608777 EN 11/2011 - Original instructions

1. Truck ................................................................................. 3
2. Safety instructions ............................................................ 4
3. Operating environment ..................................................... 7
4. Operating devices ............................................................. 9
5. Driving instructions ......................................................... 16
6. Load handling ................................................................. 20
7. Batteries ......................................................................... 22
8. Maintenance ................................................................... 27
9. Service ............................................................................ 29
10. Transportation and storage ............................................. 33
11. Troubleshooting and alarms ........................................... 34
12. Technical specifications .................................................. 35
13. EC Declaration Of Conformity ........................................ 43

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489455

1. Truck

General Information
Warehouse trucks are designed and manufactured to lift and transport materials indoors. Please read this manual
before operating or performing maintenance on the truck. After reading this manual, store it in a safe, dry place
for later use.
The truck conforms to the EN ISO 3691-1 standard, ensuring its safety according to the EU machine directive
2006/42/EC. The most important regulations and guidelines are mentioned in these instructions. As regulations
vary from country to country, we expect you to familiarize yourself with the regulations and standards valid in
your country.
For further information on trucks or training, please contact our sales organization.
A truck may cause serious accidents unless you are sufficiently familiar with its operation and unless you know
its operating and maintenance instructions. To order more copies of the instruction book, contact your dealer.

Electromagnetic compatibility
The truck conforms to the EN 12895 standard, ensuring its safety according to the EMC directive 2004/108/EC.
The truck is designed for light and heavy industry use (EN 50081-1 and EN 50082-2).
WARNING! Do not make any modifications to the electric devices in the truck without the manufacturer's
expressed permission. Modifications to electric devices may affect the electromagnetic
compatibility and, therefore, reduce operational safety.

Non-ionising radiation
The truck itself does not emit non-ionising radiation. Auxiliary devices like radio transmitter, RFID reader and
data collection system may produce non-ionising radiation which can cause harm to persons, in particular persons
with active or non-active implantable medical devices. If those auxiliary devices are installed by the user, the
user itself shall ensure that the supplier's instructions are fulfilled and no harm for the persons has risen.
NOTE Where trucks are fitted with non-ionising radiation devices, warning signs shall be installed to
the truck and supplier's instructions attached to the instruction manual.

Delivery
Before shipping, each truck is inspected carefully to make sure that the truck you receive is flawless and fully
equipped. Nevertheless, check the truck immediately after receiving it for any damages that may have occurred
during shipping.

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489456

2. Safety instructions

Instructions for site supervision

• Familiarise yourself with the operating instructions and their contents
• Train the operator on the use, safety and maintenance aspects of the truck
• Control that the operating and maintenance instructions, and safety regulations are observed

Occupational safety
• Keep the truck clean and in good working order. Carry out the daily and weekly maintenance checks in
accordance with the maintenance instructions and schedule to avoid faults and operational errors.
• If you notice any faults or deficiencies that may effect the safe operation of the truck, take the truck out of
operation until the faults or deficiencies have been remedied
• In the event of a malfunction, switch off the power and notify the site supervision.
• Do not repair anything on the truck without the permission from the site supervision
• When using the truck, you are responsible for both your own and your environment's safety
• Immediately notify the site supervision of any accidents or injuries. In such a case, leave the truck at the place
of the accident
• The truck can only be used for purposes corresponding with its equipment.

Truck operator
Requirements:

• At least 18 years old

• Sufficient physical (e.g. good hearing and sight) and mental abilities for operating the truck without risks
• Appropriately trained; familiar with operating, safety and maintenance instructions
• Has permission from the site supervision to operate the truck
• Knows and masters the drive and operational features of the truck.

Emergency procedures
If the truck falls over, hold onto the steering wheel and warn others. If the machine malfunctions, brake and switch
off the power. The truck must not be used again, until a person authorised by the supervisor has repaired the
truck.

Noise
The average noise level (LpA) to which the driver may be subjected has been measured at the driver’s ear as
per standards EN 12053:2001 and EN ISO 4871. The measured values are listed in Chapter 12, Technical
Specifications, section 8.4 in this manual.
NOTE Higher sound pressure levels may occur during the truck’s operation, caused by different
method of operation, environmental effects and other sources of noise.

Vibration
The level of vibration to which the driver is subjected (aw,z ) has been measured as per standard EN 13059:2002.
The measured values are listed in Chapter 12, Technical Specifications, section 8.4 in this manual.

Work at dangerous premises

A standard truck may not be used in an explosive atmosphere. There are specially manufactured trucks for such
premises. Contact your truck dealer for a specially designed and equipped trucks for hazardous conditions.

Repairs and structural modifications

Do not modify the truck without the manufacturer's express permission. Do not add or remove, weld or bend any
parts, as the modifications could affect the operation of the truck and might weaken its construction.

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NOTE Only in the event that the truck manufacturer is no longer in business and there is no successor
in the interest to the business, the user may arrange for a modification or alteration to a powered
industrial truck, provided, however, that the user shall:

• arrange for the modification or alteration to be designed, tested and implemented by an

engineer(s) expert in industrial trucks and their safety;
• maintain a permanent record of the design, test(s) and implementation of the modification
or alteration;
• approve and make appropriate changes to the capacity plate(s), decals, tags and instruction
handbook;
• affix a permanent and readily visible label to the truck stating the manner in which the truck
has been modified or altered together with the date of the modification or alteration, and
the name and address of the organization that accomplished the tasks.

Overhead guard and load support (applies only to trucks with mast)
Trucks driven sitting or standing that are capable of lifting a load higher than 1.8 m must be equipped with an
overhead guard. Modifications to the overhead guard that could possibly weaken its structure are not allowed. If
it is possible for objects to fall through the openings in the overhead guard, the size of the openings must be
reduced. Trucks used for transporting small objects or unstable loads must be equipped with a load support.

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Legend for warning symbols attached to the truck and used in this manual
Note! A truck may cause serious accidents unless
you are sufficiently familiar with its operation and unless
you know its operating and maintenance instructions.

For more information, see the truck manual.

Familiarise yourself with the truck manual and its
contents before operating or servicing the truck.

Do not touch moving parts.

Do not use the truck to lift persons.

Do not walk or stand underneath the truck's raised

forks.

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489457

3. Operating environment

General Information
Use the truck in dry, indoor facilities with substantially firm, smooth, level and prepared surfaces according to
standard DIN 15185-1. The truck may be continuously operated at a temperature of +5...+25°C and for short
periods at a temperature of 0...+45°C. The recommended humidity is 30...95% (non-condensing). If the operating
temperatures differ from those mentioned above, contact your truck dealer and acquire a truck specifically
designed for cold and freezing or extremely high temperatures. A special machine for freezing conditions can be
used in temperatures down to -35°C. A special machine for hot conditions can be continuously used in temperatures
up to + 45 °C.
This truck conforms to the requirements of the EU machine safety directive (2006/42/EC) and thus has the CE
marking.

Never use the truck:

• To transport or lift people
• At premises with risk of fire (ATEX premises)
• In explosive atmospheres
• At premises with insufficient floor load capacity
• If it is damaged
• As a mounting surface
• As an access board or a ladder
• To tow another truck
• Under the influence of intoxicating substances.

Free space
Make sure that the truck has sufficient moving space with respect to overhead structures. Before driving through
aisles or door openings, ensure that there is enough space for the truck, the load and yourself.
NOTE Always drive at a safe distance from the edge of loading platforms or bridges.

Bearing capacity of the floor

Make sure that the combined weight of the truck and the load does not exceed the bearing capacity of the floor.

Using elevators
You need a permission from the site supervision to use an elevator to transport the truck between floors. Make
sure that the combined weight of the truck, the load and yourself does not exceed the maximum load capacity
of the elevator. Always drive the truck into elevators and any other narrow spaces with the load in front.
NOTE Do not let other people enter the elevator while driving the truck in or out. The parking brake
of the truck must be engaged and power switched off before the elevator starts moving.

Driving on ramps
You need a permission from the site supervision to drive on a slope or ramp. The inclination of the ramp should
not exceed 10%. We recommend using warning signs in places where this is exceeded.
NOTE All truck types are not suitable for driving on ramps. Make sure that the truck you are using is
suitable for this purpose.
WARNING! Driving trucks with a gradeability of 0% is forbidden on the ramp. RISK OF OVERTURNING!
Observe extreme caution when driving on a ramp. When the truck is loaded, travel with the load pointing uphill.
To ensure steerability and braking, the grip of the ramp must be equivalent to a standard floor.
NOTE Do not turn the steering wheel abruptly on a ramp; the truck might overturn.

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Driving on loading bridges
Always check the bearing capacity and the fastening of the bridge before loading or unloading. If you need to
drive the truck onto another vehicle, ensure that the vehicle cannot move during this procedure. Do not drive to
the edges of a loading bridge because there is always the risk of overturning.

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611288

4. Operating devices

General information and intended use

The truck is a five wheel pedestrian operated electric pallet truck, equipped with a multifunctional tiller control for
driving, steering and load handling. It is designed to transport pallets and pick goods on level surfaces. Goods
can be collected onto pallets or roll containers from the first order picking level.

Type plate (1)

The truck's type plate is marked with:

• Manufacturer
• Truck type
• Year of manufacture
• Serial number
• Truck weight in operating condition without battery or accessories
• Battery minimum weight
• Battery terminal voltage
• Truck's nominal lifting capacity
• Nominal power in kW
• CE mark

Check that the plates are legible and securely attached.

Capacity plate
The capacity plate states the maximum lifting capacity at the maximum lifting height, and the lifting height with
the nominal lifting capacity. In addition, the plate states the load centre distance for the relevant lifting capacity.

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WARNING! Do not overload!

Operating devices

• Tiller arm (1)

• Truck display (2)
• Emergency stop button and key switch (3)
• Recharging plug (under the battery cover) (4)
• Mains plug of the inbuilt charger (optional) (5)

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Control panel

Emergency stop button (1).

Disconnect the truck's power supply by pressing the emergency stop button. Release the button by turning it
clockwise. Use the emergency stop button in the following cases.

• if there is a short circuit or other electrical malfunction, for example, the pump motor will not stop running or
• if an accident happens.

Key switch (2)

The key switch switches on the truck's electrical system:

• 0 = Power off (power may be still connected to certain electronic devices) (1)
• 1 = Power on, economy mode (lower energy comsumption and deceleration) (2)
The "ECO" symbol is shown in the multi-function display (optional).
• 1 = Power on, standard mode (3)

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Truck display (3)
There are two display versions available:
LED display

The device displays:

• Level of battery charge

Green: 70—100% (1)

Yellow: 40 —70% (2)
Red: 20—40% (3)
Slowly flashing red: 0—20% (battery empty, recharge immediately) (4)

• Fault codes
Flashing yellow: warning
Flashing red: error
If a fault code is displayed, contact maintenance personnel for assistance.

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 Multi-function display (optional)

The device displays:

• Level of battery charge (1)
• Indication of operational hours (2)
• System messages (2)
ECO = Economy mode selected. For further information, see chapter "Key switch".
Lo SPd = Low speed mode selected. For further information, see chapter "Tiller arm".
• Fault codes (2)
Flashing numeric code: warning
Solid numeric code: error
• LED (3)
Flashing red: error
If a fault code is displayed, contact maintenance personnel for assistance.

WARNING! Do not step on the truck! FALLING HAZARD!

Brakes
Service brake
The truck has an electric service brake for reducing the driving speed. Braking is carried out by the truck's speed
control system. During braking the driving motor runs as a generator which output energy is restored into the
battery.
To brake turn the accelerator to the opposite direction or release it to neutral.

• When you change the driving direction, the braking level is adjustable. Use the accelerator to set it suitable.
• When you release the accelerator, the braking level is not adjustable. Contact service man to set the release
braking level suitable.

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NOTE Practice braking with and without load in a safe area before you start working with the truck.
WARNING! Do not left your foot under the truck while the truck is moving. It may get trapped between the
moving truck and the floor. CRUSHING HAZARD!

Parking brake
The truck has a parking brake which holds the truck in place. The brake is an on/off-type magnetic brake.
To release the parking brake:

• tilt the tiller arm to driving position and turn the accelerator.

To apply the parking brake:

• bring the truck to a standstill and the brake will switch on automatically or
• release the tiller arm to the up position and the truck will stop immediately.

NOTE Make sure that the brake has been applied before leaving the truck.

Emergency braking
While the truck is moving, press the tiller arm to the down position or release it to the up position.
NOTE Emergency braking makes the truck uncontrollable and can cause the drive wheel to wear
unevenly.

Tiller arm

Safety button (1)

The safety button prevents you from getting squeezed between the truck and an obstacle.
When you push the safety button, the truck reverses its travelling direction and stops when the button is released.
NOTE Never use the safety button for normal driving.
Check the operation of the safety button daily before you start working with the forklift truck.

Push buttons for lifting and lowering (2)

Push button "up" to lift forks. Push button "down" to lower forks.

Horn (3)
Press the button to give an audible warning signal.

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Steering (4)
The tiller arm turns ± 95 degrees.

Accelerator (5)
Use the accelerator with your right or left hand. The more you turn the accelerator, the higher the speed. The
accelerator returns automatically to the central position when it is released. Brake smoothly by moving the
accelerator to the opposite direction.
NOTE Handle the accelerator gently.

Brake release / slow speed button (6)

The button has two functions:

• Brake release
When the tiller arm is in up position, hold the button down to release the parking brake and turn the accelerator
to drive the truck in the slow speed mode. Release the button to apply the parking brake.

Tip
Use this feature in very narrow places where there is no room to tilt the tiller arm

• Slow speed mode

When the tiller arm is in driving position, activate the slow speed mode by pressing the button once. The "Lo
SPd" symbol is shown in the multi-function display (optional). Deactivate the slow speed mode by pressing
the button once again.

Lever for lifting and lowering (optional) (7)

Pull lever "up" to lift forks. Push lever "down" to lower forks.

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611289

5. Driving instructions

Daily checks before operation

Carry out the daily maintenance check before using the truck. Neglecting daily maintenance may decrease the
safety and reliability of the truck. Notify the site supervisor immediately if you notice an error or deficiency during
the check.

• Check the truck externally to see that there are no oil leaks.
• Check all wheels for damage or wear.
• Check the battery fluid in each battery cell. Top up with battery water if needed. The fluid surface should be
about 15 mm above the plates. (Does not apply to maintenance-free batteries.)
• Check the gearbox for leaks. Also check the hydraulic pipes, hoses, and connectors. No leaks or damage
should be found.
• Switch on the power and test the operation of the lifting hydraulics by raising and lowering the forks.
• Check the operation of the accelerator and steering by driving slowly forward and backward.
• Also check the operation of the other electrical functions.
• Check that the batteries are charged and locked in place.
• Check the operation of the horn.
• Check that the emergency stop operates properly.
• Check that the safety button works.
• Make sure that the tiller arm returns to the up position.
• Check that the service brake and the parking brake functions properly.
• Check the fastenings of the lifting chain (if available).

Before you start

• Make sure that the daily maintenance has been carried out.

Driving

• Tilt the tiller arm to the driving position (tiller arm in position 1, see the picture above).
• Turn the accelerator lightly in the driving direction.
• To brake, turn the accelerator in the opposite direction to the driving direction.
• Steer the truck smoothly because abrupt movements may cause a dangerous situation, especially when
driving at high speed.

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NOTE Due to safety reasons, the truck may be adjusted to travel slower to the direction of the forks.

General driving instructions

Practice steering and controlling the truck carefully in a safe area.

• Drive slowly at intersections and when turning.

• Handle the truck responsibly and always keep it under control.
• Avoid sudden starts and stops.
• Steer and brake smoothly.
• Decrease the speed if the floor is slippery, for example, because of humidity.
• Take great care when driving on a slanted surface.
• Do not drive over any loose objects on the floor.

When driving, keep the load lowered and, if possible, tilted backwards. Do not lift the load except when stacking.
This does not apply to trucks designed to be driven with the load raised.

Be especially careful:
• When there are other people or objects in the working area.
• When the load reduces visibility.
• When driving in narrow aisles, make sure that there is enough space for the truck and the load.

Driving position
When driving a pedestrian truck in the direction of the forks, stand behind the truck and keep both your hands
on the tiller arm (see the picture below).

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When driving in the opposite direction, walk beside the truck and keep one hand on the tiller arm (see the picture
below).

Speed
Control the speed according to the situation. Take into consideration the load, visibility, and people in the working
area and the working environment. Slow down at cross aisles and whenever the vision is obstructed. If the visibility
is inadequate, use an assistant to help guide you.
Uncontrolled acceleration or braking, excessive speed at turning points, and fast and sudden turning may overturn
the load and cause an accident. In all conditions, drive the truck at a speed that enables you to stop it safely.

Stopping the truck

Brake the truck smoothly by turning the accelerator against the direction of travel (tiller arm in position 1).
You should anticipate a situation when you must brake and decrease the speed well ahead. When you release
the tiller arm to the up position or press it to the down position, the driving circuit breaks and the brake is engaged
(tiller arm in position 2).

Parking
Park the truck in a reserved parking place. When parking the truck, the forks must be lowered and the parking
brake must be on. Ensure that the truck cannot move by itself or that an inexperienced person cannot start driving
it under any circumstances.

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NOTE Never park or stack goods in front of fire doors, fire extinguishers, emergency exits and the
like. Do not park on a slanted surface.

Traffic rules
Maintain good visibility in the driving direction and keep sufficient safety distances. Follow the traffic regulations
and speed limits.
Do not drive the truck outside a private area without an order or permission from the site supervisor. Outside a
private area, the truck is subject to general traffic rules and regulations.
If a door opening is so narrow that two trucks cannot possibly pass through it at the same time, drive in the middle
of the opening. When two trucks meet in a narrow or cross aisle, the loaded truck has the right of way.
NOTE When driving, you should sound the horn when necessary to warn others in the same area.

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611290

6. Load handling
Only transport a load when it has been loaded safely.

• Always drive the truck with its forks lowered.

• When the load is raised, steer and brake carefully.
• Operate all hydraulic functions from the operator's position only. Operation outside of the operator's position
is prohibited.
• If the truck has side stabilizers, use them when loading and unloading. Raise them when driving.
• Do not let anyone, under any circumstances, walk or stand under the forks.
• Never place any part of your body between the mast structures or any moving parts of the truck.
• When carrying a load larger than the outlines of the truck, take into account the extra space it requires.
• Only handle undamaged loads.
• Place the load correctly.
• When driving the truck on slopes and ramps,
• Observe extreme caution.
• Keep the forks and load down.
• Drive straight with the load pointing uphill.
• Drive at a low speed and anticipate other traffic.
• Do not overload.

Lifting capacity
The lifting capacity of the truck is printed on the capacity plate. Obey the maximum values for load weight and
load center information in the different loading situations. Take into account the effect of any attachments on the
lifting capacity.
WARNING! Do not exceed the truck's maximum loading capacity under any circumstances.

Pallet handling (pallet trucks)

To load:

• Drive towards the pallet with the forks lowered.

• Move forward until the forks are completely under the pallet.
• Raise the pallet so that it is clearly above the floor level.

To unload:

• Stop the truck.

• Lower the forks so that they disengage.
• Reverse from the unloading location.

WARNING! Do not overload under any circumstances.

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Handling of broken pallets

WARNING! A broken pallet or an unstable load must never be left on a shelf or stack, but must always be
removed.

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611291

7. Batteries
Only appointed and trained personnel may replace and recharge batteries. Individuals maintaining batteries must
have sufficient protective clothing and eye gear. Battery charging and maintenance areas shall be arranged
according to the standard EN 50272-3 Safety requirements for secondary batteries and battery installations. Part
3: Traction batteries.
WARNING! During battery charging gases are evolved from all battery cells that are using aqueous
electrolytes. When emitted into the ambient atmosphere an explosive mixture may be created
if the hydrogen concentration exceeds 4 % hydrogen by volume in air (lower explosion limit).

• Do not handle a naked flame in the vicinity of batteries because of a risk of explosion.
• Do not smoke when working with batteries.
• Do not leave tools or other metal implements on top of the battery. Sparking or a short-circuit may cause the
battery to explode.
• When batteries are recharged, the cell plugs must be closed firmly to prevent splashing of battery fluid.
• Battery fluid is a corrosive acid solution; avoid getting it on your skin or in your eyes. The battery fluid develops
explosive gas at the end phase of recharging. Therefore, make sure that the battery has sufficient ventilation
(this does not apply to maintenance-free batteries).
• Always perform a complete battery charging, as repeated partial charging may reduce the battery life.

Opening and closing the battery cover

1. Unlock the battery cover by pushing the locking button (1). Leave the locking button open.
2. Open the battery cover (2).
3. Remove the recharging plug.
4. Perform the battery maintenance.
5. Fasten the recharging plug. Make sure that the battery cables remain completely safe within the frame of
the truck.
WARNING! Battery cables may get damaged and cause serious burning hazard if they are left outside of
the truck!
6. Close the battery cover. Make sure that the locking button returns all the way up to the locking position.

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WARNING! When closing the cover, do not leave your fingers under the cover! CRUSHING HAZARD!

Recharging the battery

Make sure that the charger is the appropriate model (correct battery type and voltage) and that the battery has
sufficient ventilation.

1. Park the truck in a reserved recharging place.

2. Switch off the power from the key switch.
3. Make sure that the charger has been switched off.
4. Open the battery cover. See instructions in section "Opening and closing the battery cover"
5. Disconnect the recharging plug, and connect it to the charger.
6. Switch on the charger.

After recharging
1. Switch off the charger.
2. Disconnect the recharging plug from the charger. Grab the handle; do not pull the cables.
3. Check the battery according to the battery manufacturer's maintenance instructions.
4. Fasten the recharging plug. Make sure that the battery cables remain completely safe within the frame of
the truck.
5. Close the battery cover.

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Battery charging with an inbuilt charger (optional)
You can access the mains plug (1) of the charger from the outside of the truck (2). Before charging, turn the key
switch off. To activate the charger, extract the mains plug and insert it into the correct mains outlet (230 V ±10%
/ 50 Hz). After activating the charger, charging process starts automatically.

The charging phase is indicated with two indicator lights - yellow (1) and green (2):

• Solid yellow: power on (3)

• Flashing yellow: a fault in the charging system (4)
• Flashing green: charging phase (5)
• Slowly flashing green: equalizing phase (6)
• Solid green: fully charged (7)

The charger will stop automatically after the charging is complete and you can unplug the mains plug and put it
back into the truck.
If there is a fault in the charging system, the charging process is stopped automatically. Unplug the mains plug
and contact maintenance personnel for assistance.

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NOTE While the plug is connected to the mains outlet, all electrical functions will remain switched off
and the truck cannot be used.
NOTE If the battery type is changed from lead-acid battery to maintenance-free battery (or vice versa),
remember to change the type setting of the battery charger accordingly (0: lead acid,
1:maintenance-free). The type selector can be found in the bottom of the inbuilt charger.
WARNING! No inflammable materials are allowed within two meters of the truck under charge or the
charger.

Measuring the battery's specific gravity

Measure the specific gravity of the battery fluid according to the manufacturer's instructions. The acid density of
a fully charged battery is 1.28 to 1.30 at +30°C. The gravity is

• 1.24 when the battery is 3/4 charged.

• 1.20 when the battery is 1/2 charged.
• 1.16 when the battery is 1/4 charged.
• 1.15 when the battery is empty. Charge the battery immediately.

Acquiring a new battery

When acquiring a battery for the truck,take the following sections of standard EN 1175-1 into consideration:

• 5.1 Traction battery (includes the requirements for the protective cover of the battery case, ventilation and
interior surface treatment)
• 7.4 Minimum marking (includes the requirements specified on the truck battery plate).

The battery plate should provide at least the following information:

• Manufacturer
• Type
• Serial number
• Nominal voltage
• Capacity (Ah / 5h)
• Service weight.

Replacing the battery

Replace the battery according to the manufacturer's instructions. When reinstalling batteries, use the appropriate
tools for moving, connecting and fastening the battery securely. Do not keep the tools or other metal implements
on top of uncovered batteries.
When replacing the battery, use one with similar dimensions and weight so that the stability or braking properties
of the truck do not decrease. The minimum weight of the battery is indicated on the identification plate of the
truck.
Make sure that the capacity of the lifting device is sufficient. When you use a lifting device for lifting the battery,
place a non-conductive plate on top of the battery to avoid the risk of a short circuit. This is not necessary if the

25
lifting device has sufficient insulation and is equipped with a distributor, or if the pole shoes and cell combinations
are fully protected.

1. Open the battery cover. See instructions in section "Opening and closing the battery cover".
2. Remove the recharging plug.
3. Open the locking device (1) with 13 mm socket wrench to release the latch.
4. Attach self-locking lifting hooks (size 5/6) to the lifting points (2).
5. Lift up the battery.
6. Insert a new battery (verify the battery type and voltage).
7. Attach the latch and close the locking device (1) with a socket wrench.
8. Fasten the recharging plug. Make sure that the battery cables remain completely safe within the frame of
the truck.
9. Close the battery cover.

Quick battery replacement (optional)

1. Open the battery cover. See instructions in section "Opening and closing the battery cover".
2. Remove the recharging plug.
3. Pull out the battery.
4. Insert a new battery (verify the battery type and voltage).
5. Fasten the recharging plug. Make sure that the battery cables remain completely safe within the frame of
the truck.
6. Close the battery cover. The cover acts as a battery locking device. Make sure that the locking button returns
all the way up to the locking position.

26
489465

8. Maintenance
Only adequately trained truck operators and servicepersons are allowed to carry out the daily and weekly check-up.
The terms of the warranty prescribe appropriate maintenance of the truck. All spare parts must be original ones.

Safety instructions for maintenance

• Keep the service area clean. Oil, grease, and water make the floor slippery.
• Remove all rings, watches and other metal jewellery. If a metal object gets into contact with an electrically
conductive part, a short-circuit or burn may result.
• Switch off the truck's power before opening the cover of the motor or the electrical system.
• Release the hydraulic pressure before opening the system.
• Dismount the seat for the duration of service work (applies only to sit-on trucks).
• Do not use your hands to check for oil leaks.
• Remember that the surfaces of the hydraulic system and the motors may be hot.
• Only use clean oil in the hydraulic system.
• When welding, always disconnect the battery and the electronic devices. Remove paint from a 10 cm radius
from the welding point to avoid creating toxic gases during welding.
• The truck must always be supported on jacks if someone needs to work underneath it.

WARNING! Do not make any alterations or repairs that can weaken the truck’s structure or endanger
safety.

Daily checks
• Check the truck externally to see that there are no oil leaks.
• Check all wheels for damage or wear.
• Check the battery fluid in each battery cell. Top up with battery water if needed. The fluid surface should be
about 15 mm above the plates. (Does not apply to maintenance-free batteries.)
• Check the gearbox for leaks. Also check the hydraulic pipes, hoses and connectors. No leaks or damage
should be found.
• Switch on the power and test the operation of the lifting hydraulics by raising and lowering the forks.
• Check the operation of the accelerator and steering by driving slowly forward and backward.
• Check also the operation of the other electrical functions.
• Check that the batteries are charged and locked in place.
• Check the operation of the horn.
• Check that the emergency stop operates properly.
• Check that the safety button works.
• Make sure that the tiller arm returns to the up position.
• Check that the service brake and the parking brake functions properly.
• Check the fastenings of the lifting chain (if available).

Weekly maintenance
• Check and clean the battery cable fastenings.
• Ensure that the air holes of the battery cell plugs are not plugged up (does not apply to maintenance-free
batteries).
• Clean the batteries with a dry rag.
• Check that the hydraulic system has no leaks.
• Check the hydraulic oil level in the oil tank. Add if necessary.
• Check that all the screws, nuts, and pipe connections are tight.
• Check that the fastening bolts of the driving wheel are tight.

27
• Check that the information plates and labels are fastened securely and are fully legible.
• Clean the truck if necessary.
• Check the length of the lifting chains. When the carriages are level with the mast, the chains should be slightly
loose. Adjust if necessary. (Does not apply to pallet trucks.)
• Apply a thin layer of lubrication on the mast's guide surfaces.

NOTE Do not let water onto the electrical devices.

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611292

9. Service
Only adequately trained servicepersons are allowed to carry out service operations. The terms of the warranty
prescribe appropriate maintenance of the truck. All spare parts must be original ones.
It is recommended that you sign a maintenance agreement with the truck dealer, who can also supply spare
parts. Only professional service ensures long-term, trouble-free truck operation. Service program monitoring
becomes easier if you enter the service dates in a service logbook. Contact our service organisation or your truck
dealer for qualified, authorized and efficient maintenance service.

Opening the covers

Open the mounting screws (1) to remove the covers.

Semi-annual inspection service (or 600 h)

Check and, if necessary, adjust or repair:

• Connections of the drive motor and pump motor.

• Operation of the accelerator.
• Operation of the microswitches or inductive sensors.
• Operation of the contactors and solenoids.
• Cables.
• Tiller arm gas spring.

29
• Function of the lift cylinder.
• Play of the fork carriage, and the slope of the forks and their condition.
• Air gap in the brake: 0.2 mm when new, maximum gap 0.6 mm.
• Clean the truck of dirt and debris inside and outside.

Annual maintenance (or 1200 h)

• Change the hydraulic oil.

Hydraulic oil recommendations:

• Normal operating conditions: ISO VG 32.

• Cold storage: ISO VG 15.
• Hot temperatures: ISO VG 46.
• Fill tank up to the volume of ¾.

Filling hole for hydraulic oil (1)

Transmission lubricant recommendation

• None.

NOTE There is no need to change the lubricant during the truck's lifetime.

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Additional maintenance work for service personnel
• Clean the hydraulic oil filter.
• Check the operation of the hydraulics and the pressure relief valves.
• Check the fastening of the gearbox.
• Check the fastening of the tiller arm.
• Check the condition of the side castor wheels and load wheels.
• Check the wear of the drive wheel:
• Drive wheel diameter is 230 mm when new
• Drive wheel has to be replaced when its diameter is 218 mm.

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Fuses

1F1 10A Line contactor fuse (2)

3F1 10A Control circuit fuse (2)
4F1 10A Optional (2)
5F1 300A Drive/pump motor fuse (1)

7F1 10A Working lights (optional)

NOTE The tightening momentum of the fuse (1) terminals is 4.5 ±1 Nm.

Ordering spare parts

When ordering spare parts, always contact your dealer or the maintenance centre. Only use original spare parts.
To ensure that you receive the correct parts, include the following information in the order:

1. Truck type
2. Serial number of the truck
3. Order number of the part
4. Name of the part
5. Number of parts ordered.

The truck's type and serial number are listed on the front page of the manual or on the identification plate of the
truck. The order number and name of the parts are listed on the spare part pages of the manual supplied with
the truck.

Hazardous waste and disposal

Hydraulic and transmission oil, as well as batteries are hazardous waste that must be disposed of accordingly.
The truck itself is not hazardous waste, and can be recycled.

32
489467

10. Transportation and storage

Transportation
Lifting the truck.

The truck can only be lifted from a marked position. Make sure that the capacity of the lifting device is sufficient.
NOTE If the truck has more than one lifting position, all of the positions must be used during lifting
the truck.
Towing the truck. The truck can only be towed with its drive wheel raised from the floor.

Storage
If the truck is not used for a lengthy period of time, it should be stored in a cool (above 0°C) and dry place on an
even surface. Before storage, complete the following:

• Charge the battery well, and recharge it every 2 or 3 months to prevent damage during storage. At the same
time, check the fluid level and add more if necessary.
• Change the hydraulic oil if the machine is not used for more than a year.
• If the machine is not used for more than a week, support the truck in such a way that the load exerted on the
drive wheel becomes lighter.

Returning the truck to operation. If the truck has been stored for several months, it must undergo maintenance
as per 600 operational hours. Otherwise normal daily maintenance and inspection are sufficient.

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492501

11. Troubleshooting and alarms

Troubleshooting

Symptom Fault Action

Truck does not move Recharging plug is unplugged. Plug in the recharging plug.

Battery is empty. Recharge the battery.

Incorrect start. Release the tiller arm and recycle the key
switch.

Emergency stop button is activated. Release the emergency stop button.

Key switch is faulty. Replace the switch.

Contact maintenance personnel.

Drive motor fuse has blown. Check the connections and cables and
replace the fuse.
Contact maintenance personnel.

Control circuit fuse has blown. Check the connections and cables and
replace the fuse.
Contact maintenance personnel.

Accelerator is faulty. Contact maintenance personnel.

Lift pump does not run Pump motor fuse has blown. Check the connections and cables and
replace the fuse.
Contact maintenance personnel.

Load handling switch is faulty. Replace the switch.

Contact maintenance personnel.

Control unit is faulty. Contact maintenance personnel.

Lifting functions improperly Overload. Reduce the load.

Battery is empty. Recharge the battery.

Not enough oil in tank. Add oil.

Oil leak. Check the joints and seals.

Contact maintenance personnel.

Pump is faulty. Contact maintenance personnel.

Dirt or wear in valves. Contact maintenance personnel.

Battery does not charge Charger is incorrectly connected. Check the connection.

Charger fuse has blown or main Check the connections and cables and
voltage is missing. replace the fuse.
Contact maintenance personnel

Battery cell’s water level or specific Check the cell voltages and specific
gravity is low. gravity. Add water and/or acid when
necessary. See section "Recharging the
Battery" in chapter 7.

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611293

12. Technical specifications

1 IDENTIFICATION

1.2 Model 1600 1800 2000 2000/700

1.3 Power source Battery Battery Battery Battery

1.4 Operating mode Pedestrian Pedestrian Pedestrian Pedestrian

1.5 Nominal capacity/load Q [kg] 1600 1800 2000 2000/700

1.6 Load center (COG) c [mm] 600 600 600 600

1.8 Load wheel axle to fork face x [mm] 960 960 960 892
(forks lowered)

1.9 Wheelbase (forks lowered) y [mm] 1360 1424 1424** 1424

2 WEIGHTS

2.1 Truck weight (without load/with [kg] 431 502 502 -

battery)(see 6.5)

2.2 Axle loadings (with nominal load [kg] 635/1396 806/1496 842/1660 -
and battery), drive/load side

2.3 Axle loadings (without load/with [kg] 332/99 381/121 381/121 -

battery), drive/load side

3 WHEELS AND TYRES

3.1 Tyres, material Vul/Vul Vul/Vul Vul/Vul Vul/Vul

(R=rubber/Vul=Vulkollan)
drive/load side

3.2 Load wheel dimensions [mm] 85x90 85x75 85x75 85x75

3.3 Drive wheel dimensions [mm] 230x70 230x70 230x70 230x70

3.4 Castor wheel dimensions [mm] 100x40 100x40 100x40 100x40

3.5 Number of the wheels (x=driven) 2/1x+2 4/1x+2 4/1x+2 4/1x+2

drive/load side

3.6 Track width (centre of tyres), b10 480 480 480 480
load side [mm]

3.7 Track width (centre of tyres), b11 375 375 375 375
drive side [mm]

4 DIMENSIONS

4.4 Lift h3 135 135 135 135/715

[mm]

4.8 Platform height [mm] - - - -

4.9 Height of the tiller arm in travel h14 1050/1372 1050/1372 1050/1372 1050/1372
position (min./max.) [mm]

4.15 Fork height, fully lowered h13 85 85 85 85

[mm]

4.19 Overall length l1 [mm] 1648 1712 1712** 1780

35
4.20 Length to face of forks l2 [mm] 498 562 562** 630

4.21 Chassis (overall width) b1/b2 720 720 720 720

[mm]

4.22 Fork dimensions s/e/l 50/165/1150 50/165/1150 50/165/1150 59/184/1150

(thickness/width/length) [mm]

4.25 Outside width over forks b5 540 540 540 540

[mm]

4.32 Ground clearance, center of m2 30 30 30 30

wheelbase (forks lowered) [mm]

4.33 Working aisle width Ast, pallet Ast 1694 1758 1758 1826
1000x1200, load crosswise [mm]

4.34 Working aisle width Ast, pallet Ast 1894 1958 1958 2026
800x1200, load lengthwise [mm]

4.35 Turning radius (forks lowered) Wa 1454 1518 1518 1518

[mm]

5 PERFORMANCE

5.1 Travel speed, laden/unladen [km/h] 6.0/6.0 6.0/6.0 6.0/6.0 6.0/6.0

5.2 Lifting speed, laden/unladen [m/s] 0.034/0.043 0.034/0.043 0.039/0.06 -

5.3 Lowering speed, laden/unladen [m/s] 0.099/0.076 0.099/0.076 0.099/0.078 -

5.7 Gradeability, laden/unladen [%] 10.0/20.0 10.0/20.0 10.0/20.0 10.0/20.0

5.10 Service brake Electrical Electrical Electrical Electrical

6 MOTORS

6.1 Drive motor S2 60 min [kW] 1.0 1.0 1.0 1.0

6.2 Lift motor S3 15% [kW] 0.8 0.8 1.2 1.2

6.4 Battery voltage/capacity/ 5 h [V/Ah] 24/150 24/250 24/250 24/150

6.5 Battery weight [kg] 151 212 212 151

8 MISCELLANEOUS

8.1 Speed control type Stepless Stepless Stepless Stepless

8.4*) Level of noise at the ear level of [dB (A)] 55 55 64 -

the driver according to EN 12
053:2001 and EN ISO 4871 in
work LpA

Level of noise at the ear level of [dB (A)] 64/63/0 64/63/0 64/76/0 -
the driver according to EN 12
053:2001 and EN ISO 4871,
drive/lift/idle LpA
2
Whole body vibration according [m/s ] - - - -
to EN 13 059:2002
2
Hand-arm vibration according to [m/s ] < 2.5 < 2.5 < 2.5 < 2.5
EN 059:2002

36
* Uncertainty of 4 dB(A) in section 8.4.
**Quick battery replacement option increases the dimension 72 mm.

Manufacturer reserves the right to make technical changes.

37
Model 1600

Fork width Fork length

b5 [mm] l [mm]

520 1150
540 1150
660 1000
Options Options
min. 480 min. 1000
max. 660 max. 2350

Working aisle width (mm)

Pallet size Handling AST

800x1200 Lengthwise 1894

1000x1200 Crosswise 1694

38
Model 1800

Fork width Fork length

b5 [mm] l [mm]

520 1150
540 1150
660 1000
Options Options
min. 480 min. 1000
max. 660 max. 2350

Working aisle width (mm)

Pallet size Handling AST 3

800x1200 Lengthwise 1958

1000x1200 Crosswise 1758

39
Model 2000

Fork width Fork length

b5 [mm] l [mm]

520 1150
540 1150
660 1000
Options Options
min. 480 min. 1000
max. 660 max. 2350

Working aisle width (mm)

Pallet size Handling AST 3

800x1200 Lengthwise 1958

1000x1200 Crosswise 1758

40
Model 2000/700

Fork width Fork l length

b5 [mm] l [mm]

540 1150

Working aisle width (mm)

Pallet size Handling AST 3

800x1200 Lengthwise 2026

1000x1200 Crosswise 1826

41
42
611294

13. EC Declaration Of Conformity

(Directive 2006/42/EC, Annex II A)

Rocla Oy declares that this machine; which has been launched onto the market, meets the requirements set to
this machine in the Directive on the Approximation of the laws of the Member States Relating to Machinery
(2006/42/EC) and EMC Directive (2004/108/EC); and furthermore declares that the following harmonized standards
have been followed:

• EN ISO 3691-1 - Industrial trucks - Safety requirements and verification.

• EN 12895 Industrial trucks - Electromagnetic compatibility.

For the name and address of the person authorized to compile the technical file, see the end of this document.

2011-08-26 Järvenpää, Finland

Tapio Rummukainen
Acting Managing Director

Technical Information:
ROCLA OY / Henry Tekoniemi
P.O. Box 88
FIN-04401 JÄRVENPÄÄ
FINLAND

43