Operating Instructions Electric Reach Truck

Operating Instructions
Electric reach truck
R14X, R16X, R17X,

R17XHD
116 807 10 01 EN – 02/2006
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 – 116 807 10 01 EN – 02/2006 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
The battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Operator adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Braking – twin pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Braking – single pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Driving – twin pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Driving – single pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Starting on an incline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Operating the mast and attachments (with two joystick control) . . . . . . . . . . . . . . . . . . 63
Operating the mast and attachments (with three joystick control) . . . . . . . . . . . . . . . . . 67
Operating the mast and attachments (with four joystick control) . . . . . . . . . . . . . . . . . . 70
Handling loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Before leaving the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Operating Instructions – 116 807 10 01 EN – 02/2006 III

Table of contents
g
360° Steering (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Operator code entry (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Data Logger (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Truck data management – LFM (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Exterior lights (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5 Maintenance
Maintenance safety guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Report of Thorough Examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Covers and cowlings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Emergency lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Emergency steering and parking brake release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Slinging the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Jacking the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Towing procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Mast unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Recommended lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Inspection and maintenance data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Inspection and maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Routine inspection and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Pre-shift checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Inspection and maintenance after the first 50 hours of operation . . . . . . . . . . . . . . . . . . 113
Inspection and maintenance as required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Inspection and maintenance every 1000 hours (250 hours cold store version) . . . . . . . 113
Inspection and maintenance every 2000 hours (1000 hours cold store version) . . . . . . 114
Inspection and maintenance every 5000 hours (2500 hours cold store version) . . . . . . 114
Inspection and maintenance every 10000 hours or 5 years, whichever is earlier (5000
hour or 30 months cold store version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Inspection and maintenance as required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Clean the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Check the battery electrolyte level and specific gravity . . . . . . . . . . . . . . . . . . . . . . . . . 116
Lubricate the lift chains and mast channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Adjust the lift chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Replace the hydraulic hoses and pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Check the drive wheel nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Check the load wheel axle bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
IV Operating Instructions – 116 807 10 01 EN – 02/2006

Table of contents
g
Adjust the parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

1000 hr Inspection and maintenance (250 hr cold store) . . . . . . . . . . . . . . . . . . . . . . . 121
Check the condition and security of the wheels and tyres . . . . . . . . . . . . . . . . . . . . . . . 121
Check the condition of the battery and battery cables . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Check the condition and security of electrical connections and cables . . . . . . . . . . . . . 124
Check the parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Check the hydraulic hoses and pipes for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Check the lift chains for condition and security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Lubricate the mast channels, reach channels and lift chains . . . . . . . . . . . . . . . . . . . . 126
Lubricate the fork carriage plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Lubricate the sideshift bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Lubricate the tilt bearings (manual tilt only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Check the hydraulic oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Lubricate the seat support post and seat runners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Check the clearance of the mast retainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Lubricate the mast rollers and chain head pulleys (cold store only) . . . . . . . . . . . . . . . . 129
Lubricate the mast hose pulley and mast cable pulley assembly (cold store only) . . . . . 132
Lubricate the lift carriage rollers (cold store only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Lubricate the reach carriage rollers (cold store only) . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Check the brake fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Check the traction motor brake for wear and adjustment . . . . . . . . . . . . . . . . . . . . . . . 135
Check the load wheel brake pads for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Replace the hydraulic tank breather filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Grease the load wheel bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Check condition of brake pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Change the hydraulic oil and suction filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
10000 hr Inspection and maintenance (5000 hr cold store) . . . . . . . . . . . . . . . . . . . . . . 139
Change the brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Operating Instructions – 116 807 10 01 EN – 02/2006 V

Table of contents
g
Taking the truck out of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Decommissioning the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
6 Technical data
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Technical data – 1.4 tonne capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Technical data – 1.7 tonne capacity (heavy duty) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Battery data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Mast variations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Annex
7 Circuit diagrams
Hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Hydraulic circuit - keycode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Circuit Diagram (1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Circuit diagram - keycode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Lighting circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Lighting circuit - keycode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
VI Operating Instructions – 116 807 10 01 EN – 02/2006

1
Introduction and general description

Introduction
Introduction
Using this manual To keep your warranty valid, and to ensure
safety, all maintenance should only be carried
In order to reduce the risk of personal injury,
out by qualified persons authorised by your
injury to others, and to prevent possible
local distributor.
damage to the truck, the comments below
used in this manual indicate specific dangers
or unusual information that requires special Referenced standards
attention: This truck complies with the standard
DANGER EN1726-1, (Safety of industrial trucks —
Self-propelled trucks up to and including
Indicates hazards that may result in bodily injury or 10 000 kg capacity and industrial tractors with
death and/or severe product damage.
a drawbar pull up to and including 20 000 N —
Part 1: General requirements), which meets
WARNING with the specific essential requirements of the
EU Directive 98/37/CE for Safety of machinery
Indicates hazards that may result in bodily injury
and/or severe product damage. It also complies with the standard EN 12895
for Electromagnetic Compatibility and sub-
sequent amendments for materials handling
CAUTION trucks, which meets with the specific essential
requirements of Directive 89/336/CEE.
Indicates hazards that may result in damage to, or
destruction of the product. Sound level tests are performed in accordance
with standard EN 12053
ENVIRONMENT NOTE Vibration level tests are performed in ac-
Indicates hazards that may be harmful to the cordance with standards EN 13059 and EN
environment. 12096
NOTE Approved applications

Identifies technical information requiring Your truck is designed for transporting and
special attention because the connection may lifting stable loads as stated on the load
not be obvious even to skilled personnel. capacity plate within a temperature range
of −10 °C to +40 °C (−30 °C to +40 °C cold
Your lift truck store version).
Your truck offers the best in economy, safety In particular, we draw your attention to the
and driving convenience. However, preserv- accompanying booklet (VDMA or BITA for
ing the qualities of the truck for a long and UK market) concerning the safe operation
profitable service life, and making full use of and accident prevention for fork lift trucks, to
it’s benefits in operation relies mainly on the the safety guidelines for gas vehicles and the
operator. regulations for use of the truck on public roads.
This User Manual describes all you must The booklet for users of industrial and rough
know about starting, running, servicing and terrain trucks (VDMA or BITA for UK market)
maintaining your truck. must be followed under all circumstances by
the operator and service personnel.
Follow the instructions for operating the truck
and carry out the maintenance and care The user, and not the manufacturer, is re-
prescribed in the Inspection and Maintenance sponsible for any injury or damage arising as
Schedule regularly and on time. a result of misuse, neglect, abuse, alterations,
2 Operating Instructions – 116 807 10 01 EN – 02/2006

Introduction and general description 1
Introduction
incorrect maintenance or repairs and applica- Flooring requirements

tions not authorised by the manufacturer.
The truck has no suspension system, there-
Should you want to use the truck for applica- fore floors must be even, level and free of
tions not covered in these instructions, please holes or cracks which could lead to damage.
contact your local distributor. No modifica-
tions or conversions may be made, or addi- NOTE
tional equipment fitted to your truck, without
For detailed floor specification please contact
prior permission of the manufacturer.
your local distributor.
For attachments, the operating instructions
supplied by the attachment manufacturer are Technical note
applicable.
This User Manual or excerpts thereof may
NOTE only be copied, translated or transmitted to
third parties after prior written approval by the
If fitting an attachment, then an additional manufacturer.
capacity plate is required.
We pursue a policy of continuous improve-
NOTE ment in design and manufacture of our prod-
ucts. The illustrations and technical details
It is recommended that trucks fitted with auto
referring to design, fittings, and engineering of
tilt are not used to stack or de-stack loads on
lift trucks are subject to change or modification
the following types of racking.
as a result of technological progress by the
• Gravity / live racking manufacturer.
• Push back racking
We are therefore unable to consider any
claims based on the specification, illustrations,
NOTE and descriptions contained in this User
For drive-in racking applications, please refer Manual.
to your local distributor.
Please submit all enquiries concerning orders
CAUTION for spare parts to your local distributor, making
sure to give the correct delivery address.
Operating on long slopes and gradients over a 10%
is not advisable due to the prescribed minimum For repairs use only genuine spare parts. Only
brake applications and the truck stability characte- in this way can it be guaranteed that your truck
ristics. maintains its original technical standard.
The climbing ability rates given in the data sheet
are based on the tractive force of the truck and When ordering spare parts, please specify the
they apply only for crossing obstacles and minor part number and state the following truck data.
differences in the floor/road level. Please contact
your local distributor before driving on long slopes. Truck type:
DANGER
Never use a standard truck in areas where there is a Manufacturer’s serial No./year built:
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 Delivery date:
accompanied by a specific EC statement of confor-
mity and the appropriate User Manual.
Operating Instructions – 116 807 10 01 EN – 02/2006 3

Introduction
Please also specify the production number of Check the battery electrolyte level and
the mast, when ordering mast parts. specific gravity
Check the hydraulic oil level
Mast Number: Check the braking systems for correct and
safe operation
Check the steering system for correct and
safe operation
Mast lift height [mm] : Check the traction system for correct and
safe operation
Check the mast and any attachments for
correct and safe operation
In order to avoid later complaints and incon-
venience to customers, you are requested to
When taking over the fork lift truck, transfer ascertain that the truck is in satisfactory condi-
the data from the type plates into this User tion and fully equipped at the time of delivery
Manual. This information can be found on and to acknowledge the correct installation of
the type plate attached to the operator’s the truck in the manufacturer’s certificate of
console. We recommend that you transfer this conformity.
information to this manual for ease of future
reference. The following technical documents belong to
each fork lift truck:
Truck takeover • User Manual
Every truck undergoes careful inspection • EC Certificate of Conformity (The manu-
before leaving the factory in order to make facturer certifies that the industrial truck
sure that it will be in good condition and fully conforms to all relevant EC directives.)
equipped as ordered when delivered. • Spare Parts Catalogue (On CD)
Your local distributor is under obligation to • Booklet for users of industrial and rough
recheck the following before delivery and to terrain trucks (VDMA or BITA for UK market)
hand the truck over in full working order.
Check the security of the drive wheel nuts
Check the security of the load wheel axle
bolts

Introduction and general description 1
General description
General description
Introduction adjustable to meet individual operational
needs. Power is transmitted to the drive wheel
Your truck, which complies with all relevant EC
via a spur and bevel transmission.
directives, has been developed to meet the
most arduous application requirements. The
main design features result from a thorough Electrical system
analysis of today’s warehouse logistics to The truck is fitted with an advanced high
achieve maximum productivity. The overall frequency digital control system for traction,
design concept ensures excellent operator steering and load handling. This system,
comfort contributing significantly to high work which incorporates automatic regenerative
throughput with minimum fatigue. electric braking, reacts progressively to
operator demand and provides extremely
Operator’s compartment and controls smooth movements. This technology ensures
maximum efficiency from the truck and a
The operator’s compartment provides all the
high number of work cycles from the battery.
space any operator would need to work in
Parameter adjustment allows the truck to be
total comfort. Because the cabin space is so
tailored to suit a particular requirement and
generous the operator is always well within
integrated diagnostics via a CAN bus system
the profile of the truck for complete safety
ensure rapid servicing and maximum uptime.
and protection. The large ’business-class’ full
suspension seat provides all the adjustments
necessary to enable every operator to find the Steering
best driving position. Electrical ’fly by wire’ steering reduces opera-
A compact steering wheel, joystick controls, tor fatigue, ensures excellent manoeuvrability
and hand controls which are used regularly are and generally improves work handling. The
integrated into the adjustable seat armrests. steering system provides force feedback to
the steering wheel, ensuring optimum steer-
The unique position of the angled seat closer ing control. 360° Steering is available as an
to the mast results in an unparalleled view of option.
the load and storage zones.
Twin or single accelerator pedals enable fast Mast, hydraulics and reach system
and efficient manoeuvring and a digital display
keeps the operator informed of the truck’s The new concept ultra wide mast provides a
operational status at all times. panoramic view of the load and storage zones.
Unlike conventional reach trucks, the mast
Chassis is fixed to the chassis and does not move.
Instead, the reach carriage extends and
The chassis has been designed to achieve retracts a short distance independently of
maximum strength and rigidity. The mounting the mast. This unique construction minimises
of the battery beneath the chassis results in a mast deflection, and the mass of the mast
very low centre of gravity providing impressive enhances the truck’s weight distribution
static and dynamic stability. resulting in excellent stability and high residual
capacities.
Drive and transmission
Through-the-mast reeving for all hydraulic
A powerful AC drive motor provides rapid functions ensures unrestricted visibility
and seamless acceleration to maximum through the mast. Sealed for life angled rollers
speed and all performance parameters are ensure smooth, rapid, lift/lower movements.

General description
A powerful AC pump motor with automatic Brakes

slowdown at full lift, gives rapid lift movement,
The trucks have three independent braking
whilst automatic slowdown at both ends of the
systems:
reach movement ensures smooth, fast, safe
and accurate load handling cycles. • Hydraulic footbrake operating on drive and
load wheels
Comprehensive mast dampening measures
results in seamless mast function under all • Parking brake operating on drive motor
conditions since the control system automat- • Regenerative electric braking occurs
ically smooths out any sharp joystick move- automatically when either accelerator
ments the operator might make. demand is reduced or the opposite direction
of travel is selected

2
Safety
2 Safety
Operator safety guidelines

NOTE DANGER
The safety rules within this manual must be One of the major causes of accidents involving lift
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
¾ If the truck shows signs of damage or
• Rules for roadways and work areas
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
¾ Always maintain the truck in good condition,
braking
this will ensure any potential risks are kept
• Service and repair information to a minimum.
• Recurrent inspections, accident prevention
¾ Keep any warning labels or plates attached
check
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
approved by your local distributor.
Practice driving, control and steering opera-
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
¾ Do not overload the truck beyond it’s rated the 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 1.7 tonne LPAZ = Refer to
EN 12053 from the weighted values in the all models manufacturer
operating modes DRIVING, LIFTING and (without cabin)
IDLING. 1.4 to 1.7 tonne LPAZ = Refer to
The A-weighted averaged emission sound all models (with manufacturer
pressure level at the operator’s position is as cabin)
follows: Uncertainty KPA = Refer to
manufacturer
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 tonne aW,ZS = 0.57 m/s2
1.7 tonne aW,ZS = 0.68 m/s2
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
2
8
7 3
4
6
5 116-39
1 Truck type/capacity plate 6 Cold store hydraulic oil label

2 Attachment capacity plate 7 Standing on forks warning label
3 Cold store label 8 Standing under raised load warning label
4 Battery changing label 9 Joystick operation labels
5 Serial number (Stamped)
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
116-41
1 Overhead guard 12 Hydraulic control valve

2 Seat 13 Horn
3 Steering wheel 14 Hose cassette
4 Electronic control unit 15 Battery
5 Brake fluid reservoir 16 Reach cylinders
6 Hydraulic tank and filter 17 Load wheel and brake
7 Lift motor and pump unit 18 Forks
8 Steering unit 19 Load handler comprising lift carriage, reach
9 Traction motor carriage and fork carriage.
10 Gearbox 20 Primary lift cylinder
11 Drive wheel 21 Protective screen
22 Mast unit

Operating controls and indicators
Operating controls and indica-

tors
Twin pedal controls
116-02
1 Steering wheel 9 Clipboard (Option)

2 Accelerator pedal - forks trailing 10 Lift and reach control joystick
3 Brake pedal 11 Sideshift control joystick
4 Emergency isolator 12 Horn push
5 Adjustable console clamping handwheel 13 Automatic sideshift centralisation (Option)
(Option) 14 Automatic fork level (Option)
6 Keyswitch 15 Parking brake
7 Operator’s display 16 Accelerator pedal - forks leading
8 Optional accessory switches
NOTE
Alternative joystick configurations may be
fitted.

Single pedal controls
116-03
1 Steering wheel 9 Lift and reach control joystick

2 Brake pedal 10 Sideshift control joystick
3 Emergency isolator 11 Direction switch
4 Adjustable console clamping handwheel 12 Horn push
(Option) 13 Automatic sideshift centralisation (Option)
5 Keyswitch 14 Automatic fork level (Option)
6 Operator’s display 15 Parking brake
7 Optional accessory switches 16 Accelerator pedal
8 Clipboard (Option)
NOTE
Alternative joystick configurations may be
fitted.

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.
Depressing the emergency isolator while travelling
will inhibit operation of regenerative electric bra-
king.
¾ Pull the red knob (1) up to restore electrical

power. 116-500
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.
116-512

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.
116-574
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.
116-513

Operator’s display
2 3 4 5 6 7 8
9
Km/h
MPH P
ft/in
mm
1
Lb 10
Kg
%
Hr
-
+
11
21
Hr
Km PM
Miles AM
12
116-590
20 19 18 17 16 15 14 13
1 Steering Indicator 12 Service indicator
2 Fork tilt indicator 13 Cabin heater indicators (Option)
3 Sideshift centre indicator 14 Clock
4 Interlock warning indicator 15 Temperature warning indicators
5 Slow speed indicator 16 Data Logger communication indicator
6 Fork height command indicators (Option)
7 Fork height display 17 Cabin intercom volume (Option)
8 Battery discharge indicator 18 Battery change indicators
9 Parking brake indicator 19 Service interval elapsed indicator
10 Brake fluid warning indicator 20 Hour meter
11 Battery lock warning indicator 21 Message panel

Steering indicator
NOTE 1
The appearance of the steering indicator dis-
play can be changed to suit customer pref-
erences 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
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
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

1 2
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 can show the remaining
charge as a percentage of the rated capacity
or the estimated remaining operating time
in hours. Mode of operation is set using di-
agnostic software, please contact your local
3
distributor.
NOTE 116-595
To prevent damage to the battery, the display

will indicate zero percent or hours 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
NOTE
The clock can be turned off, and the mode
116-597
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 1
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 2
changing procedure.
116-598

Over temperature indicators

Should prolonged overload conditions exist,
then the motors or controller may become too 1
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- 2
tor or controller become to hot.
Icons (3) will flash should the steering motor 4
become to hot.
NOTE 3
If a motor or the controller becomes too hot,
then it’s performance will be reduced until it 116-601
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.
116-599

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
readings for a brief period when the truck is 4 Hr
switched on. Please contact your local distrib-
utor.
Hr
5
(2) Time to next service
116-600
(3) Traction motor operational time
(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 bat-
tery lock warning will illuminate during some
+
stages 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-
1 2
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 5 4 3
icon to indicate when the forks are in the
stack or de-stack position.
116-612
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 stack-
ing or de-stacking a load.
Operation - actual height mode mm

With the forks below the free lift height, the
display will show five horizontal bars. When
mm
the forks are raised above the free lift height,
the display will show the height of the forks.
in
NOTE
If the truck is switched on with the forks above ft/in
the free lift height, then only slow speed
lift/lower and traction will be available. To
initialise the system, lower the forks to below ft/in
the free lift height.
ft/in
The system can be configured to display
height information in either mm, inches, or
feet and inches.
116-608

NOTE
Units of measurement cannot be altered by
the operator. Please contact your local distrib-
utor.
Operation - shelf mode mm 1 2

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 4 3
If the truck is switched on with the forks above in 1 2

the free lift height, then only slow speed
lift/lower and traction will be available. To
initialise the system, lower the forks to below ft/in
the free lift height.
¾ With the forks above the free lift height,

4 3
operate the lift/lower joystick. 116-609
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 mm

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 1
icon (2) is displayed.
2
NOTE
The de-stack icon (1) will be displayed briefly in
as the load is raised past the de-stacking level.
The load is now at the correct height and can ft/in

1
be placed in the racking.
2
116-610
De-stacking a load - shelf mode mm

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
1
The forks are now at the correct height and the
load can be removed from the racking.
Warehouse zones in
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 1

four zones, or ten shelf levels in ten zones can
be programmed into the system.
116-611
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.
116-42

4
Operation
4 Operation
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.
¾ Remove any load from the forks.
¾ Raise the lift carriage and lock in position
using the lift carriage locking plate.
¾ Turn the keyswitch off, depress the emer-
gency isolator and disconnect the battery.
¾ Remove the battery using a hand pallet
truck of sufficient capacity (see truck
type/capacity plate for battery weight).
116-548
¾ Raise the drive wheel clear of the floor, and
block securely.
DANGER
Never enter the vacant battery compartment wi-
thout first disconnecting any power supply and
securing the lift carriage.
The lift carriage can only be lowered when a battery
is connected. Before entering the battery compart-
ment always:
¾ Ensure that the lift carriage locking plate has
been fitted correctly.
¾ Ensure that no slave batteries are connected.

Operation 4
¾ Check the tightness of the drive wheel se-

curing nuts.
For effective wheel fixing, tighten the wheel
nuts to 140 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.
116-529
Check the load wheel axle bolts

removing a load wheel axle, the security of
the bolts MUST be checked within 50 hours
of operation.
For effective fixing, tighten the bolts diametri-
cally to 135 Nm.
NOTE
If it is found necessary to tighten the load wheel
axle bolts to the correct torque, then they must
be checked again after 50 hours. Repeat the
116-535

4 Operation
Pre-shift checks
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.
116-501
116-514

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 116-52
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 side door inter-
lock.
NOTE
For any attachments, additional interlocks
may be fitted. These should be checked for
correct and safe operation.

4 Operation
Pre-shift checks
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

116-536
bodies.
¾ Check the overhead guard for damage.
¾ Check for any loose panels and covers.
¾ Ensure the protective screen is clean.
¾ Check the tyres for damage and foreign
objects.
¾ Remove any loose items left on the truck.
Report any defects to supervision.
Check the lift carriage locking plate

¾ Open the side door.
¾ Check that the lift carriage locking plate is
present and secured in position.
Should the lift carriage locking plate be miss-
ing, then report to supervision.
After use, ALWAYS return the lift carriage
locking plate to it’s storage location.
116-607

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 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 catch and open the side door.
116-537
¾ Unplug the battery plug (1) from the battery

connector.
¾ Insert the charger plug into the battery con-
nector.
¾ Operate the battery charger in accordance
with the manufacturer’s instructions.
Removing the battery – using a hand

pallet truck
DANGER
The battery is heavy.
When transporting the battery using a hand pallet
truck, keep speed to a minimum and avoid sharp
turns. 116-51
If transporting the battery on slopes, then the pallet

truck must be equipped with brakes.

¾ Raise the forks sufficiently to enable the lift
carriage locking plate to be fitted.

Operation 4
The battery
¾ Fit the lift carriage locking plate, ensuring

that it is located correctly on both retaining
lugs.
NOTE
The lift carriage locking plate is stored behind
the side door.
¾ Slowly lower the forks until the lift carriage

contacts the locking plate.
emergency isolator.
CAUTION
116-560
components.
Before connecting or disconnecting the battery,
ensure the truck is switched off, and the emergency
isolator is depressed.
NOTE
If during battery change the truck is switched
off with the forks raised above the free lift
height, then after switching on, only slow
speed lift/lower will be available. After switch-
ing the truck on, lower the forks to below the
free lift height to regain full speed lift/lower.
¾ Open the side door and disconnect the bat-

tery.
¾ Using a hand pallet truck of sufficient capac-
ity (see truck type/capacity plate for battery
weight), raise the battery until the retaining
latches disengage.
CAUTION
Raising the battery excessively can cause damage
to components within the battery compartment.
Only raise the battery sufficiently to allow the bat-
tery retaining latches to disengage.
NOTE
Do not raise the battery more than necessary.
¾ Slowly withdraw the battery from the battery

compartment. 116-538

4 Operation
The battery
¾ To replace the battery, reverse the removal

procedure, ensuring that both battery re-
taining latches are engaged correctly.
NOTE
DANGER
Battery size and weight determines load capacity
and truck stability.
The replacement battery MUST be identical in size
and weight to the standard battery.
Changing the battery – using changing

station
¾ Raise the lift carriage sufficiently to allow
the battery to pass under the forks.
NOTE
When the mast is raised, check that the mast
cable sled does not obscure the external bat-
tery socket.
¾ Align the truck as accurately as possible

with the vacant roller stand on the battery
changing station.
116-06
¾ On the vacant roller stand, ensure that the
left-hand pedal (1) is in the lowered position,
and the right-hand pedal (2) is in the raised
position.
CAUTION
To avoid serious damage, it is imperative that when
depositing a discharged battery on the vacant roller
stand, that the pedals are in the correct position.
After changing the battery. it is recommended that
the right-hand pedal (2) on the vacant roller stand is
raised
¾ Slowly manoeuvre the truck over the roller

stand, until the battery comes into contact
with the stops.
¾ Apply the parking brake, turn the keyswitch
off, and depress the emergency isolator.

Operation 4
The battery
CAUTION
components.
Before connecting or disconnecting the battery or
auxiliary power lead, ensure the truck is switched
off, and the emergency isolator is depressed.
NOTE
If during battery change the truck is switched
off with the forks raised above the free lift
height, then after switching on, only slow
speed lift/lower will be available. After switch-
ing the truck on, lower the forks to below the
free lift height to regain full speed lift/lower.
¾ On the roller stand, raise the left-hand pedal
(1).
116-07
¾ Unplug the battery, and plug the connector

(4) into the auxiliary socket (3).
¾ Close the side door.
116-566

4 Operation
The battery
¾ Plug the auxiliary power lead into the exter-

nal socket (5).
¾ Release the emergency isolator, switch on
and slowly manoeuvre the truck clear of the
battery.
116-567
¾ Reposition the truck in line with the charged

battery on the battery changing station.
When repositioning, manoeuvre the truck so
as not to foul the auxiliary power lead, and be
aware of the length of the lead.
¾ Slowly manoeuvre the truck until the
charged battery is located fully within the
battery compartment.
¾ Apply the parking brake, turn the keyswitch
off, and depress the emergency isolator.
116-588

Operation 4
The battery
¾ On the roller stand, lower both the right and

left-hand pedals (6) and (7), ensuring that
the pawl on lever (7) is engaged.
CAUTION
Forcing the right-hand pedal (7) down fully could
result in damage.
Only push the pedal down sufficiently enough to
engage the battery retaining latches. 6 7
¾ Unplug the auxiliary power lead from the

external socket.
¾ Open the side door, remove the battery plug
from the auxiliary socket and connect the
battery.
116-568
¾ Close the side door.
¾ Release the emergency isolator, switch on,
and slowly manoeuvre the truck away from
the battery changing station.
CAUTION
To avoid serious damage, it is imperative that the
battery is located correctly and the retaining latches
are engaged.
Before manoeuvring the truck away from the bat-
tery changing station, ensure that the battery is
located correctly and secured within the battery
compartment.
DANGER
Battery size and weight determines load capacity
and truck stability. 116-569
The replacement battery MUST be identical in size
and weight to the standard battery.

4 Operation
Operator adjustments
WARNING
Making adjustments while traveling 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

When mounting or dismounting the truck al-
ways use the handle and step provided.
116-53
Adjusting the seat backrest

¾ Lift lever (1) and move the seat backrest to
the desired position.
¾ Release lever (1).
Adjusting the seat suspension

The seat suspension can be adjusted accord-
ing to the weight of the operator.
¾ Using handle (4), in conjunction with in-
dicator (5), adjust the seat suspension as
necessary.
Adjusting the seat height

116-12
¾ Whilst sitting on the seat, lift lever (7).
¾ Raise or lower the seat to the desired height.

Operation 4
NOTE
The seat is raised with the aid of gas springs.
¾ Release lever (7) to lock the seat at the

desired height.
Adjusting the seat position

¾ Lift lever (3) and slide the seat backwards or
forwards to the desired position.
¾ Release lever (3).
NOTE
After releasing the lever, gently rock the seat
to ensure that the catch is engaged.
Adjusting the seat lumber support

Switch (2) is used to adjust lumber support.
¾ Press the top of the switch to increase lum-
ber support.
¾ Press the bottom of the switch to decrease
lumber support.
Rotating the seat (Option)
The seat can be rotated through 10°

¾ Lift lever (6) and rotate the seat to the de-
sired position.
¾ Release lever (6)
NOTE
Prolonged sitting can put excessive strain on
the spine. Prevent strain with regular light
exercising.

4 Operation
Adjusting the left-hand armrest

The left-hand armrest is fully adjustable to
provide a comfortable operating position.
¾ Slacken the armrest clamping handwheel
(8).
¾ Adjust the armrest to the desired position.
¾ Tighten the armrest clamping handwheel.
116-09
Adjusting the right-hand armrest

The right-hand armrest is fully adjustable to
provide a comfortable operating position.
¾ Slacken the armrest clamping handwheel
(9).
¾ Adjust the armrest to the desired position.
¾ Tighten the armrest clamping handwheel.
116-10

Operation 4
Adjusting the operator’s console (Option)

The height of the operator’s console is ad-
justable.
¾ Slacken the console clamping handwheel
(1).
¾ Adjust the console to the desired height.
¾ Tighten the console clamping handwheel.
116-515
Adjusting the clipboard (Option)

The clipboard can be adjusted to a comfort-
able position.
¾ To adjust the clipboard, pull the bottom
edge out.
¾ To return the clipboard, push the bottom
edge back.
116-54

4 Operation
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 op-
erates the brake on the traction motor and
both load wheel brakes. It is recommended,
that before taking the truck into service, oper-
ators acquaint themselves with the function
and effect of this brake while the truck is in an
unladen condition.
116-502
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 116-503
programmed to ’auto apply’ for certain events
such as the seat being vacated.

Operation 4
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.

4 Operation
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 op-
erates the brake on the traction motor and
both load wheel brakes. It is recommended,
that before taking the truck into service, oper-
ators acquaint themselves with the function
and effect of this brake while the truck is in an
unladen condition.
116-505
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
(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 116-504
programmed to ’auto apply’ for certain events
such as the seat being vacated.

Operation 4
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.

4 Operation
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.
116-506
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).
116-516

Operation 4
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.
116-507
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.
116-508
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

4 Operation
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.
116-509
¾ Insert the key (3) and turn fully clockwise.

The operator’s display (2) will illuminate.
¾ Fully retract the forks.
116-517

Operation 4
Travel with the forks trailing

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.
116-510
NOTE
Travel with the forks leading

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.
116-510
NOTE

4 Operation
Starting on an incline
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
116-510
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.
116-59

Operation 4
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.
116-518
¾ To lower the lift carriage, move joystick (1)

smoothly in direction (D).
Lowering speed is determined by how far the
joystick is moved.
Lowering speed is reduced automatically at
ground level.
NOTE
On trucks fitted with auto tilt, in order to lower
the lift carriage fully the reach carriage must
be extended.
NOTE
The joystick returns to the neutral position
when released.

4 Operation
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.
NOTE
If fitted with auto tilt, the forks will be automat-
ically tilted to the horizontal position when the
reach carriage is extended.
¾ To retract the reach carriage, move joystick

(1) smoothly in direction (A). 116-518

joystick is moved.
NOTE
If fitted with auto tilt, the forks will be automati-
cally tilted to the travel position when the reach
carriage is retracted.
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) 116-519
to shift the fork carriage right.

Operation 4
Sideshift speed is determined by how far the

joystick is moved.
NOTE
when released.
¾ To automatically centralise the fork carriage

(Option), press button (3).
NOTE
This button is intended to automatically cen-
tralise the unladen forks. If the button is used
when laden, the forks may not stop at the cen-
tralised position.
NOTE
Keep the button depressed until the fork car-
riage is centralised.
Operating tilt (Option)

If fitted with manual 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
(2) smoothly in direction (A).
Tilt speed is determined by how far the joystick
is moved.
NOTE
when released.
¾ To automatically level the unladen forks 116-519

(Option), push button (4).
NOTE
This button is intended to automatically level
the unladen forks. If the button is used when
laden, the forks will not stop at horizontal
NOTE
Keep the button depressed until the forks are
level.

4 Operation
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 three joystick control)

tachments (with three joystick
control)
NOTE
each joystick.

smoothly in direction (B).
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
the joystick progressively again in direction ’B’
to raise the lift carriage slowly to full lift height. 116-530

smoothly in direction (A).
joystick is moved.
ground level.
NOTE
To lower the lift carriage fully, the reach car-
riage must be extended.
NOTE
when released.

4 Operation
Operating reach
joystick is moved.
NOTE
The forks will be automatically tilted to the
horizontal position when the reach carriage is
extended.

116-531
joystick is moved.
NOTE
The forks will be automatically tilted to the
travel position when the reach carriage is re-
tracted.
NOTE
when released.
Operating sideshift
NOTE
CAUTION
¾ Move joystick (3) smoothly in direction (A)

¾ Move joystick (3) smoothly in direction (B) 116-532

Operation 4

joystick is moved.
NOTE
when released.

NOTE
tralised position.
NOTE

DANGER
truck stability.
stability.
any attachments.

local distributor.
NOTE
attachment.
NOTE
not available.

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

tachments (with four joystick
control)
NOTE
each joystick.

smoothly in direction (B).
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
the joystick progressively again in direction ’B’
to raise the lift carriage slowly to full lift height. 116-520

smoothly in direction (A).
joystick is moved.
ground level.
NOTE
when released.

Operation 4
Operating reach
joystick is moved.
joystick is moved.
at the end of travel. 116-521
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.
¾ To automatically level the unladen forks

(Option), push button (4).
116-522
NOTE
This button is intended to automatically level
the unladen forks. If the button is used when
laden, the forks will not stop at horizontal.
NOTE
Keep the button depressed until the forks are
level.

4 Operation
Operating sideshift
NOTE
CAUTION
¾ Move joystick (5) smoothly in direction (A)

¾ Move joystick (5) smoothly in direction (B) 116-523
joystick is moved.
NOTE
when released.

NOTE
tralised position.
NOTE


Operation 4
DANGER
truck stability.
stability.
any attachments.

local distributor.
NOTE
attachment.
NOTE
not available.

4 Operation
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 nec-
essarily 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. 116-68
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

Operation 4
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.
During battery changing, only stand under the ele-
vated forks after having read, understood, and
followed the correct procedure and safety precauti-
ons described in this manual.
116-86

4 Operation
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 116-67
The centre of gravity of the load must be lo-

cated at the mid point between the two forks.
De-stacking a load
NOTE
On trucks fitted with auto tilt, the reach car-
riage should be extended before picking up a
load at ground level.
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.
NOTE 116-533

reach carriage is extended. During auto tilt,
the heels of the forks are raised or lowered,
the fork tips remain at the same level.
¾ Raise the forks to a position for clear entry

into the pallet or load.
¾ Fully extend the reach carriage.
¾ If necessary operate the sideshift to position
the forks centrally.

Operation 4
Handling loads

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.
¾ Lift the load slowly and carefully clear of the
racking.
¾ Tilt the forks backward just sufficient to sta-
bilise the load.
NOTE
carriage is retracted. During auto tilt, the heels
of the forks are raised or lowered, the fork tips
remain at the same level.

¾ Drive away from the racking until the load is
clear.
¾ Fully retract the reach carriage.
NOTE
Before retracting the reach carriage, ensure
that there is adequate clearance both above
and below the load.
¾ Lower the load carefully to just above the

load wheel legs.
¾ Tilt the forks backward fully to the travel
position.
NOTE

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. 116-70
Never transport unstable loads.
Stacking a load
NOTE
On trucks fitted with auto tilt, the reach car-
riage should be extended before placing a
load at ground level.
¾ Approach the stack and align the load as

carefully and accurately as possible.
¾ Tilt the forks to the horizontal position.
NOTE
116-71
reach carriage is extended. During auto tilt,
the heels of the forks are raised or lowered,
the fork tips remain at the same level.
¾ Raise the load to just above the required

stacking height.
¾ Drive towards the racking to bring the load
to the correct position.

Operation 4
Before leaving the truck
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 Drive away from the racking until the forks
are clear.
¾ Lower the forks until just clear of the ground.
¾ Tilt the forks to the travel position.
NOTE

¾ Ensure the truck is parked so as not to
cause a hazard or obstruction.
On trucks with manual tilt

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). 116-524
¾ Disconnect the battery if the truck is not

being used for a prolonged period.
On trucks with auto tilt

¾ Apply the parking brake (2).

4 Operation
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.

Operation 4
360° Steering (Option)

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 opposite LEDs (1 and 2) on the
steering indicator will illuminate indicating the
orientation of the steer wheel.
¾ Tilt the fork carriage back.
NOTE
carriage is retracted.

116-72
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.
The steering indicator will stop flashing, and

a single LED (1) will indicate the direction of
travel.
116-511
¾ Gently press the accelerator pedal. The
travel speed will depend on how far the
pedal is pressed.

4 Operation
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.

Operation 4
Operator code entry (Option)

The operator code entry unit comprises a
twelve digit keypad mounted on the right hand
armrest, and a rotary on/off switch in place of
the keyswitch.
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.
116-525
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

4 Operation
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

Operation 4
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 1 to enable the truck. All operator 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

4 Operation
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 oper-
ator is already a learner, or ’0’if not a learner.
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.

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

The Data Logger system comprises a twelve
digit keypad mounted on the right hand arm-
rest 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
116-525
¾ Using the keypad enter your personal five
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.
116-95

4 Operation
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 right hand armrest, 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.
116-526
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

Operation 4
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,
then the red status LED (2) will illuminate. 116-527
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.

4 Operation
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

Operation 4
Exterior lights (option)

NOTE
The position of individual switches on the
switch panel may vary.
¾ Operate the rocker switch (1) to switch on

the left hand working lamp.
¾ Operate the rocker switch (2) to switch on
the right hand working lamp.
116-528

4 Operation

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
in this manual are limited to general servicing, ¾ Protective equipment i.e. goggles and
checks and lubrication. For repair work, gloves must be worn at all times when
additional precautions may be necessary. working on batteries.
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 on the raised lift carriage or mast, always
can result in the malfunction of safety-critical com-
ensure that they are secured against
ponents.
accidental movement.
Only carry out inspection and maintenance routines
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 stand close to drawbars, slings or chains
characteristics before taking the truck into service.
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.
¾ Never wear rings, wrist watches, jewellery,
An alert, cautious mechanic is a safe one.
loose or dangling items of clothing such
as ties, torn clothing, scarves, unbuttoned
¾ Before attempting any repair work, apply
jackets or overalls with open zip fasteners
the parking brake, turn the keyswitch off,
that could get caught up in moving parts.
disconnect the battery, and, unless the
Always wear approved safety clothing.
particular routine being performed requires
otherwise, chock the load wheels securely ¾ Never carry out maintenance or servicing
front and rear. operations on the truck with anyone sat on
the seat, unless that person is fully trained
¾ Before carrying out any electrical mainte-
and involved in the operation being carried
nance or checks, raise the drive wheel clear
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
environment. Please observe the following:
¾ Perform a functional check and trial run
after every service. • Follow the manufacturer’s safety and dis-
posal instructions when using lubricants
and cleaning compounds
Handling lubricants
• Avoid spilling lubricants. Remove any
Always handle lubricants safely and as spillage immediately with a suitable
specified by the manufacturer. absorbent, and dispose of as per local
legislative requirements
Only store lubricants in approved containers
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
• Dispose of used parts, empty containers,
Clean the area surrounding the part in ques- filters etc. as per local legislative
tion before lubrication, filter renewal or repairs requirements
in the hydraulic system.
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

Removing the motor/control unit cover
¾ Raise the seat fully.
¾ Remove the two securing screws (1) lo-
cated at the rear of the cover.
116-541
¾ Release the front securing lug (2)and re-

move the motor/control unit cover.
NOTE
The cover will need to be flexed slightly during
removal, do not bend the cover excessively.
WARNING
2
The motors can become very hot. Risk of scalding.
Before working on or near the motors, ensure they
have cooled sufficiently.
Raising the seat to the maintenance po-

sition
To facilitate some maintenance procedures, 116-542
the seat can be raised beyond it’s normal max-
imum height.
¾ Remove the motor/control unit cover.
¾ Ensure the seat backrest is upright, and
slide the seat fully forward.

Maintenance 5
Covers and cowlings
¾ Undo the two securing screws (1) and re-

move the seat height limit bracket (2).
1
116-539
¾ Lift lever (2).

¾ Raise the seat fully.
NOTE
The seat is raised with the aid of gas springs.
116-540

5 Maintenance
Covers and cowlings
Removing the floorplate

1
¾ Slacken the two fasteners (1).
¾ Slide the trim panel (2) up.
¾ Remove the nut and washer (3).
¾ Remove the rubber floor mat.
3
116-583
¾ Release the three floorplate clamping

screws.
¾ Remove the floorplate.
Removing the operator’s step
NOTE
To gain access to the emergency lower valve,
the operator’s step will need to be removed.
¾ Remove the floorplate.
116-584

Maintenance 5
Fuses
¾ Remove the four nuts and washers, and two

screws.
¾ Remove the operator’s step.
116-585
Fuses
Main circuit fuses
The fuses for the main circuits are:
1 3F1 50A Power steering pump motor

2 1F1 425A Main power circuits
116-106

5 Maintenance
Emergency lower
Ancillary circuit fuses

The fuses for the ancillary circuits are:
1 1F4 5A 24 V supply
2 6F1 5A Battery discharge indicator
3 5F1 5A Lighting (Option)
4 1F6 5A Horn and heated seat (Option)
5 F8 5A Parking brake
6 IF2 5A Keyswitch
NOTE
Although these fuses are interchangeable with
automotive fuses, automotive fuses MUST 116-107
NOT be used. Only fuses supplied by the

manufacture have sufficient voltage capability
to ensure correct operation at truck voltages.
Emergency lower
In the unlikely event of complete electrical
failure, the lift carriage can lowered manually
in order that the truck can be moved to a safe
position.
To manually lower the lift carriage, use the
emergency lower valve (1) located under the
operator’s step.
¾ Raise the seat fully and remove the motor
cover.
¾ Remove the floorplate and operator’s step.
¾ Using a screwdriver, slowly release the 1
valve to allow the lift carriage to be lowered.
116-586
¾ Ensure valve is retightened once the forks
are lowered.

Maintenance 5
Emergency steering and parking brake release
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.

¾ If necessary lower the lift carriage using the
emergency lower procedure.
116-545
cover.
¾ Release the parking brake by using three
M5 x 20 screws (1) to force the internal pads
away from the drum.
¾ Special tool (3), which engages on the gear-
box toothed ring, allows the drive wheel to
be turned manually using a ’T’ bar and ex-
tension (2).
NOTE
Before use, apply a small amount of grease to
the special tool.
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.

5 Maintenance
Slinging the truck
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.
High lift mast
NOTE 1
It is not necessary to remove the battery.

¾ Thread two equal length slings of suitable
capacity through the cutouts in the inner
mast top cross member (2) as shown. 2
¾ Attach the ends of the slings to the crane
hook, ensuring that the hook safety latch (1)
is closed.
¾ Protect the slings where they pass over
sharp edges.
116-630

Maintenance 5
Slinging the truck
Low lift mast
NOTE 1
It is not necessary to remove the battery.

¾ Fit two equal length slings of suitable ca-
pacity around both the inner mast top cross 2
member (2) and the middle mast top cross 3
member (3) as shown. Ensure that the
slings do not foul on the hydraulic pipes.
CAUTION
Positioning the slings incorrectly in the centre of the
mast cross members could lead to serious damage.
116-631
Ensure that the two slings are positioned as far
apart as possible on the mast cross members.
Ensure that the slings are only passed around the
two rearmost cross members.
¾ Attach the ends of the slings to the crane

hook, ensuring that the hook safety latch (1)
is closed.
¾ Protect the slings where they pass over
sharp edges.

5 Maintenance
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 (1) under the power unit
chassis.
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 (2).

116-543

Maintenance 5
Jacking the truck
Raising the load wheels

¾ Position the jack (1) under the load wheel
leg.
DANGER
Do not position the jack on the sloping section of the
load wheel leg.
Only position the jack on the horizontal section of
the load wheel leg as close to the load wheel as
possible (3).
¾ Raise the load wheel clear of the floor.

DANGER 116-544

Only raise the wheel just clear of the floor.
¾ After jacking, block the truck securely (2).

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 Lower the lift carriage to just clear of the

ground.
¾ Remove any load from the forks
¾ Disconnect the battery plug. 116-632
¾ Attach the towing vehicle using two equal

length slings secured around the lift car-
riage and lower mast cross members as
shown.
NOTE
Ensure that the slings are positioned on the
outside of the fork carriage.
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 two primary lift cylinders raise the lift car-
riage to the free lift height.
The first stage of the telescopic secondary lift
cylinders then raise the middle and outer mast
sections together.
The second stage of the telescopic secondary
lift cylinders then raise the outer mast section.
Mast and lift carriage removal

DANGER
Removing the mast or lift carriage requires special
knowledge and tools.
116-576
Mast or lift carriage removal must only be carried
out by the trained personnel of your local distributor.
Securing the raised lift carriage

DANGER
ment always:

¾ Raise the lift carriage sufficiently to enable
the lift carriage locking plate to be fitted. 116-560
¾ Fit the lift carriage locking plate, ensuring

that it is located correctly on both retaining
lugs.
NOTE
The lift carriage locking plate is stored behind
the side door.
¾ Slowly lower the lift carriage until it contacts

the locking plate.
¾ Turn the keyswitch off and remove the key.

5 Maintenance
Mast unit
¾ Depress the emergency isolator.

tery.
NOTE
Locking the hose cassette

WARNING
The hose cassette (4) is under spring tension and
must be secured against rewinding.
Always lock the hose cassette (4) before discon-
necting the hose couplings or working on the hose
cassette itself.

¾ Raise the lift carriage and instal the lift car-
riage locking plate.
¾ Turn the keyswitch off and remove the key.
¾ Depress the emergency isolator.
tery.
type/capacity plate for battery weight)
block securely.
DANGER
ment always:
¾ On the hose cassette, turn the locking pawl

(2) anticlockwise from the released position
(1) to the locked position (3).

Maintenance 5
Mast unit
¾ Pull the hose from the hose cassette until

the locking pawl engages in a ratchet on the
hose cassette.
To unlock the hose cassette.
¾ Whilst pulling on the hose to release the ten-
sion, turn the pawl clockwise to the released
position (1).
WARNING
The hose cassette is locked under spring tension.
If removed from the truck, do not unlock the hose
cassette without first releasing the tension. Please
116-547

5 Maintenance
Recommended lubricants
Recommended lubricants
Hydraulic oil Steering drive gears
STANDARD Multi purpose grease containing 5% Molyb-
denum Disulphide
Hydraulic oil grade HLP to DIN 51524 part 2
Viscosity ISO VG 46.
e.g. Shell Aeroshell 17
Cloud point lower than -10°C when tested
to IP 216.82
General purpose oil
COLD STORE (STAY IN and IN - OUT)
Engine Oil SAE 20W/50
Anti wear hydraulic oil
Grade ISO VG 22-32
Viscosity index ≥ 300 Chain Spray
STANDARD
e.g Shell Tellus Arctic 32
Chain spray
NOTE COLD STORE
The above specification is a high Viscosity Cold store chain spray
Index oil, which allows the use of hydraulics
in ambient temperatures between −30 °C and
+40 °C (Oil temperatures between −30 °C and Brake fluid
+80 °C) Original ATE brake fluid to DOT3, type “S”,
classification to FMVSS 116 or SAE J 1703
Multipurpose grease issue 1980 and ISO 4925.
STANDARD NOTE
Lithium-based grease to DIN51825, For any further information, we recommend
KP2K-20 that you contact your local distributor.
COLD STORE
Low temperature clay based grease
Gear oil
Use only oil of classification SHC,
e.g. Mobil SHC 75w/90

Maintenance 5
Inspection and maintenance data
Inspection and maintenance data

Assembly Material/Lubricant Capacity/Adjustment value
Hydraulic system Suction filter element
Breather filter
Hydraulic oil 30 litres (tank only)
Wheels Drive wheel nuts 140 Nm
Load wheel axle bolts 135 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
Tilt bearings Grease As required
Sideshift bearings Grease As required
Seat support post 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 User Manual are sufficient. However, should
first discharging the steering capacitor can lead to
damage of the CAN interface drivers.
the truck be used in harsh environments, then
more frequent maintenance and lubrication
It is imperative, that before working on the control
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- NOTE
NECTED.
It is preferable to use less lubricant more often,
Check that the voltage between 3F1 and the main
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 interlock switches
before the start of each shift.
¾ Check general condition of truck
¾ Check battery state of charge
¾ Check the lift carriage locking plate
¾ Check all controls and their operation
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 bearings
¾ Check the drive wheel nuts ¾ Lubricate the sideshift bearings
¾ Check the load wheel axle bolts 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 Adjust the lift chains
out as necessary.
¾ Replace the hydraulic hoses
¾ Clean the truck
¾ Check the drive wheel nuts
¾ Check the battery electrolyte level and
¾ Check the load wheel axle bolts
specific gravity
¾ Adjust the parking brake
¾ Lubricate the lift chains and mast channels
Inspection and maintenance every 1000 hours (250 hours cold store version)
¾ Check the condition and security of the ¾ Lubricate the fork carriage plate
wheels and tyres
¾ Lubricate the sideshift bearings
¾ Check the condition of the battery and
¾ Lubricate the tilt bearings (manual tilt only)
battery cables
¾ Check the hydraulic oil level
¾ Check the condition and security of electri-
cal connections and cables ¾ Lubricate the seat support post and seat
runners
¾ Check the parking brake
¾ Check the clearance of the mast retainers
¾ Check the hydraulic hoses and pipes for
damage ¾ Lubricate the mast roller and chain head
pulleys (cold store only)
¾ Check the lift chains for condition and
security ¾ Lubricate the mast hose pulley and mast
cable pulley assembly (cold store only)
¾ Lubricate the mast channels, reach chan-
nels and lift chains

5 Maintenance
¾ Lubricate the lift carriage rollers (cold store ¾ Lubricate the reach carriage rollers (cold
only) store only)
Carry out the 1000 hours inspection and ¾ Check the traction motor brake for wear and
maintenance, then: adjustment
¾ Check the brake fluid level ¾ Check the load wheel brake pads for wear
¾ Replace the hydraulic tank breather filter
Carry out the 2000 hours inspection and ¾ Check condition of brake pipes
maintenance, then:
¾ Change the hydraulic oil and suction filter
¾ Grease the load wheel bearings
Inspection and maintenance every 10000 hours or 5 years, whichever is earlier

(5000 hour or 30 months cold store version)
Carry out the 5000 hours inspection and ¾ Change the brake fluid
maintenance, then:

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 116-536
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. 116-562
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.
116-77

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

removing the drive wheel, the security of the
nuts MUST be checked within 50 hours of
operation.
116-548
block securely.
DANGER
ment always:

Maintenance 5

curing nuts.
quence shown.
NOTE
116-529
Check the load wheel axle bolts

¾ After removing a load wheel axle the secu-
rity of the bolts MUST be checked within 50
hours of operation.
¾ For effective fixing, tighten the bolts diamet-
rically to 135 Nm.
NOTE
tightening procedure every 50 hours until the 116-535

5 Maintenance
Adjust the parking brake

The red parking brake indicator on the oper-
ator’s display will flash if the brake pads are
worn excessively, or the brake requires ad-
justment.
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- 116-577
sion.

Maintenance 5
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
DANGER
116-548
ment always:
¾ Check the drive wheel tyre for damage,

deformation or wear.
¾ Remove all swarf, metal, stone and other
matter embedded in the tyre.

5 Maintenance

curing nuts.
quence shown.
NOTE
116-529
Load wheels
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.
¾ Check the security of the load wheel axle
securing bolts.
For effective fixing, tighten the bolts diametri- 116-549
cally to 135 Nm.
NOTE

Maintenance 5
Check the condition of the battery

and battery cables
WARNING
ries.
flames.
¾ Only charge batteries is designated areas. 116-556

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 condition of the mast cable.
cover.
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 116-557
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
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.
NOTE
DANGER
Never use a truck with a defective braking system. 116-577
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 116-551
pins as specified and approved by the manufactu-
rer.

5 Maintenance
Lubricate the mast channels, reach

channels and lift chains
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. 116-562
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 Apply chain spray to the reach channels on
both sides. Operate the reach to ensure
all working surfaces of the reach channels
have been lubricated.
116-563

Maintenance 5
Lubricate the fork carriage plate

¾ Lubricate the fork carriage plate top edges
with general purpose grease.
WARNING
Manual handling risk. The forks are heavy.
Take care when manoeuvring the forks on the fork
carriage plate.
116-78
Lubricate the sideshift bearings

¾ Using a suitable grease gun, lubricate the
top rollers and bottom slides.
116-80

5 Maintenance
Lubricate the tilt bearings (manual tilt

only)
¾ Fully lower the lift carriage and extend the
reach carriage.
¾ Using a suitable grease gun, lubricate both
tilt bearings.
116-580
Check the hydraulic oil level

Carry out this operation with lift carriage fully
lowered and the reach carriage retracted.
emergency isolator.
¾ Observe the hydraulic oil level against the
fluid level mark (2) on the hydraulic tank.
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).
116-552

Maintenance 5
Lubricate the seat support post and

seat runners
¾ Slide the seat fully forward.
¾ Using chain spray, lubricate the seat sup-
port post.
CAUTION
Chain spray is extremely difficult to remove from
polycarbonate windows.
When using chain spray on trucks fitted with a ca-
bin, ensure that no overspray comes into contact
with the polycarbonate windows.
¾ Using multipurpose grease, lubricate both

seat runners. 116-589
Check the clearance of the mast

retainers
The clearance of both mast retainers should
be checked and if necessary adjusted every
1000 hours.
NOTE
We strongly recommend that this operation is
carried out by your local distributor.
116-629
Lubricate the mast rollers and chain

head pulleys (cold store only)
¾ Raise the lift carriage sufficiently, and fit the
lift carriage locking plate.

5 Maintenance

four bottom mast rollers.
116-579
¾ Using a suitable grease gun, lubricate both

chain head pulleys.
NOTE
Any excess grease should be removed from
around the mast hose. It is important that the
hose is free of grease.
116-570

Maintenance 5
On trucks fitted with a high lift mast

six top mast rollers.
116-571
On trucks fitted with a low lift mast

four top mast rollers.
116-572

5 Maintenance
Lubricate the mast hose pulley and

mast cable pulley assembly (cold
store only)
¾ Fully lower the lift carriage and extend the
reach carriage.
mast hose pulley.
NOTE
Any excess grease should be removed from
around the hose pulley. It is important that the
hoses are free of grease. 116-564

mast cable pulley and sled rollers.
116-565

Maintenance 5
Lubricate the lift carriage rollers (cold

store only)
¾ Raise the lift carriage sufficiently to gain
access to the grease nipples on the two
bottom rollers.
six lift carriage rollers.
116-581
Lubricate the reach carriage rollers

(cold store only)
two front reach rollers.
116-575

5 Maintenance

two rear reach rollers.
NOTE
On trucks fitted with manual tilt, the two rear
grease nipples are located on the tilt actuating
arms.
116-582

Maintenance 5

Check the brake fluid level
NOTE
A brake fluid level indicator is fitted, and will
indicate if the brake fluid level is low. However
it is advisable to check the brake fluid level
every 2000 hours.

emergency isolator.
¾ Check the level of the brake fluid reservoir
is up to the maximum mark (1).
The level must never drop below the minimum
116-553
mark (2).
¾ Top up with brake fluid if necessary, in ac-
cordance with the lubrication table.
Check the traction motor brake for

wear and adjustment
NOTE
DANGER
sion.
116-550

5 Maintenance
Check the load wheel brake pads for

wear
NOTE
DANGER
sion.
116-578
Replace the hydraulic tank breather

filter
emergency isolator.
¾ Remove and discard the breather (1) and
seal (2).
¾ Fit new breather and seal.
116-554

Maintenance 5

Grease the load wheel bearings
NOTE
To grease load wheel bearings please contact
116-578
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 the lift carriage

fully lowered and the fork carriage reached
back.
emergency isolator.
116-558
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.
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.
¾ Replace outlet hose, ensuring clip (1) is

secure.

Maintenance 5

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
116-559

5 Maintenance
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 encour-
Measures before taking the truck out of ages 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 ¾ Lubricate the truck.
reach mechanism, and if fitted, operate any
attachments several times. ¾ Follow the battery manufacturer’s instruc-
tions for putting the battery into service.
¾ Lower the forks onto a support until the
chains are slack. ¾ Check the hydraulic oil for condensation
water, and change oil if necessary.
¾ Check hydraulic oil level and top up if
required. ¾ Perform the same services as for commis-
sioning.
¾ Fully charge the battery.
¾ Take the truck into service.
¾ Apply a thin film of oil or grease on all
unpainted mechanical parts. If the truck is to be taken out of operation for
over six months, contact your local distributor
¾ Lubricate the truck. for further measures.
¾ Spray all open electrical contacts with a
suitable contact spray.
Decommissioning the truck

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.

6
Technical data
6 Technical data
Dimensions
Dimensions
h4
Q h3
c h1
h6
h2
h7
l4
m2 h8
205 y s
l2 x
l7
l1
a a a
= 100 mm
2 2 2
b1 b10 b5 b3 b4 b11 b2
Wa
Ast

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 (t) 1.4
(Capacity may be reduced for high lift)
1.6 Load centre c mm 600/500
1.8 Axle centre to fork face x mm 41
1.9 Wheelbase y mm 1130
Weights – 1.4 tonne

Service weight
2.1 kg 3620
(Weight may vary with alternative lift heights)
Axle load without load, front (drive)/rear (load)
2.3 kg 1960/1660
(Axle load may vary with alternative lift heights)
Axle load, reach carriage extended with load, front
2.4 (drive)/rear (load) kg 910/4110
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 230 x 140
3.5 Wheels, number front (drive)/rear (load) 1x/2
3.6 Track width, front (drive) mm 0
3.7 Track width, rear (load) mm 1055
Dimensions – 1.4 tonne

Mast/fork carriage tilt, forward/backward
4.1 ° 0/2.5 (2/2.5)
(Figures in brackets for manual tilt)
4.2 Height of mast, lowered h1 mm 2955
4.3 Free lift h2 mm 2041
Lift
4.4 h3 mm 6355
(For other heights, see Mast Variations)

6 Technical data

4.5 Height of mast, extended h4 mm 7314
Height of overhead guard (cabin)
4.7 (Figure in brackets is for optional guard with in- h6 mm 2190 (2365)
creased headroom)
4.8 Height of seat, minimum/maximum h7 mm 970/1130
4.10 Height of load wheel legs h8 mm 245
4.19 Overall length l1 mm 2294
4.20 Length to fork face l2 mm 1294
4.21 Overall width b1/b2 mm 1270/1270
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 820
4.25 Fork spread, minimum/maximum b5 mm 316/710
4.26 Width between load wheel legs b4 mm 910
4.28 Reach travel l4 mm 170
4.31 Ground clearance, mast m1 mm -
4.32 Ground clearance, centre of wheelbase m2 mm 70
Aisle width with pallet 1000 x 1200 across forks
4.33 Ast mm 2666 (2494)
(Figure in brackets is for intrusive stacking)
Aisle width with pallet 800 x 1200 along forks
4.34 Ast mm 2761 (2694)
4.35 Turning radius Wa mm 1335
4.37 Length of chassis l7 mm 1451
Performance – 1.4 tonne

Travel speed, with/without load
5.1 (Speed may vary with alternative lift heights) km/h 14/14
(Reduced speed available on request)
Lifting speed, with/without load
5.2 (Speed may vary with alternative lift heights) m/s 0.56/0.7
Lowering speed, with/without load
5.3 m/s 0.55/0.45
(Speed may vary with alternative lift heights)
Reach speed, with/without load
5.4 m/s 0.10/0.105
5.7 Climbing ability, with/without load, 30 minute rating % 3.9/7.1
Maximum climbing ability, with/without load, 5
5.8 % 10/10
minute rating

Technical data 6

Acceleration time, with/without load
5.9 s 5.8/5
(Reduced acceleration available on request)
5.10 Service brake Hydraulic/electric
AC Drive – 1.4 tonne

6.1 Drive motor, 60 minute rating kW 6
6.2 Lift motor, 15% rating kW 15
6.3 Battery according to DIN 43531/35/36 A, B, C, no DIN 43531A
6.4 Battery voltage/rated capacity (5h) V/Ah 48/480
6.5 Battery weight (±5%) kg 720
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
Refer to manufac-
8.4 Noise level at operator’s ear dB (A)
turer

6 Technical data

1.3 Battery
power
1.4 Seated
order picker
Load capacity
1.5 Q (t) 1.6

Service weight
2.1 kg 3810
2.3 kg 1980/1830

3.1 P/P
= polyurethane

4.1 ° 0/2.5 (2/2.5)
Lift
4.4 h3 mm 6355

Technical data 6

creased headroom)
4.8 Height of seat, minimum/maximum h7 mm 1135 (1295
4.33 Ast mm 2666 (2494)
4.34 Ast mm 2761 (2694)

5.3 m/s 0.55/0.45
5.4 m/s 0.10/0.105
5.8 % 10/10
minute rating

6 Technical data

5.9 s 5.8/5

Refer to manufac-
turer
Other – 1.6 tonne

Refer to manufac-
turer

Technical data 6

1.3 Battery
power
1.4 Seated
order picker
Load capacity
1.5 Q (t) 1.7

Service weight
2.1 kg 3746
2.3 kg 1817/1929

3.1 P/P
= polyurethane

4.1 ° 0/2.5 (2/2.5)
Lift
4.4 h3 mm 6355

6 Technical data

creased headroom)
4.33 Ast mm 2882 (2710)
4.34 Ast mm 2977 (2910)

5.3 m/s 0.55/0.45
5.4 m/s 0.10/0.105
5.8 % 10/10
minute rating

Technical data 6

5.9 s 5.8/5

Refer to manufac-
turer
Other – 1.7 tonne

Refer to manufac-
turer

6 Technical data
Technical data – 1.7 tonne capacity (heavy duty)

Characteristics – 1.7 tonne (heavy duty)
1.3 Battery
power
1.4 Seated
order picker
Load capacity
1.5 Q (t) 1.7
Weights – 1.7 tonne (heavy duty)

Service weight
2.1 kg 4330
2.3 kg 2100/2230
Wheels and tyres – 1.7 tonne (heavy duty)

3.1 P/P
= polyurethane
Dimensions – 1.7 tonne (heavy duty)

4.1 ° 0/2.5 (2/2.5)
Lift
4.4 h3 mm 6355

Technical data 6
Dimensions – 1.7 tonne (heavy duty)

creased headroom)
4.33 Ast mm 2882 (2710)
4.34 Ast mm 2977 (2910)
Performance – 1.7 tonne (heavy duty)

5.3 m/s 0.55/0.45
5.4 m/s 0.10/0.105
5.8 % 10/10
minute rating

6 Technical data
Performance – 1.7 tonne (heavy duty)

5.9 s 5.8/5
AC Drive – 1.7 tonne (heavy duty)

Refer to manufac-
turer
Other – 1.7 tonne (heavy duty)

Refer to manufac-
turer

Technical data 6
Battery data
Battery data
b
a
h2
116-587
Floorplate Box size Weight Kg

Wheelbase Voltage Cell type
height (a x b x h2) ±5%
DIN 43531 A
1346 800 48 8 PzS 880L 1315
(830 x 954 x 627)
DIN 43531 A
1346 800 48 8 PzS 720L 1084
(830 x 954 x 537)
DIN 43531 A
1346 635 48 8 PzS 640L 946
(830 x 954 x 462)
DIN 43531 A
1130 800 48 6 PzS 660L 1013
(830 x 738 x 627)
DIN 43531 A
1130 800 48 6 PzS 540L 835
(830 x 738 x 537)
DIN 43531 A
1130 635 48 6 PzS 480L 720
(830 x 738 x 467)

6 Technical data
Mast variations
Height of mast, Height of mast,
Lift Lift height Free lift
lowered extended
(h3) (h3 + s) (h2)
(h1) (h4)
4 655 4 700 2 455 5 614 1 541
5 155 5 200 2 455 6 114 1 541
5 755 5 800 2 955 6 714 2 041
6 355 6 400 2 955 7 314 2 041
6 655 6 700 2 955 7 614 2 041
6 955 7 000 2 955 7 914 2 041
7 255 7 300 3 455 8 214 2 541
7 555 7 600 3 455 8 514 2 541
7 955 8 000 3 455 8 914 2 541
8 255 8 300 3 455 9 214 2 541
8 555 8 600 3 955 9 514 3 041
8 955 9 000 3 955 9 914 3 041
9 155 9 200 3 955 10 114 3 041
9 455 9 500 3 955 10 414 3 041
9 755 9 800 3 955 10 714 3 041
10 155 10 200 4 455 11 114 3 041
10 655 10 700 4 455 11 614 3 541
10 755 10 800 4 455 11 714 3 541
11 155 11 200 4 930 12 114 4 016
11 455 11 500 4 930 12 414 4 016
NOTE
Maximum lift (h3 + s) for 1.4 tonne capacity =
9500 mm

Index
g
NUMBERS AND SYMBOLS Chassis

General description . . . . . . . . . . . . . .. 5
360° Steering . . . . . . . . . . . . . . . . . . . . . 81
Circuit diagram . . . . . . . . . . . . . . . . . . 171
A Hydraulic . . . . . . . . . . . . . . . . . . . . 168
Approved applications . . . . . . . . . . . . . . . 2 Lighting . . . . . . . . . . . . . . . . . . . . . 178
Cleaning the truck . . . . . . . . . . . . . . . . 115
B Clipboard
Battery Adjusting . . . . . . . . . . . . . . . . . . . . . 53
Changing - with changing station . . . . 46 Controls
Check charge . . . . . . . . . . . . . . . . . . 40 Check operation . . . . . . . . . . . . . . . . 41
Check condition . . . . . . . . . . . . . . . 123 Controls and indicators
Check electrolyte level and specific Single pedal . . . . . . . . . . . . . . . . . . . 18
gravity . . . . . . . . . . . . . . . . . . . . 116 Twin pedal . . . . . . . . . . . . . . . . . . . . 17
Connecting to a charger . . . . . . . . . . 43
D
Removing . . . . . . . . . . . . . . . . . . . . . 44
Specifications . . . . . . . . . . . . . . . . . 155 Data Logger . . . . . . . . . . . . . . . . . . . . . . 87
Before leaving the truck . . . . . . . . . . . . . 79 Decommissioning the truck . . . . . . . . . 140
Brakes Definition of direction of travel . . . . . . . . . 36
Adjust the parking brake . . . . . . . . . 120 Drive and transmission
Change fluid . . . . . . . . . . . . . . . . . . 139 General description . . . . . . . . ....... 5
Check load wheel brake pads . . . . . 136 Driving – single pedal . . . . . . . . . . . . . . . 60
Check luid level . . . . . . . . . . . . . . . . 135 Changing direction of travel . . . . . . . . 62
Check piping . . . . . . . . . . . . . . . . . . 137 Switching on . . . . . . . . . . . . . . . . . . . 60
Check the parking brake . . . . . . . . . 124 Travel with the forks leading . . . . . . . . 61
Check traction motor brake . . . . . . . 135 Travel with the forks trailing . . . . . . . . 61
General description . . . . . . . . . . . . . . . 6 Driving – twin pedal . . . . . . . . . . . . . . . . 58
Braking – single pedal . . . . . . . . . . . . . . 56 Changing direction of travel . . . . . . . . 59
Engaging and releasing the parking Switching on . . . . . . . . . . . . . . . . . . . 58
brake . . . . . . . . . . . . . . . . . . . . . . 56 Travel with the forks leading . . . . . . . . 59
Hydraulic footbrake . . . . . . . . . . . . . . 56 Travel with the forks trailing . . . . . . . . 59
Regenerative traction brake . . . . . . . . 56
Braking – twin pedal . . . . . . . . . . . . . . . . 54
E
Engaging and releasing the parking Electrical system
brake . . . . . . . . . . . . . . . . . . . . . . 54 General description . . . . . . . . . . . . ... 5
Hydraulic footbrake . . . . . . . . . . . . . . 54 Emergency isolator . . . . . . . . . . . . . . . . 19
Regenerative traction brake . . . . . . . . 54 Emergency lower . . . . . . . . . . . . . . . . . 100
Emergency steering and parking brake
C release . . . . . . . . . . . . . . . . . . . 101
Capacity plate . . . . . . . . . . . . . . . . . . . . 15
Chain head pulleys
F
Lubricate . . . . . . . . . . . . . . . . . . . . 129 Flooring requirements . . . . . . . . . . . . . . . 3

Index
g
Floorplate Hydraulic tank

Removing . . . . . . . . . . . . . . . . . . . . . 98 Replace breather filter . . . . . . . . . . . 136
Fork carriage plate Replace suction filter . . . . . . . . . . . . 138
Lubricate . . . . . . . . . . . . . . . . . . . . 127
Forks
I
Adjusting . . . . . ............ . . . . 76 Identification plates and labels
Fuses . . . . . . . . . . ............ . . . . 99 Location . . . . . . . . . . . . . . . . . . . . . . 14
Ancillary circuits ............ . . . 100 Inspection and maintenance
Main circuits . . . ............ . . . . 99 After the first 50 hours of operation . . 113
As required . . . . . . . . . . . . . . . . . . . 113
G Every 1000 hours . . . . . . . . . . . . . . 113
General view of truck . . . . . . . . . . . . . . . 16 Every 10000 hours . . . . . . . . . . . . . 114
Every 2000 hours . . . . . . . . . . . . . . 114
H Every 5000 hours . . . . . . . . . . . . . . 114
Handling loads . . . . . . . . . . . . . . . . . . . . 74 Pre-shift . . . . . . . . . . . . . . . . . . . . . 113
Capacity plate example . . . . . . . . . . . 74 Inspection and maintenance as
De-stacking a load . . . . . . . . . . . . . . 76 required
Load centre distance and load Adjust the lift chains . . . . . . . . . . . . . 117
capacity . . . . . . . . . . . . . . . . . . . . 74 Adjust the parking brake . . . . . . . . . 120
Stacking a load . . . . . . . . . . . . . . . . . 78 Check the battery electrolyte level
Transporting a load . . . . . . . . . . . . . . 78 and specific gravity . . . . . . . . . . . 116
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Check the drive wheel nuts . . . . . . . 118
Hose cassette Check the load wheel axle bolts . . . . 119
Locking . . . . . . . . . . . . . . . . . . . . . . 108 Clean the truck . . . . . . . . . . . . . . . . 115
Hose pulley Lubricate the lift chains and mast
Lubricate . . . . . . . . . . . . . . . . . . . . 132 channels . . . . . . . . . . . . . . . . . . 117
Hydraulic hoses Replace the hydraulic hoses . . . . . . 118
Check . . . . . . . . . . . . . . . . . . . . . . . 125 Inspection and maintenance data . . . . . 111
Hydraulic hoses and pipes
Replace . . . . . . . . . . . . . . . . . . . . . 118
Hydraulic oil
Change . . . . . . . . . . . . . . . . . . . . . 138
Check level . . . . . . . . . . . . . . . . . . . 128

Index
g
Inspection and maintenance every Inspection and maintenance every

1000 hours 5000 hours
Check the clearance of the mast Change the hydraulic oil and suction
retainers . . . . . . . . . . . . . . . . . . 129 filter . . . . . . . . . . . . . . . . . . . . . . 138
Check the condition and security Check condition of brake pipes . . . . 137
of electrical connections and Grease the load wheel bearings . . . . 137
cables . . . . . . . . . . . . . . . . . . . . 124 Interlock switches
Check operation . . . . . . . . . . . . . . . . 41
the wheels and tyres . . . . . . . . . . 121
Check the condition of the battery J
and battery cables . . . . . . . . . . . 123
Check the hydraulic hoses and Jacking the truck . . . . . . . . . . . . . . . . . 104
pipes for damage . . . . . . . . . . . . 125 Raising the drive wheel . . . . . . . . . . 104
Check the hydraulic oil level . . . . . . . 128 Raising the load wheels . . . . . . . . . . 105
Check the lift chains for condition
and security . . . . . . . . . . . . . . . . 125 L
Check the parking brake . . . . . . . . . 124 Lift carriage
Lubricate the fork carriage plate . . . . 127 Securing for maintenance work . . . . 107
Lubricate the lift carriage rollers . . . . 133 Lift carriage rollers
Lubricate the mast channels, reach Lubricate . . . . . . . . . . . . . . . . . . . . 133
channels and lift chains . . . . . . . 126 Lift chains
Lubricate the mast hose pulley and Adjust . . . . . . . . . . . . . . . . . . . . . . . 117
mast cable pulley assembly . . . . 132
Check . . . . . . . . . . . . . . . . . . . . . . . 125
Lubricate the mast rollers and chain
Lubricate . . . . . . . . . . . . . . . . 117, 126
head pulleys . . . . . . . . . . . . . . . 129
Lift height indicator . . . . . . . . . . . . . . . . . 32
Lubricate the reach carriage rollers . 133
Actual height mode . . . . . . . . . . . . . . 32
Lubricate the seat . . . . . . . . . . . . . . 129
De-stacking a load . . . . . . . . . . . . . . 34
Lubricate the sideshift bearings . . . . 127
Displaying the current selected zone . 35
Lubricate the tilt bearings . . . . . . . . . 128
Selecting a new zone . . . . . . . . . . . . 35
Inspection and maintenance every
10000 hours Shelf mode . . . . . . . . . . . . . . . . . . . . 33
Change the brake fluid . . . . . . . . . . . 139 Stacking a load . . . . . . . . . . . . . . . . . 34
Inspection and maintenance every Warehouse zones . . . . . . . . . . . . . . . 34
2000 hours Lighting
Check the brake fluid level . . . . . . . . 135 Exterior . . . . . . . . . . . . . . . . . . . . . . . 91
Check the load wheel brake pads Lubricants . . . . . . . . . . . . . . . . . . . . . . 110
for wear . . . . . . . . . . . . . . . . . . . 136 Brake fluid . . . . . . . . . . . . . . . . . . . 110
Check the traction motor brake for Chain Spray . . . . . . . . . . . . . . . . . . 110
wear and adjustment . . . . . . . . . 135 Gear oil . . . . . . . . . . . . . . . . . . . . . . 110
Replace the hydraulic tank breather General purpose oil . . . . . . . . . . . . . 110
filter . . . . . . . . . . . . . . . . . . . . . . 136
Hydraulic oil specification . . . . . . . . 110
Multipurpose grease . . . . . . . . . . . . 110
Steering drive gears . . . . . . . . . . . . 110

Index
g
M Operating the mast and attachments

(with two joystick control) . . . . . . . 63
Mast
Attachments . . . . . . . . . . . . . . . . . . . 66
Check mast retainers . . . . . . . . . . . 129
Extending the reach carriage . . . . . . . 64
Mast cable pulley assembly
Lowering the lift carriage . . . . . . . . . . 63
Lubricate . . . . . . . . . . . . . . . . . . . . 132
Raising the lift carriage . . . . . . . . . . . 63
Mast channels
Retracting the reach carriage . . . . . . . 64
Lubricate . . . . . . . . . . . . . . . . 117, 126
Sideshift . . . . . . . . . . . . . . . . . . . . . . 64
Mast rollers
Tilting the fork carriage back . . . . . . . 65
Lubricate . . . . . . . . . . . . . . . . . . . . 129
Tilting the fork carriage forward . . . . . 65
Mast unit . . . . . . . . . . . . . . . . . . . . . . . 107
Operator code entry . . . . . . . . . . . . . . . . 83
Description of operation . . . . . . . . . . 107
Accessing supervisor menus . . . . . . . 84
Removal . . . . . . . . . . . . . . . . . . . . . 107
Add/delete operator PINs . . . . . . . . . 85
Mast variations . . . . . . . . . . . . . . . . . . 156
Changing the supervisor PIN . . . . . . . 84
Mast, hydraulics and reach system
Disable/enable the truck . . . . . . . . . . 85
General description . . . . . . . . . . . . . . . 5
List operator PINs . . . . . . . . . . . . . . . 86
Motor cover
Logging off . . . . . . . . . . . . . . . . . . . . 83
Removing . . . . . . . . . . . . . . . . . . . . . 96
Logging on . . . . . . . . . . . . . . . . . . . . 83
Mounting and dismounting the truck . . . . 50
Set/reset learner operation . . . . . . . . 86
N Operator’s compartment
General description . . . . . . . . . . . . . . . 5
Noise emission levels . . . . . . . . . . . . . . . 10
Operator’s console
O Adjusting . . . . . . . . . . . . . . . . . . . . . 53
Operator’s controls
Operating the mast and attachments
(with four joystick control) . . . . . . . 70 General description . . . . . . . . . . . . . . . 5
Attachments . . . . . . . . . . . . . . . . . . . 72 Operator’s display . . . . . . . . . . . . . . . . . 21
Extending the reach carriage . . . . . . . 71 Battery change indicators . . . . . . . . . 27
Lowering the lift carriage . . . . . . . . . . 70 Battery discharge indicator . . . . . . . . 26
Raising the lift carriage . . . . . . . . . . . 70 Battery lock warning . . . . . . . . . . . . . 30
Retracting the reach carriage . . . . . . . 71 Brake fluid level warning . . . . . . . . . . 30
Sideshift . . . . . . . . . . . . . . . . . . . . . . 72 Clock . . . . . . . . . . . . . . . . . . . . . . . . 27
Tilting the fork carriage back . . . . . . . 71 Fork tilt indicator . . . . . . . . . . . . . . . . 24
Tilting the fork carriage forward . . . . . 71 Hour meter . . . . . . . . . . . . . . . . . . . . 29
Operating the mast and attachments Interlock warning indicator . . . . . . . . . 25
(with three joystick control) . . . . . . 67 Message panel . . . . . . . . . . . . . . . . . 22
Attachments . . . . . . . . . . . . . . . . . . . 69 Over temperature indicators . . . . . . . 28
Extending the reach carriage . . . . . . . 68 Parking brake warning . . . . . . . . . . . . 29
Lowering the lift carriage . . . . . . . . . . 67 Service interval elapsed indicator . . . . 28
Raising the lift carriage . . . . . . . . . . . 67 Service warning . . . . . . . . . . . . . . . . 31
Retracting the reach carriage . . . . . . . 68 Sideshift centre indicator . . . . . . . . . . 25
Sideshift . . . . . . . . . . . . . . . . . . . . . . 68 Slow speed indicator . . . . . . . . . . . . . 26
Steering indicator . . . . . . . . . . . . . . . 22

Index
g
Operator’s step Sideshift bearings

Removing . . . . . . . . . . . . . . . . . . . . . 98 Lubricate . . . . . . . . . . . . . . . . . . . . 127
Slinging the truck
P High lift mast . . . . . . . . . . . . . . . . . . 102
Pre-shift checks . . . . . . . . . . . . . . . . . . . 40 Low lift mast . . . . . . . . . . . . . . . . . . 103
Check all controls and their operation . 41 Starting on an incline . . . . . . . . . . . . . . . 62
Check all Interlock switches . . . . . . . . 41 Steering
Check general condition of truck . . . . 42 General description ............... 5
Check the battery charge . . . . . . . . . . 40 Steering wheel . . . . . . . . . . . . . . . . . 19
Check the lift carriage locking plate . . 42
T
R Taking the truck out of operation . . . . . . 140
Reach carriage rollers Technical data
Lubricate . . . . . . . . . . . . . . . . . . . . 133 1.4 tonne capacity . . . . . . . . . . . . . . 143
Reach channels 1.6 tonne capacity . . . . . . . . . . . . . . 146
Lubricate . . . . . . . . . . . . . . . . . . . . 126 1.7 tonne capacity . . . . . . . . . . . . . . 149
Referenced standards . . . . . . . . . . . . . . . 2 1.7 tonne capacity (heavy duty) . . . . 152
Routine inspection and maintenance . . 112 Technical note . . . . . . . . . . . . . . . . . . . . . 3
Running-in . . . . . . . . . . . . . . . . . . . . . . . 38 Tilt bearings
Check the drive wheel nuts . . . . . . . . 38 Lubricate . . . . . . . . . . . . . . . . . . . . 128
Check the load wheel axle bolts . . . . . 39 Towing procedure . . . . . . . . . . . . . . . . 106
Truck data management . . . . . . . . . . . . 88
S Logging off . . . . . . . . . . . . . . . . . . . . 90
Safety Logging on . . . . . . . . . . . . . . . . . . . . 89
General maintenance safety . . . . . . . 94 Status LEDs . . . . . . . . . . . . . . . . . . . 90
Handling lubricants . . . . . . . . . . . . . . 95 Truck condition codes . . . . . . . . . . . . 88
Operator safety guidelines . . . . . . . . . . 8 Truck takeover . . . . . . . . . . . . . . . . . . . . . 4
Report of Thorough Examination . . . . 95 Truck type plate . . . . . . . . . . . . . . . . . . . 15
Safety symbols . . . . . . . . . . . . . . . . . . 2 Tyres
Seat Check condition . . . . . . . . . . . . . . . 121
Adjusting left hand armrest . . . . . . . . 52
Adjusting right hand armrest . . . . . . . 52 V
Adjusting suspension . . . . . . . . . . . . 50 Vibration levels . . . . . . . . . . . . . . . . . . . 11
Adjusting the backrest . . . . . . . . . . . . 50
Adjusting the height . . . . . . . . . . . . . . 50 W
Adjusting the lumber support . . . . . . . 51 Wheels
Adjusting the position . . . . . . . . . . . . 51 Check condition and security . . . . . . 121
Lubricate . . . . . . . . . . . . . . . . . . . . 129 Check the drive wheel nuts . . . . 38, 118
Raising fully for maintenance Check the load wheel axle
procedures . . . . . . . . . . . . . . . . . 96 bolts . . . . . . . . . . . . . . . . . . 39, 119
Rotating . . . . . . . . . . . . . . . . . . . . . . 51 Grease load wheel bearings . . . . . . 137

Linde AG
Geschäftsbereich Linde Material Handling
Linde AG
Linde Material Handling Division
116 807 10 01 EN – 02/2006

Operating Instructions
Electric reach truck
R14X, R16X, R17X,

R17XHD
Annex 116 807 10 01 EN – 02/2006
7
Circuit diagrams
7 Circuit diagrams
Hydraulic circuit
Hydraulic circuit
E 14 14-1
3 4 5 6
B C D A
M
7
MP 2Y33 2Y2
2Y31
P1
8
2Y1
T
9 G
2Y11
P2 5
2Y32 15 20
16
10 A B1
19
A1
B
2Y9 13
F
A1 6
2Y12
11
12 B1
2Y8 18
17 19
2
A 2Y11
2
15-1 2 20
5
A
B1
1
B
A1
1
16 1
2Y12
6
18 19

Circuit diagrams 7
Hydraulic circuit - keycode

A OIL RESERVOIR 5 Lower speed select valve 14 Lift cylinders (low lift, without 18 Tilt cylinders (option)
booster)
1 Suction filter 6 Lower valve proportional control 19 Reach cylinders
14-1 Lift cylinders (high lift, with booster)
2 Breather filter 7 Safety stop valve 20 Sideshift cylinders
F HOSE CASSETTE
B PUMP 1 8 Lift valve
G CARRIAGE VALVE BLOCK
C PUMP 2 9 Relief valve 280 bar
15 Direction control - Auto tilt
D PUMP MOTOR 10 2nd pump offload valve
15-1 Direction control - Manual tilt
E CHASSIS VALVE BLOCK 11 Pressure compensated flow control
valve 16 Reach brake valve (load motion
3 Manual emergency lower (screw control with damping)
operated) 12 Auxiliary proportional section for
head valve functions 17 Pilot operated check for tilt back
4 Pressure compensating flow load holding
control valve 13 Shuttle valve

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 - keycode

Code Explanation of function Code Explanation of function Code Explanation of function Code Explanation of function
A1 Module – power 1F4 Fuse – converter U1 2S28 Switch – auto tilt centre 2X15 Connector – 2B1 (6 way)
A2 Module – control 1F6 Fuse – horn and heated seat 2S29 Switch – auto sideshift centre 2X17 Connector – chassis valves (10
way)
A11 Module – charge resistor 3F1 Fuse – power steering 4S1 Switch – horn push
2X26 Connector – 2B2 (6 way)
1A4 Accelerator 5F1 Fuse – lighting U1 Converter – 48 V / 13 V
3A1 Module – steering 6F1 Fuse – Battery discharge indicator U2 Converter – 48 V / 13 V
2X34 Connector – reach position
9A12 Assembly – seat G1 Battery X2 Connector – seat (42 way) potentiometer (4 way)
1B1 Sensor – traction motor tachome- 4H1 Horn X10 Connector – Battery 2X35 Connector – 2B24 (4 way)
ter
K1 Contactor – main X11 Connector – power supply 2X36 Connector – lower sensors (4 way)
1B4 Sensor – traction motor tempera-
ture K2 Relay – charge resistor X12 Connector – charge resistor (6 2X38 Connector – lift carriage valves (4
way) way)
1B5 Alarm – travel K3 Relay – charge resistor
X13 Connector – control module (121 2X39 Connector – mast cable (10 or 16
2B1 Joystick – lift/reach 1M1 Motor – traction way) way)
2B2 Joystick – tilt/sideshift 2M1 Motor – lift X14 Connector – power module (29 2X40 Connector – mast and lift carriage
2B3 Joystick – 5th/6th hydraulics way) (6 way)
9M1 Motor – traction MOS fan
X48/C Connector – power steering (4 2X46 Connector – 2B26 (4 way)
2B4 Sensor – lift motor temperature 9M2 Motor – traction motor fan way)
2X50 Connector – Auto tilt/sideshift
2B8 Sensor – lift motor tachometer 9M4 Motor – lift MOS fan X49/G Connector – power steering (8 switches
2B24 Sensor – lower A way)
6P1 Module – display 2X83 Connector – 2B8 (4 way)
X50/L Connector – power steering (8
2B26 Sensor – lower B 6P12 Module – Datalogger/keypad 2X86 Connector – tilt position poten-
way)
tiometer (4 way)
3B1 Sensor – steering wheel encoder 2R11 Resistor – reach position poten- 1X7 Connector – 1B4 and Y1 (4 way)
tiometer 2X87 Connector – sideshift position
3B2 Sensor – steering 90 degree 1X9 Connector – direction/horn switch potentiometer (4 way)
2R12 Resistor – tilt position potentiome- (6 way)
3B3 Sensor – steering 180 degree ter 2X88 Connector – lift carriage (4 way)
1X10 Connector – accelerator (4 way)
3B4 Sensor – steering 360 degree 2R13 Resistor – sideshift position 3X1 Connector – power steering (16
potentiometer 1X14 Connector – footbrake (3 way) way)
6B11 Sensor – temperature
S1 Keyswitch 1X15 Connector – diagnostic (7 way) 3X4A Connector – steering wheel
7B17 Sensor – battery lock encoder (10 way)
S2 Switch – emergency isolator 1X16 Connector – 1B1 (4 way)
7B18 Sensor – battery lock 3X4B Connector – 3B1 8 way)
S3 Switch – brake fluid level 1X32 Connector – seat (6 way)
7B19 Sensor – door 3X8 Connector – 3B2 (4 way)
1S1 Switch – seat 1X34 Connector – travel alarm (2 way)
8B11 Sensor – height encoder 3X9 Connector – 3B3 (4 way)
1S4 Switch – parking brake 1X38 Connector – left foot switch (3 way)
8B12 Sensor – height reference 3X10A Connector – 3B4 (4 way)
1S5 Switch – footbrake 1X77 Connector – parking brake switch
F1 Fuse – main 3X10B Connector – 360 degree sensor (4
1S11 Switch – left foot (2 way)
F8 Fuse – parking brake way)
1S13 Switch – direction 3X15 Connector – power steering (10
1F2 Fuse – keyswitch
way)

7 Circuit diagrams
Code Explanation of function Code Explanation of function Code Explanation of function

3X17 Connector – power steering (10 7X74 Connector – 7B17 (4 way) Y1 Solenoid – traction motor brake Colour abbreviations
way)
7X75 Connector – 7B18 (4 way) 2Y1 Valve – lift BK Black
4X1 Connector – horn (2 way)
7X76 Connector – 7B19 (4 way) 2Y2 Valve – lower BN Brown
5X1 Connector – lighting (4 way)
7X78 Connector – door sensor and 2Y8 Valve – reach extend, sideshift OG Orange
6X1 Connector – display (16 way) power supply interlock (4 way) right, tilt forward (option)
YE Yellow
6X9 Connector – console (16 way) 8X38 Connector – 8B11 (4 way) 2Y9 Valve – reach retract, sideshift left,
tilt back (option) RD Red
6X60 Connector – Datalogger/keypad (5 8X39 Connector – 8B12 (2 way)
way) 2Y11 Valve – reach select GN Green
6X61 Connector – Datalogger/keypad (4 2Y12 Valve – sideshift select BU Blue
way) 9X1 Connector – traction MOS fan (2
way) 2Y31 Valve – lock VT Violet
6X63 Connector – options (10 way)
9X2 Connector – traction motor fan (2 2Y32 Valve – dump GY Grey
7X72 Connector – 7B17 (4 way) way)
2Y33 Valve – 3rd stage lower WH White
7X73 Connector – 7B18 (4 way) 9X12 Connector – lift MOS fan (2 way)
4Z1 Suppression – horn

Circuit diagrams 7

7 Circuit diagrams
Lighting circuit
Lighting circuit
5X1
BK
+48V Keyswitch :3
5X1 5X4
GNWH BN
+48V Battery :1 :1
5S1 :2 5S2 :2
0 1 :3 0 1 :3
YEGN
BU
5X4 5X4
:4 :3
BNOG
BNRD
5X27 5X27 5X27

:4 :5 :6
BN
BN
BN
5E11:1
5E10 :1
RD
YEGN
:31
:1 :1 :1 :1
22R 50W
5E5
5E6
5E11 M 5R10
:31 :31 :2 :2
:2
BK
BU
5E11:2 5E10:2
BU
BU
BU
5X27 5X27 5X27

:1 :2 :3
BU
5X1
BU SP1
0V :2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Circuit diagrams 7
Lighting circuit - keycode
Lighting circuit - keycode

Code Explanation of function Code Explanation of function Colour abbreviations
5E5 Light - LH Working lamp 5S2 Switch - RH Working lamp Colour abbreviations RD Red
5E6 Light - RH Working lamp 5X1 Connector - 4 way Lighting BK Black GN Green
5E10 Light - Rotating beacon 5X4 Connector - 4 way Console BN Brown BU Blue
5E11 Light - Xenon beacon 5X27 Connector - 6 way Lights OG Orange VT Violet
5R10 Resistor - Rotating beacon YE Yellow GY Grey
5S1 Switch - LH Working lamp WH White

Linde AG
Geschäftsbereich Linde Material Handling
Linde AG
Linde Material Handling Division
116 807 10 01 EN – 02/2006

Operating Instructions Electric Reach Truck

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Operating Instructions Electric Reach Truck

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Operating Instructions

Electric reach truck

R14X, R16X, R17X,

Linde - Your Partner

Operating Instructions – 116 807 10 01 EN – 02/2006 I

1 Introduction and general description

3 Getting to know the truck

Operating Instructions – 116 807 10 01 EN – 02/2006 III

360° Steering (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

IV Operating Instructions – 116 807 10 01 EN – 02/2006

Adjust the parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Operating Instructions – 116 807 10 01 EN – 02/2006 V

Taking the truck out of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

VI Operating Instructions – 116 807 10 01 EN – 02/2006

Introduction and general description

NOTE Approved applications

2 Operating Instructions – 116 807 10 01 EN – 02/2006

incorrect maintenance or repairs and applica- Flooring requirements

Operating Instructions – 116 807 10 01 EN – 02/2006 3

4 Operating Instructions – 116 807 10 01 EN – 02/2006

Operating Instructions – 116 807 10 01 EN – 02/2006 5

A powerful AC pump motor with automatic Brakes

6 Operating Instructions – 116 807 10 01 EN – 02/2006

Operator safety guidelines

8 Operating Instructions – 116 807 10 01 EN – 02/2006

Operating procedures ¾ If possible cross rail tracks, door thresholds

Operating Instructions – 116 807 10 01 EN – 02/2006 9

¾ Be aware of protruding forks which could Parking

Noise emission levels

10 Operating Instructions – 116 807 10 01 EN – 02/2006

Frequency characteristic for human body vibrations

Operating Instructions – 116 807 10 01 EN – 02/2006 11

12 Operating Instructions – 116 807 10 01 EN – 02/2006

Getting to know the truck

Location of identification plates and labels

1 Truck type/capacity plate 6 Cold store hydraulic oil label

14 Operating Instructions – 116 807 10 01 EN – 02/2006

Truck type/capacity plate

1 Manufacturer 7 CE symbol (The symbol certifies that all

Operating Instructions – 116 807 10 01 EN – 02/2006 15

General view of truck

1 Overhead guard 12 Hydraulic control valve

16 Operating Instructions – 116 807 10 01 EN – 02/2006

Operating controls and indica-

1 Steering wheel 9 Clipboard (Option)

Operating Instructions – 116 807 10 01 EN – 02/2006 17

Single pedal controls

1 Steering wheel 9 Lift and reach control joystick

18 Operating Instructions – 116 807 10 01 EN – 02/2006

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

Steering the truck

Operating Instructions – 116 807 10 01 EN – 02/2006 19

Operating the horn

20 Operating Instructions – 116 807 10 01 EN – 02/2006

Operating Instructions – 116 807 10 01 EN – 02/2006 21

When the truck is switched on, the drive wheel

MESSAGE EXPLANATION ACTION REQUIRED

22 Operating Instructions – 116 807 10 01 EN – 02/2006

MESSAGE EXPLANATION ACTION REQUIRED

Operating Instructions – 116 807 10 01 EN – 02/2006 23

MESSAGE EXPLANATION ACTION REQUIRED

Fork tilt indicator

The numerical display (2) displays the precise