check the tyres for damage and foreign
objects.
¾ Remove any loose items left on the truck.
Report any defects to supervision.

Operation 4
The battery
The battery
Connecting the battery to an external
charger
WARNING
Batteries can be hazardous when being handled
and maintained. During charging, explosive hydro-
gen gas is released.
¾ Always handle, charge and maintain batteries
according to the manufacturer’s instructions
supplied with the battery.
¾ Protective equipment i.e. goggles and gloves
must be worn at all times when working on batte-
ries.
¾ Do not expose the battery to sparks or naked
flames.
¾ Only charge batteries is designated areas.
¾ Battery charging and storage areas must be well
ventilated.
¾ Always follow the manufacturer’s instructions
supplied with the battery charger.
If you do not have these instructions, then please
contact you local distributor.
¾ Lower the forks.

¾ Turn the keyswitch off and depress the
emergency isolator.
CAUTION
Connecting or disconnecting the battery with the
truck switched on could cause damage to electrical
components.
Before connecting or disconnecting the battery,
ensure the truck is switched off, and the emergency
isolator is depressed.

4 Operation
The battery
¾ Release the battery connector locking plate

(1) and unplug the battery connector (2).
¾ Insert the charger connector (4) into the

battery connector (3).
¾ Switch on the battery charger.
Reaching the battery out

The battery must be reached out for inspection
or routine maintenance.
¾ Lower the forks to just above the ground.
¾ Return the mast to the fully reached back
position.

Operation 4
The battery
¾ Lift the battery trolley locking lever (1) and

reach the battery forward. The battery un-
locked warning indicator on the operator’s
display will illuminate.
¾ To relocate the battery, operate the reach
lever to reach the battery in until the battery
unlocked warning indicator on the opera-
tor’s display extinguishes.
CAUTION
Ensure that the battery cables are not twisted when
reaching the battery back.
DANGER
Do not use the truck with the battery reached for-
ward.
Changing the battery (hoist method)

DANGER
When lifting the battery with a crane, ensure that no
persons are within the vicinity. Never step under an
elevated load.
CAUTION
components.
Use lifting equipment of sufficient capacity for

the weight of the battery. (See Battery Plate).
¾ Reach battery fully forward.
¾ Apply the parking brake, turn the keyswitch
off, and depress the emergency isolator.
and unplug the battery from the truck.
¾ Connect the lifting equipment to the battery
and lift the battery up and outwards from the
truck. Ensure the battery does not hit the
mast or power unit chassis.

4 Operation
The battery
WARNING
Manual handling risk. The battery is heavy.
Take care when manoeuvring the battery from the
chassis.
¾ Reverse the procedure to fit the battery.

¾ Reconnect the battery, ensuring the battery
connector locking plate is engaged.
¾ Turn the keyswitch on and operate the
reach lever to reach the battery in until the
battery unlocked warning indicator on the
operator’s display extinguishes.
CAUTION
NOTE
The battery cable is designed to minimise
the free cable projecting beyond the battery
face. In order to maintain this condition it is
necessary to replace the battery so that the
face adjacent to the cable route and negative
terminal is nearest to the truck bulkhead. With
some batteries the positive terminal is also on
the same face as the cable route.
CAUTION
It is essential that the battery is correctly seated on
the battery trolley before reaching back and locking
into position.
DANGER
The replacement battery MUST be identical in size
and weight to the standard battery.
Any deviations in size or weight, please con-

tact your local representative.
Changing the battery (roll on, roll off)

WARNING
Manual handling risk. The battery is heavy.
Take care when manoeuvring the battery from the
chassis.

Operation 4
The battery
CAUTION
Before changing the battery, ensure that the roller
stand is adjusted so that it’s rollers are level with
those on the truck battery trolley. Failure to do so
could cause damage to the battery trolley rollers
and locking mechanism.
CAUTION
components.
¾ Drive the truck up to the battery roller stand

(1).
¾ Reach the battery forward, manoeuvre the
truck until the battery is aligned with the
vacant track on the roller stand.
and unplug the battery from the truck.
¾ Open the latch (2)on the roller stand.
NOTE
The latch hinges over to secure one battery
alternately.

4 Operation
The battery
¾ Undo the securing latch clamp (4) and re-

lease the battery securing latch (3) on the
truck battery trolley.
¾ Push the battery from the truck onto the
roller stand. Hinge the securing latch (2)
over to retain the battery.
¾ Connect a slave lead between the charged
battery and truck battery plug.
¾ Release the emergency isolator, switch on
and manoeuvre the truck to align the truck
battery trolley with the charged battery.
¾ Push the charged battery onto the truck
trolley and secure with the securing latch
(3), ensuring clamp (4) is tightened.
¾ Disconnect the slave lead.
¾ Connect the truck battery plug, ensuring
that the battery locking plate is engaged.
¾ Release the emergency isolator, switch on,
and operate the reach lever to reach the
battery in until the battery unlocked warning
indicator on the operator’s display extin-
guishes.
CAUTION
DANGER
The replacement battery MUST be identical in size
and weight to the standard battery.
Any deviations in size or weight, please con-

tact your local representative

Operation 4
Operator adjustments
WARNING
Making adjustments while travelling could lead to
loss of control.
Only make adjustments while the truck is statio-
nary.
After making an adjustment, ensure the item is se-
cured in position.
Mounting and dismounting the truck

CAUTION
Never use the steering wheel or hydraulic levers as
a means of pulling yourself onto the truck.
When mounting or dismounting the truck always
use the handle provided.
CAUTION
On trucks fitted with a cab, always alight from the
truck backwards as shown, using the inner door pull
for support.
Do not use the rear bumper as a step.

4 Operation
Steering column adjustment

The steering column can be adjusted for
height and rake.
¾ Slacken the steering column clamping knob
(1).
¾ Adjust the steering column to the desired
position.
¾ Tighten the steering column clamping knob.
Seat adjustments
¾ To move the seat forward or back, lift lever
(5) and while sat on the seat slide to the
required position and release the lever (5)
to lock into the nearest notch.
¾ The handwheel (4) is for height adjustment.
Rotate the handwheel clockwise to raise the
seat. Rotate the handwheel anticlockwise
to lower the seat.
¾ Lever (3) is used to set the height of the
seat when it is unoccupied. To adjust the
height, sit on the seat and slide lever (3)
to the right. Use handwheel (4) to adjust
seat to the desired height. When the seat
height adjustment is correct, slide lever (3)
to the left to limit seat movement when it is
unoccupied.
¾ Button (2) is used to adjust lumber support.
¾ Lever (1) must be lifted to alter the rake of
the seat back. The rake can be adjusted to
three positions.

Operation 4
Braking – twin pedal

Regenerative traction brake
The truck is automatically braked by regen-
erative action when either the accelerator
demand is reduced or the opposite direction of
travel is selected.
DANGER
In an emergency do not rely on regenerative bra-
king to stop the truck.
Always use the hydraulic footbrake (2) in an emer-
gency.
Hydraulic footbrake
¾ Release the accelerator pedals (1 & 3).
¾ Press brake pedal (2).
NOTE
Depressing the brake pedal hydraulically ope-
rates both load wheel brakes. It is recommen-
ded that before taking the truck into service,
that operators acquaint themselves with the
function and effect of this brake while the truck
is in an unladen condition.
Engaging and releasing the parking

brake
For your own safety ALWAYS use the parking
brake to park the truck, and during stacking
and de-stacking operations.
¾ If the parking brake is released, push button
(5).
The parking brake will engage and the parking
brake applied warning indicator (4) on the
operator’s display will illuminate.
NOTE
The parking brake will be applied automati-
cally under certain fault conditions, and can be
programmed to ’auto apply’ for certain events
such as the seat being vacated.

4 Operation
¾ If the parking brake is engaged, push button

(5).
The parking brake will release and the parking
operator’s display will extinguish.
CAUTION
Do not use the parking brake to stop the truck while
travelling.
Only use the parking brake when the truck is statio-
nary.

Operation 4
Braking – single pedal

Regenerative traction brake
The truck is automatically braked by regen-
erative action when either the accelerator
demand is reduced or the opposite direction of
travel is selected.
DANGER
In an emergency do not rely on regenerative bra-
king to stop the truck.
Always use the hydraulic footbrake (1) in an emer-
gency.
Hydraulic footbrake
¾ Release the accelerator pedal (2).
¾ Press brake pedal (1).
NOTE
Depressing the brake pedal hydraulically ope-
rates both load wheel brakes. It is recommen-
ded that before taking the truck into service,
that operators acquaint themselves with the
function and effect of this brake while the truck
is in an unladen condition.

brake
For your own safety ALWAYS use the parking
brake to park the truck, and during stacking
and de-stacking operations.
¾ If the parking brake is released, push button
(4).
The parking brake will engage and the parking
operator’s display will illuminate.
NOTE
The parking brake will be applied automati-
cally under certain fault conditions, and can be
programmed to ’auto apply’ for certain events
such as the seat being vacated.

4 Operation
¾ If the parking brake is engaged, push button

(4).
The parking brake will release and the parking
operator’s display will extinguish.
CAUTION
Do not use the parking brake to stop the truck while
travelling.
Only use the parking brake when the truck is statio-
nary.

Operation 4
Driving – twin pedal

Switching on
¾ Connect the battery.
¾ Sit on the seat.
¾ Lift the emergency isolator (1) if it has been
pressed.
NOTE
Ensure no controls are being operated.
¾ Insert the key (4) and turn fully clockwise.
The operator’s display (3) will illuminate.
¾ Raise the forks to clear the ground.
¾ Fully retract the forks.
¾ Release the parking brake (2).
Travel with the forks trailing

¾ Gently press the left accelerator pedal (5).
The truck will move in the forks trailing direc-
tion. Travel speed will depend on how far the
pedal is pressed.
NOTE
Depressing the accelerator pedal fully will not
increase the rate of acceleration as maximum
acceleration is controlled automatically.

4 Operation
Travel with the forks leading

¾ Gently press the right accelerator pedal (6).
The truck will move in the forks leading direc-
tion. Travel speed will depend on how far the
pedal is pressed.
NOTE
Changing direction of travel

¾ Release the depressed accelerator pedal.
¾ Press the pedal for the opposite direction.
The truck will be electrically braked to a stand-
still and then accelerated in the opposite direc-
tion.
The accelerator pedals can be changed di-
rectly from forks leading to forks trailing direc-
tion of travel.
Travel control will be easier if feet rest on both
accelerator pedals.
NOTE

Operation 4
Driving – single pedal

Switching on
¾ Sit on the seat.
¾ Lift the emergency isolator (1) if it has been
pressed.
NOTE
Ensure no controls are being operated.
¾ Insert the key (3) and turn fully clockwise.
The operator’s display (2) will illuminate.
¾ Fully retract the forks.
Travel with the forks trailing

¾ Press the left foot interlock pedal (7).
¾ Select the forks trailing direction of travel
by pressing the left end (A) of the direction
switch (6).
NOTE
The direction selection switch is momentary
and will return to the neutral position when
released.
¾ Gently press the accelerator pedal (4).
Travel speed will depend on how far the pedal
is pressed.
NOTE

4 Operation
Travel with the forks leading

¾ Press the left foot interlock pedal (7).
¾ Select the forks leading direction of travel
by pressing the right end (B) of the direction
switch (6).
NOTE
released.
¾ Press the accelerator pedal (4).
Travel speed will depend on how far the pedal
is pressed.
NOTE
Changing direction of travel

¾ Press the opposite end of direction switch
(6) to change the direction of travel.
The truck is electrically braked until it stops
and then restarts in the opposite direction of
travel.
The direction of travel can be changed without
releasing the accelerator pedal or applying the
brake.
¾ Press the left end (A) for forks trailing.
¾ Press the right end (B) for forks leading.
NOTE

Operation 4
Starting on an incline
Starting on an incline
When the truck is to be stopped and started on
an incline the procedure is as follows:
¾ Stop the truck under controlled electrical
and hydraulic braking.
¾ Apply the parking brake.
¾ To move off, press the accelerator. The
drive motor holds the truck under reduced
power.
¾ Release the parking brake.

4 Operation
Operating the mast and attachments (with two joystick control)
Operating the mast and at-

tachments (with two joystick
control)
NOTE
Observe the operating symbols adjacent to
each joystick.
Raising and lowering the lift carriage

¾ To raise the lift carriage, move joystick (1)
smoothly in direction (C).
Lifting speed is determined by how far the
joystick is moved.
The lift carriage is bought to a smooth stop at
maximum lift by switching off the pump motor
automatically shortly before maximum lift.
NOTE
If full lift movement is necessary, return the
joystick to the neutral position, and then move
the joystick progressively again in direction (C)
to raise the lift carriage slowly to full lift height.
¾ To lower the lift carriage, move joystick (1)
smoothly in direction (D).
Lowering speed is determined by how far the
joystick is moved.
NOTE
The joystick returns to the neutral position
when released.

Operation 4
Operating reach
¾ To extend the reach carriage, move joystick
(1) smoothly in direction (B).
Reach speed is determined by how far the
joystick is moved.
The reach carriage is bought to a smooth stop
at the end of travel.
¾ To retract the reach carriage, move joystick
(1) smoothly in direction (A).
joystick is moved.
NOTE
when released.
Operating sideshift
NOTE
Before operating the sideshift, ensure that the
load is either fully reached out or raised clear
of the load wheel legs.
CAUTION
Do not use the sideshift to push loads.
Only use the sideshift when the load is raised clear
of the floor or racking.
¾ Move joystick (2) smoothly in direction (D)

to shift the fork carriage left.
¾ Move joystick (2) smoothly in direction (C)
to shift the fork carriage right.
NOTE
when released.

4 Operation
Operating tilt
¾ To tilt the fork carriage forward, move joy-
stick (2) smoothly in direction (B).
¾ To tilt the fork carriage back, move joystick
Tilt speed is determined by how far the joystick
is moved.
NOTE
when released.
Operating attachments (Option)

Attachments can be mounted on the reach
carriage as optional equipment.
DANGER
Fitting an attachment can affect load capacity and
truck stability.
¾ Never fit an attachment unless your local dis-
tributor has determined that safe operation is
assured in respect to load capacity and truck
stability.
¾ Always observe the additional capacity plate for
any attachments.
Operate attachments in accordance with the

manufacturer’s instructions. If you do not have
these instructions, then please contact your
local distributor.
NOTE
Some attachments are interlocked to prevent
accidental operation. In this case, the joystick
must be depressed in order to operate the
attachment.
NOTE
For some attachments the sideshift function is
not available.

Operation 4
Operating the mast and attachments (with four joystick control)
Operating the mast and at-

tachments (with four joystick
control)
NOTE
Observe the operating symbols adjacent to
each joystick.
Raising and lowering the lift carriage

¾ To raise the lift carriage, move joystick (1)
smoothly in direction (B).
Lifting speed is determined by how far the
joystick is moved.
¾ The lift carriage is bought to a smooth stop
at maximum lift by switching off the pump
motor automatically shortly before maxi-
mum lift.
NOTE
If full lift movement is necessary, return the
joystick to the neutral position, and then move
the joystick progressively again in direction ’B’
to raise the lift carriage slowly to full lift height.
¾ To lower the lift carriage, move joystick (1)
smoothly in direction (A).
Lowering speed is determined by how far the
joystick is moved.
NOTE
when released.

4 Operation
Operating reach
¾ To extend the reach carriage, move joystick
joystick is moved.
¾ To retract the reach carriage, move joystick
joystick is moved.
NOTE
when released.
Operating tilt
¾ To tilt the fork carriage forward, move joy-
stick (3) smoothly in direction (A).
¾ To tilt the fork carriage back, move joystick
Tilt speed is determined by how far the joystick
is moved.
NOTE
when released.

Operation 4
Operating sideshift
NOTE
Before operating the sideshift, ensure that the
load is either fully reached out or raised clear
of the load wheel legs.
CAUTION
Do not use the sideshift to push loads.
Only use the sideshift when the load is raised clear
of the floor or racking.
¾ Move joystick (4) smoothly in direction (A)

to shift the fork carriage left.
¾ Move joystick (4) smoothly in direction (B)
to shift the fork carriage right.
NOTE
when released.
Operating attachments (Option)

Attachments can be mounted on the reach
carriage as optional equipment.
DANGER
Fitting an attachment can affect load capacity and
truck stability.
¾ Never fit an attachment unless your local dis-
tributor has determined that safe operation is
assured in respect to load capacity and truck
stability.
¾ Always observe the additional capacity plate for
any attachments.
Operate attachments in accordance with the

manufacturer’s instructions. If you do not have
these instructions, then please contact your
local distributor.
NOTE
Some attachments are interlocked to prevent
accidental operation. In this case, the joystick
must be depressed in order to operate the
attachment.

4 Operation
NOTE
For some attachments the sideshift function is
not available.

Operation 4
Handling loads
Handling loads
Load centre distance and load capacity
Before lifting a load, the relationship between
the load capacity, load centre distance and
maximum lift height must be understood.
The load centre distance is the distance be-
tween the heel of the fork and the centre of
gravity of the load (1).
NOTE
The centre of gravity of the load may not ne-
cessarily be at the centre of the load.
The load capacity is the weight of load which
can be raised safely to a specified height at a
given load centre distance.
NOTE
Reduce the load capacity and consult your
local distributor when:
• transporting off centre loads.
• lifting a load with a long load centre dis-
tance.
• fitting optional auxiliary equipment.
Capacity plate example

Load centre distance = 600 mm
Height of lift = 6700 mm
116-66
The maximum permissible load in this case is 6700 1400 1400
1400 kg
¾ Before picking up a load, observe the load
capacity plate.
¾ Similarly, observe the load capacity plate
diagram for any attachments fitted. 500
600
116-66

4 Operation
Handling loads
DANGER
Never allow persons to be elevated on either the
forks, or on a pallet placed on the forks.
If the truck is to be used for elevating persons, then
it MUST be fitted with a purposely designed working
platform. Ensure the platform and securing method
is suitable for the truck. Please contact your local
distributor.
116-85
DANGER
Standing, or walking under an elevated load is ex-
tremely dangerous.
During stacking and de-stacking operations, do not
allow persons to stand or pass under an elevated
load.
116-86

Operation 4
Handling loads
Adjusting the forks

¾ Lift fork latches up.
¾ Adjust the spacing of the forks to suit the
load to be lifted.
¾ Position the forks equidistant from the cen-
tre of the fork carriage.
¾ Check that the latches engage correctly in a
castellation.
WARNING
Manual handling risk. The forks are heavy.
Take care when positioning the forks.
NOTE
The centre of gravity of the load must be loca-
ted at the mid point between the two forks.
De-stacking a load
¾ Approach the load and align the forks as
carefully and accurately as possible. The
centre of gravity of the load should be cen-
tral between the forks.
¾ Tilt the forks to the horizontal position.
¾ Raise the forks to a position for clear entry
into the pallet or load.
¾ If necessary operate the sideshift to position
the forks centrally.
¾ Fully extend the reach carriage.
¾ Lift the load slowly and carefully clear of the
racking.
¾ Tilt the forks backward just sufficient to sta-
bilise the load.
¾ Fully retract the reach carriage.
¾ Lower the load carefully to just above the
load wheel legs.
¾ Tilt the forks backward fully to the travel
position.

4 Operation
Handling loads
Transporting a load
For optimal visibility drive with the forks trail-
ing.
When travelling on slopes the load must al-
ways face uphill.
Travel with the reach carriage retracted, load
centred against the fork carriage or backrest
(Option), with the forks/load to a height just
above the load wheel legs.
Truck speed must be reduced on uneven or
wet surfaces and in areas of reduced visibility.
Never drive or turn across a slope.
Work with a guide if your vision is obscured.
Never transport unstable loads.
Stacking a load
¾ Approach the stack and align the load as
carefully and accurately as possible.
¾ Tilt the forks to the horizontal position.
¾ Raise the load to just above the required
stacking height.
¾ If necessary operate the sideshift to position
the load centrally.
¾ Slowly lower the forks until the load is posi-
tioned on the racking.
¾ Lower the forks until just clear of the ground.
¾ Tilt the forks to the travel position.

Operation 4
Before leaving the truck
Before leaving the truck

¾ Ensure the truck is parked so as not to
cause a hazard or obstruction.
¾ Tilt the forks fully forward.
¾ Fully lower the lift carriage.
¾ Apply the parking brake (2).
¾ Turn off the keyswitch and remove the key
(1).
¾ Press the emergency isolator (3).
¾ Disconnect the battery if the truck is not
being used for a prolonged period.

4 Operation
Cold store cabin
Cold store cabin

For operating trucks in a cold store environ-
ment, a cold store cabin is available.
This polycarbonate glazed cabin provides the
operator with the following comforts:
• Thermostatically controlled cabin heater
with temperature adjustment.
• Two way voice intercom to ensure the oper-
ator is aware of, and can have voice contact
with others in the warehouse.
• Window heating. This is necessary should
the truck be driven out of the cold store to an
ambient environment.
• Interior lighting with ON/OFF switch.
The control switches for these functions are
mounted in the cabin ceiling and on the steer-
ing binnacle.
Entry to the operator’s cabin is through the
rear door. Ensure the door is firmly closed
before moving off.

Operation 4
Cold store cabin
Heater control
The twin element cabin heater is controlled
using a three position switch (1) which is
mounted in the cabin ceiling.
Position 1 OFF
Position 2 ON
Fan and one heater element
Position 3 BOOST
Fan and two heater elements
Three lamps, one internal to the switch (1) and

two separate (2), indicate the current state of
the heater.
Position 1 All lamps off 115-98
Position 2 Switch internal lamp (1)

illuminated continuously, and
one lamp (2) illuminated when
the heater element is on.
Position 3 Switch internal lamp (1)
illuminated continuously, and
both lamps (2) illuminated 3 3
when the heater elements are
on.
Two air vents (3) can be adjusted to direct the

air flow.
NOTE
The heater will only operate when the cabin
door is closed. 115-98

4 Operation
Cold store cabin
Temperature control
Rocker switch (1) which is mounted in the
cabin ceiling, is used to set the cabin temper-
ature. 1
Operate the rocker switch (1) until the oper-

ator’s display indicates the desired tempera-
ture.
NOTE
The temperature can be adjusted from 5°C
(41°F) to 30°C (86°F). To switch between °C
and °F, continue to operate the rocker switch
beyond the upper or lower adjustment values.
e.g below 5°C, the display will change to 86°F
115-100
Intercom
¾ Operate the press-to-talk button which is
located on the steering binnacle, to enable
outgoing speech whilst muting incoming
speech.
NOTE
The intercom will only operate when the cabin
door is closed.
115-101

Operation 4
Cold store cabin
Intercom volume 1
Rocker switch (1) which is mounted in the
cabin ceiling, is used to set the intercom vol-
ume.
¾ To adjust the cabin internal speaker vol-
ume, operate the rocker switch (1).
The display will indicate the intercom volume.
¾ To adjust the cabin external speaker vol- 1 2
ume, operate the rocker switch (1) whilst
+
pressing the press-to-talk button (2).
The display will indicate the intercom volume.
115-102
Window heater timer

Operate the window heater timer before driv- 1
ing the truck out of the cold store. Pre-heating
the windows prevents instant frosting that
would otherwise occur if the cold windows
were to come in contact with ambient temper-
ature air.
¾ Operate the switch (1) which is mounted
in the cabin ceiling, to turn on the window 2
heater timer.
The switch will illuminate to indicate that the
timer is running.
NOTE 3
115-103
Every time the switch (1) is pressed, the timer

is reset to it’s preset value.
To set the window heater timer:
¾ Operate the temperature control rocker
switch (2) whist holding down the timer
switch (1).
The display will indicate the set time in minutes
(3).

4 Operation
Cold store cabin
Interior lighting
Switch (1) is used control both interior lights. 1
115-104
Exterior lights
Two position rocker switch (1) is used to con-
trol the exterior lighting.
115-106

Operation 4
Cold store cabin
Side windows
Both cabin side windows can be opened from
either the inside or the outside by sliding the
two knobs (1) towards one another.
Preventing ice damage 1 1
CAUTION
When trucks that operate within a cold store are
brought outside and left standing for a time, con-
densation may form.
In order to prevent possible damage by the forma-
tion of ice, it is essential that all condensation is
removed from the truck before re-entering the cold
store environment.
115-105
Cleaning the cabin

CAUTION
Under no circumstances should chemical cleaners
be used to clean the polycarbonate windows as
these can cause permanent damage.
The windows must only be cleaned using a propri-
etary, non abrasive, water based window cleaning
solution. For stubborn localised deposits, white
spirit may be used sparingly, providing it is rinsed
off immediately.
When cleaning the windows, particular care must
be taken so as not to scratch the protective surface
coating.

4 Operation
360° Steering (Option)
360° Steering (Option)

NOTE
The appearance of the steering indicator dis-
play can be changed to suit customer pre-
ferences using diagnostic software. Please
This system has no stops on the steering
turntable so that the direction of the truck can
be reversed by continuing to rotate the steer-
ing wheel.
¾ Sit on the seat.
¾ Lift the emergency isolator if it has been
pressed.
¾ Insert the key and turn fully clockwise.
The operator’s display will illuminate and two
diametrically opposed arrow icons (1) on the
steering indicator will be displayed indicating
the orientation of the steer wheel.
¾ Tilt the fork carriage back.
¾ Press the left foot interlock pedal.

Operation 4
Opposite direction steering (Option)
¾ Select the required direction of travel by

pressing the direction selection switch (3).
Left hand end (A) for travel with the forks
trailing. Right hand end (B) for travel with
the forks leading.
NOTE
released.
A single arrow icon (2) will indicate the direc-
tion of travel.
¾ Gently press the accelerator pedal. The
travel speed will depend on how far the
pedal is pressed.
NOTE
NOTE
If the seat is vacated, then a direction of travel
must be re-selected in order for traction to
be available. A short delay is provided for
intermittent releases.
Opposite direction steering

(Option)
DANGER
The driving characteristics of this truck may be dif-
ferent to other vehicles on site.
Please refer to attached labels.
If unfamiliar with this type of steering, the op-

erator should fully acquaint themselves with
this special feature during training.
Practice driving, control and steering oper-
ations with the truck unladen until they are
completely understood.

4 Operation
Height pre-selector - LPS (option)
Height pre-selector - LPS

(option)
The height pre-selector system enables
the truck operator to accurately stack and
de-stack loads by entering shelf heights on a
keypad mounted on the steering binnacle.
CAUTION
During commissioning the system is set up to suit
individual customer warehouse installations.
It is therefore essential that operators familiarise
themselves with specific operating characteristics
of the system installed before taking the truck into
service.
Also, if changes are made to any system parame-
ters, then operators should be made aware of such
changes, and if necessary familiarise themselves
with any new operating characteristics before ta-
king the truck back into service.
NOTE
It remains the responsibility of the operator to
verify that the forks are in the correct position
before stacking/de-stacking a load.
NOTE
The operator’s display will only convey height
pre-selector information when in automatic
mode.
Commissioning the system

During commissioning various system pa-
rameters are set up according to customer
requirements and the warehouse installation.
These parameters include:
Zone format
Shelf heights
Operator input mode
Auto-sequence mode
Units of measurement
NOTE
Parameters set up during commissioning
cannot be changed by the operator. Please

Operation 4
Zone formats
During commissioning one of four zone for-
mats will be selected depending on the ware-
house installation.
Zone Format Description
Ten zones, each with ten shelf heights. The distance between the stack and
10 x 10
de-stack heights is the same for all shelf heights
Four zones, each with twenty-five shelf heights. The distance between the
4 x 25
stack and de-stack heights is the same for all shelf heights
One zone with five hundred shelf heights. The distance between the stack
1 x 500
and de-stack heights is the same for all shelf heights
One zone with two hundred and fifty shelf heights. The distance between
1 x 250
the stack and de-stack heights can be different for each shelf height
Operator input mode

During commissioning one of four input modes
will be selected.
The input mode determines how the operator
inputs stacking and de-stacking commands.
Input
To stack a load To de-stack a load
mode
Enter a one or two digit number rep-
Enter a one or two digit number repre-
1 resenting the required shelf height fol-
senting the required shelf height
lowed by the ENT key
Enter a one digit number representing Enter a one digit number representing
2
the required shelf height followed by 1 the required shelf height followed by 0
Enter a two digit number with preceding Enter a two digit number with preceding
3 zeros if necessary representing the zeros if necessary representing the
required shelf height followed by 1 required shelf height followed by 0
Enter a three digit number with preced- Enter a three digit number with preced-
4 ing zeros if necessary representing the ing zeros if necessary representing the
required shelf height followed by 1 required shelf height followed by 0
LPS sequence mode

During commissioning one of four LPS se-
quence modes will be selected.
The LPS sequence mode determines lift and
lower interlocking during a stack/de-stack op-
eration.

4 Operation
LPS sequence
The system will remain in automatic mode until
mode
1 The lift/lower joystick is released
The lift/lower joystick is released when the forks are at the selected height
or the lift/lower joystick is not operated within a predetermined time limit.
2 Automatic mode will resume if the joystick is released and re-operated
within this time limit.
or any key on the keypad is pressed
The lift/lower joystick is released when the forks are at the selected height.
3 Automatic mode will resume if the joystick is released and re-operated.
The load has been picked up or put down at the selected height. Automatic
4 mode will resume if the joystick is released and re-operated.
Display
The display comprises a numeric display (1), a
unit of measure indicator (2), a stack/de-stack A
icon (3), two direction indicator icons (4 and 5),
Ft / in
and an automatic mode indicator (6). mm
Initialising the system
NOTE
If the truck is switched on when the forks are
above the reference height, then only slow lift
will be available. The slow speed icon (7) will
be displayed to notify the operator of reduced
performance.
¾ Lower the forks to below the reference
height.
¾ For zone formats 1 x 250 and 1 x 500, the
display will briefly show _ _ _ as the system
is referenced.
NOTE
In order to prevent slow lift, always lower the
forks to the ground before turning the truck off.

Operation 4
Displaying the current selected zone

(zone formats 10 x 10 and 4 x 25)
¾ Press the ENT key on the keypad.
rent selected zone.
NOTE
Zone selection is preserved when the
keyswitch is turned off, or the battery is
disconnected.
116-613
Selecting a new zone (zone formats 10 x

10 and 4 x 25)
¾ On the keypad, press the ENT key, followed
by the desired zone number.
rent zone, then once entered, shows the newly
selected zone.
NOTE
To select zone 10, press ENT , followed by 0 .
NOTE
The keys must be pressed within ½ second of
each other. 116-614
NOTE
A zone can only be selected if there are shelf
levels programmed into it. Please contact your
local distributor.
Stacking a load (zone formats 10 x 10

and 4 x 25)
¾ Ensure the correct zone is selected.
¾ Pick up the load to be stacked.
¾ Position the truck within the aisle at the face
of the correct storage location.

4 Operation

¾ Using the keypad :
For input mode 1
1
¾ Enter the one or two digit number represent-
ing the shelf level required followed by the
ENT key.
2
For input mode 2
¾ Enter the one digit number representing the
shelf level required followed by 1
3
For input mode 3
¾ Enter the two digit number with preceding
zeros representing the shelf level required
followed by 1 4
For input mode 4 116-635
¾ Enter the three digit number with preceding

followed by 1
NOTE
each other.
NOTE
If the selected level has not been program-
med, then _PrG_ will be displayed.
NOTE
If the selected level is out of range, or the
wrong sequence of digits has been entered,
then _Err_ will be displayed.

Operation 4
The display (1) will indicate the selected level,

and once the entry has been accepted, icon
(3) will be displayed indicating stacking mode.
One of the direction icons (2) will be displayed
to indicate lift or lower.
¾ Operate the lift/lower control fully according
to the display within a preset time. Lift/lower 1
will operate at full speed.
2 3
116-636
When the forks are within 1000 mm (39") of

the selected level, the display will show both
the selected shelf level (1) and the distance to A
the selected level (2) will begin to decrement
towards zero. mm
The automatic mode indicator (4), and one of

the lift/lower icons (3) will flash during the com-
plete operation to indicate automatic mode.
Lift/lower will slow down and then stop when
the selected level is reached. The lift/lower A
icon (3) will extinguish. Ft / in
NOTE
If the forks are not horizontal when the selec-
ted level is reached, then the tilt angle indicator
will flash and bleep. Continue to operate the
lift/lower control until the forks are horizontal.
¾ Once lift/lower has stopped and the forks
are horizontal, release the lift/lower control.
NOTE
If the lift/lower control is released before the
forks are horizontal, then the tilt control must
be used to level the forks.
¾ Check that the load is in the correct position,
and if necessary operate the sideshift to
position the load centrally.

4 Operation
¾ Release the parking brake and drive to-

wards the racking to bring the load to the
correct position.
¾ Drive away from the racking until the forks
are clear.
De-stacking a load (zone formats 10 x 10

and 4 x 25)
¾ Ensure the correct zone is selected.
For input mode 1
1
ing the shelf level required.
For input mode 2 2
For input mode 3 3
followed by 0
4
For input mode 4
116-638
followed by 0
NOTE
each other.

Operation 4
NOTE
NOTE
(3) will be displayed indicating de-stacking
mode.
¾ Operate the lift/lower control fully according 1
to the display within a preset time. Lift/lower
2 3
116-639
When the forks are within 1000 mm (39") of

the selected level, the display will show both
the selected shelf level (1) and the distance to A
the selected level (2) will begin to decrement
towards zero. mm

the lift/lower icons (3) will flash during the com-
the selected level is reached. The lift/lower A
icon (3) will extinguish. Ft / in
NOTE
ted level is reached, then the tilt angle indicator 116-640


4 Operation
NOTE
¾ Check that the forks are in the correct posi-
tion, and if necessary operate the sideshift
to position the forks centrally.
¾ Drive towards the racking to insert the forks
into the pallet, ensuring the fork tips do not
foul loads behind the stack, and that the
load rests against the front face of the forks
or load backrest if fitted.
racking.
bilise the load.
¾ Drive away from the racking until the load is
clear.
¾ Fully retract the fork carriage.
load wheel legs.
position.
Stacking a load (zone formats 1 x 250

and 1 x 500)
¾ Pick up the load to be stacked.

Operation 4

For input mode 1
1
ing the shelf level required followed by the
ENT key.
2
For input mode 2
3
For input mode 3
followed by 1 4
For input mode 4 116-635

followed by 1
NOTE
each other.
NOTE
NOTE

4 Operation

(3) will be displayed indicating stacking mode.
¾ Operate the lift/lower control fully according
to the display within a preset time. Lift/lower 1
2 3
116-636
When the forks are within 1000 mm (39") of the

selected level, the display will show both the
selected shelf level (1) and a decrementing
digit (2), where each decrement is equal to
10 mm (0.4 in).
the lift/lower icons (3) will flash during the com- A
the selected level is reached. The lift/lower
icon (3) will extinguish.
NOTE
ted level is reached, then the tilt angle indicator
NOTE
¾ Check that the load is in the correct position,
and if necessary operate the sideshift to
position the load centrally.

Operation 4
¾ Release the parking brake and drive to-

wards the racking to bring the load to the
correct position.
¾ Drive away from the racking until the forks
are clear.
De-stacking a load (zone formats 1 x 250

and 1 x 500)
For input mode 1
1
ing the shelf level required.
For input mode 2 2
For input mode 3 3
followed by 0
4
For input mode 4
116-638
followed by 0
NOTE
each other.

4 Operation
NOTE
NOTE
(3) will be displayed indicating de-stacking
mode.
¾ Operate the lift/lower control fully according 1
to the display within a preset time. Lift/lower
2 3
116-639
When the forks are within 1000 mm (39") of the

selected level, the display will show both the
selected shelf level (1) and a decrementing
digit (2), where each decrement is equal to
10 mm (0.4 in).
the lift/lower icons (3) will flash during the com- A
the selected level is reached. The lift/lower
icon (3) will extinguish.
NOTE
ted level is reached, then the tilt angle indicator 116-642


Operation 4
NOTE
¾ Check that the forks are in the correct posi-
tion, and if necessary operate the sideshift
to position the forks centrally.
¾ Drive towards the racking to insert the forks
into the pallet, ensuring the fork tips do not
foul loads behind the stack, and that the
load rests against the front face of the forks
or load backrest if fitted.
racking.
bilise the load.
¾ Drive away from the racking until the load is
clear.
¾ Fully retract the fork carriage.
load wheel legs.
position.

4 Operation
Operator code entry (Option)

The operator code entry unit comprises a
twelve digit keypad (1) mounted on the steer-
ing binnacle, and a rotary on/off switch (2).
The unit requires the operator to enter a five
digit personal identification number (PIN) in
order to operate the truck, thus preventing
unauthorised use.
Logging on
¾ Turn the rotary switch on.
The display will indicate that a PIN is required.
¾ Using the keypad enter your personal five
digit PIN.
NOTE
NOTE: The default operator PIN is 1 2 3 4
5.
¾ Press the ENT key (2).
Logging off
¾ Press and hold the CLR key (1) for one
second.
¾ Turn the rotary switch off.
NOTE
If the operator’s seat is vacated for any length
of time the truck will automatically log off and
the operator will have to re-enter their PIN in
order to operate the truck.
116-95

Operation 4
Accessing supervisor menus

The display will indicate that a PIN is required.
¾ Using the keypad, enter the supervisor five
digit PIN followed by 0 .
NOTE
The default supervisor pin is 9 8 7 6 5 . It
is recommended that the supervisor change
their PIN when taking delivery of the truck.
¾ Press the ENT key.
The system is now ready for a valid supervisor
command to be entered. 116-615
Valid supervisor commands are:
0 0 1 Change supervisor PIN

0 0 2 Enable/disable the truck
0 0 4 Add/delete operator PINs
0 0 5 List operator PINs
0 0 6 Set/reset learner operator
Changing the supervisor PIN

¾ Log on as supervisor and access the super-
visor command menus.
¾ Using the keypad, enter 0 0 1 .
¾ Enter the new supervisor PIN.
¾ Re-enter the new supervisor PIN to confirm.
116-616

4 Operation
Disable/enable the truck

¾ Enter 0 to disable the truck. All operator
PINs become invalid and the truck inopera-
ble.
NOTE
Supervisor PIN remains valid.
¾ Enter CLR to log off.
¾ Enter to enable the truck. All operator
1 116-617
PINs become valid and the truck can be

operated as normal.
¾ Enter CLR to log off.
Add/delete operator PINs

To delete an existing operator PIN:
¾ Enter the operator PIN.
¾ Enter 1 to confirm deletion, or 0 to cancel.
To add a new operator PIN:
¾ Enter the new PIN.
¾ Enter 1 to confirm new PIN, or 0 to cancel.
116-618

Operation 4
List operator PINs

The display will show the first operator PIN.
¾ Use the ENT key to scroll through all opera-
tor PINs.
NOTE
The display will show five dashes to indicate
the end of list.
¾ Press the CLR key at any time to exit. 116-619
Set/reset learner operation

To set/reset learner operation:
¾ Enter the operator PIN.
NOTE
The display will show ’1’ if the selected ope-
rator is already a learner, or ’0’if not a lear-
ner.
¾ Enter 1 to set the operator as a learner. 116-620
Truck performance will be reduced for this

operator.
¾ Enter 0 to set the operator as non learner.
Full truck performance will be available for
this operator.

4 Operation
Data Logger (Option)
Data Logger (Option)

The Data Logger unit comprises a twelve digit
keypad mounted on the steering binnacle and
a rotary on/off switch in place of the keyswitch.
The system requires the operator to enter a
personal identification number (PIN) in order
to operate the truck, thus preventing unautho-
rised use.
Once logged on, the system records truck
utilisation and operating data.
Logging on
¾ Using the keypad enter your personal five 116-95
digit PIN.
¾ Press the ENT key (2).
Logging off
¾ Press the CLR key (1)
¾ Turn the rotary switch off.
NOTE
If the operator’s seat is vacated for any length
of time the truck will automatically log off and
the operator will have to re-enter their PIN in
order to operate the truck.

Operation 4
Truck data management – LFM (Option)
Truck data management –

LFM (Option)
This system comprises a data storage unit
(FDE unit) with integral keypad mounted on
the steering binnacle, and a rotary on/off
switch in place of the keyswitch.
The system requires the operator to enter a
personal identification number (PIN), and de-
pending on system configuration, an optional
truck condition code in order to operate the
truck, thus preventing unauthorised use.
Once logged on, the system records truck
utilisation and operating data.
Truck condition codes

Depending on system configuration, opera-
tors may be required to enter a truck condition
code after their PIN. This code indicates the
state of the truck.
The following codes are available:
0 = Truck in working order
1 = Request service (truck is not ready for operation)
2 = Request maintenance (truck is ready for operation)
3 = Traction problem
4 = Hydraulic problem
5 = Steering problem
6 = Damaged in accident
7 = User defined
8 = User defined
9 = User defined
NOTE
Condition codes 7 , 8 and 9 are defined by
the user. Please contact supervision for defi-
nition of these codes.
NOTE
If a problem is noticed after logging on with
condition code 0 (truck in working order), then

4 Operation
the operator must log off, and log on again with

the appropriate code.
Logging on
¾ Press any key on the keypad to activate the
FDE unit.
The green status LED (2) will flash.
¾ Using the keypad, enter your personal PIN,
and if required, a truck condition code.
NOTE
NOTE: The default operator PIN is 0 0 0 0
0.
NOTE
If a mistake is made while entering your PIN,
116-527
then the red status LED (2) will illuminate.
The PIN can be re-entered after pressing the
* key (4). After three incorrect PIN inputs,
the red status LED (2) will illuminate, and the
green status LED (2) will flash. PIN entry will
be disabled for 10 minutes. The disabled pe-
riod can be interrupted by entering a special
PIN, please contact supervision.
¾ Press the # key (3) to confirm entry.
The green status LED (2) will illuminate.
¾ Turn the rotary switch fully clockwise to turn
the truck on.
NOTE
If both the green (2) and red (1) status LEDs
are illuminated, then the memory is full and
data must be read out, please contact super-
vision immediately.

Operation 4
Logging off
¾ Turn the rotary switch fully anti-clockwise to
turn the truck off.
After a short delay, the red status LED (1) will
illuminate briefly, and then both the green (2)
and red (1) status LEDs will flash. During this
period the truck can be turned on again using
the rotary switch. Both LEDs will then go out,
the current operator has been logged off and
the system is in standby mode.
NOTE
Pressing the # key (3) after turning the truck
off will immediately log off the current operator.
116-527
Status LEDs
A combination of two LEDs indicate FDE unit
status as follows:
RED GREEN FDE status

Off Off Standby mode
Off Flashing Prompt for PIN input
On Off Incorrect PIN input
Off On Correct PIN input
Flashing On Memory 90% full – data read out required
On On Memory 100% full – data read out required
On Flashing PIN entry disabled
Flashing Flashing Transition to standby mode
Off Slow flashing Maintenance requested

4 Operation
Closed circuit television
Side guidance for drive-in

racking
This system uses the aisle way with spigots to
support each pallet.
¾ Ensure the guide rollers (4) are aligned with
the guide rails (3) before entry into the aisle.
¾ Elevate the load/pallet (1) to the required
stacking level. Enter the aisle and proceed
to the desired spigot point.
¾ Lower the pallet onto the spigots (2).
This system provides maximum use of the
aisle and racking but load stacking must be
rotated systematically.

1
Closed circuit television enables the opera-
tor to stack and de-stack loads at high levels
without having to look upwards, thus avoiding
neck and shoulder strain.
NOTE
The camera image will only be displayed on
the monitor when the forks are raised above
the free lift height.
The monitor can be adjusted to a comfortable
viewing position by releasing the clamping
knob (1).
9 8 7 6 5 4 3 2
Image adjustments
2 Enter
3 Selection setting +
NOTE
4 Selection setting -
All settings made using the front button panel 5 Option
6 Contrast
can also be adjusted in the operator menu.
7 Brightness
8 Automatic brightness on/off
NOTE 9 Camera selection (not used)
Image adjustments can be disabled. Please

Automatic brightness on/off
¾ Press the automatic brightness button (8)
once to enter back light compensation/zero
lux mode.

Operation 4
¾ Press the plus button (3) to toggle back light

compensation between on and off.
NOTE
Back light compensation is used for an enhan-
ced picture when looking at dark objects in a
light environment.
¾ Press the minus button (4) to toggle zero lux
between on and off.
NOTE
Zero lux is used for increased sensitivity in low
light environments.
Brightness adjustment
¾ Press the brightness button (7) once to en-
ter the brightness adjustment mode.
¾ Use the plus (3) and minus (4) buttons to
adjust the image brightness.
Contrast adjustment
¾ Press the contrast button (6) once to enter
the contrast adjustment mode.
adjust the image contrast.
Saturation adjustment
¾ Press the contrast button (6) and the bright-
ness button (7) together to enter the satura-
tion adjustment mode.
adjust the image saturation.

4 Operation
Operator menu operation

¾ Press the enter button (2) once to open the
operator menu. The following buttons are
used to navigate through the menus.
operator menu
Minus (4) Go to the next menu option
standby
Plus (3) Go to the previous menu option info
Select or activate the
Enter (2)
highlighted option
Option (5) Return to the previous menu ver:
objects in C3
monitor are
closer than C2
they appear C1
NOTE
When using the operator menu, if a button
is not pressed during a five second period 115-109
then the monitor will display a small message

describing the function of the current selected
menu option.
Stand by
This option switches the monitor to stand by
mode.
Press the enter button (2) to power on.
Info
This option displays monitor information.

5
Maintenance
5 Maintenance
Maintenance safety guidelines
Maintenance safety guidelines

NOTE of the ground and securely chock the truck
in position.
The maintenance safety guidelines contained
¾ Protective equipment i.e. goggles and
in this manual are limited to general servicing,
gloves must be worn at all times when
checks and lubrication. For repair work,
working on batteries.
additional precautions may be necessary.
Please contact your local distributor. ¾ Take the necessary fire precautions when
working on batteries.
No changes, modifications or additions may
be made to the truck without approval from the ¾ Always handle, charge and maintain
manufacturer. batteries according to the manufacturer’s
instructions supplied with the battery.
DANGER
¾ Before attempting repairs or adjustments
Incorrect inspection and maintenance procedures
can result in the malfunction of safety-critical com-
on the raised lift carriage or mast, always
ponents. ensure that they are secured against
Only carry out inspection and maintenance routines accidental movement.
if you have been trained, and are authorised to do ¾ Always ensure any lifting equipment is of
so.
sufficient capacity and has the relevant
certification. All blocks, jacks and chains
DANGER etc. are subject to regular examination and
must only be used for the purpose intended.
Do not make modifications to the drive or braking
parameters without informing operators. ¾ Use only prescribed attachment points
If modifications are made to the drive or braking when towing or lifting. Attach connections
parameters, then it is imperative that operators are carefully. Check that the pins and/or bolts
informed of such changes so that they are able provided are secure before loading. Never
to familiarise themselves with the new operating
characteristics before taking the truck into service. stand close to drawbars, slings or chains
that are working under load.
¾ Before disconnecting hydraulic connec-
DANGER
tions, ensure that there is no pressure in the
The majority of accidents and injuries that occur system.
in workshops are caused by the failure to observe
some basic rules of care and safety, and for this ¾ Do not allow hydraulic oil under pressure,
reason, in most cases they can be avoided. for example at a leak, to penetrate the skin.
Follow the safety guidelines below, anticipate Medical aid is required if such an injury
potential hazards, and act with the necessary care occurs.
and caution to reduce the risk to a minimum.
An alert, cautious mechanic is a safe one. ¾ Never wear rings, wrist watches, jewellery,
loose or dangling items of clothing such
¾ Before attempting any repair work, apply as ties, torn clothing, scarves, unbuttoned
the parking brake, turn the keyswitch off, jackets or overalls with open zip fasteners
disconnect the battery, and, unless the that could get caught up in moving parts.
particular routine being performed requires Always wear approved safety clothing.
otherwise, chock the load wheels securely ¾ Never carry out maintenance or servicing
front and rear. operations on the truck with anyone sat on
¾ Before carrying out any electrical mainte- the seat, unless that person is fully trained
nance or checks, raise the drive wheel clear and involved in the operation being carried
out.

Maintenance 5
Report of Thorough Examination
¾ Never switch on the truck or operate an Only use clean containers when replenishing
attachment from any position other than the fuels and lubricants.
operator’s seat.
CAUTION
¾ The design of service steps or platforms
Chain spray is extremely difficult to remove from
used in the workshop or on site must comply polycarbonate windows.
with current regulations.
When using chain spray on trucks fitted with cabins,
¾ Label all controls to indicate a service or ensure that no overspray comes into contact with
repair operation is being carried out. the polycarbonate windows.
¾ Protective equipment i.e. goggles, mask

etc. must be worn at all times when using ENVIRONMENT NOTE
compressed air or steam cleaning equip- Lubricants and compounds used during
ment. maintenance procedures can be harmful to the
¾ Perform a functional check and trial run after environment. Please observe the following:
every service. • Follow the manufacturer’s safety and
disposal instructions when using lubricants
Handling lubricants and cleaning compounds
• Avoid spilling lubricants. Remove any spil-
Always handle lubricants safely and as lage immediately with a suitable absorbent,
specified by the manufacturer. and dispose of as per local legislative re-
Only store lubricants in approved containers quirements
at specified storage locations. As they could • Always dispose of used or contaminated
be flammable, do not let them come in contact lubricants as specified. Follow laws and
with hot objects or naked flames. regulations
Clean the area surrounding the part in ques- • Dispose of used parts, empty containers,
tion before lubrication, filter renewal or repairs filters etc. as per local legislative require-
in the hydraulic system. ments
Report of Thorough Examination

The accident prevention rules in some coun- lift trucks are thoroughly examined periodically
tries require that the fork lift truck must be by a competent person, and that supporting
checked periodically for proper operation by records are available for inspection. Non
trained personnel. compliance with these requirements may
result in legislative action.
In the UK, the specific requirements of LOLER
1998 and PUWER 1998, state that lift truck Please contact your local distributor.
users are required by law to ensure that their

5 Maintenance
Covers and cowlings
Covers and cowlings

Opening the motor cover
For ease of access to the motors and hydraulic
tank, the seat unit is mounted on a pivot which
enables it to be swung out from the chassis as
a complete unit.
¾ Remove the securing screw (1).
¾ Swing the seat assembly out from the chas-
sis, until it locates in the open position.
WARNING
The motors can become very hot. Risk of scalding.
Before working on or near the motors, ensure they
have cooled sufficiently.
¾ To close, swing the seat assembly back into

the chassis.
¾ Replace the securing screw (1).
¾ To remove the seat assembly completely,
disconnect the seat wiring, and lift the as-
sembly from the pivot.
WARNING
Manual handling risk. The seat assembly is heavy.
Assistance should be sought if it is to be completely
removed.
Removing the floorplate

¾ Open the motor cover.
¾ Remove the two securing screws (1).
¾ Lift the floorplate from the truck.
NOTE
The left foot interlock switch (if fitted) is at-
tached to the floorplate.

Maintenance 5
Fuses
Opening the top cover

¾ Turn the keyswitch off.
¾ Unplug the battery.
¾ Unscrew the emergency isolator knob (2).
¾ Undo the two socket head screws in the
cover (1). Open the cover fully.
¾ Reverse the procedure to close the cover.
¾ Replace the emergency isolator (2).
Fuses
Main circuit fuses
The fuses for the main circuits are:
1 3F1 50A Power steering pump motor

2 1F1 425A Main power circuits

5 Maintenance
Fuses
Ancillary circuit fuses

The fuses for the ancillary circuits are:
F8 5A Truck control circuits

1F2 10A Truck control circuits
1F6 5A Horn
2F2 5A Hydraulic valves
5F1 5A Lighting
6F1 5A Battery monitor
9F29 5A Cooling fans
NOTE
Although these fuses are interchangeable with
automotive fuses, automotive fuses MUST
NOT be used. Only fuses supplied by the
manufacture have sufficient voltage capability
to ensure correct operation at truck voltages.

Maintenance 5
Emergency lower
Emergency lower
In the event of power failure, the forks can
lowered manually in order that the truck can
be moved to a safe position.
Standard chassis
To manually lower the forks, use the emer-
gency lower valve which is located on the
hydraulic control valve. (Refer to attached la-
bel).
¾ After ensuring that no persons are in the
vicinity, slowly release the valve to allow the
lift carriage to be lowered.
¾ Ensure valve is re-tightened once the forks
are lowered.
Wide chassis
On wide chassis trucks, the emergency lower
valve is operated remotely.
are lowered.

5 Maintenance
Emergency steering and parking brake release
Narrow chassis
On narrow chassis trucks, the emergency
lower valve is operated remotely.
are lowered.
Emergency steering and park-

ing brake release
NOTE
In the unlikely event of complete electrical
failure, then the parking brake will be applied
and steering becomes unavailable. In order
to remove the truck from an aisle the following
procedure must be followed.
WARNING
When the parking brake is released, the truck is in
an unbraked condition.
Before releasing the parking brake, ensure that the
truck is either on level ground, or that chocks are
available to prevent the truck from rolling away.
¾ Turn the keyswitch off, depress the emer-

gency isolator and disconnect the battery.
¾ Insert two M6 x 55 mm screws (1), and
tighten fully to mechanically release the
parking brake.

Maintenance 5
Slinging the truck
¾ Special tool (2), which engages on the gear-

box toothed ring, allows the drive wheel to
be turned manually using an extension bar
and ratchet.
NOTE
Apply a small amount of grease to hole (3)
before using special tool (2).
¾ Attach the towing vehicle (with sufficient
tractive force) with a suitable rope or sling
around the chassis.
¾ Using extreme caution, very slowly ma-
noeuvre the truck from the aisle.
CAUTION
The above procedure should only be used in order
to remove the truck from an aisle.
Once clear of the aisle, remove the load and follow
the normal towing procedure.
Slinging the truck

DANGER
Only use lifting equipment with sufficient lifting ca-
pacity.
Refer to truck type/capacity plate for truck and bat-
tery weights.
DANGER
Never step under an elevated load.
When lifting the truck with a crane, ensure that no
persons are within the vicinity.
¾ Reach the mast fully back.

¾ Fix two double loop slings around the mast
upper cross member.
¾ Protect the truck parts in contact with the
slings.

5 Maintenance
Securing for transportation
Securing for transportation

CAUTION
When lashing down the truck for transportation, use
the points on the overhead guard and reach legs as
indicated.
Using different lashing point to those shown could
result in damage to the truck.

¾ Chock the truck securely both front and
rear.
¾ Lash down the truck as shown.
NOTE
Protect the straps from sharp edges on the
overhead guard.

Maintenance 5
Jacking the truck
Jacking the truck

DANGER
Only use a toe jack with sufficient lifting capacity.
Refer to truck type/capacity plate for truck and bat-
tery weights.
DANGER
Never work on, or leave a raised truck unattended
when supported by the jack.
Always block the raised truck securely after jacking.
Raising the drive wheel

¾ Securely chock both load wheels.
¾ Position the jack under the power unit chas-
sis.(1).
¾ Raise the drive wheel clear of the floor.
DANGER
Do not raise the truck more than necessary.
Only raise the wheel just clear of the floor.
¾ After jacking, block the truck securely.
Raising the load wheels

¾ Position the jack under the load wheel
leg.(2)
¾ Raise the load wheel clear of the floor.
DANGER
Only raise the wheel just clear of the floor.
¾ After jacking, block the truck securely.

5 Maintenance
Towing procedure
Towing procedure
DANGER
With the battery disconnected and the drive wheel
raised clear of the ground, only the load wheel hy-
draulic brakes are operative.
When towing the truck do not exceed the maximum
recommended speed of 2.5 km/h.
When towing on slopes, reduce speed to an abso-
lute minimum and keep chocks at hand.
¾ Reach the mast unit out and lower the load.

¾ Remove the load.
¾ Attach the towing vehicle (with sufficient
tractive and braking force) with a suitable
rope or chain to the fork carriage.
¾ Disconnect the battery plug.
¾ Raise the drive wheel using a suitable main-
tenance dolly or fork lift truck.
DANGER
Only raise the drive wheel just clear of the floor.
¾ One person should be on the truck being

towed to operate the brakes if necessary.

Maintenance 5
Mast unit
Mast unit
Mast operation
The fork carriage rises up to the free lift height
by means of the chain of the primary jack. The
secondary lift jack lifts the inner mast. The
inner mast is raised via the chain pulley at
twice the speed. The secondary jack is fitted
on the extensible middle mast.
Work on the mast and the reach frame

part of the truck
DANGER
Before attempting repairs or adjustments on the
reach frame, the raised fork carriage or mast, al-
ways ensure that the following safety procedures
are carried out.
Securing the reach frame against reach-

ing in or out
DANGER
Before work in front of or behind the reach frame,
securing against reaching in or out is required.

¾ Lower the fork carriage fully.
¾ Reach the reach frame out.
¾ Insert a wood block (1) between the mast
and the battery.
¾ Reach the frame back until it is stopped by
the wood block.
¾ Switch off and remove the key.
¾ Disconnect the battery plug.

5 Maintenance
Mast unit
Securing the mast

¾ Raise the forks.
¾ Close the chain after passing it over the
outer mast cross member (1) and under the
centre mast cross member (2).
¾ Lower the mast until it comes into contact
with the chain.
¾ Lower the fork carriage until it rests in the
end stop.
Mast and lift carriage removal

DANGER
Removing the mast or lift carriage requires special
knowledge and tools.
Mast or lift carriage removal must only be carried
out by the trained personnel of your local distributor.

Maintenance 5
Recommended lubricants
Hydraulic oil
STANDARD
Hydraulic oil grade HLP to DIN 51524 part 2
Viscosity ISO VG 46.
Cloud point lower than -10°C when tested
to IP 216.82
COLD STORE (STAY IN and IN - OUT)
Anti wear hydraulic oil
Grade ISO VG 22-32
Viscosity index ≥ 300
e.g Shell Tellus Arctic 32
NOTE
The above specification is a high Viscosity
Index oil, which allows the use of hydraulics
in ambient temperatures between −30 °C and
+40 °C (Oil temperatures between −30 °C and
+80 °C)
Multipurpose grease
STANDARD
Lithium-based grease to DIN51825,
KP2K-20
COLD STORE
Low temperature clay based grease
Gear oil
Use only oil of classification SHC,
e.g. Mobil SHC 75w/90
Steering drive gears

Multi purpose grease containing 5% Molyb-
denum Disulphide
Trucks manufactured prior to serial number
G1X115U52000
Shell Aeroshell 17 (No longer available)
Trucks manufactured after serial number
G1X115U52000
Shell Aeroshell 33MS

5 Maintenance
CAUTION
The two grease type are not compatible, and must
not be mixed.
If in doubt as to the type of grease applied to the
drive gears, then all traces of the existing grease
must be removed before applying Aeroshell 33MS
General purpose oil

Engine Oil SAE 20W/50
Chain Spray
STANDARD
Chain spray
COLD STORE
Cold store chain spray
Brake fluid
Original ATE brake fluid to DOT3, type “S”,
classification to FMVSS 116 or SAE J 1703
issue 1980 and ISO 4925.
NOTE
For any further information, we recommend
that you contact your local distributor.

Maintenance 5
Inspection and maintenance data
Inspection and maintenance data

Assembly Material/Lubricant Capacity/Adjustment value
Hydraulic system Suction filter element
Breather filter
Wheels Drive wheel nuts 195 Nm
Electrical system Main fuse 425 amp
Power steering fuse 50 amp
Ancillary circuit fuses 5 amp
Battery Distilled water As required
Petroleum jelly As required
Mast channels Chain spray As required
Mast chains Chain spray As required
Reach channels Chain spray As required
Seat runners Grease As required

5 Maintenance
Inspection and maintenance schedule

Routine inspection and maintenance
Your truck will remain operational only if the DANGER
maintenance and checks are carried out
The majority of accidents and injuries that occur
regularly and according to the information in workshops are caused by the failure to observe
and instructions in this User Manual. The some basic rules of care and safety, and for this
maintenance may only be carried out by reason, in most cases they can be avoided.
qualified authorised personnel. This work can Always follow the maintenance safety guidelines
be carried out by your local distributor under a when carrying out inspection and maintenance
service contract. routines.
If you wish to do the work yourself, we rec-

ommend that the first three customer service ENVIRONMENT NOTE
checks be carried out by your local distribu- Some lubricants and compounds can be
tor’s service engineer in the presence of the harmful to the environment. Always follow
responsible mechanic in your workshop, so maintenance safety guidelines when handling
that your staff can receive the appropriate in- lubricants and compounds during mainte-
struction. nance procedures.
For all maintenance, the truck must be placed
on a level surface and the wheels secured. Maintenance and lubrication intervals
CAUTION If used in a clean, dry atmosphere, the mainte-
nance and lubrication intervals outlined in this
Working on the electrical control system without
first discharging the steering capacitor can lead to User Manual are sufficient. However, should
damage of the CAN interface drivers. the truck be used in harsh environments, then
It is imperative, that before working on the control more frequent maintenance and lubrication
system, that the battery is disconnected, and the will substantially increase the service life of
steering capacitor voltage is discharged. The stee- the truck.
ring capacitor voltage can be safely discharged by
operating the horn with the battery plug DISCON-
NECTED.
NOTE
Check that the voltage between 3F1 and the main It is preferable to use less lubricant more often,
negative is less than 5V before working on the truck. than a lot of lubricant less frequently.
DANGER
Incorrect inspection and maintenance procedures
can result in the malfunction of safety-critical com-
ponents.
Only carry out inspection and maintenance routines
if you have been trained, and are authorised to do
so.

Maintenance 5
Pre-shift checks
The following checks should be carried out ¾ Check all controls and their operation
before the start of each shift.
¾ Check interlock switches
¾ Check battery state of charge
¾ Check general condition of truck
Inspection and maintenance after the first 50 hours of operation

¾ Check all controls and their operation ¾ Replace the hydraulic suction line filter
¾ Check the brake operation ¾ Lubricate the tilt and sideshift slider pad.
¾ Check the drive wheel nuts ¾ Lubricate the mast and lift chain
¾ Check the tyres for damage and foreign
objects
Inspection and maintenance as required

The following procedures should be carried ¾ Lubricate the lift chains and mast channels
out as necessary.
¾ Adjust the lift chains
¾ Clean the truck
¾ Replace the hydraulic hoses
¾ Check the battery electrolyte level and
¾ Check the drive wheel nuts
specific gravity
¾ Replace the battery trolley slides
Inspection and maintenance every 1000 hours (250 hours cold store version)
¾ Check the condition and security of the ¾ Lubricate the mast hose pulley assemblies
wheels and tyres
¾ Lubricate the reach channels and rollers
¾ Check the condition of the battery and
¾ Check and lubricate the battery trolley
battery cables
slides and associated mechanism
¾ Check the condition and security of electri-
¾ Check the hydraulic fluid level
cal connections and cables
¾ Lubricate the fork carriage and sideshift
¾ Check the parking brake gap
slider pad
¾ Check the hydraulic hoses and pipes for
¾ Check condition of the side guide rollers
damage
(option)
¾ Check the lift chains for condition and
¾ Lubricate cold store cab hinges and door
security
latch (option)
¾ Lubricate the mast, mast rollers, lift chains
and chain pulleys

5 Maintenance
¾ Check the brake fluid level ¾ Replace the hydraulic tank breather filter
¾ Check the load wheel brake shoes for wear ¾ Check the reach carriage rollers, adjust if
required
¾ Grease the load wheel bearings
¾ Check condition of brake pipes
¾ Change the hydraulic oil and suction filter
Inspection and maintenance every 10000 hours or 5 years, whichever is earlier

(5000 hour or 30 months cold store version)
¾ Change the brake fluid

Maintenance 5

Clean the truck
NOTE
The necessity of cleaning depends on the
use of the truck. If used with aggressive me-
dia such as salt water, fertiliser, chemicals,
cement etc., clean the truck thoroughly after
every shift.
When cleaning lift chains, only use paraffin.
DANGER
Cleaning chains with steam or jet cleaners can
cause rapid and dangerous corrosion.
If cleaning chains with a steam or jet cleaner cannot
be avoided, then the following procedure must be
observed:
¾ Only use clean water or steam. Do not use ag-
gressive, caustic or chlorine based cleaners
¾ Immediately after cleaning, dry the chain using
compressed air, ensuring all moisture is remo-
ved from between the links.
¾ After thorough drying, immediately lubricate the
chain using chain spray, ensuring lubricant pe-
netrates the links.
Hot steam or intensive degreasing solutions

should be used with utmost care. The grease
in the sealed for life bearings will dissolve and
leak out. As re-greasing is not possible, the
bearings will be damaged.
CAUTION
Under no circumstances should the polycarbonate
windows on trucks fitted with a cabin be cleaned
with chemical cleaners as these can cause perma-
nent damage.
Only clean the windows using a proprietary non
abrasive, water based window cleaning solution.
For stubborn localised deposits, white spirit may be
used sparingly, providing it is rinsed off immedia-
tely.
When cleaning polycarbonate windows, particular
care must be taken so as not to scratch the protec-
tive surface coating.

5 Maintenance
CAUTION
Motors and electrical control units can be damaged
by the ingress of steam or water.
When washing with a steam or jet cleaner, do not
directly expose the motors, control unit and insula-
ting material to the jet. Cover them first.
Clean the oil filler openings along with the

surrounding area and the grease nipples prior
to lubrication.
When cleaning with compressed air, first re-
move stubborn deposits with a cold cleaner.
Check the battery electrolyte level

and specific gravity
WARNING
ries.
flames.
¾ Only charge batteries is designated areas. 116-37

ventilated.
¾ The battery electrolyte level and specific

gravity should be checked in accordance
with the battery manufacturer’s recommen-
dations.
CAUTION
Batteries that are discharged to under 20% of the
rated capacity are over discharged. Over dischar-
ging batteries will shorten their service life and could
nullify the battery warranty.

Maintenance 5
Lubricate the lift chains and mast

channels
¾ Lubricate the lift chains over the full working
length with chain spray.
NOTE
If necessary, the chains should be cleaned to
ensure penetration of lubricant.
DANGER
The use of cold cleaners, chemical cleaning agents
and caustic or acidic and chlorinated fluids can be a
direct cause of lift chain failure.
¾ Lubricate the mast channels over the full

working length using chain spray.
NOTE
Extend the mast to full lift height to gain access
to the areas of the roller track that would nor-
mally be covered when the mast is closed.
Adjust the lift chains
NOTE
When the truck is being used, chains are sub-
ject to elongation and consequently have to be
regularly adjusted.
DANGER
The examination and adjustment of lift chains
should only be carried out by certified personnel
who have received the relevant training.
DO NOT adjust or make an assessment of chain
condition unless you have been certified to do so.

5 Maintenance
Replace the hydraulic hoses and

pipes
Hydraulic hoses and pipes should be replaced
as required.
NOTE
We strongly recommend that this operation be
carried out by your local distributor.
Check the drive wheel nuts

¾ After taking delivery of the truck, or after
removing the drive wheel, the security of the
nuts MUST be checked within 50 hours of
operation.
quence shown.
NOTE

Maintenance 5
Replace the battery trolley slides

¾ The battery trolley slides (1) should be re-
placed if showing signs of excessive wear.
WARNING
Excessive battery trolley slide wear could affect
battery security.
We strongly recommend that this operation be car-
ried out by your local distributor.

5 Maintenance
1000 hr Inspection and maintenance (250 hr cold store)

Check the condition and security of
the wheels and tyres
DANGER
Worn or damaged tyres can affect truck stability.
Always replace worn or damaged tyres promptly.
Drive wheel
¾ Check the drive wheel tyre for damage,
deformation or wear.
¾ Remove all swarf, metal, stone and other
matter embedded in the tyre.
¾ Check the tightness of the drive wheel se-

curing nuts.
quence shown.
NOTE
Load wheels
116-529
¾ Raise the load wheels clear of the ground
and block securely.
¾ Check the load wheel tyres for damage,
deformation or wear.
¾ Remove all swarf, metal, stone and other
matter embedded in the tyres.
¾ Check the wheels rotate freely.

Maintenance 5
Check the condition of the battery

and battery cables
WARNING
ries.
flames.
¾ Only charge batteries is designated areas.
ventilated.
¾ Check that there are no cracked cells, de-

formed plates or loss of electrolyte.
¾ Check all connections for security.
¾ Check cable insulation for wear and dam-
age.
¾ Check battery/charger connectors and ca-
bles for damage and burnt contacts.
¾ Ensure insulators on cell connections are
present and undamaged.
¾ Check the tops of the cells are dry and
clean.
¾ Check lifting eyes for corrosion and deterio-
ration.
Report any corrosion or deterioration in any
part of the battery to supervision.

5 Maintenance

electrical connections and cables
¾ Check the tightness of connections and
remove all traces of corrosion.
¾ Check that battery cables are undamaged
and well insulated.
¾ Check electric motor cable connections for
security, and make sure that there are no
signs of corrosion.
¾ Check that all motor cables are undamaged
and well insulated.
NOTE
Corroded connections and damaged cables
cause voltage drops and overheating which
can lead to operating problems.
¾ Eliminate all traces of corrosion and renew
damaged cables.
Check the parking brake gap
NOTE
A parking brake wear indicator is fitted, and
will indicate if the parking brake pads are worn
excessively. However it is advisable to check
the parking brake every 1000 hours. Maxi-
mum allowed gap is 0.8 mm
NOTE
We strongly recommend that this operation
and other brake adjustments be carried out by
DANGER
Never use a truck with a defective braking system.
If defects in the braking system become apparent,
park the truck in a safe place, and report to supervi-
sion.

Maintenance 5
Check the hydraulic hoses and pipes

for damage
¾ Examine the outer cover of hoses for signs
of embrittlement, tears, blisters, ballooning
or cracks.
¾ Check that hoses are not twisted, kinked or
crushed.
¾ Replace any defective hoses or pipes.
¾ Check that all clips that support hoses and
pipes are fitted and replace any worn or
damaged clips that may cut or damage the
hoses.
¾ Check for signs of chafing and ensure that
hoses are routed clear of both very hot and
moving parts.
NOTE
Should hoses be subject to acids, solvents,
steam cleaning, salt water or ozone, the in-
spection period should be reduced.
Check the lift chains for condition

and security
DANGER
The examination and adjustment of lift chains
should only be carried out by certified personnel
who have received the relevant training.
DO NOT adjust or make an assessment of chain
condition unless you have been certified to do so.
DANGER
The fitting of chains not specified by the manufactu-
rer is prohibited.
Only fit replacement chains, chain anchors, anchor
pins as specified and approved by the manufactu-
rer.

5 Maintenance
Lubricate the mast, mast rollers, lift

chains and chain pulleys
¾ Lubricate the lift chains over the full working
length with chain spray.
NOTE
If necessary, the chains should be cleaned to
ensure penetration of lubricant.
DANGER
The use of cold cleaners, chemical cleaning agents
and caustic or acidic and chlorinated fluids can be a
direct cause of lift chain failure.
¾ Lubricate the mast channels over the full

working length using chain spray.
NOTE
Extend the mast to full lift height to gain access
to the areas of the roller track that would nor-
mally be covered when the mast is closed.
¾ Lubricate the chain pulleys and primary lift
jack pulley.
¾ Lubricate the mast rollers (cold store only).
¾ Lubricate the fork carriage rollers (cold store
only).

Maintenance 5
Lubricate the mast hose pulley as-

semblies (cold store only)
¾ Lubricate the top and bottom mast hose
pulley assemblies.
NOTE
Any excess grease should be removed from
around the hose pulley assemblies. It is im-
portant that the hoses are free of grease.
Lubricate the reach channels and

rollers
¾ Apply chain spray to the reach channels (2)
on both sides. Operate the reach to ensure
all working surfaces of the reach channel
have been lubricated and to gain access to
the rear reach rollers.
¾ Lubricate the front reach rollers on both
sides (1), and the rear reach rollers (cold
store only).

5 Maintenance
¾ Lubricate the side rollers (cold store only).
Check and lubricate the battery trol-

ley slides and associated mecha-
nism
¾ Check the battery trolley slides for signs of
excessive wear.
WARNING
Excessive battery trolley slide wear could affect
battery security.
We strongly recommend that this operation be car-
ried out by your local distributor.
¾ Lubricate with general purpose grease the

battery trolley slides.
¾ Lubricate the battery rollers.
WARNING
Manual handling risk. The battery and battery trol-
ley are heavy.
Take care when manoeuvring battery or trolley.

Maintenance 5
Check the hydraulic oil level

Carry out this operation with forks in the low-
ered position and with the mast reached in.
¾ Observe the hydraulic oil level against the
fluid level marks on the hydraulic tank.
NOTE
The tank has two level marks labelled 184 and
187. These labels refer to the mast type fitted
on the truck. The mast type can be determined
from the mast serial number which is stamped
on the mast.
¾ If necessary, remove the filler cap (1) and
replenish the tank to the correct level with
clean oil.
¾ Replace the filler cap (1).
Lubricate the fork carriage and

sideshift slider pad
¾ Lubricate the fork carriage top edges (1)
with general purpose grease.
WARNING
Manual handling risk. The forks are heavy.
Take care when manoeuvring the forks on the car-
riage plate.
¾ Lubricate the sideshift slider pad (2) with

general purpose grease.
NOTE
The sideshift slider pad should be lubricated
every time the truck is cleaned.

5 Maintenance
Check condition of side guide rollers

(option)
¾ Check for wear or damage on side guidance
rollers.
¾ Check that rollers are secure and free to
rotate.
Lubricate cold store cab hinges and

door latch (option)
¾ Using fresh grease, lubricate both door
hinges and the door securing latch.

Maintenance 5

Check the brake fluid level
NOTE
A brake fluid level indicator is fitted, and will
indicate when the brake fluid level is low. Ho-
wever it is advisable to check the brake fluid
level every 2000 hours.
¾ Remove the floorplate.
¾ Check the level of the brake fluid reservoir is
up to the maximum mark (1). The level must
never drop below the minimum mark (2).
¾ Top up with brake fluid if necessary, in ac-
cordance with the lubrication table.
CAUTION
Do not allow brake fluid to come in contact with the
reach cylinder.
Protect the reach cylinder from spillage prior to
topping up.
Check the load wheel brake shoes

for wear
NOTE
DANGER
sion.

5 Maintenance
Replace the hydraulic tank breather

filter
¾ Fully lower the forks.
emergency isolator.
¾ Pull out the breather (1) and discard.
¾ Fit new breather.
Check the reach carriage rollers,

adjust if required
¾ Check the adjustment on the front and rear
rollers of the reach carriage.
NOTE
We strongly recommend that this operation is
carried out by your local distributor.

Maintenance 5

Grease the load wheel bearings
NOTE
To grease load wheel bearings please contact
Check condition of brake pipes
NOTE
DANGER
sion.

5 Maintenance
Change the hydraulic oil and suction

filter
WARNING
The hydraulic fluid can become very hot. Risk of
scalding.
Ensure the hydraulic oil has cooled sufficiently be-
fore carrying out the following procedure.
Carry out this operation with forks in the low-

ered position and with the mast reached in.
emergency isolator.
¾ Slacken the securing clip (1) on the outlet
hose.
¾ Pull the outlet hose from the filter assembly.
¾ Release and remove the filter cap by
squeezing the two tabs (2).
¾ Lift the filter (3) from the tank. Allow to drain
and discard.
¾ Empty the hydraulic tank using a suitable
hand-pump.
¾ Refill the tank to the correct level with clean
hydraulic oil.
NOTE
The tank has two level marks labelled 184 and
187. These labels refer to the mast type fitted
on the truck. The mast type can be determined
from the mast serial number which is stamped
on the mast.
¾ Place a new filter element (3) into the tank
and replace the filter cap.
¾ Prime the pump by filing the outlet hose with
clean hydraulic oil.
CAUTION
Failure to prime the pump will cause it to run dry
causing premature failure.
Ensure the pump is primed by filling the outlet hose
with hydraulic oil prior to running.

Maintenance 5
¾ Replace outlet hose, ensuring clip (1) is

secure.

5 Maintenance

Change the brake fluid
CAUTION
It is recommended the brake fluid should be chan-
ged every 10000 hours or 5 years, whichever is
earlier.
NOTE

Maintenance 5
Decommissioning the truck
Taking the truck out of operation

If the truck is taken out of operation for over two ¾ Cover the truck with a cotton sheet to protect
months, it must be parked in a well ventilated, it against dust.
frost free, clean and dry room and the following
measures must be carried out. NOTE
Do not use a polythene sheet as this encoura-
Measures before taking the truck out of ges the formation of condensation.
operation
¾ Thoroughly clean the truck. Putting the truck back into operation
¾ Fully elevate the lift carriage several times, ¾ Thoroughly clean the truck.
tilt the forks forward and back, operate the
reach mechanism, and if fitted, operate any ¾ Lubricate the truck.
attachments several times. ¾ Follow the battery manufacturer’s instruc-
¾ Lower the forks onto a support until the tions for putting the battery into service.
chains are slack. ¾ Check the hydraulic oil for condensation
¾ Check hydraulic oil level and top up if water, and change oil if necessary.
required. ¾ Perform the same services as for commis-
¾ Fully charge the battery. sioning.
¾ Apply a thin film of oil or grease on all ¾ Take the truck into service.
unpainted mechanical parts. If the truck is to be taken out of operation for
¾ Lubricate the truck. over six months, contact your local distributor
for further measures.
¾ Spray all open electrical contacts with a
suitable contact spray.

We recommend that this work is carried out ¾ Follow the manufacturer’s instructions for
by an approved dismantler (scrap dealer). If disposal of old batteries.
however you wish to carry out the work your-
¾ Dispose of the parts in accordance with le-
self, then the following should be observed.
gal requirements after receiving permission
¾ Notify the appropriate authorities in writing from the appropriate authorities.
in accordance with legal requirements of
each country before decommissioning the NOTE
truck.
The customer is entirely responsible for any
¾ Dismantle as many parts of the truck as breach of legal requirements before, during,
possible and separate them according to and after dismantling and disposing of truck
material for recycling. parts.
¾ Check the legal requirements for disposing
of toxic substances such as hydraulic oil,
batteries etc. and proceed as instructed.

5 Maintenance

6
Technical data
6 Technical data
Dimensions
Dimensions

Technical data 6
Technical data – 1.4 tonne capacity

Characteristics – 1.4 tonne
Power unit: battery, diesel, petrol, LP gas, mains
1.3 Battery
power
Operation: Manual, pedestrian, stand-on, seated,
1.4 Seated
order picker
Load capacity
1.5 Q (kg) 1400
(Capacity may be reduced for high lifts)
1.6 Load centre c mm 600/500
1.8 Axle centre to fork face x mm 311
1.9 Wheelbase y mm 1275
Weights – 1.4 tonne

Service weight
2.1 kg 2890
(Weight may vary with alternative lift heights)
Axle load without load, front (drive)/rear (load)
2.3 kg 1800/1090
(Axle load may vary with alternative lift heights)
Axle load, reach carriage extended with load, front
2.4 (drive)/rear (load) kg 520/3770
Axle load, reach carriage retracted with load, front
Wheels and tyres – 1.4 tonne

Tyres, front (drive)/rear (load) C = cushion rubber, P
3.1 P/P
= polyurethane
3.2 Tyre size, front (drive) wheel mm 343 x 135
3.3 Tyre size, rear (load) wheel mm 285 x 100
3.5 Wheels, number front (drive)/rear (load) (x = driven) 1x/2
3.6 Track width, front (drive) b10 mm 0
3.7 Track width, rear (load) b11 mm 1150
Dimensions – 1.4 tonne

4.1 Mast/fork carriage tilt, forward/backward ° 2/4
4.2 Height of mast, lowered h1 mm 2110
4.3 Free lift h2 mm 1261
Lift
4.4 h3 mm 4655
(For other heights, see Mast Variations)
4.5 Height of mast, extended h4 mm 5395

6 Technical data

4.7 Height of overhead guard (cabin) h6 mm 2110
4.8 Height of seat, minimum/maximum h7 mm 940/1030
4.10 Height of reach legs h8 mm 310
4.19 Overall length l1 mm 2184
4.20 Length to fork face l2 mm 1184
4.21 Overall width b1/b2 mm 1234/1250
4.22 Fork dimensions s/e/l mm 40 x 80 x 1000
4.23 Fork carriage to DIN 15173, class/form A,B 2A
4.24 Width of fork carriage b3 mm 830
4.25 Fork spread, minimum/maximum b5 mm 296/690
4.26 Width between reach legs b4 mm 922
4.28 Reach travel l4 mm 496
4.31 Ground clearance, mast m1 mm 75
4.32 Ground clearance, centre of wheelbase m2 mm 75
4.33 Aisle width with pallet 1000 x 1200 across forks Ast mm 2655
4.34 Aisle width with pallet 800 x 1200 along forks Ast mm 2715
4.35 Turning radius Wa mm 1540
4.37 Length of chassis l7 mm 1638
Performance – 1.4 tonne

Travel speed, with/without load
5.1 (Speed may vary with alternative lift heights) km/h 13.5/13.5
(Reduced speed available on request)
Lifting speed, with/without load
5.2 m/s 0.34/0.6
(Speed may vary with alternative lift heights)
Lowering speed, with/without load
5.3 m/s 0.55/0.45
Reach speed, with/without load
5.4 m/s 0.15/0.15
5.7 Climbing ability, with/without load, 30 minute rating % 4.5/8.2
Maximum climbing ability, with/without load, 5
5.8 % 10/10
minute rating
Acceleration time, with/without load
5.9 s 5.5/4.8
(Reduced acceleration available on request)
5.10 Service brake Hydraulic/electric

Technical data 6
Drive – 1.4 tonne

6.1 Drive motor, 60 minute rating kW 6.5
6.2 Lift motor, 15% rating kW 14
Battery according to DIN
6.3 (Alternative batteries increase length to fork face 43531C
and 90° stacking aisle widths)
6.4 Battery voltage/rated capacity (5h) V/Ah 48/420
6.5 Battery weight (±5%) kg 750
Refer to manufac-
6.6 Power consumption according to VDI cycle kW/h
turer
Other – 1.4 tonne

8.1 Type of drive control Electronic/stepless
8.2 Working pressure for attachments bar 200
8.3 Oil flow for attachments l/min 6.5
Noise level at operator’s ear
8.4 (Figure shown is without cabin, 66 dB (A) when cabin dB (A) 63
fitted)

6 Technical data
Technical data – 1.4 tonne capacity (heavy duty)

Characteristics – 1.4 tonne (heavy duty)
1.3 Battery
power
1.4 Seated
order picker
Load capacity
1.5 Q (kg) 1400
Weights – 1.4 tonne (heavy duty)

Service weight
2.1 kg 3030
2.3 kg 1830/1190
Wheels and tyres – 1.4 tonne (heavy duty)

3.1 P/P
= polyurethane
Dimensions – 1.4 tonne (heavy duty)

Lift
4.4 h3 mm 6355

Technical data 6

Performance – 1.4 tonne (heavy duty)

5.2 m/s 0.32/0.49
5.3 m/s 0.55/0.45
5.4 m/s 0.15/0.15
5.8 % 10/10
minute rating
5.9 s 5.8/5.0

6 Technical data
Drive – 1.4 tonne (heavy duty)

Refer to manufac-
turer
Other – 1.4 tonne (heavy duty)

fitted)

Technical data 6
Technical data – 1.4 tonne capacity (narrow chassis)

Characteristics – 1.4 tonne (narrow chassis)
1.3 Battery
power
1.4 Seated
order picker
Load capacity
1.5 Q (kg) 1400
Weights – 1.4 tonne (narrow chassis)

Service weight
2.1 kg 2820
2.3 kg 1760/1060
Wheels and tyres – 1.4 tonne (narrow chassis)

3.1 P/P
= polyurethane
Dimensions – 1.4 tonne (narrow chassis)

Lift
4.4 h3 mm 4655

6 Technical data

Performance – 1.4 tonne (narrow chassis)

5.2 m/s 0.34/0.6
5.3 m/s 0.55/0.45
5.4 m/s 0.15/0.15
5.8 % 10/10
minute rating
5.9 s 5.5/4.8

Technical data 6
Drive – 1.4 tonne (narrow chassis)

6.3 (Alternative batteries increase length to fork face 43531B
Refer to manufac-
turer
Other – 1.4 tonne (narrow chassis)

8.4 Noise level at operator’s ear dB (A) 63

6 Technical data

1.3 Battery
power
1.4 Seated
order picker
Load capacity
1.5 Q (kg) 1600

Service weight
2.1 kg 2940
2.3 kg 1900/1040

3.1 P/P
= polyurethane

Lift
4.4 h3 mm 4655

Technical data 6


5.2 m/s 0.34/0.6
5.3 m/s 0.55/0.45
5.4 m/s 0.15/0.15
5.8 % 10/10
minute rating
5.9 s 5.5/4.8

6 Technical data
Drive – 1.6 tonne

Refer to manufac-
turer
Other – 1.6 tonne

fitted)

Technical data 6

Characteristics – 1.6 tonne (heavy duty)
1.3 Battery
power
1.4 Seated
order picker
Load capacity
1.5 Q (kg) 1600
Weights – 1.6 tonne (heavy duty)

Service weight
2.1 kg 3070
2.3 kg 1995/1075
Wheels and tyres – 1.6 tonne (heavy duty)

3.1 P/P
= polyurethane

Lift
4.4 h3 mm 6355

6 Technical data

Performance – 1.6 tonne (heavy duty)

5.2 m/s 0.3/0.48
5.3 m/s 0.55/0.4
5.4 m/s 0.15/0.15
5.8 % 10/10
minute rating
5.9 s 5.8/5.0

Technical data 6
Drive – 1.6 tonne (heavy duty)

Refer to manufac-
turer
Other – 1.6 tonne (heavy duty)

fitted)

6 Technical data

1.3 Battery
power
1.4 Seated
order picker
Load capacity
1.5 Q (kg) 1600

Service weight
2.1 kg 2820
2.3 kg 1760/1060

3.1 P/P
= polyurethane

Lift
4.4 h3 mm 4655

Technical data 6


5.2 m/s 0.34/0.6
5.3 m/s 0.55/0.45
5.4 m/s 0.15/0.15
5.8 % 10/10
minute rating
5.9 s 5.5/4.8

6 Technical data

Refer to manufac-
turer


Technical data 6

1.3 Battery
power
1.4 Seated
order picker
Load capacity
1.5 Q (kg) 2000

Service weight
2.1 kg 3260
2.3 kg 2120/1140

3.1 P/P
= polyurethane

Lift
4.4 h3 mm 4655

6 Technical data

Length to fork face
4.20 (Lifts 6355 mm and above increase length to fork l2 mm 1261
face and 90° stacking aisle widths by 27 mm)
Overall width
4.21 (Alternative widths over reach legs of 1400 mm and b1/b2 mm 1234/1250
1600 mm are available)
Aisle width with pallet 1000 x 1200 across forks
4.33 (Lifts 6355 mm and above increase length to fork Ast mm 2770
Aisle width with pallet 800 x 1200 along forks

5.2 m/s 0.3/0.48
5.3 m/s 0.55/0.4
5.4 m/s 0.15/0.15

Technical data 6

5.8 % 10/10
minute rating
5.9 s 5.8/5.0
Drive – 2.0 tonne

Refer to manufac-
turer
Other – 2.0 tonne

fitted)

6 Technical data

1.3 Battery
power
1.4 Seated
order picker
Load capacity
1.5 Q (kg) 2000

Service weight
2.1 kg 3100
2.3 kg 1840/1260

3.1 P/P
= polyurethane

Lift
4.4 h3 mm 4655

Technical data 6

Length to fork face
4.20 (Lifts 6355 mm and above increase length to fork l2 mm 1361
Aisle width with pallet 1000 x 1200 across forks
Aisle width with pallet 800 x 1200 along forks

5.2 m/s 0.3/0.48
5.3 m/s 0.55/0.4
5.4 m/s 0.15/0.15
5.8 % 10/10
minute rating

6 Technical data

5.9 s 5.8/5.0

Refer to manufac-
turer


Technical data 6
Mast variations
Mast variations
Triplex clearview fixed masts with tilting car-
riage (2° forward, 4° back) and integrated
sideshift (80mm each side)
1.4 tonne standard and narrow chassis
Height of mast, Height of mast,

Lift Free lift
lowered extended
(h3) (h2)
(h1) (h4)
4 655 1 261 2 110 5 395
5 155 1 627 2 476 5 895
5 755 1 627 2 476 6 495
6 255 2 061 2 910 6 995
6 655 2 061 2 910 7 395
6 955 2 061 2 910 7 695
7 255 2 527 3 376 7 995
7 555 2 527 3 376 8 295
7 955 2 527 3 376 8 695
8 255 2 527 3 376 8 995
8 555 3 061 3 910 9 295
1.6 tonne standard and narrow chassis

Lift Free lift
lowered extended
(h3) (h2)
(h1) (h4)
4 655 1 261 2 110 5 395
5 155 1 627 2 476 5 895
5 755 1 627 2 476 6 495
6 255 2 061 2 910 6 995
6 655 2 061 2 910 7 395
6 955 2 061 2 910 7 695
7 255 2 527 3 376 7 995
7 555 2 527 3 376 8 295
7 955 2 527 3 376 8 695
8 255 2 527 3 376 8 995
8 555 3 061 3 910 9 295

6 Technical data
Mast variations

Lift Free lift
lowered extended
(h3) (h2)
(h1) (h4)
8 955 3 061 3 910 9 695
9 155 3 061 3 910 9 895
9 455 3 061 3 910 10 195
The following lifts are available within the pa-

rameters indicated for the models shown:
1.4 tonne (heavy duty) - 6 355 to 8 555 mm
2.0 tonne - 4 355 to 11 455 mm

Lift Free lift
lowered extended
(h3) (h2)
(h1) (h4)
4 355 1 261 2 110 5 095
4 655 1 627 2 476 5 395
5 155 1 627 2 476 5 895
5 755 2 061 2 910 6 495
6 355 2 081 2 930 7 139
6 655 2 081 2 930 7 439
6 955 2 581 3 430 7 739
7 255 2 581 3 430 8 039
7 555 2 581 3 430 8 339
7 955 2 581 3 430 8 739
8 255 2 581 3 430 9 039
8 555 3 081 3 930 9 339
8 955 3 081 3 930 9 739
9 155 3 081 3 930 9 939
9 455 3 081 3 930 10 239
9 655 3 081 3 930 10 439
9 955 3 581 4 430 10 739
10 155 3 581 4 430 10 939
10 455 3 581 4 430 11 239

Technical data 6

Lift Free lift
lowered extended
(h3) (h2)
(h1) (h4)
10 655 3 581 4 430 11 439
10 955 4 081 4 930 11 739
11 155 4 081 4 930 11 939
11 455 4 081 4 930 12 239
Alternative lift heights available on request.

Lift height = h3 + s + 10 mm

6 Technical data

Index
g
NUMBERS AND SYMBOLS Check the reach carriage rollers, adjust

if required . . . . . . . . . . . . . . . . . . 138
360° Steering . . . . . . . . . . . . . . . . . . . . . 76
Circuit diagram . . . . . . . . . . . . . . 187 – 190
A Hydraulic . . . . . . . . . . . . . . . . . . . . 200
Circuit diagram - variable electric
Approved applications . . . . . . . . . . . . . . . 2 brake . . . . . . . . . . . . . . . . . 193 – 196
B Cleaning the truck . . . . . . . . . . . . . . . . 123
Closed circuit television . . . . . . . . . . . . 100
Battery
Image adjustments . . . . . . . . . . . . . 100
Changing the battery (hoist method) . 43 Operator menu operation . . . . . . . . 102
Changing the battery (roll on, roll off) . 44
Cold store cabin . . . . . . . . . . . . . . . . . . . 70
Check charge . . . . . . . . . . . . . . . . . . 38
Cleaning . . . . . . . . . . . . . . . . . . . . . . 75
Check condition . . . . . . . . . . . . . . . 129 Exterior lights . . . . . . . . . . . . . . . . . . 74
Check electrolyte level and specific
Heater control . . . . . . . . . . . . . . . . . . 71
gravity . . . . . . . . . . . . . . . . . . . . 124
Intercom . . . . . . . . . . . . . . . . . . . . . . 72
Connecting to a charger . . . . . . . . . . 41
Intercom volume . . . . . . . . . . . . . . . . 73
Reaching the battery out . . . . . . . . . . 42
Interior lighting . . . . . . . . . . . . . . . . . 74
Before leaving the truck . . . . . . . . . . . . . 69
Preventing ice damage . . . . . . . . . . . 75
Brakes
Side windows . . . . . . . . . . . . . . . . . . 75
Change fluid . . . . . . . . . . . . . . . . . . 142
Temperature control . . . . . . . . . . . . . 72
Check fluid level . . . . . . . . . . . . . . . 137
Window heater timer . . . . . . . . . . . . . 73
Check load wheel brake shoes . . . . . 137
Controls
Check piping . . . . . . . . . . . . . . . . . . 139
Check operation . . . . . . . . . . . . . . . . 39
Check the parking brake gap . . . . . . 130
Controls and indicators
General description . . . . . . . . . . . . . . . 6
Single pedal . . . . . . . . . . . . . . . . . . . 18
Braking – single pedal . . . . . . . . . . . . . . 51
Twin pedal . . . . . . . . . . . . . . . . . . . . 17
brake . . . . . . . . . . . . . . . . . . . . . . 51 Covers and cowlings . . . . . . . . . . . . . . 106
Hydraulic footbrake . . . . . . . . . . . . . . 51 Opening the motor cover . . . . . . . . . 106
Regenerative traction brake . . . . . . . . 51 Opening the top cover . . . . . . . . . . . 107
Braking – twin pedal . . . . . . . . . . . . . . . . 49 Removing the floorplate . . . . . . . . . . 106
Engaging and releasing the parking D
brake . . . . . . . . . . . . . . . . . . . . . . 49
Hydraulic footbrake . . . . . . . . . . . . . . 49 Data Logger . . . . . . . . . . . . . . . . . . . . . . 96
Regenerative traction brake . . . . . . . . 49 Decommissioning the truck . . . . . . . . . 143
Definition of direction of travel . . . . . . . . . 36
C Drive and transmission
Capacity plate . . . . . . . . . . . . . . . . . . . . 15 General description . . . . . . . . ....... 5
Chain pulleys Driving – single pedal . . . . . . . . . . . . . . . 55
Lubricate . . . . . . . . . . . . . . . . . . . . 132 Changing direction of travel . . . . . . . . 56
Chassis Switching on . . . . . . . . . . . . . . . . . . . 55
General description . . . . . . . . . . . . . . . 5 Travel with the forks leading . . . . . . . . 56
Travel with the forks trailing . . . . . . . . 55

Index
g
Driving – twin pedal . . . . . . . . .... .... 53 Height pre-selector . . . . . . . . . . . . . . . . . 78

Changing direction of travel .... .... 54 Auto sequence mode . . . . . . . . . . . . 79
Switching on . . . . . . . . . . . .... .... 53 Commissioning . . . . . . . . . . . . . . . . . 78
Travel with the forks leading .... .... 54 De-stacking a load (zone formats 1
Travel with the forks trailing .... .... 53 and 2) . . . . . . . . . . . . . . . . . . . . . 84
De-stacking a load (zone formats 3
E and 4) . . . . . . . . . . . . . . . . . . . . . 89
Electrical system Display . . . . . . . . . . . . . . . . . . . . . . . 80
General description . . . . . . . . . . . . . .. 5 Displaying the current selected zone . 81
Emergency isolator . . . . . . . . . . . . . . . . 19 Initialising the system . . . . . . . . . . . . 80
Emergency lower . . . . . . . . . . . . . . . . . 109 Input mode . . . . . . . . . . . . . . . . . . . . 79
Emergency steering and parking brake Selecting a new zone . . . . . . . . . . . . 81
release . . . . . . . . . . . . . . . . . . . 110 Stacking a load (zone formats 1 and
2) . . . . . . . . . . . . . . . . . . . . . . . . . 81
F Stacking a load (zone formats 3 and
4) . . . . . . . . . . . . . . . . . . . . . . . . . 86
Forks
Zone formats . . . . . . . . . . . . . . . . . . 79
Adjusting . . . . . ............ ... . 67
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Fuses . . . . . . . . . . ............ ... 107
Hydraulic hoses
Ancillary circuits ............ ... 108
Check . . . . . . . . . . . . . . . . . . . . . . . 131
Main circuits . . . ............ ... 107
Hydraulic hoses and pipes
G Replace . . . . . . . . . . . . . . . . . . . . . 126
Hydraulic oil
General view of truck . . . . . . . . . . . . . . . 16
Change . . . . . . . . . . . . . . . . . . . . . 140
H Check level . . . . . . . . . . . . . . . . . . . 135
Hydraulic tank
Handling loads . . . . . . . . . . . . . . . . . . . . 65
Replace breather filter . . . . . . . . . . . 138
Capacity plate example . . . . . . . . . . . 65
Replace suction filter . . . . . . . . . . . . 140
De-stacking a load . . . . . . . . . . . . . . 67
Load centre distance and load I
capacity . . . . . . . . . . . . . . . . . . . . 65
Stacking a load . . . . . . . . . . . . . . . . . 68 Identification plates and labels
Transporting a load . . . . . . . . . . . . . . 68 Location . . . . . . . . . . . . . . . . . . . . . . 14
Inspection and maintenance
After the first 50 hours of operation . . 121
As required . . . . . . . . . . . . . . . . . . . 121
Every 1000 hours . . . . . . . . . . . . . . 121
Every 10000 hours . . . . . . . . . . . . . 122
Every 2000 hours . . . . . . . . . . . . . . 122
Every 5000 hours . . . . . . . . . . . . . . 122
Pre-shift . . . . . . . . . . . . . . . . . . . . . 121

Index
g
Inspection and maintenance as Inspection and maintenance every

required 2000 hours
Adjust the lift chains . . . . . . . . . . . . . 125 Check the brake fluid level . . . . . . . . 137
Check the battery electrolyte level Check the load wheel brake shoes
and specific gravity . . . . . . . . . . . 124 for wear . . . . . . . . . . . . . . . . . . . 137
Check the drive wheel nuts . . . . . . . 126 Replace the hydraulic tank breather
Clean the truck . . . . . . . . . . . . . . . . 123 filter . . . . . . . . . . . . . . . . . . . . . . 138
Lubricate the lift chains and mast Inspection and maintenance every
channels . . . . . . . . . . . . . . . . . . 125 5000 hours
Replace the battery trolley slides . . . 127 Change the hydraulic oil and suction
filter . . . . . . . . . . . . . . . . . . . . . . 140
Replace the hydraulic hoses . . . . . . 126
Check condition of brake pipes . . . . 139
Inspection and maintenance data . . . . . 119
Grease the load wheel bearings . . . . 139
Inspection and maintenance every
1000 hours Interlock switches
Check and lubricate the battery Check operation . . . . . . . . . . . . . . . . 39
trolley slides and associated
mechanism . . . . . . . . . . . . . . . . 134 J
Check condition of side guide Jacking the truck . . . . . . . . . . . . . . . . . 113
rollers . . . . . . . . . . . . . . . . . . . . 136 Raising the drive wheel . . . . . . . . . . 113
Check the condition and security Raising the load wheels . . . . . . . . . . 113
of electrical connections and
cables . . . . . . . . . . . . . . . . . . . . 130 L
the wheels and tyres . . . . . . . . . . 128 Lift chains
Check the condition of the battery Adjust . . . . . . . . . . . . . . . . . . . . . . . 125
and battery cables . . . . . . . . . . . 129 Check . . . . . . . . . . . . . . . . . . . . . . . 131
Check the hydraulic hoses and Lubricate . . . . . . . . . . . . . . . . 125, 132
pipes for damage . . . . . . . . . . . . 131 Lift height indicator . . . . . . . . . . . . . . . . . 32
Check the hydraulic oil level . . . . . . . 135 Actual height mode . . . . . . . . . . . . . . 32
Check the lift chains for condition De-stacking a load . . . . . . . . . . . . . . 34
and security . . . . . . . . . . . . . . . . 131
Displaying the current selected zone . 35
Check the parking brake gap . . . . . . 130
Selecting a new zone . . . . . . . . . . . . 35
Lubricate cold store cab hinges and
Shelf mode . . . . . . . . . . . . . . . . . . . . 33
door latch . . . . . . . . . . . . . . . . . . 136
Stacking a load . . . . . . . . . . . . . . . . . 34
Lubricate the fork carriage and
sideshift slider pad . . . . . . . . . . . 135 Warehouse zones . . . . . . . . . . . . . . . 34
Lubricate the mast hose pulley Lubricants . . . . . . . . . . . . . . . . . . . . . . 117
assemblies . . . . . . . . . . . . . . . . 133 Brake fluid . . . . . . . . . . . . . . . . . . . 118
Lubricate the mast, mast rollers, lift Chain Spray . . . . . . . . . . . . . . . . . . 118
chains and chain pulleys . . . . . . . 132 Gear oil . . . . . . . . . . . . . . . . . . . . . . 117
Lubricate the reach channels and General purpose oil . . . . . . . . . . . . . 118
rollers . . . . . . . . . . . . . . . . . . . . 133 Hydraulic oil specification . . . . . . . . 117
Inspection and maintenance every Multipurpose grease . . . . . . . . . . . . 117
10000 hours
Steering drive gears . . . . . . . . . . . . 117
Change the brake fluid . . . . . . . . . . . 142

Index
g
M Operator code entry . . . . . . . . . . . . . . . . 92

Accessing supervisor menus . . . . . . . 93
Mast channels
Add/delete operator PINs . . . . . . . . . 94
Lubricate . . . . . . . . . . . . . . . . 125, 132
Changing the supervisor PIN . . . . . . . 93
Mast rollers
Disable/enable the truck . . . . . . . . . . 94
Lubricate . . . . . . . . . . . . . . . . . . . . 132
List operator PINs . . . . . . . . . . . . . . . 95
Mast unit . . . . . . . . . . . . . . . . . . . . . . . 115
Logging off . . . . . . . . . . . . . . . . . . . . 92
Description of operation . . . . . . . . . . 115
Logging on . . . . . . . . . . . . . . . . . . . . 92
Removal . . . . . . . . . . . . . . . . . . . . . 116
Set/reset learner operation . . . . . . . . 95
Securing the mast . . . . . . . . . . . . . . 116
Operator’s compartment
Securing the reach frame against
reaching in or out . . . . . . . . . . . . 115 General description . . . . . . . . . . . . . . . 5
Work on the mast and the reach Operator’s controls
frame part of the truck . . . . . . . . . 115 General description . . . . . . . . . . . . . . . 5
Mast variations . . . . . . . . . . . . . . . . . . 171 Operator’s display . . . . . . . . . . . . . . . . . 21
Mast, hydraulics and reach system Battery change indicators . . . . . . . . . 27
General description . . . . . . . . . . . . . . . 5 Battery discharge indicator . . . . . . . . 26
Mounting and dismounting the truck . . . . 47 Battery lock warning . . . . . . . . . . . . . 30
Brake fluid level warning . . . . . . . . . . 30
N Clock . . . . . . . . . . . . . . . . . . . . . . . . 27
Noise emission levels . . . . . . . . . . . . . . . 10 Fork tilt indicator . . . . . . . . . . . . . . . . 24
Hour meter . . . . . . . . . . . . . . . . . . . . 29
O Interlock warning indicator . . . . . . . . . 25
Operating the mast and attachments Message panel . . . . . . . . . . . . . . . . . 22
(with four joystick control) . . . . . . . 61 Over temperature indicators . . . . . . . 28
Attachments . . . . . . . . . . . . . . . . . . . 63 Parking brake warning . . . . . . . . . . . . 29
Extending the reach carriage . . . . . . . 62 Service interval elapsed indicator . . . . 28
Lowering the lift carriage . . . . . . . . . . 61 Service warning . . . . . . . . . . . . . . . . 31
Raising the lift carriage . . . . . . . . . . . 61 Sideshift centre indicator . . . . . . . . . . 25
Retracting the reach carriage . . . . . . . 62 Slow speed indicator . . . . . . . . . . . . . 26
Sideshift . . . . . . . . . . . . . . . . . . . . . . 63 Steering indicator . . . . . . . . . . . . . . . 22
Tilting the fork carriage back . . . . . . . 62 Opposite direction steering . . . . . . . . . . . 77
Tilting the fork carriage forward . . . . . 62
Operating the mast and attachments P
(with two joystick control) . . . . . . . 58
Pre-shift checks . . . . . . . . . . . . . . . . . . . 38
Attachments . . . . . . . . . . . . . . . . . . . 60
Check all controls and their operation . 39
Extending the reach carriage . . . . . . . 59
Check all Interlock switches . . . . . . . . 39
Lowering the lift carriage . . . . . . . . . . 58
Check general condition of truck . . . . 40
Raising the lift carriage . . . . . . . . . . . 58
Check the battery charge . . . . . . . . . . 38
Retracting the reach carriage . . . . . . . 59
Sideshift . . . . . . . . . . . . . . . . . . . . . . 59 R
Tilting the fork carriage back . . . . . . . 60
Reach carriage rollers
Tilting the fork carriage forward . . . . . 60
Lubricate . . . . . . . . . . . . . . . . . . . . 133

Index
g
Reach channels Technical data

Lubricate . . . . . . . . . . . . . . . . . . . . 133 1.4 tonne capacity . . . . . . . . . . . . . . 147
Referenced standards . . . . . . . . . . . . . . . 2 1.4 tonne capacity (heavy duty) . . . . 150
Replace the battery trolley slides . . . . . . 127 1.4 tonne capacity (narrow chassis) . 153
Routine inspection and maintenance . . 120 1.6 tonne capacity . . . . . . . . . . . . . . 156
Running-in . . . . . . . . . . . . . . . . . . . . . . . 38 1.6 tonne capacity (heavy duty) . . . . 159
Check the drive wheel nuts . . . . . . . . 38 1.6 tonne capacity (narrow chassis) . 162
2.0 tonne capacity . . . . . . . . . . . . . . 165
S 2.0 tonne capacity (narrow chassis) . 168
Safety Technical note . . . . . . . . . . . . . . . . . . . . . 3
General maintenance safety . . . . . . 104 Towing procedure . . . . . . . . . . . . . . . . 114
Handling lubricants . . . . . . . . . . . . . 105 Truck data management . . . . . . . . . . . . 97
Operator safety guidelines . . . . . . . . . . 8 Logging off . . . . . . . . . . . . . . . . . . . . 99
Report of Thorough Examination . . . 105 Logging on . . . . . . . . . . . . . . . . . . . . 98
Safety symbols . . . . . . . . . . . . . . . . . . 2 Status LEDs . . . . . . . . . . . . . . . . . . . 99
Seat adjustments . . . . . . . . . . . . . . . . . . 48 Truck condition codes . . . . . . . . . . . . 97
Securing for transportation . . . . . . . . . . 112 Truck takeover . . . . . . . . . . . . . . . . . . . . . 3
Side guidance . . . . . . . . . . . . . . . . . . . 100 Truck type plate . . . . . . . . . . . . . . . . . . . 15
Slinging the truck . . . . . . . . . . . . . . . . . 111 Tyres
Starting on an incline . . . . . . . . . . . . . . . 57 Check condition . . . . . . . . . . . . . . . 128
Steering
General description . . . . . . . . . . . . . . . 5
V
Steering wheel . . . . . . . . . . . . . . . . . 19 Vibration levels . . . . . . . . . . . . . . . . . . . 11
Steering column adjustment . . . . . . . . . . 48
W
T Wheels
Taking the truck out of operation . . . . . . 143 Check condition and security . . . . . . 128
Check the drive wheel nuts . . . . 38, 126
Grease load wheel bearings . . . . . . 139

Linde Material Handling GmbH
115 807 10 01 EN – 03/2009

Operating Instructions
Electric reach truck
R14, R14HD, R14N, R16,

R16HD, R16N, R20, R20N
Annex 115 807 10 01 EN – 03/2009
7
Circuit diagrams
7 Circuit diagrams

Circuit diagrams 7
Circuit Diagram (1 of 4)

7 Circuit diagrams

Circuit diagrams 7

7 Circuit diagrams

Circuit diagrams 7
Circuit diagram (Standard) - keycode

Code Explanation of function Code Explanation of function Code Explanation of function Code Explanation of function
A2 Module – Control, 9-49 :64 - Relay driver 4 1A4 Accelerator, 155-159 3F1 Fuse – Power steering, 4
:1 - Main contactor -ve :66 - CAN Lo 2A1 Module – Hydraulic power block 5F1 Fuse – Lighting circuit, 104
LAC1, 26-41
:3 - Main contactor +ve :67 - CAN Lo 6F1 Fuse – Battery monitor, 66
:11 - Enable
:4 - Battery voltage :72 - Speed Override G1 Battery, 2-3
:12 - Error
:6 - 13 volt :73 - Brake potentiometer U1 4H1 Horn, 113
:13 - CAN Hi
:8 - Parking brake :74 - Neutral K1 Contactor – Main, 7,12
:14 - CAN Lo
:9 - Enable :76 - Brake potentiometer U2 K2 Relay – Charge resistor, 46,53
3A1 Module – Steering, 183-210
:13 - Enable :79 - 0 volt K3 Relay – Charge resistor, 51,57
B1 Sensor – Battery lock, 71-75
:17 - Reverse :85 - 0 volt 1M1 Motor – Traction, 14-16
1B1 Sensor – Traction motor tachometer,
:18 - Tacho B :87 - Encoder B 9-12 2M1 Motor – Hydraulic, 34-36
:19 - Accelerator 1 :91 - 5th hydraulic 1B4 Sensor – Traction motor tempera- 9M1 Motor – Traction MOS fan, 74
ture, 17-18
:20 - Accelerator 2 :92 - 6th hydraulic 9M2 Motor – Traction motor fan, 78
1B5 Alarm – Reverse, 28-29
:21 - Drive C1 :93 - +5 volt 9M4 Motor – Hydraulic MOS fan, 76
1B12 Sensor – Height encoder, 78-81
:30 - CAN Hi :94 - UPA lift 6P1 Module – display, 65-85
2B1 Joystick – Lift and reach, 123-128
:31 - CAN Lo :95 - Encoder reach/lift stop :1 - 13 volt
2B2 Joystick – Tilt and sideshift, 130-135
:33 - Seat switch :101 - Encoder A :2 - Brake fluid
2B3 Joystick – 5th and 6th hydraulics,
:34 - Error :102 - Lift enable 137-142 :3 - Battery monitor +ve
:35 - Parking brake :103 - RMP 2B4 Sensor – Lift motor temperature, 37 :5 - Encoder A
:36 - Forward :104 - Spare 2B8 Sensor – Lift motor tachometer, :6 - Encoder B
29-32
:37 - Tacho A :107 - 5th hydraulic :7 - Encoder reach/lift stop
2B18 Sensor – Reach out, 116-119
:47 - CAN Hi :108 - 6th hydraulic :8 - Battery locked
2B20 Sensor – Lift stop, 91-94
:48 - CAN Hi :111 - Spare :9 - Traction MOS fan
2B21 Sensor – Reach back, 121-124
:51 - Error :118 - Valve +ve :11 - Traction motor fan
8B5 Sensor – Reference, 78-82
:52 - Drive enable A11 Module – Charge resistor, 50-55 :12 - Hydraulic MOS fan
9E11 Seat heater and lumber control,
:53 - UPA Traction 1A1 Module – Traction power block 108-109 :13 - Spare (load sensor)
LAC1, 6-22 F8 Fuse – Control circuit, 5
:54 - Footbrake switch :14 - CAN Hi
:11 - Enable
:55 - Left foot switch 1F1 Fuse – Main circuit, 4 :15 - CAN Lo
:12 - Error
:57 - Drive C2 1F2 Fuse – Control circuit, 48-49 :16 - 0 volt
:13 - CAN Hi
:60 - +5 volt 1F6 Fuse – Horn, 108 R3 Resistor – CAN bus, 8
:14 - CAN Lo
:63 - Relay driver 3 2F2 Fuse – Hydraulic valves, 119 R4 Resistor – CAN bus, 40

7 Circuit diagrams
1R25 Resistor – Brake, 144 1X7 Connector – Traction motor temper- 2X26 Connector – Tilt/side shift lever (6 9X1 Connector – Traction MOS fan (2
ature(2 way), 17-18 way), 131-134 way), 74
3R11 Potentiometer – Steering wheel, 190
1X9 Connector – Direction/horn switch (6 2X27 Connector – 5th/6th hydraulics UPA 9X2 Connector – Traction motor fan (2
3R12 Potentiometer – Steering drive, 209 way), 112, 164-169 (6 way), 138-141 way), 77-78
6R1 Resistor – CAN bus, 69 1X10 Connector – Accelerator (4 way), 2X37 Connector – Hydraulic power block 9X12 Connector – Hydraulic MOS fan (2
155-159 (16 way), 28-41 way), 79
S1 Keyswitch, 51
1X14 Connector – Footbrake (3 way), 2X81 Connector – Lift stop/slow sensor (4 Y1 Solenoid – Traction motor brake, 44
S2 Switch – Emergency isolator, 2-3 19-20 way), 91-94
2Y1 Valve – Lift, 130
S3 Switch – Brake fluid level, 79 1X15 Connector – Diagnostic (7 way), 2X81A Connector – Lift stop sensor (4 way),
93-98 91-94 2Y2 Valve – Lower, 132
1S1 Switch – Seat, 172
1X16 Connector – Traction tachometer (4 2X83 Connector – Lift tachometer (4 way), 2Y8 Valve – Reach out, 134
1S4 Switch – Parking brake, 175 way),9-12 28-32
2Y9 Valve – Reach back, 136
1S5 Switch – Footbrake, 20 1X17 Connector – Traction power block 3X1 Connector – Steer unit (16 way),
(16 way), 9-21 184-191 2Y11 Valve – Tilt forward, 138
1S11 Switch – Left foot, 25
1X32 Connector – Seat (6 way), 108-109, 3X4 Connector – Steering potentiometer 2Y12 Valve – Tilt back, 140
1S13 Switch – Direction, 156-160 175 feedr (6 way), 192-200
2Y13 Valve – Side shift left, 142
2S13 Switch – 8.5 metre, 89 1X34 Connector – Travel alarm (2 way), 3X15 Connector – Steering interface (10
28-29 way), 188-210+ 2Y14 Valve – Side shift right, 144
4S1 Switch – Horn push, 113
1X36 Connector – 8.5 metre switch (4 3X18 Connector – Steering potentiometer 2Y15 Valve – Auxiliary 1, 146
U1 Converter – 48 V / 24 V, 60-64 way), 88-90 (10 way), 190-200
2Y16 Valve – Auxiliary 2, 148
1V23 Diode – Electromagnetic brake, 43 1X38 Connector – Left foot switch (3 way), 3X19 Connector – Steering drive (6 way),
24-25 209-214 2Y31 Valve – Lock, 128
X1 Connector – Battery lock (5 way),
1X78 Connector – Electromagnetic brake 4X1 Connector – Horn (2 way), 113 4Z1 Suppression – Horn, 109-111
72-75
(2 way), 41
X5 Connector – Binnacle (10 way), 5X1 Connector – Lighting supplies (4
1X80 Connector – Brake potentiometer (4 way), 94-97 Colour abbreviations
50-57, 175
way), 155-159
X8 Connector – Converter (6 way), 6X1 Connector – Display (16 way), 66-85 BK Black
60,64 2X6A Connector – Reach out sensor (5
way), 116-119 6X60 Connector – Datalogger/keypad (5 BN Brown
X10 Connector – Battery, 2-3 way), 55-58
2X6B Connector – Reach back sensor (5 BU Blue
X12 Connector – Charge resistor (6 way), way), 121-124 6X63 Connector – Option supplies (10
46, 53-57 way), 99-102, 166-170 GN Green
2X7 Connector – Hydraulic motor
X13 Connector – Control module (121 temperature sensor (2 way), 37-38 8X23 Connector – Reference sensor (4 GY Grey
way), 10-49, 119-177 way), 78-81
2X15 Connector – Lift/reach lever (6 way), OG Orange
X48/C Connector – Steering CAN bus (5 124-127 8X23A Connector – 8B5 (4 way), 83-86
way), 203-206 RD Red
2X17 Connector – Reach carriage (16 8X25 Connector – Height encoder (6 way),
X49/G Connector – Wheel position input (8 way), 126-150 83-86 VT Violet
way), 210+
2X19 Connector – 5th/6th hydraulics UPA 8X25A Connector – 1B12 (4 way), 78-81 WH White
X50/L Connector – Steering wheel input (8 (6 way), 158-163
way), 193-198 8X30 Connector – Height encoder (10 YE Yellow
2X20 Connector – Reach carriage (24 way), 74-80
1X4 Connector – Brake switch (8 way), way), 77-84, 117-163
175

Circuit diagrams 7
Circuit Diagram - variable electric brake (1 of 4)

7 Circuit diagrams

Circuit diagrams 7

7 Circuit diagrams

Circuit diagrams 7
Circuit diagram (Variable electric brake) - keycode

A2 Module – Control, 9-49 :64 - Relay driver 4 1A4 Accelerator, 155-159 2B4 Sensor – Lift motor temperature, 37
:1 - Main contactor -ve :66 - CAN Lo 1A15 Module – Variable electric brake, 2B8 Sensor – Lift motor tachometer,
38-44 29-32
:3 - Main contactor +ve :67 - CAN Lo
:1 - 0 volt 2B18 Sensor – Reach out, 116-119
:4 - Battery voltage :72 - Speed Override
:2 - Pulse input 2B20 Sensor – Lift stop, 91-94
:6 - 13 volt :73 - Brake potentiometer U1
:5 - Enable 2B21 Sensor – Reach back, 121-124
:8 - Parking brake :74 - Neutral
:6 - Status out 8B5 Sensor – Reference, 78-82
:9 - Enable :76 - Brake potentiometer U2
:7 - 0 volt 9E11 Seat heater and lumber control,
:13 - Enable :79 - 0 volt 108-109
:14 - 48 volt
:17 - Reverse :85 - 0 volt F8 Fuse – Control circuit, 5
:16 - CAN Hi
:18 - Tacho B :87 - Encoder B 1F1 Fuse – Main circuit, 4
:17 - Direction input
:19 - Accelerator 1 :91 - 5th hydraulic 1F2 Fuse – Control circuit, 48-49
:28 - Brake +
:20 - Accelerator 2 :92 - 6th hydraulic 1F6 Fuse – Horn, 108
:30 - CAN Lo
:21 - Drive C1 :93 - +5 volt 2F2 Fuse – Hydraulic valves, 119
:42 - Brake -ve
:30 - CAN Hi :94 - UPA lift 3F1 Fuse – Power steering, 4
2A1 Module – Hydraulic power block
:31 - CAN Lo :95 - Encoder reach/lift stop LAC1, 26-41 5F1 Fuse – Lighting circuit, 104
:33 - Seat switch :101 - Encoder A :11 - Enable 6F1 Fuse – Battery monitor, 66
:34 - Error :102 - Lift enable :12 - Error 9F29 Fuse – Cooling fans, 60
:35 - Parking brake :103 - RMP :13 - CAN Hi G1 Battery, 2-3
:36 - Forward :104 - Spare :14 - CAN Lo 4H1 Horn, 113
:37 - Tacho A :107 - 5th hydraulic 3A1 Module – Steering, 183-210 K1 Contactor – Main, 7,12
:47 - CAN Hi :108 - 6th hydraulic B1 Sensor – Battery lock, 71-75 K2 Relay – Charge resistor, 46,53
:48 - CAN Hi :111 - Spare 1B1 Sensor – Traction motor tachometer, K3 Relay – Charge resistor, 51,57
9-12
:51 - Error :118 - Valve +ve 1M1 Motor – Traction, 14-16
1B4 Sensor – Traction motor tempera-
:52 - Drive enable A11 Module – Charge resistor, 50-55 ture, 17-18 2M1 Motor – Hydraulic, 34-36
:53 - UPA Traction 1A1 Module – Traction power block 1B5 Alarm – Reverse, 28-29 9M1 Motor – Traction MOS fan, 74
LAC1, 6-22 1B12 Sensor – Height encoder, 78-81
:54 - Footbrake switch 9M2 Motor – Traction motor fan, 78
:11 - Enable
:55 - Left foot switch 2B1 Joystick – Lift and reach, 123-128 9M4 Motor – Hydraulic MOS fan, 76
:12 - Error
:57 - Drive C2 2B2 Joystick – Tilt and sideshift, 130-135 6P1 Module – display, 65-85
:13 - CAN Hi
:60 - +5 volt 2B3 Joystick – 5th and 6th hydraulics, :1 - 13 volt
:14 - CAN Lo 137-142
:63 - Relay driver 3 :2 - Brake fluid

7 Circuit diagrams
:3 - Battery monitor +ve X5 Connector – Binnacle (10 way), 1X80 Connector – Brake potentiometer (4 5X1 Connector – Lighting supplies (4
50-57, 175 way), 145-149 way), 94-97
:5 - Encoder A
X8 Connector – Converter (6 way), 1X81 Connector – Variable electric brake 6X1 Connector – Display (16 way), 66-85
:6 - Encoder B 60,64 module, 38-43
6X60 Connector – Datalogger/keypad (5
:7 - Encoder reach/lift stop X10 Connector – Battery, 2-3 2X6A Connector – Reach out sensor (5 way), 55-58
way), 116-119
:8 - Battery locked X12 Connector – Charge resistor (6 way), 6X63 Connector – Option supplies (10
46, 53-57 2X6B Connector – Reach back sensor (5 way), 99-102, 166-170
:9 - Traction MOS fan way), 121-124
X13 Connector – Control module (121 8X23 Connector – Reference sensor (4
:11 - Traction motor fan way), 10-49, 119-177 2X7 Connector – Hydraulic motor way), 78-81
temperature sensor (2 way), 37-38
:12 - Hydraulic MOS fan X48/C Connector – Steering CAN bus (5 8X23A Connector – 8B5 (4 way), 83-86
way), 203-206 2X15 Connector – Lift/reach lever (6 way),
:13 - Spare (load sensor) 124-127 8X25 Connector – Height encoder (6 way),
X49/G Connector – Wheel position input (8 83-86
:14 - CAN Hi way), 210+ 2X17 Connector – Reach carriage (16
way), 126-150 8X25A Connector – 1B12 (4 way), 78-81
:15 - CAN Lo X50/L Connector – Steering wheel input (8
way), 193-198 2X19 Connector – 5th/6th hydraulics UPA 8X30 Connector – Height encoder (10
:16 - 0 volt (6 way), 158-163 way), 74-80
1X4 Connector – Brake switch (8 way),
R3 Resistor – CAN bus, 8 175 2X20 Connector – Reach carriage (24 9X1 Connector – Traction MOS fan (2
way), 77-84, 117-163 way), 74
R4 Resistor – CAN bus, 40 1X7 Connector – Traction motor temper-
ature(2 way), 17-18 2X26 Connector – Tilt/side shift lever (6 9X2 Connector – Traction motor fan (2
1R25 Resistor – Brake, 144 way), 131-134 way), 77-78
1X9 Connector – Direction/horn switch (6
3R11 Potentiometer – Steering wheel, 190 way), 112, 164-169 2X27 Connector – 5th/6th hydraulics UPA 9X12 Connector – Hydraulic MOS fan (2
(6 way), 138-141 way), 79
3R12 Potentiometer – Steering drive, 209 1X10 Connector – Accelerator (4 way),
155-159 2X37 Connector – Hydraulic power block Y1 Solenoid – Traction motor brake, 34
6R1 Resistor – CAN bus, 69 (16 way), 28-41
1X14 Connector – Footbrake (3 way), 2Y1 Valve – Lift, 130
S1 Keyswitch, 51 19-20 2X81 Connector – Lift stop/slow sensor (4
way), 91-94 2Y2 Valve – Lower, 132
S2 Switch – Emergency isolator, 2-3 1X15 Connector – Diagnostic (7 way),
93-98 2X81A Connector – Lift stop sensor (4 way), 2Y8 Valve – Reach out, 134
S3 Switch – Brake fluid level, 79 91-94
1X16 Connector – Traction tachometer (4 2Y9 Valve – Reach back, 136
1S1 Switch – Seat, 172 way),9-12 2X83 Connector – Lift tachometer (4 way),
28-32 2Y11 Valve – Tilt forward, 138
1S4 Switch – Parking brake, 175 1X17 Connector – Traction power block
(16 way), 9-21 3X1 Connector – Steer unit (16 way), 2Y12 Valve – Tilt back, 140
1S5 Switch – Footbrake, 20 184-191
1X32 Connector – Seat (6 way), 108-109, 2Y13 Valve – Side shift left, 142
1S11 Switch – Left foot, 25 175 3X4 Connector – Steering potentiometer
feed (6 way), 192-200 2Y14 Valve – Side shift right, 144
1S13 Switch – Direction, 156-160 1X34 Connector – Travel alarm (2 way),
28-29 3X15 Connector – Steering interface (10 2Y15 Valve – Auxiliary 1, 146
2S13 Switch – 8.5 metre, 89 way), 188-210+
1X36 Connector – 8.5 metre switch (4
2Y16 Valve – Auxiliary 2, 148
4S1 Switch – Horn push, 113 way), 88-90 3X18 Connector – Steering potentiometer
1X38 Connector – Left foot switch (3 way), (10 way), 190-200 2Y31 Valve – Lock, 128
U1 Converter – 48 V / 24 V, 60-64
24-25 3X19 Connector – Steering drive (6 way), 4Z1 Suppression – Horn, 109-111
1V23 Diode – Electromagnetic brake, 36 1X78 Connector – Electromagnetic brake 209-214
X1 Connector – Battery lock (5 way), (2 way), 41 4X1 Connector – Horn (2 way), 113
72-75

Circuit diagrams 7
Colour abbreviations Colour abbreviations Colour abbreviations Colour abbreviations

BK Black GN Green RD Red WH White
BN Brown GY Grey VT Violet YE Yellow
BU Blue OG Orange

7 Circuit diagrams
Hydraulic circuit
Hydraulic circuit
5
4
2Y2
M
3 MP
6
P A
T
T1
A1.1
7
2Y31
2Y1
2Y11
B1
A1
2Y12
25bar 8
2Y13
B2
9
A2
2Y14
2Y9
B3
10
A3
2Y8
2Y16
2
B4
A4
1 2Y15

Circuit diagrams 7
Hydraulic circuit - keycode
Hydraulic circuit - keycode

1. Hydraulic tank
2. Filter
3. Hydraulic pump
4. Pump motor
5. Hydraulic control valve
6. Lift cylinders
7. Lift cylinder flow control valve
8. Tilt cylinders
9. Sideshift cylinder
10. Reach cylinder

Linde Material Handling GmbH
115 807 10 01 EN – 03/2009

115-03 Operator Manual 1158071001EN 03-2009 PDF

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Operating Instructions

Electric reach truck

R14, R14HD, R14N, R16,

Linde - Your Partner

Operating Instructions – 115 807 10 01 EN – 03/2009 I

1 Introduction and general description

3 Getting to know the truck

Operating Instructions – 115 807 10 01 EN – 03/2009 III

360° Steering (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

IV Operating Instructions – 115 807 10 01 EN – 03/2009

Lubricate the lift chains and mast channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Operating Instructions – 115 807 10 01 EN – 03/2009 V

Taking the truck out of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

VI Operating Instructions – 115 807 10 01 EN – 03/2009

Introduction and general description

2 Operating Instructions – 115 807 10 01 EN – 03/2009

When taking over the fork lift truck, transfer

Operating Instructions – 115 807 10 01 EN – 03/2009 3

4 Operating Instructions – 115 807 10 01 EN – 03/2009

Operating Instructions – 115 807 10 01 EN – 03/2009 5

6 Operating Instructions – 115 807 10 01 EN – 03/2009

Operator safety guidelines

8 Operating Instructions – 115 807 10 01 EN – 03/2009

Operating procedures ¾ If possible cross rail tracks, door thresholds

Operating Instructions – 115 807 10 01 EN – 03/2009 9

¾ Be aware of protruding forks which could Parking

Noise emission levels

10 Operating Instructions – 115 807 10 01 EN – 03/2009

Frequency characteristic for human body vibrations

Operating Instructions – 115 807 10 01 EN – 03/2009 11

12 Operating Instructions – 115 807 10 01 EN – 03/2009

Getting to know the truck

Location of identification plates and labels

1 Truck type/capacity plate 4 Serial number (Stamped)

14 Operating Instructions – 115 807 10 01 EN – 03/2009

Truck type/capacity plate

1 Manufacturer 7 CE symbol (The symbol certifies that all

Operating Instructions – 115 807 10 01 EN – 03/2009 15

General view of truck

1 Mast unit 13 Gearbox

16 Operating Instructions – 115 807 10 01 EN – 03/2009

Operating controls and indica-

1 Steering wheel 11 Emergency isolator

Operating Instructions – 115 807 10 01 EN – 03/2009 17

Single pedal controls

1 Steering wheel 12 Direction selection switch

18 Operating Instructions – 115 807 10 01 EN – 03/2009

¾ Pull the red knob (1) up to restore electrical

Steering the truck

Operating Instructions – 115 807 10 01 EN – 03/2009 19

Operating the horn

20 Operating Instructions – 115 807 10 01 EN – 03/2009

Operating Instructions – 115 807 10 01 EN – 03/2009 21

MESSAGE EXPLANATION ACTION REQUIRED

22 Operating Instructions – 115 807 10 01 EN – 03/2009

MESSAGE EXPLANATION ACTION REQUIRED

Operating Instructions – 115 807 10 01 EN – 03/2009 23

MESSAGE EXPLANATION ACTION REQUIRED

Fork tilt indicator

24 Operating Instructions – 115 807 10 01 EN – 03/2009

Sideshift centre indicator

Interlock warning indicator

Operating Instructions – 115 807 10 01 EN – 03/2009 25