Operator’s Manual

Electric Pallet Truck

2TWB40

WARNING
Do not use the pallet truck before reading and
understanding these operating instructions.
NOTE:

• Keep this book in the manual holder of

the truck for operator reference.
Version 2/2022

2TWB40-SMS-001-EN
This page is intentionally left blank
FOREWORD
Before operating the truck, read this ORIGINAL OPERATORS MANUAL carefully and
understand the usage of the truck completely. Improper operation could be hazardous.
Operating this truck requires knowledge which can be acquired from this instruction handbook,
along with proper training. This handbook must be kept available throughout the entire period of use
of the industrial truck.

YOU MUST BE TRAINED AND CERTIFIED TO OPERATE THIS TRUCK! READ AND OBEY ALL
WARNINGS AND INSTRUCTIONS IN THIS MANUAL AND ON THE TRUCK!

Only properly trained and authorized operators are allowed to operate a powered industrial truck.
Your employer must train you and certify that you are qualified to operate this truck in the specific
environment in which the truck will operate. This is required by ANSI-ITSDF B56.1 and OSHA 29
CFR 1910.178. The training must satisfy ANSI and OSHA requirements which includes reading and
understanding the instructions and warnings in this manual. According to ANSI-ITSDF B56.1, safe
operation is the responsibility of the operator. You and others can be seriously injured or even killed
if you don’t use this truck correctly. Before operating your truck, inspect your truck and ensure that it
is in correct working order. This truck was designed and built to industry and government standards
in effect at the time of manufacture. For more information see following:
- ANSI / ITSDF B56.1: “Safety Standard for Low Lift and High Lift Trucks” (Safety Code or Powered
Industrial Trucks). Published by: Industrial Truck Standards Development Foundation, 1750 K Street
NW, Suite 460, Washington DC 20009.
- OSHA 1910.178: “OSHA Safety and Health Standards (29 CFR 1910)”, ”Subpart N-Materials
Handling and Storage”, Section 1910.178 ”Powered Industrial Truck”. Available online at
www.osha.gov
- UL 583 (Underwriters Laboratory)
- ANSI Z535.4 (American National Standards Institute)
- NFPA 505: “Fire Safety Standard for Powered Industrial Trucks; Type Designations, Areas of Use,
Maintenance and Operation”.
- Accident Prevention Manual for Industrial Operations: Two volumes:
“Administration and Programs”, and “Engineering and Technology”, Available from:
National Safety Council, 444 North Michigan Avenue, Chicago, IL 60611.

This sign indicates hazard situations, if not avoided, will result in serious injury
or death. The instructions or precautions to this message must be observed to avoid the potential
risk of injury or death.

If not followed, warning indicates hazard situations which may lead to serious
injury or death. The instructions or precautions to this message must be observed to avoid the
potential risk of injury or death.

1
 If not followed, caution indicated situations which may lead to minor or moderate
injury or property damage. Instructions or precautions must be observed to avoid injury or property
damage.

Recycling and Discarding:

• To avoid damage to the environment, do not dispose of hazardous items such as used oil, batteries,
filters, tires, etc. yourself. These items must be stored properly in a safe location to prevent fire and
to prevent harm to the environment. Dispose of such waste products in accordance with your local
laws and regulations, or contact your dealer or a hazardous waste expert.

• As part of the daily pre- operation inspection, check around the truck to ensure that there is no oil or
fluid leaks. Leaking fluid will pollute the environment and may indicate a problem with the truck.
Make sure to have proper materials on hand for cleanup of any spills that may occur and follow their
directions for disposal.

• Your truck is built with parts that contain recyclable materials. Make sure that those materials are
appropriately recycled when the entire truck or components are to be disposed of.

Copyright

The copyright remains with the manufacturer mentioned on the dataplate. Products and specifications
may be subject to change. This handbook is for the purpose of operating /servicing the pallet truck and
may describe features that may not be included on the model you purchased.

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TABLE OF CONTENTS

1. CORRECT APPLICATION ................................................................................................................4

2. DESCRIPTION OF THE PALLET TRUCK ........................................................................................5
a. Overview of the main components ................................................................................................5
b. Technical specifications .................................................................................................................6
c. Description of warning labels ........................................................................................................8
d. Dataplate / nameplate ...................................................................................................................9
3. WARNINGS AND SAFETY INSTRUCTIONS ...................................................................................9
4. INSTALLATION, TRANSPORTING, LONG TERM STORAGE ....................................................... 11
a. Installation ................................................................................................................................... 11
b. Lifting/ transportation ................................................................................................................... 11
c. Long Term Storage/ Scrapping ....................................................................................................12
5. DAILY INSPECTION .......................................................................................................................12
6. OPERATING INSTRUCTIONS .......................................................................................................12
a. Parking .......................................................................................................................................12
b. Lifting..........................................................................................................................................13
c. Lowering......................................................................................................................................13
d. Travelling .....................................................................................................................................13
e. Steering .......................................................................................................................................14
f. Braking ........................................................................................................................................14
g. Malfunctions ................................................................................................................................14
h. Emergency ..................................................................................................................................14
7. BATTERY CHARGING AND REPLACEMENT ...............................................................................15
a. Replacement ...............................................................................................................................15
b. Battery indicator ..........................................................................................................................16
c. Charging.....................................................................................................................................16
8. REGULAR MAINTENANCE ...........................................................................................................17
a. Maintenance checklist .................................................................................................................17
b. Lubricating points ........................................................................................................................19
c. Check and refill hydraulic oil........................................................................................................19
d. Checking electrical fuses ............................................................................................................19
9. TROUBLESHOOTING ....................................................................................................................20
10. WIRING/ CIRCUIT DIAGRAM ........................................................................................................21
a. Electrical circuit diagram .............................................................................................................21
b. Hydraulic circuit ...........................................................................................................................22
11. DECAL DETAILS: ...........................................................................................................................23

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 1. CORRECT APPLICATION
Before operating this pallet truck, truck operators must read,be familiar with, and abide by the rules and
practices in this Operator’s Manual, know and follow the ANSI-ITSDF B56.1 standard and OSHA
regulations, and also know and follow the safety rules at the location where the truck is being operated.

The trucks described in this handbook are self-propelled electric power pallet trucks, with electrically
powered low height lifting function. The trucks are designed to lift, lower and transport palletized loads.

Incorrect usage can cause bodily injury or can damage equipment or property.

The operator and user are required to ensure the correct usage of this pallet truck and that this pallet
truck is operated only by staff who is trained, authorized, and certified to use this truck.

The pallet truck has to be used on substantially firm, smooth, prepared, level and adequate surfaces.
The truck is intended to be used for indoor applications with ambient temperatures between +41°F/ +5°C
and +104°F/+40°C and for various transportation applications without crossing permanent obstacles,
potholes, or debris. Operating on ramps exceeding values given in the truck specifications is not allowed.
While operating, the load must be placed approximately on the longitudinal load center of the truck.

Lifting or transporting people is forbidden. This includes the operator riding on the truck.

If used on tail lifts or dock plates, please follow the operating instructions and the rules as outlined in
ANSI-ITSDF B56.1 for that type of equipment.

The load handling capacity is marked on the capacity sticker as well as on the dataplate. The operator
must follow the warnings and safety instructions on the truck.

Operating environment lighting levels must be a minimum of 50 Lux.

Modification:
Per ANSI-ITSDF B56.1 and OSHA, no modifications or alterations that affect the capacity, safety, or
stability of this pallet truck shall be made without the prior written approval of the original truck
manufacturer. This includes changes affecting items such as braking, steering, electrical, visibility and
the addition of removable attachments. Changes to the dataplate, decals, tags, and operation and
maintenance handbooks may be necessary.

By not observing these instructions, the warranty may become void and possible OSHA violations may
occur.

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 2. DESCRIPTION OF THE PALLET TRUCK
a. Overview of the main components

Fig. 1: Overview main components: 2TWB40

1. Electrical box cover

2. Battery discharge indicator
3. Tiller
4. Accelerator
5. Auto-reversing (belly) button
6. Instrument board cover
7. Emergency button
8. Key switch
9. Fork chassis
10. Load wheels
11. Drive wheel
12. Hydraulic cylinder

The truck is equipped with an Emergency button (7) which stops all lifting-, lowering-, driving- functions
and engages the electromagnetic brake when it is pushed. To release, pull the Emergency button (7) up,
allow the controller to complete start up, and the truck can be operated.

The truck is equipped with an Auto-reversing (belly) button (5) which switches the driving function away
from the operator if the tiller contacts the operator while the tiller is in the operating zone. Follow the
instructions given on the decals for additional functions.

5
b. Technical specifications

Fig. 2: Technical specifications

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Table 1: Technical specifications
Technical Specifications
1.2 Manufacturer`s type designation 2TWB40
Distinguishing mark

1.3 Power Type Battery

1.4 Operator type Pedestrian
1.5 Load Capacity / rated load Q (t/ lb) 1.8 / 4000
1.6 Load center distance c (mm/ in) 600 / 24
1.8 Load distance, center of drive axle to fork X (mm / in) 932 / 36.71)
1.9 Wheelbase y (mm / in) 1295 / 51.01)
2.1 Service weight kg / lb 415 / 915
Weight

2.2 Axle loading, loaded front/rear kg / lb 785/1430 / 1730/3153

2.3 Axle loading, unloaded front/ rear kg / lb 335/80 / 739/176
3.1 Tires Polyurethane (PU)
3.2 Tire size, front (drive) ∅ x w (mm / in) 210x70 / 8.3x2.8
Tires, chassis

3.3 Tire size, rear (load) ∅ x w (mm / in) 74x100 / 2.9x3.9

3.4 Additional wheels (dimensions) ∅ x w (mm) N/A
3.5 Wheels, number front (drive) / rear (load) 1/2
3.6 Tread, front b 10 (mm / in) 560 / 22.0
3.7 Tread, rear b 11 (mm / in) 525 / 20.7
4.4 Lift height h 3 (mm / in) 120 / 4.7
4.9 Height of tiller in drive position min. / max. h 14 (mm / in) 770/1230 / 30.3/48.5
4.15 Height, lowered h 13 (mm / in) 75 / 2.96
4.19 Overall length l 1 (mm / in) 1720 / 67.8
Dimensions

4.20 Length to face of forks l 2 (mm / in) 570 / 22.5

4.21 Overall width b 1 (mm / in) 729 / 28.7
4.22 Fork dimensions s/e/l (mm / in) 50/160/1150 / 1.97/6.3/45.3
4.25 Distance between fork-arms b 5 (mm /in) 685 / 27
4.32 Ground clearance, center of wheelbase m 2 (mm / in) 25 / 1
4.34 Aisle width for pallets 1000X1200 (40 x 48) Ast (mm / in) 2240 / 88.3
4.35 Turning radius Wa (mm / in) 1495 / 58.91)
5.1 Travel speed, loaded/ unloaded km/h / mph 5.0/5.2 / 3.1/3.2
Performance

5.2 Lift speed, loaded/ unloaded m/s / fpm 0.025/0.030 / 4.3/5.9

5.3 Lowering speed, loaded / unloaded m/s / fpm 0.030/0.025 / 5.9/4.5
5.8 Gradeability, loaded/ unloaded % 8/12
5.10 Service brake Electromagnetic
6.1 Drive motor rating S2 60min kW / HP 0.75 /1
6.2 Lift motor rating at S3 10% kW / HP 0.8 / 1.1
Motors

6.3 Battery acc. to DIN 43531 /35 / 36 A, B, C, no /

6.4 Battery voltage, nominal capacity K5 V/Ah 24/160
6.5 Battery weight (minimum) kg/ lb 145 / 320
6.6 Energy consumption acc. to VDI cycle KWh/h 0.30
8.1 Type of drive control AC -Speed Control
8.4 Sound level at driver`s ear acc. to EN 12053 dB(A) 69
1.2 Manufacturer`s type designation
1） Load section lowered:+62mm / 2.5 in.

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c. Description of warning labels
Fig. 3: Warning labels

A Read and follow this instruction I Danger- Battery

D Hook mark J Danger- No riding
F Oil filling point K Warning- Electrical devices
G Warning- Proper operation L Dataplate / Name plate
H Caution- Charging
M Capacity sticker

Follow the instructions given on the decals. Replace the decals if they are damaged or missing. See
Section 11 for decal text / details.

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d. Dataplate / nameplate

Fig.4: Dataplate Example

1 Model 8 Battery hour rate

2 Serial number 9 Battery model
3 System voltage 10 Battery manufacturer
4 Truck weight with battery 11 Battery weight
5 Truck weight without battery 12 Max. battery capacity
6 Manufacturing date 13 Option
7 Load center distance

3. WARNINGS AND SAFETY INSTRUCTIONS

DO NOT:
• Put any part of your body, including your hand or foot, under or into the lifting
mechanism.
• Allow anyone other than the operator to stand in front of or behind the truck when it
is moving or lifting/lowering.
• Overload the truck.
• Put your foot in front of the wheels. Injury could result.
• Lift or transport people.
• Push or pull loads.
• Unload or load the truck on ramps.
• Load only on one side of the forks or only on the end of the forks. The load must be
distributed evenly on both forks.
• Use the truck with loose, unstable, and/or unbalanced loads.
• Use the truck in a manner not approved in this manual or by the manufacturer.
• Lift the load if the wind force may affect the stability of the load. Lifted loads could
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 become unstable when high wind forces are present.

Watch the difference in floor levels when operating. The load could fall or you could lose control of the
truck. Keep watching the condition of the load. Stop operating the truck if the load becomes unstable. If
the load is sliding off of the truck, brake the truck and activate the emergency button (7).

If the truck malfunctions, follow the instructions in chapter 6. Perform the daily inspection as per chapter
5 and maintenance work according to the schedule in chapter 8. This truck is not designed to be water
resistant. Use the truck under dry conditions only.

Prolonged, continuous operation might cause damage due to high temperatures. Stop operation if the
temperature of the power pack or hydraulic oil is too high.

• When operating the pallet truck, the operator is required to wear safety shoes.
• The truck is intended to be used for indoor applications with ambient temperatures
between +41°F/5°C and +104°F/40°C.
• The operating area lighting must be minimum of 50 Lux.
• Operation of the truck on ramps is not allowed.
• To prevent unintended operation, switch off the truck when it is not attended.
(Unattended: Truck is out of operator line of sight, or operator is more than 25 ft. / 8
m away from the truck).

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 4. INSTALLATION, TRANSPORTING, LONG TERM STORAGE
a. Installation
Table 2: Installation data
Type 2TWB40
Installation weight [lb/kg] 915 /415
67.8x28.7x52.6/
Dimensions [in/mm]
1720x729x1335

After receiving your new pallet truck, or for re-installing after storage, perform the following steps before
operating the truck:
• Check if all parts are included and not damaged.
• Make sure the tiller is assembled correctly (electric socket is
connected and fixed, circlip of the axle is installed.
• Check that the batteries are charged as per chapter 7.
• Perform the daily inspection in chapter 5 and maintenance check
found in chapter 8.

b. Lifting/ transportation
For lifting or transporting, remove the load, lower the forks to the
lowest position and secure the truck with dedicated lifting /strapping
gear according to the following figures.
Fig. 5: Lifting with a crane
Lifting

USE DEDICATED CRANE AND LIFTING EQUIPMENT

DO NOT STAND UNDER THE TRUCK WHEN LIFTED.
DO NOT WALK INTO THE LIFTING ZONE; HAZARD
AREA DURING LIFTING.

Park the truck and secure the truck according to the points
identified in fig. 5. Lift the truck to its designated location and
make sure the truck is on stable ground before removing the
lifting gear. Fig. 6: Fixing points

Transportation

DURING TRANSPORTATION ON A VEHCILE / TRAILER ALWAYS FASTEN THE

TRUCK SECURELY

Lower the forks and park the truck. Fasten the truck according to fig. 6 by securing tie down straps /

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 chains to each side of the crane hook holes and fasten the other side to the transporting vehicle /
trailer.

c. Long Term Storage/ Scrapping

For storage, remove the load, lower the truck to the lowest position, grease all fittings as listed in chapter
8, and protect the truck against corrosion and dust. Remove the batteries and place the truck on blocks
to keep the wheels from flat spotting during storage.

For scrapping at the end of the truck’s useful life, contact your local dealer or a designated recycling
company. Oil, batteries and electric components must be recycled as per federal and local regulations.

5. DAILY INSPECTION
At the beginning of each shift and before operating the truck, check it’s condition, giving special attention
to the following:

Remove any load from the truck and lower the forks.

DO NOT USE THE TRUCK IF ANY MALFUNCTION IS FOUND.

• Check for scratches, deformation or cracks.
• Check if there is any oil leakage from the cylinder.
• Check the vertical creep (downward drift) of the forks.
• Check the smooth movement of the wheels.
• Check the function of the emergency brake by activating the emergency button.
• Check, the tiller arm auto reversing switch and auto braking functions.
• Check the lifting and lowering functions by operating the buttons.
• Check if all bolts and nuts are tightened firmly.
• Visual check if there are any broken hoses or broken electric wires.

6. OPERATING INSTRUCTIONS
BEFORE OPERATING THIS TRUCK, PLEASE
FOLLOW THE WARNINGS AND SAFETY
INSTRUCTIONS (CHAPTER 3).

Make sure, that the load is palletized and stable and that the daily
inspection is carried out.
Insert the key into the key switch (8) and turn the truck on. Press
the horn button (14) to verify operation.

a. Parking
DO NOT PARK THE TRUCK ON INCLINED
SURFACES Fig.7: Operating controls

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 The truck is equipped with an automatic electromagnetic parking brake that automatically sets if the
power is off or the battery is disconnected. Always lower the forks fully before shutting the truck off.
Turn the key switch (8) to off and press the emergency switch (7) to shut off all power to the truck.

b. Lifting
DO NOT OVERLOAD THE TRUCK! THE MAXIMUM CAPACITY IS 4000 lbs. /1800kg.

Only travel with the forks fully supporting the pallet. Enter
with the truck in the lowered position and press the lifting
button (14) until you reached the desired lifting height.

c. Lowering
Come to a stop and press the lowering button (15) carefully.
Lower the load until the forks are clear of the pallet, then
drive the truck carefully out of the pallet.
Fig. 8: Load facing uphill

d. Travelling
TRAVEL ON INCLINES ONLY WITH THE LOAD FACING UPHILL.
DO NOT TRAVEL ON INCLINES MORE THAN THE MAXIMUM SLOPE SPECIFIED
WITH THE TECHNICAL DATA. (8% loaded/ 12% unloaded)

After starting the truck by turning on the key switch (8), move the tiller to the operating zone (‘F’,
fig.9).
Turn the accelerator knob (4) to the desired direction forward ‘Fw.’ or backwards ‘“Bw.’ (fig. 9).

Fig. 9: Operating direction

Control the travelling speed by moving the accelerator knob (4) carefully until you reached the
desired speed. If you move / release the accelerator knob back to the neutral position, the controller
decelerates the truck until the truck stops. When the truck comes to a complete stop, the parking
brake will automatically be engaged. Drive the truck carefully to the destination. Watch the route
conditions and adjust the travelling speed with the accelerator knob to allow safe operation.

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 Turtle Speed operation: Press the button (16) to enter into turtle (slow) speed mode. The button will
light up and will allow the truck to remain in low speed mode until the button is pushed again to
release turtle mode. Use of the turtle speed is recommended when operating in confined /
congested areas or when pivoting a load inside a trailer.

e. Steering
Steer the truck by moving the tiller to the left or right side. Steering effort will decrease when the
truck is moving.

f. Braking
THE BRAKING PERFORMANCE DEPENDS ON THE SURFACE CONDITIONS AND
TIRE LOAD CONDITONS OF THE TRUCK.

The braking function can be activated in several ways:

• By moving the accelerator knob (4) back to the initial ‘0’ position or by releasing the knob, the
regenerative braking is activated. The truck will brake until it comes to a stop.
• By moving the accelerator knob (4) from one driving direction directly to the opposite direction,
the regenerative braking will function until it starts travelling in the opposite direction.
• The truck will brake if the tiller is moved up or down into the braking zones (‘B’). If the tiller is
released, the tiller moves automatically up to the upper braking zone (‘B’). The truck brakes until
it stops.
• The auto reversing (belly) button (1) helps prevent the operator from being crushed. If this
button is activated, the truck decelerates and/or starts travelling in the backwards direction (‘Bw.’)
for a short distance and stops. Be aware that this function will activate if the operator contacts
the switch at any time the tiller is in the operating zone, including if the truck is not moving.

g. Malfunctions
If there is a malfunction or the truck is inoperative, park the truck in a safe area if possible, stop
using the truck and activate the emergency button (7) by pushing it. Turn the keyswitch to off and
remove the key (8). Immediately inform your manager and/or call your service provider, and follow
your lock out/ tag out procedures. If necessary, remove the truck out of the operating area by using
dedicated towing/ lifting equipment.

h. Emergency
In case of emergency or in the event of tip over or off dock incident, immediately keep a safe
distance from the equipment and report the situation to your manager. If safe to do so, push the
emergency button (7). All electrical functions will be stopped.

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7. BATTERY CHARGING AND REPLACEMENT
• Only qualified personnel are allowed to service or charge the batteries. The instructions of this
handbook and any supplied by from the battery manufacturer must be observed.
• The batteries are sealed, maintenance-free type liquid-acid traction batteries. Battery re-filling
is prohibited.
• Please follow federal and local regulations regarding recycling of batteries when it is time to
dispose of the battery.
• Flames and/or open fires around batteries is prohibited. Gasses released during charging could
cause an explosion!
• In the battery charging area, flammable materials are not allowed. Smoking is prohibited and
the area must be ventilated.
• Park the truck before starting charging or installing/changing the batteries
• Before finishing any maintenance work, make sure that all battery cables are connected
properly and that they are not contacting other components of the truck.

The truck is equipped with following sealed liquid-acid traction battery type as standard:
2pcs 12 V/ 160 Ah (C5) Wt. Each: 115lbs / 52KG +/- 5%

ONLY USE SEALED LIQUID-ACID BATTERIES WITH THE BATTERY WEIGHT AS

SPECIFIED ON THE DATAPLATE. USING THE INCORRECT BATTERY WEIGHT
WILL AFFECT THE CAPACITY AND STABILITY OF THE TRUCK.

ONLY OPERATE THE TRUCK WITHIN THE BATTERY

TEMPATURE OPERATING RANGE.

a. Replacement
Park the truck securely and switch off the truck with the key switch
(8), and push the emergency button (7). Open the battery cover,
disconnect the battery plug (17), then lift the battery out with a
crane.

Fig. 10: Battery removal

Unbolt the six screws (18) on the main cover and remove the cover (19).
Unbolt and remove the negative terminals (indicated with ‘-‘) first, then unbolt and remove the
positive terminals (indicated with ‘+’) and put the cables aside. Then take out the batteries with the
upper battery first.

The battery installation and cable hook-up is in the reverse order

of removal.
CONNECT THE POSITIVE TERMINALS FIRST,
OTHERWISE THE TRUCK ELECTRONICS COULD BE
DAMAGED.

15 Fig. 11: Battery replacement

b. Battery indicator
Discharge status is indicated by ten red LED segments.

Battery Discharged Battery charged

Fig.12: Battery discharge indicator

When the battery is fully charged, the LED segment at the 1 will be lit. As the battery’s
state-of-charge decreases, the LED segment will move left towards the 0 one segment at a
time. When nearing fully discharged the following will happen:
• At 70% depth of discharge, the 2nd from left LED flashes, indicating “energy reserve”.
• At 80% depth of discharge, the 2 left LEDs alternately flash, indicating “empty”. Charge the
battery as soon as possible.

OPERATION PAST THE 80% DEPTH OF DISCHARGE POINT CAN CAUSE THE
TRUCK TO LOOSE POWER AND SUDDENLY AND WITHOUT WARNING COME TO
AN ABRUPT STOP. PERMANENT DAMAGE TO THE BATTERIES MAY OCCUR.

Fig.13: Charging Cord

c. Charging
ONLY USE THE SUPPLIED CHARGER FOR
CHARING THE BATTERY!
• Before using the charger, please fully understand and
follow the charger instructions.
• The charging room must be properly ventilated.
• The charge status can be only checked from the
battery discharge indicator. To check the state of
charge, the charging cycle must be interrupted and Fig.13: Battery charging
the truck must be turned on.

To start charging, park the truck at a dedicated, secured

area with a dedicated wall outlet. Lower the forks and remove the load. Switch the truck keyswitch
off and connect the charger power plug (21) to the wall outlet. The charger will start charging the
battery automatically.

Charging is finished when the charging LED (fig.14) produces a permanent green light. The charger
then changes to a float mode to maintain the battery state of charge.

16
 The following table shows the function of the LED-status:

Table 3: LED-Status
LED- signal Function
Red flashing Fault
Yellow (flashing) No battery connected
Yellow (solid) Normal charging
Green (solid) Fully charged

When charging is finished, disconnect the power cord from the

wall socket and place it in the designated pocket. Fig.14: LED- Status

8. REGULAR MAINTENANCE
• Only qualified and trained personnel are allowed to do maintenance on this truck.
• Before servicing, remove the load from the forks and lower the forks to the lowest position.
• If you need to lift the truck, follow chapter 4b by using designated securing or jacking
equipment.
• Before working, put supporting safety devices (designated lift jacks, wedges or wooden blocks)
under the truck to protect against accidental lowering, movement or slipping.
• Please pay attention when servicing the tiller arm. The gas pressure spring is pre-loaded by
compression, improper servicing can cause injury by sudden movement of the arm.
• Use only approved original spare parts from your dealer.
• Leakage of hydraulic fluid can cause failures and accidents. Repairs should not be delayed.
• Adjustment of the hydraulic pressure valve may only be done by trained service technician.
• When changing the wheels, please follow the supporting instructions above.
• The casters must be round and they should have no abnormal abrasion.
• Please follow the items on maintenance checklist to insure proper operation.

a. Maintenance checklist
Table 4: Maintenance checklist
Interval(Month)
1 3 6 12
Hydraulic
1 Check the hydraulic cylinder(s), piston for damage, noise and leakage •
2 Check the hydraulic joints and hose for damage and leakage •
3 Inspect the hydraulic oil level, refill if necessary •
4 Change the hydraulic oil ( 12 months or 1500 working hours ) •
5 Check and adjust function of the hyd. pressure valve (1800kg +0/+10%) •
Mechanical system
6 Inspect the forks for deformation and cracks •
7 Check the chassis for deformation and cracks •
17
 8 Check that all screws are fixed •
9 Check the push rods for deformation and damage •
10 Check the gearbox for noise and leakage •
11 Inspect the wheels for deformation and damage •
12 Inspect and lubricate the steering bearing •
13 Inspect and lubricate the pivot points •
14 Lubricate the grease nipples •
Electrical system
15 Inspect the electric wiring for damage •
16 Check the electric connections and terminals •
17 Test the Emergency switch function •
18 Check the electric drive motor for noise and damage •
19 Test the display •
20 Check that correct fuses are being used •
21 Test the warning signal •
22 Check the contactor(s) •
23 Check the frame leakage (insulation test) •
24 Check function and mechanical wear of the accelerator •
25 Check the electrical system of the drive motor •
Braking system
26 Check brake performance, if necessary replace the brake disc or adjust the air gap •
Battery
27 Check the battery voltage •
28 Clean and grease the terminals and check for corrosion and damage •
29 Check the battery housing for damage •
30 Check and if necessary refill the battery with distillated water (Excludes sealed type) •
Charger
31 Check the main power cable for damages •
32 Check the start-up protection during charging •
Function
33 Check the horn function •
34 Check the air gap of the electromagnetic brake •
35 Test the emergency braking •
36 Test the reverse and regenerative braking •
37 Test the auto-reversing (belly) button function •
38 Check the steering function •
39 Check the lifting and lowering function •
40 Check the tiller arm switch function •
General
41 Check if all decals are legible and complete •
42 Inspect the casters, adjust the height or replace if worn out. •
43 Carry out a test run •

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 b. Lubricating points
Lubricate the marked points according to the maintenance
checklist. The required grease specification is NLGI Grade #2
EP grease.

1. Load wheel bearings

2. Caster bearings
3. Gear box
4. Electric turning system
5. Hydraulic system
Fig.15: Lubrication Points
6. Joint

c. Check and refill hydraulic oil

The required hydraulic fluid- type is

• H-LP 46 (ISO46) / DIN 51524 /SAE MS1004- Zinc Free

• Viscosity is 41.4 - 47
• Capacity is 0.7L

Check the oil level with the truck in the lowered position. Oil fill should between 0.6L to 0.8L.
If necessary add oil at the filling point.
Waste oil must be properly disposed of and recycled according to your federal and local regulations.

d. Checking electrical fuses

Remove the main cover. The fuses are located according to fig. 16. Use only the correct size fuse for
replacement as listed in Table 5.

Table 5: Fuse Sizes

Fuse Number Rating

FU01 150A
FU02 80A
FU1 10A

Fig.16: Fuse Locations

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9. TROUBLESHOOTING

• If the truck malfunctions, first follow the instructions mentioned in chapter 6.

Table 6: Troubleshooting
TROUBLE CAUSE REPAIR
Load weight too high Lift only the max. capacity
mentioned on the dataplate
Battery discharged Charge the battery
Lifting fuse faulty Check and replace the lifting
Load can’t be lifted fuse
Hydraulic oil level too low Check and refill the hydraulic oil
Oil leakage Repair the hoses and/or the lift
cylinder seals.
Oil leakage from Excessive quantity of oil. Reduce oil quantity to level
air breather outlined in Section 8c.
Battery is charging Charge the battery completely
and then remove the main
power plug from the electrical
socket.
Battery not connected Connect the battery correctly
Fuse faulty Check and replace fuses as
Truck not operating needed
Low battery Charge the battery
Combined emergency switch is Reset the emergency switch by
activated pulling up on the knob.
Tiller in the operating zone at key First move the tiller to the
on. braking zone, then bring to
operating zone.

If the truck malfunctions and can’t be moved out of the working area, move the truck per the instructions
in section 4b.

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10. WIRING/ CIRCUIT DIAGRAM
a. Electrical circuit diagram

FU01: 150A
FU02: 80A
FU1: 10A

Fig. 17: Electric diagram

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 Table 7: Description of electrical diagram
Code Item Code Item
GB Battery P Indicator
SM DC power switch B Tiller
Et Controller C Capacitor
KMt Main contactor HA Horn
FU01 Fuse 150A SU Micro switch
FU02 Fuse 80A YV Electromagnetic valve
FU1 Fuse 10A Mt Traction motor
SY Key switch YB Electromagnetic brake
KMp Lifting contactor K Relay
Mp Pump motor U Charger
FU2 Fuse 0.5A S1、S2、S3、S4、S5 Micro switch
SA Proximity switch

b. Hydraulic circuit

Lift cylinder

Lowering valve

Pressure valve
Throttle valve

Hydraulic power pack

(motor and pump)

Oil tank

Fig. 18: Hydraulic circuit

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 11. Decal details:

Read and follow this instruction (A) Danger- Battery (I)

Oil filling point (F)

Warning- No riding (J)

Warning- Proper Operation (G)

Warning- Electrical devices (K)

Caution - Charger (H)

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