Jungheinrich ETX 513 Operating Instructions Manual

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ETX 513 / ETX 515

Operating instructions

51190312

04.19

03.11

en-GB

ETX 513

ETX 515

Table of Contents

Summary of Contents for Jungheinrich ETX 513

Page 1 ETX 513 / ETX 515 03.11 Operating instructions en-GB 51190312 04.19 ETX 513 ETX 515...
Page 3 Declaration of Conformity Manufacturer Jungheinrich AG, 22039 Hamburg, Germany Description Industrial truck Type Option Serial no. Year of manufacture ETX 513 ETX 515 On behalf of Date EU DECLARATION OF CONFORMITY The undersigned hereby declare that the powered truck described in detail complies with the current versions of European Directives 2006/42/EG (Machinery Directive) and 2014/30/EU (Electromagnetic Compatibility - EMC).
Page 5 Foreword Notes on the operating instructions The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide sufficient instruction for the safe operation of the industrial truck. The information is provided clearly and concisely. The chapters are arranged by letter and the pages are numbered continuously.
Page 6 Copyright Copyright of these operating instructions remains with JUNGHEINRICH AG. Jungheinrich Aktiengesellschaft Friedrich-Ebert-Damm 129 22047 Hamburg - Germany Tel: +49 (0) 40/6948-0 www.jungheinrich.com...
Page 7: Table Of Contents
Contents Correct Use and Application General Correct application Approved application conditions Proprietor responsibilities Adding attachments and/or accessories Truck Description Application Travel direction definition Assemblies and Functional Description Functional Description Assembly Overview Technical Specifications Performance data Dimensions (as per data plate) Mast versions Weights Wheels, chassis...
Page 8 Battery - Servicing, Recharging, Replacement Safety Regulations Governing the Handling of Lead-Acid Batteries General notes on handling batteries Battery types Dimensions of the battery compartment Exposing the battery Charging the battery Battery removal and installation Removing and installing the battery with a battery roller stand (single part batteries) Battery assembly / removal using a fork lift truck (two part batteries) "Battery lock"...
Page 9 Travel cutout override (o) Lift cutout override (o) Lower cutout override (o) End of aisle safety device (o) WG emergency operation (event messages 3670 / 3752) Recovering the truck from a narrow aisle / Moving the truck without a battery Personal safety system (o) Personal Protection System (PPS) Functional description...
Page 10 Restoring the truck to service after decommissioning Safety tests to be performed at intervals and after unusual incidents Final de-commissioning, disposal Human vibration measurement Maintenance, Inspection and Changing of Maintenance Parts Requiring Replacement Maintenance Contents ETX 513-515 Owner Customer Service...
Page 11 Appendix JH Traction Battery Operating Instructions These operating instructions apply only to Jungheinrich battery models. If using another brand, refer to the manufacturer's operating instructions.
Page 13: A Correct Use And Application
A Correct Use and Application General The industrial truck described in the present operating instructions is designed for lifting, lowering and transporting load units. It must be used, operated and serviced in accordance with the present instructions. Any other type of use is beyond the scope of application and can result in damage to personnel, the industrial truck or property.
Page 14: Approved Application Conditions
Approved application conditions DANGER! Do not exceed the permissible surface and spot load limits on the travel routes. At blind spots get a second person to assist. NOTICE The industrial truck must not be used in fire or explosion endangered areas, or areas threatened by corrosion or excessive dust.
Page 15 Safety distances (interpreted safety distance) The racking systems must be set up for the ETX. The safety distances stipulated by Jungheinrich (interpreted safety distance) must always be observed. – For a rail-guided truck there must be a minimum safety distance on both sides of100 mm between: –...
Page 16: Proprietor Responsibilities
Proprietor responsibilities For the purposes of the present operating instructions the “proprietor” is defined as any natural or legal person who either uses the industrial truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting) the proprietor is considered the person who, in accordance with existing contractual agreements between the owner and user of the industrial truck, is charged with operational duties.
Page 17: B Truck Description
B Truck Description Application The ETX with a standard attachment is an electric three-way order picker. The ETX with a telescopic table is an electric two-way order picker. The ETX is designed to transport and pick goods on level surfaces in accordance with the VDMA guideline.
Page 18 Safety distances (interpreted safety distance) The racking systems must be set up for the ETX. The safety distances stipulated by Jungheinrich (interpreted safety distance) must always be observed. – For a rail-guided truck there must be a minimum safety distance on both sides of100 mm between: –...
Page 19: Travel Direction Definition
Travel direction definition The following determinations have been made for travel direction specification: Item Travel direction Left Drive direction Load direction Right...
Page 20: Assemblies And Functional Description
Assemblies and Functional Description Functional Description Safety mechanisms – An enclosed truck geometry with rounded edges ensures safe truck handling. The overhead guard protects the driver from falling objects. – The drive wheel and the load wheels are protected by a solid skirt. A slight danger nevertheless remains for third parties.
Page 21 Emergency Stop safety feature – If an error is detected by the controller the truck automatically brakes to a halt. Control indicators on the driver’s display indicate the emergency stop. Each time the truck is switched on, the system performs a self test which only releases the parking brake (emergency stop) if the functional test is positive.
Page 22 Steering – Extremely smooth steering with threephase drive system (sturdy and maintenance-free threephase motor with no wear parts). – The steering wheel is integrated in the control panel. The position of the steered drive wheel is shown in the driver's display. The maximum steer angle is ± 90°. –...
Page 23 Hydraulic system – All hydraulic operations are controlled by a sturdy, maintenance-free AC motor with no wear parts and with a flanged low emission gear pump. – Oil is distributed via magnetic switch valves. The varying oil requirements are controlled by the speed of the motor. –...
Page 24 – Radio with CD player and MP3 interface. – Synchronised swivel. – Mechanical and electrical interfaces for material flow management systems. – Jungheinrich ISM: Information system for truck management (o). – Modular system of lift and travel cutouts plus speed reductions. – Jungheinrich Warehouse Navigation: –...
Page 25 Rack Height Select (o) Rack Height Select can be used both to lift and lower the load as well as for stacking and retrieving. With rack height select, the drive can select the required lift height via a keypad. Lifting automatically ends when the required lift height is reached. Rack Height Select is designed for a range of warehouse areas with different rack heights.
Page 26: Assembly Overview
Assembly Overview 21,22...
Page 27 Item Description t Steering wheel t Control panel and driver's display t "Hydraulic functions" control lever t Key switch t Emergency Disconnect switch t Overhead guard t Mast o Mast bracing (depending on mast height) t Handles t Battery connector (under the battery cover) t Battery cover t Side panel t Swivel/traverse frame...
Page 28: Technical Specifications
Values indicated with *) may vary depending on the configuration of the truck (e.g. mast, etc.). Performance data 4.1.1 Truck performance data with standard attachment Description ETX 513 ETX 515 Q Capacity (where D = 600 mm) 1250 1500 D Load centre distance...
Page 29 4.1.2 Truck performance data with telescopic table Description ETX 513 T/F ETX 515 T/F Q Capacity (where D = 600 mm) 1200** 1200** D Load centre distance Operation Two-way truck Travel speed without load (free km/h ranging) Travel speed with load (free ranging)
Page 30: Dimensions (As Per Data Plate)
Dimensions (as per data plate) 4.2.1 Dimensions of the ETX 513 / ETX 515 with standard attachment...
Page 31 The data (performance data, dimensions and weights) for the particular truck supplied can be found on the data plate. ETX 513 with 550 telescopic mast (ZT mast) ETX 515 with 550 telescopic mast (ZT mast)
Page 33 The data (performance data, dimensions and weights) for the particular truck supplied can be found on the data plate. ETX 513 with 550 telescopic mast (ZT mast) ETX 515 with 550 telescopic mast (ZT mast)
Page 34 4.2.2 Dimensions of ETX 513 T/F / ETX 513 T/F with telescopic table...
Page 35 The data (performance data, dimensions and weights) for the particular truck supplied can be found on the data plate. ETX 513 with 550 telescopic mast (ZT mast) ETX 515 with 550 telescopic mast (ZT mast)
Page 37 The data (performance data, dimensions and weights) for the particular truck supplied can be found on the data plate. ETX 513 with 550 telescopic mast (ZT mast) ETX 515 with 550 telescopic mast (ZT mast)
Page 38: Mast Versions
Mast versions 4.3.1 Standard mast version with telescopic mast (ZT) Description ETX 513 ETX 515 Mast height retracted 2570 - 5070 2670 - 5720 Lift 3000 - 8000 3000 - 9000 Mast height extended 4150 - 9150 4250 - 10250...
Page 39 4.3.2 Standard mast with two stage triplex mast (DZ) Description ETX 513 ETX 515 Mast height retracted 2900 - 4700 3200 - 5800 Free lift 1750 - 3550 1950 - 4550 Lift 5500 - 10000 6000 - 13000 Mast height extended...
Page 40: Weights
Weights 4.4.1 Basic truck / mast weight including attachment Basic truck weight (excl. battery) The weight of the basic truck (36) is shown in the following table. Truck Weight of basic truck ETX 513 2400 kg ETX 515 2500 kg...
Page 41 Example: Required information: (see truck data plate) – Type of industrial truck = ETX 513 – Net weight of the industrial truck without battery = 5302 kg (example) Formula: B = A - 2400 kg = 5302 kg - 2400 kg = 2902 kg...
Page 42 The data (performance data, dimensions and weights) for the particular truck supplied can be found on the data plate. ETX 513 with 550 telescopic mast (ZT mast) ETX 515 with 550 telescopic mast (ZT mast)
Page 43: Wheels, Chassis
The load / drive wheels can only be disassembled or assembled by the manufacturer's customer service department which has been trained to do this. Exceptionally, this task may be performed by a customer service organisation authorised by the manufacturer. ETX 513 Description ETX 513 Tyres...
Page 44: Engine Data
The noise level is measured at the level of the driver's ear. Vibration Weighted vibration acceleration on seat: – ETX 513: aw,zS = 0,56 m/s² – ETX 515: aw,zS = 0,56 m/s² in accordance with EN 13059. Seat cushioning: –...
Page 45 No changes to electric or electronic components or their arrangement may be made without the written agreement of the manufacturer. WARNING! Medical equipment can be damaged by non-ionised radiation Electrical equipment on the truck emitting non-ionised radiation (e.g. wireless data transmission) can affect operators' medical equipment (pacemakers, hearing aids etc.) and result in malfunctions.
Page 46: Conditions Of Use
Conditions of use Ambient temperature – operating at 5°C to 40°C Special equipment and authorisation are required if the truck is to be constantly used in conditions of extreme temperature or air humidity fluctuations. The truck is not authorised for use in cold stores. The truck must only be used in an closed indoor environment.
Page 47: Electrical Requirements
Electrical requirements The manufacturer certifies compliance with the requirements for the design and manufacture of electrical equipment, according to EN 1175 "Industrial Truck Safety - Electrical Requirements", provided the truck is used according to its purpose.
Page 48: Identification Points And Data Plates
Identification points and data plates Warnings and notices such as capacity charts, strap points and data plates must be legible at all times. Replace if necessary.
Page 49 Item Description Strap points for crane lifting "Tipover procedure" warning “No passengers” decal "Do not step onto or beneath the load, risk of trapping" warning notice “Laser beam” warning "Hazards in narrow aisle" warning notice Test plaque (o) “Read operating instructions” notice Capacity decal Truck data plate "Add hydraulic oil"...
Page 50: Data Plate
Data plate Item Description Item Description Type Year of manufacture Serial number Load centre (mm) Rated capacity (kg) Output Battery voltage (V) Min./max. battery weight (kg) Net weight w.o. battery (kg) Manufacturer Option Manufacturer’s logo For queries regarding the truck or ordering spare parts always quote the truck serial number (55).
Page 51: Truck Capacity Plate
Truck capacity plate CAUTION! Accident risk from fork replacement If you replace the forks with ones that differ from the originals, the capacity will change. uWhen replacing the forks you must attach an additional capacity plate to the truck. uTrucks supplied without forks are given a capacity plate for standard forks (length: 1200 mm).
Page 52: Attachment Capacity Plate
Attachment capacity plate The attachment capacity plate indicates the industrial truck's capacity Q [in kg] in conjunction with the respective attachment. The serial number specified in the load chart must match the data plate of the attachment, as the specific capacity for each truck is indicated by the manufacturer.
Page 53: Stability
Stability WARNING! Loss of stability can cause accidents The stability as indicated in the capacity plate can only be guaranteed with the components (battery, mast) as shown on the data plate. Only manufacturer- approved batteries may be used. The truck's stability has been tested according to latest technological standards. These take into account the dynamic and static tipover forces that can occur if used correctly.
Page 55: C Transport And Commissioning
C Transport and Commissioning Transport The truck can be transported in two different ways, depending on the height of the mast and the local conditions. – Vertically with the mast and load handler assembled (for low heights) – Vertically with the mast and load handler disassembled (for large truck heights).
Page 56: Lifting By Crane
Lifting by crane Lifting by crane with mast assembled WARNING! Improper lifting by crane can result in accidents The use of unsuitable lifting gear can cause the truck to crash when being lifted by crane. Prevent the truck and mast from striking other objects when they are being raised, and avoid any uncontrolled movement.
Page 57 Safe lifting of the basic truck by crane with mast assembled Requirements – Park the truck on a level surface. – Lower the load handler to the ground, see page 168. – Turn the industrial truck off with the key switch (8) and remove the key. –...
Page 58: Lifting The Basic Truck By Crane
Lifting the basic truck by crane WARNING! Improper lifting by crane can result in accidents The use of unsuitable lifting gear can cause the truck to crash when being lifted by crane. Prevent the truck and mast from striking other objects when they are being raised, and avoid any uncontrolled movement.
Page 59 – Dismantle the mast. The mast can only be disassembled by the manufacturer's specialist customer service personnel who have been trained to do this. Exceptionally, this task may be performed by a customer service organisation authorised by the manufacturer. – Remove the battery from the truck's battery compartment, see page 84. Tools and Material Required –...
Page 60: Lifting The Mast By Crane
Lifting the mast by crane WARNING! Improper lifting by crane can result in accidents The use of unsuitable lifting gear can cause the truck to crash when being lifted by crane. Prevent the truck and mast from striking other objects when they are being raised, and avoid any uncontrolled movement.
Page 61 Secure mast lifting by crane Requirements – Park the truck on a level surface. – Lower the load handler to the ground, see page 168. – Turn the industrial truck off with the key switch and remove the key. – Press the EMERGENCY DISCONNECT down. –...
Page 62: Lifting The Battery By Crane
Lifting the battery by crane WARNING! Improper lifting of the battery by crane can cause accidents The use of unsuitable lifting gear can cause the battery to crash when being lifted by crane. Prevent the battery from striking other objects when they are being raised, and avoid any uncontrolled movement.
Page 63 Safe lifting of the battery by crane Requirements – Battery removed, see page 84. Tools and Material Required – Crane lifting gear with sufficient capacity – Pallet – Lashing strap Procedure The weight of the battery to be taken into account when loading by crane can be taken from the battery data plate.
Page 64: Securing The Truck During Transport
Securing the truck during transport Basic truck transport retainer WARNING! Accidental movement during transport Improper fastening of the truck and mast during transport can result in serious accidents. uLoading must only be performed by specialist personnel trained for this purpose. The specialist personnel must be instructed in securing loads on road vehicles and handling load securing devices.
Page 65 Procedure • Relieve the drive wheel (31). To do this place the hard wooden blocks (81) under the chassis on either side at the height of the drive wheel (31). • Place wedges (78) in front of the load wheels (24) to prevent the truck from moving accidentally.
Page 66: Mast Transport Retainer
Mast transport retainer WARNING! Accidental movement during transport Improper fastening of the truck and mast during transport can result in serious accidents. uLoading must only be performed by specialist personnel trained for this purpose. The specialist personnel must be instructed in securing loads on road vehicles and handling load securing devices.
Page 67 Procedure • Place the mast (11) on two identical pallets (85). WARNING! Torn tie-down straps / tensioning belts can cause accidents Tie-down straps / tensioning belts can tear when routed over "sharp" edges. uProtect the tie-down straps / tensioning belts with a suitable support (69). uDo not route the tie-down straps / tensioning belts over "sharp"...
Page 68: Transport Retainer For Basic Truck With The Mast Assembled
Transport retainer for basic truck with the mast assembled WARNING! Accidental movement during transport Improper fastening of the truck and mast during transport can result in serious accidents. uLoading must only be performed by specialist personnel trained for this purpose. The specialist personnel must be instructed in securing loads on road vehicles and handling load securing devices.
Page 69 Procedure • Using a wooden plank, pallet or a rubber mat (89) from the attachment (83) to the front of the transporter; ensure a positive fit. • Relieve the drive wheel (31). To do this place the hard wooden blocks (81) under the chassis on either side at the height of the drive wheel (31).
Page 70: Using The Truck For The First Time
Using the Truck for the First Time Safety Instructions for Assembly and Commissioning WARNING! Incorrect assembly can result in accidents The assembly of the truck at the application site, commissioning and driver training must only be performed by the manufacturer's customer service representatives who have been specially trained for these tasks.
Page 71: Installing And Removing The Mast
Installing and removing the mast WARNING! The mast can only be disassembled / assembled by the manufacturer's specialist customer service personnel who have been trained to do this. Exceptionally, this task may be performed by a customer service organisation authorised by the manufacturer.
Page 72: Commissioning
Commissioning Preparing the truck for operation after delivery or transport Requirements – Unload the truck from the van, lorry or trailer. – Assemble the mast. The mast can only be assembled by the manufacturer's specialist customer service personnel who have been trained to do this. Exceptionally, this task may be performed by a customer service organisation authorised by the manufacturer.
Page 73 • Fit the battery if necessary (see page 84). • Charge battery (see page 84). • Check hydraulic oil level and top up if necessary (see page 346). • Check that all safety mechanisms are present and test them (e.g. tilt safety devices etc.).
Page 74: Tilt Safety Device
Tilt safety device Depending on the tilt test the ETX may be supplied with tilt safety devices (28). The tilt safety devices are fitted to the left and right of the rear truck chassis. When a tilt safety device (28) is used, under the right side panel (16) an "X" is engraved in the chassis (34) after the serial number (see page 46).
Page 75: D Battery - Servicing, Recharging, Replacement
D Battery - Servicing, Recharging, Replacement Safety Regulations Governing the Handling of Lead-Acid Batteries Maintenance personnel Batteries may only be charged, serviced or replaced by trained personnel. This operator manual and the manufacturer’s instructions concerning batteries and charging stations must be observed when carrying out the work. Fire protection Do not smoke and avoid naked flames when handling batteries.
Page 76: General Notes On Handling Batteries
General notes on handling batteries WARNING! Batteries can be hazardous Batteries contain an acid solution which is poisonous and corrosive. Above all avoid any contact with battery acid. uDispose of used battery acid in accordance with regulations. uAlways wear protective clothing and goggles when working with batteries. uDo not let battery acid come into contact with skin, clothing or eyes.
Page 77: Battery Types
ETX 513 3 PzS 465 465 Ah 2 x 40 V 2 x 619 kg 80 V 1,238 kg ETX 513 T/F 3 PzS 465 465 Ah 2 x 40 V 2 x 619 kg 80 V 1,863 kg ETX 515...
Page 78: Dimensions Of The Battery Compartment
Length (L) Width (W) Height (H) 1072 mm 583 mm 923,5 mm ETX 513 ETX 513 T/F Maximum battery height = 880 mm 1072 mm 870 mm 923,5 mm ETX 515 ETX 515 T/F Maximum battery height = 880 mm...
Page 79 WARNING! Loss of stability can cause accidents The weight and dimensions of the battery have a considerable effect on the operational safety of the industrial truck. When replacing the battery equipment, make certain that the battery dimensions, types and weights of the replacement battery are identical with those of the previously used battery.
Page 80: Exposing The Battery
Exposing the battery CAUTION! Trapping hazard There is a risk of trapping when you close the battery cover. uMake sure there is nothing between the battery cover and the truck when you close the battery cover. WARNING! An unsecured truck can cause accidents Parking the truck on an incline or with a raised load handler is dangerous and is strictly prohibited.
Page 81 • Unlatch the battery cover (15). To do this open the locks (96) on either side of the battery cover (15). • Open up battery cover (15). • Attach the battery cover (15) to the mast (11) using the hook (97). The battery cover (15) is open and prevented from closing automatically.
Page 82: Charging The Battery
Charging the battery WARNING! The gases produced during charging can cause explosions The battery produces a mixture of nitrogen and hydrogen (electrolytic gas) during charging. Gassing is a chemical process. This gas mixture is highly explosive and must not be ignited. uSwitch the charging station and truck off first before connecting/disconnecting the charging cable of the battery charging station to/from the battery connector.
Page 83 Safety procedures for charging batteries Requirements – Park the truck securely, see page 180. – Expose the battery, see page 78. – Switch off the charger. – Correct charging program set on charger. Procedure • Disconnect the battery (14). • Connect the charge cable of the battery charging station battery...
Page 84 WARNING! The gases produced during charging can cause explosions The battery produces a mixture of nitrogen and hydrogen (electrolytic gas) during charging. Gassing is a chemical process. This gas mixture is highly explosive and must not be ignited. uSwitch the charging station and truck off first before connecting/disconnecting the charging cable of the battery charging station to/from the battery connector.
Page 85 Preparing the battery for operation after charging Requirements – The battery (98) is fully charged. Procedure • Switch off the charger. • Disconnect the battery charging station cable from the battery connector (14). Check all cables and plug connections for visible signs of damage.
Page 86: Battery Removal And Installation
Battery removal and installation WARNING! Accident risk during battery removal and installation Due to the battery weight and acid there is a risk of trapping or burning when the battery is removed and installed. uNote the "Safety regulations for handling acid batteries" section in this chapter. uWear personal protective equipment (e.g.
Page 87 – Expose the battery, see page 78. Tools and Material Required – Battery roller stand Procedure • Remove the battery connector (14). • Disassemble the side panels (16): • Pull up and lift out the side panels (16) (see arrow direction "A"). •...
Page 88 CAUTION! Hand / arm trapping hazard There is a risk of trapping when you close the battery cover and fit the side panels, battery retainers, battery locks and battery. uMake sure there is nothing between the parts mentioned above and the truck when you fit the battery, retainers and side panels.
Page 89 CAUTION! Open covers can cause injury and accidents uThe covers (battery cover, side panels, drive compartment cover etc.) must be closed during operation. • Assemble the side panels (16): • Insert the bottom section of the side panels (16) at an angle into the chassis (see arrow direction "A").
Page 90: Battery Assembly / Removal Using A Fork Lift Truck (Two Part Batteries)
Battery assembly / removal using a fork lift truck (two part batteries) Removing the battery Requirements – Park the truck on a level surface. – Expose the battery, see page 78. Tools and Material Required – Fork lift truck with a minimum fork length of 880 mm and a capacity in excess of 1,5 t..
Page 91 Carefully pull out the battery (98) on the left or right hand sides using a forklift truck. NOTICE Risk of material damage When replacing and installing the batteries avoid damaging the truck chassis, batteries and battery compartment. uUse a jack with sufficient capacity and the correct fork length. uInsert the forks of the truck used for assembly / removal carefully into the fork shoe of the battery roller stand.
Page 92 CAUTION! Hand / arm trapping hazard There is a risk of trapping when you close the battery cover and fit the side panels, battery retainers, battery locks and battery. uMake sure there is nothing between the parts mentioned above and the truck when you fit the battery, retainers and side panels.
Page 93 Insert the battery in the battery compartment: NOTICE Risk of material damage When replacing and installing the batteries avoid damaging the truck chassis, batteries and battery compartment. uUse a jack with sufficient capacity and the correct fork length. uInsert the forks of the truck used for assembly / removal carefully into the fork shoe of the battery roller stand.
Page 94: "Battery Lock" Sensors (O)
"Battery lock" sensors (o) CAUTION! An unsecured battery can result in accidents If the battery retrainers are not applied in the chassis, the battery may slide out of the battery compartment when the truck moves. uApply the battery lock in the chassis. uOnly short shunting operations can be performed without the battery locks.
Page 95 The speed restriction is removed once the battery retainer(s) is/are inserted in the chassis. The "battery lock not applied" symbol (103) fades out. The truck can now travel again at the approved speed. Hydraulic operations are not affected if the battery retainers are not in place.
Page 97: Operation
E Operation Safety Regulations for the Operation of the Forklift Truck Driver authorisation The truck may only be used by suitably trained personnel, who have demonstrated to the proprietor or his representative that they can drive and handle loads and have been authorised to operate the truck by the proprietor or his representative.
Page 98 Hazardous area WARNING! Risk of accidents / injury in the hazardous area of the truck The hazardous area is defined as the area in which a person is at risk due to truck movement, lifting operations, the load handler (e.g. forks or attachments) or the load itself.
Page 99: Displays And Controls
Displays and Controls Controls and displays on the control panel...
Page 101 Item Control / display Function t Steers the truck in the required direction. Steering wheel Switches control current on and off. Key switch and key Removing the key prevents the truck from being switched on by unauthorised personnel. Emergency Disconnects the main power supply, all truck Disconnect switch operations are disabled.
Page 102 Item Control / display Function t Provides infinitely variable braking control. Brake pedal t Infinite travel speed control. Accelerator pedal In addition to the key switch. Releases the truck response with card or transponder. ISM access module o – Time out monitoring –...
Page 103 Item Control / display Function Changes menu: When you press the "Quit sub- “Quit sub-menu” menu" button the menu currently shown in the button driver's display changes to the higher-level menu. Cursor keys for Controls and settings for standard functions (e.g. special hydraulic setting the time) and additional functions (e.g.
Page 104 Item Control / display Function Controls the hydraulic functions, e.g. Main Lift raise "Hydraulic and lower, fork carriage rotate in conjunction with functions" control the "Fork carriage rotate" button (119), attachment lever traverse in conjunction with the "Attachment rotate" button (120). o Button for optional functions.
Page 105: Driver's Display
Driver's display Item Symbol Display Function Truck is ready for operation. "Parking brake Indicates the truck is stationary applied" indicator Parking brake (drive wheel brake) is applied. "Drive wheel brake Indicates the truck has come to a halt referencing" and the drive wheel brake is being indicator referenced.
Page 106 Item Symbol Display Function Indicates the current steer angle with Steer angle display reference to the centre position. Rail guidance: Steer angle display is replaced by the following symbols: Symbol lights up as soon as the truck is "Truck guided (with automatically guided and has received an aisle detection)"...
Page 107 Item Symbol Display Function Wire guidance: Steer angle display is replaced by the following symbols: “Acquisition in Symbol lights up as soon as the truck has progress” acquired the guide wire. Symbol lights up as soon as the truck is "Truck guided (with automatically guided on the wire and has aisle detection)"...
Page 108 Item Symbol Display Function Displays: – Truck model 125 "Truck features" – Truck features (wire guidance / rail guidance) – Serial number Shows the lift height of the forks after “Overall lift” referencing. "Main Lift raise" t Requests Main Lift to raise. referencing "Main Lift lower"...
Page 109 Item Symbol Display Function Indicates that there are people / obstacles in the warning field of the “Warning field personal protection system in the narrow infringement” aisle, see page 240. indicator The truck brakes. During this time the travel speed is restricted to slow travel (2,5 km/h).
Page 110 Item Symbol Display Function “Guide wire Wire guidance sensors that have detection” detected the guide wire illuminate. "Deadman button Truck is ready for operation. not pressed" Deadman button not applied. "Emergency Truck is ready for operation. Disconnect switch Emergency Disconnect switch pressed. pressed"...
Page 111: Hourmeter
Item Symbol Display Function "Rack height select" / "Horizontal positioning" symbols (o), see page 262 or see page 276. Denotes standard equipment Denotes optional equipment WG Wire guidance RG Rail Guidance Hourmeter Prepare the truck for operation, see page 139 or see page 140. Service hours are counted while the truck is operational and the deadman button is pressed.
Page 112: Bar Display" Battery Discharge Indicator
"Bar display" battery discharge indicator The standard setting for the battery discharge indicator / discharge monitor is based on standard batteries. When using maintenance-free or special batteries the display and cutout points of the battery discharge monitor must be set by authorised specialist personnel.
Page 113 2.4.1 Battery discharge monitor with bar display When a battery is discharged to the permissible level (residual capacity) the battery symbol in the driver's display is empty and flashing. An indicator appears in the driver's display. Main Lift and Auxiliary Lift raising is inhibited. Battery symbol Meaning Battery is charged.
Page 114: Percentage Display" Battery Discharge Indicator (O)
"Percentage display" battery discharge indicator (o) The standard setting for the battery discharge indicator / discharge monitor is based on standard batteries. When using maintenance-free or special batteries the display and cutout points of the battery discharge monitor must be set by authorised specialist personnel.
Page 115 2.5.1 Percentage display battery discharge monitor (o) If a battery is discharged to less than 31 % for wet-cell batteries or 41 % for gel batteries (residual capacity), the battery symbols flashes in the driver's display. Main Lift and Auxiliary Lift raising is disabled below 21 % for wet-cell batteries and 31 % for gel batteries.
Page 116: Driver's Display Function Symbols
Driver's display function symbols Procedure The "Functions" button (104) underneath the symbols (137) in the driver's display activate confirm respective function. The symbol (137) has a dark background. The following details the symbols for the displayed functions. Symbol and meaning Function Standard attachment, fork operation “Synchronised rotate...
Page 117 Symbol and meaning Function Indicates that it is possible to “Automatic fork automatically rotate the fork carriage to synchronised right rotate” the right and traverse the load handler to display the left. “Automatic fork Activates automatic fork carriage synchronised right rotate” synchronised right rotate and load button handler left traverse.see page 177.
Page 118 Symbol and meaning Function Telescopic table, fork operation “Single telescopic fork” Indicates that operation with single display telescopic forks is possible. Activates the single telescopic fork. This “Single telescopic fork” hydraulic function is controlled with the button "hydraulic functions" control lever, see page 256.
Page 119 Symbol and meaning Function “Bottom telescopic forks - Indicates that the “Bottom telescopic asynchronous forks - asynchronous movement” movement” display function can be operated. Activates asynchronous movement of the “Bottom telescopic forks - bottom telescopic forks. asynchronous This hydraulic function is controlled with movement”...
Page 120 Symbol and meaning Function Attachment / fork positioner / sideshift “Fork positioner / Changes the menu to “Fork positioner / sideshift menu change” sideshift” functions. display “Fork positioner / Activates fork positioner / sideshift menu sideshift menu change” change. button “Symmetrical fork Indicates that symmetrical fork positioner”...
Page 121 Symbol and meaning Function Attachment, fork tilt, special attachment o Indicates that fork tilt is possible. “Fork tilt” display Activates fork tilt. “Fork tilt” button This hydraulic function is controlled with the "hydraulic functions" control lever. “Special attachment” Indicates that a special attachment can display be operated.
Page 122 Symbol and meaning Function Personal Protection System (PPS) Indicates that there are people / obstacles in the protection field of the “Protection field personal protection system in the narrow infringement” display aisle, see page 241. The truck brakes to a halt. Overrides the protective function and enables inching speed (2,5 km/h) if there “Protection field...
Page 123 Symbol and meaning Function Warnings Appears as soon as lift cutout is “Fwd./Rev. travel only activated due to low battery capacity. due to low battery The truck can now only move forward or capacity” display in reverse. Confirms lift cutout for low battery “Acknowledge lift cutout capacity and releases travel.
Page 124 Symbol and meaning Function Indicates that the sub-menu (e.g. set Quit sub-menu date / time) can be quit. Changes menu: When you press the "Quit sub-menu" button the menu “Quit sub-menu” button currently shown in the driver's display changes to the "Truck functions" menu. Appears when the truck has been "Battery latch not switched on but the battery latch has not...
Page 125 Symbol and meaning Function Optional equipment “Work lights / fan menu Changes the menu to “work lights / fan change” display menu change” functions. “Work lights / fan menu Activates the work lights / fan menu change” button change. “Overhead guard work Indicates that the overhead guard work lights”...
Page 126: Preparing The Truck For Operation
Preparing the Truck for Operation WARNING! Risk of accidents in the hazardous area of the truck Before the truck can be started, operated or a load unit lifted, transported or lowered, the driver must ensure that there is nobody within the hazardous area. uInstruct other people to move out of the hazardous area of the industrial truck.
Page 127 3.1.1 Visual external inspection of the whole truck for damage Procedure • Check truck for damage. • Check mast bracing for damage (o). • Check driver's seat for damage. • Check driver's seat setting and adjust if necessary (see page 130). •...
Page 128 3.1.2 Hydraulic system visual inspection Procedure • Check entire truck externally for signs of leakage: • check the hydraulic cylinders. • check the hydraulic ports. • check the lines. • check the hoses. WARNING! Damaged / leaky hydraulic cylinders, ports, lines and hoses must be replaced before the truck is started.
Page 129 3.1.3 Battery visual inspection Procedure • Check the battery and battery container for damage. • Check the battery connector cable connections for damage. • Check battery cables and cell connectors for damage. • Check battery connectors for damage. • Check the battery connectors are secure. •...
Page 130: Entry And Exit
Entry and exit Requirements – Load handler fully lowered. Procedure Always enter and exit the truck as you face the load direction. To enter and exit, hold onto the handles (139) and use the step (140). • Enter or leave the truck. CAUTION! No more than one person may operate the truck at a time.
Page 131 Procedure • Before operating, adjust the driver’s seat and control panel so that all the controls are within reach and can be applied without having to strain. • Adjust the visibility aid equipment (mirrors, camera systems etc.) so that the working environment can be clearly seen.
Page 132 3.3.1 Adjusting the driver’s seat The procedure for adjusting the driver’s seat applies to standard models. For other models, follow the manufacturer’s setting instructions. When adjusting, ensure that all controls are within easy reach. WARNING! Risk of accidents and damage to health An incorrectly adjusted driver’s seat can result in accidents and damage to health.
Page 133 Adjusting the backrest Procedure • Sit on the driver’s seat. • Pull the lever (141) to adjust the backrest. • Adjust the backrest tilt. • Release the lever (141) again. The backrest is locked. The backrest is now set. Adjusting the seat position CAUTION! An unsecured driver's seat can cause injury An unsecured driver's seat can slide out of its guide during travel, resulting in...
Page 134 3.3.2 Control panel height adjustment The height of the control panel (118) can be vertically adjusted by 90 mm. CAUTION! An unsecured control panel can cause accidents and injury An unsecured control panel can slide during operation and result in accidents. uThe control panel must be locked in place when the truck is in operation.
Page 135 3.3.3 Control panel longitudinal adjustment The control panel (118) can be adjusted horizontally by 200 mm. CAUTION! An unsecured control panel can cause accidents and injury An unsecured control panel can slide during operation and result in accidents. uThe control panel must be locked in place when the truck is in operation. uDo not adjust the control panel during operation.
Page 136: Industrial Truck Operation
Industrial Truck Operation Safety regulations for truck operation Travel routes and work areas Only use lanes and routes specifically designated for truck traffic. Unauthorised third parties must stay away from work areas. Loads must only be stored in places specially designated for this purpose. The truck must only be operated in work areas with sufficient lighting to avoid danger to personnel and materials.
Page 137 Ground and ground conditions The ground on which the trucks are used must be level and smooth. There must not be any gaps, drainage systems etc. in this area. The ground must be well maintained to keep it free of contamination, obstacles and liquids that could affect the safe operation of the truck.
Page 138 Visibility when travelling outside the narrow aisle The driver must look in the direction of travel and must always have a clear view of the route ahead. Loads that affect visibility must be positioned at the rear of the truck. If this is not possible, a second person must walk in front of the truck as a lookout.
Page 139 Negotiating lifts Lifts may only be entered if they have sufficient capacity, are suitable for driving on and authorised for truck traffic by the owner. The driver must satisfy himself of the above before entering these areas. The truck must enter lifts with the load in front and must take up a position which does not allow it to come into contact with the walls of the lift shaft.
Page 140 Type of loads to be carried The operator must make sure that the load is in a satisfactory condition. Loads must always be positioned safely and carefully. Use suitable precautions to prevent parts of the load from tipping or falling down. Prevent liquid loads from sloshing out. WARNING! Accident risk when transporting liquid loads The following risks may be present when transporting liquid loads:...
Page 141: Preparing The Truck For Operation
Preparing the truck for operation Switching on the truck Requirements – Visual inspections and operations to be performed before starting daily operation, see page 124. – Connect the battery to the truck. – Insert and lock the battery latch. – Insert and lock the side panels correctly. –...
Page 142: Preparing The Truck For Operation With An Additional Access Code (O)
Preparing the truck for operation with an additional access code Optionally, the truck can be prepared for operation with an additional 5 digit access code. Up to 99 different access codes can be set. The various access codes can be assigned specific travel, steering and hydraulic programs (see page 258).
Page 143 Procedure • In the driver's display (107) you will be prompted to enter your 5 digit access code. Enter the access code, to do this: Unless the correct access code is entered, none of the truck's functions will work. • Press the "Select" button (147) in the cursor field.
Page 144: Checks And Operations To Be Carried Out When The Truck Is Operational
Checks and operations to be carried out when the truck is operational DANGER! Truck defects can result in accidents Do not use the truck if the brake system, steering and/or hydraulic system is defective or faulty. If damage or other defects are discovered on the truck or attachment (special equipment), the truck must be taken out of service until it has been repaired.
Page 145 Procedure • Test warning indicators and safety devices: • Test the Emergency Disconnect by pressing the Emergency Disconnect switch. The main circuit is disconnected and no truck operations can be performed. Now turn the Emergency Disconnect to unlock it. • Test the horn by pressing the "horn" button. •...
Page 146: Main Lift Referencing
Main Lift referencing The symbols (151,152) indicate that a reference run is required, as indicated by the driver's display. After the reference run the controller releases all the truck operations at full speed. The reference run also adjusts the height display. Referencing the Main Lift Requirements –...
Page 147 Lift cutout with referencing CAUTION! An extended mast can cause accidents The lift cutout is an auxiliary function designed to support the operator which however does not release him from his responsibility to stop hydraulic operations e.g. when confronted with an obstacle. Procedure •...
Page 148 Load handler post-referencing (sideshift / fork carriage) The load handler needs to be post-referenced in case the position of the load handler (attachment position, fork carriage rotation) has changed while the truck was switched off. When the truck is switched on again the "traverse reference run" (154) and "rotate reference run"...
Page 149 "Rotate" referencing Procedure • Do not press the deadman button (18). • Press and hold down on the "Fork carriage rotate" button (119). • Carry out a fork carriage 180° rotation: • Turn the "Hydraulic functions" control lever (113) clockwise = Fork carriage right rotation.
Page 150: Date And Time Setting
Date and time setting Date and time format The date and time format can only be changed by the manufacturer's customer service department. Format Date Time Standard setting dd.mm.yyyy hh:mm:ss US setting mm.dd.yyyy hh:mm:ss am/pm Selecting the “Set Date/Time” menu Requirements –...
Page 151 Date and time setting Procedure • Press the "Select" button (147) in the cursor field. The first digit of the date is displayed "dark". • The operator cursor keys (156,157) to choose the required setting in the selected field: • Cursor key (156): increase number. •...
Page 152: Emergency Disconnect
Emergency Disconnect...
Page 153 CAUTION! Accident risk Applying the Emergency Disconnect switch during travel will cause the truck to brake to a halt at maximum force. This may cause the load to slide off the forks. There is a higher risk of accidents and injury! The operation of the Emergency Disconnect button must not be affected by any objects placed in its way.
Page 154: Travel
Travel CAUTION! Do not drive the truck unless the panels and covers are closed and properly locked. The truck can be operated in 3 modes: – Free ranging in the apron field (FR) – Rail guided (RG), see page 156. –...
Page 155 • Apply the accelerator pedal (20). The travel speed is governed by the accelerator pedal (20). The travel speed is infinitely controlled by the accelerator pedal (20). The further the accelerator pedal (20) is pressed, the greater the travel speed. •...
Page 156: Steering
Steering Requirements – Prepare the truck for operation, see page 139 or see page 140. Procedure • Steering outside narrow aisles: • Turn the steering wheel (5) to the left or right, depending on the travel direction. The drive wheel position (124) is indicated on the driver's display (107). •...
Page 157 Braking with the coasting brake ( Procedure • Do not apply the accelerator pedal (20) while travelling. The accelerator pedal (20) reverts to the neutral position. The truck brakes via the traction controller. Braking with the brake pedal ( Procedure •...
Page 158: Negotiating Narrow Aisles
4.11 Negotiating narrow aisles 4.11.1 Negotiating narrow aisle with rail-guided trucks (o) WARNING! Unauthorised entry of narrow aisles by other trucks or people can cause accidents Unauthorised personnel must not enter narrow aisles (truck lanes in racking systems with safety distances < 500 mm), nor must any personnel cross through them. These work areas must be marked and identified accordingly.
Page 159 NOTICE Note the safety clearances between the truck and rack uMaintain a minimum 100 mm safety distance between a rail guided truck and the rack. uMaintain a minimum 125 mm safety distance between a wire guided truck and the rack. WARNING! Objects protruding out of the racks can be hazardous The driver of the truck in a narrow aisle can be injured by objects protruding from the...
Page 160 Procedure Rail-guided trucks are fitted with sensors or RFID readers. These sensors activate aisle detection when the truck enters an aisle. WARNING! Faulty or loose guide rails can be dangerous Do not operate the truck in narrow aisles with faulty or loose guide rails. The lack of guidance could cause a collision between the truck and the racks.
Page 161 Procedure • Determine the travel direction: • Push the travel direction switch (105) right = Travel in load direction • Push the travel direction switch (105) left = Travel in drive direction • Apply the accelerator pedal (20). The travel speed governed accelerator pedal (20).
Page 162 Leaving the narrow aisle Procedure • Drive the truck completely out of the narrow aisle. • Bring the truck to rest. CAUTION! You can only change from automatic to manual steering once the truck has fully exited the narrow aisle. •...
Page 163 4.11.2 Negotiating narrow aisles with wire-guided trucks (o) WARNING! Unauthorised entry of narrow aisles by other trucks or people can cause accidents Unauthorised personnel must not enter narrow aisles (truck lanes in racking systems with safety distances < 500 mm), nor must any personnel cross through them. These work areas must be marked and identified accordingly.
Page 164 NOTICE Note the safety clearances between the truck and rack uMaintain a minimum 100 mm safety distance between a rail guided truck and the rack. uMaintain a minimum 125 mm safety distance between a wire guided truck and the rack. WARNING! Objects protruding out of the racks can be hazardous The driver of the truck in a narrow aisle can be injured by objects protruding from the...
Page 165 CAUTION! A non-guided truck can cause accidents When a wire guided truck has been switched off and on again, the wire guidance will no longer be active. The same applies if the guide system is faulty or switched off and on again. If you continue to travel a warning sounds and the speed is reduced. uWhen starting or continuing the truck after the wire guidance has been deactivated, note the position of the drive wheel as manual steering is now activated again.
Page 166 Procedure The truck should preferably acquire the wire in the load direction, as this involves less time and distance. • Press the deadman button. • Approach the guide wire (164) with the industrial truck (162) at an angle and at reduced speed.
Page 167 Procedure • Determine the travel direction: • Push the travel direction switch (105) right = Travel in load direction • Push the travel direction switch (105) left = Travel in drive direction • Apply the accelerator pedal (20). The travel speed governed accelerator pedal (20).
Page 168 Leaving the narrow aisle Procedure • Drive the truck completely out of the narrow aisle. • Bring the truck to rest. CAUTION! You can only change from automatic to manual steering once the truck has fully exited the narrow aisle. •...
Page 169: Diagonal Travel
4.12 Diagonal travel Requirements – Prepare the truck for operation, see page 139 or see page 140. – Drive the truck into the narrow aisle and establish automatic guidance, see page 156. Procedure • Press the deadman button (18). • Diagonal travel (simultaneous travel and lifting/lowering) can be achieved by pressing the "Hydraulic functions"...
Page 170: Lifting / Lowering - Outside And Inside Narrow Aisles
4.13 Lifting / lowering – outside and inside narrow aisles 4.13.1 Main Lift raise/lower WARNING! Accident risk when lifting and lowering Other people can be injured in the truck's hazardous area. The hazardous area is defined as the area in which people are at risk from the truck movement, the load handler, attachments etc.
Page 171 WARNING! Unauthorised lowering speeds can cause accidents The line break safety valve in the Main Lift hydraulic cylinders stops the load handler from lowering if the lowering speed is out of range (> 0,6 m/s). If the safety valve applies for an unauthorised lowering speed, determine the cause. uIf there no leakage in the hydraulic system, raise the Main Lift slightly and then lower it again slowly.
Page 172 CAUTION! Positioning or blocking the load handler The lift chains may sag when positioning or blocking the load handler. There is a risk of the load handler dropping suddenly once no longer supported or when the block is released. If the load handler drops suddenly, the lift chains or hydraulic hoses may become damaged.
Page 173 Requirements – Prepare the truck for operation, see page 139 or see page 140. Procedure • Press the deadman button (18). • Main lift - raise: • Turn the "Hydraulic functions" control lever (113) clockwise. • Main Lift - lower: •...
Page 174: Traversing / Rotating Outside And Inside Narrow Aisles
4.14 Traversing / rotating outside and inside narrow aisles WARNING! Risk of trapping when swivelling or moving the forks Other people can be injured in the truck's hazardous area. The hazardous area is defined as the area in which people are at risk from movement of the load handler, attachments etc.
Page 175 WARNING! A faulty attachment can be hazardous Check the attachment daily for external signs of damage or defects. Faulty attachments can cause the load to fall. uReport any defects immediately to your supervisor. uTag out and decommission a faulty lift truck. uOnly return the truck to service when you have identified and rectified the fault.
Page 176 4.14.1 Attachment traverse Requirements – Prepare the truck for operation, see page 139 or see page 140. Procedure • Do not press the deadman button (18). • Press and hold down on the "Attachment traverse" button (120). • Traverse attachment to the right: •...
Page 177 4.14.2 Fork carriage rotation Requirements – Prepare the truck for operation, see page 139 or see page 140. Procedure • Do not press the deadman button (18). • Press and hold down on the "Fork carriage rotate" button (119). • Rotate fork carriage right: •...
Page 178 4.14.3 Manual traverse/rotate operation (t) In manual traverse/rotate operation the fork carriage rotates as the attachment is moving. Requirements – Prepare the truck for operation, see page 139 or see page 140. Procedure • Do not press the deadman button (18). •...
Page 179 4.14.4 Automatic traverse/rotate operation (o) In automatic traverse/rotate operation the fork carriage rotates as the attachment is moving. Requirements – Prepare the truck for operation, see page 139 or see page 140. Procedure • Do not press the deadman button (18). •...
Page 180 4.14.5 Manual synchronised rotation until forks are in centre position (o) With "Manual synchronised rotation until forks are in centre position" the fork carriage is rotated 90° from the home position and the attachment is positioned in the centre of the traverse/pivot frame. Requirements –...
Page 181 • Synchonised fork carriage 90° right rotation and load handler centre traverse: • Press and hold down on the (104) button under the "Synchronised rotation until forks in centre position" symbol (169) until the attachment comes to rest and rotary movement stops. •...
Page 182: Parking The Truck Securely
4.15 Parking the truck securely WARNING! An unsecured truck can cause accidents Parking the truck on an incline, without the brakes applied or with a raised load / load handler is dangerous and is strictly prohibited. uAlways park the truck on a level surface. In special cases the truck may need to be secured with wedges.
Page 183 Parking the truck securely Procedure • Park the truck on a level surface. • Fully lower the mast. • Press the deadman button (18). • Push the "hydraulic functions" control lever (113) down. • Set the attachment to the home position (t), see page 182. •...
Page 184 4.15.1 Traversing and rotating the attachment in the home position (t) Requirements – Prepare the truck for operation, see page 139 or see page 140. Procedure • Do not press the deadman button (18). • Traverse the attachment to the right or left limit position of the sideshift frame (113), see page 174.
Page 185 4.15.2 Traversing the telescopic table to the centre position (o) Requirements – Prepare the truck for operation, see page 139 or see page 140. Procedure • Do not press the deadman button (18). • Traverse the telescopic table to the centre position (113). The driver's display shows the "Telescopic table in home position"...
Page 186: Order Picking And Stacking
Order picking and stacking Adjusting the forks WARNING! Unsecured and incorrectly positioned loads can cause accidents Before lifting a load unit the driver must ensure that it has been correctly palletised and the truck’s capacity is not exceeded. uInstruct other people to move out of the hazardous area of the industrial truck. Stop working with the truck if people do not leave the hazardous area.
Page 187 WARNING! Incorrect fork adjustments can cause accidents To lift the load securely, the fork tines should be as far apart as possible and centrally positioned with respect to the fork carriage. The load centre of gravity must be centrally aligned between the forks. WARNING! Unsecured forks can cause accidents forks...
Page 188: Replacing The Forks
Replacing the forks WARNING! Faulty fork tines can cause accidents Faulty fork tines can cause the load to fall. uDo not operate the truck with faulty forks. uIf one fork tine is damaged, both fork tines must be replaced. uReport any defects immediately to your supervisor. uTag out faulty forks and withdraw them from use.
Page 189 CAUTION! Trapping risk when moving the forks You can trap your arms and legs when moving the forks on the fork carriage. uWear personal protective equipment (e.g. safety boots etc.) when replacing the forks. uAlways push the forks away from your body, never towards it. uSecure heavy forks with lifting slings and a crane before pushing them down from the fork carriage.
Page 190 Disassembling the forks Requirements – Truck parked securely, see page 180. – Load handler lowered and forks not touching the ground. Procedure • Disassemble extension safety mechanism (172). • Lift up the locking lever (170). • Carefully push the fork tines (23) off the fork carriage (171).
Page 191 Assembling the forks Requirements – Truck parked securely, see page 180. – Mast lowered. – Fork carriage raised so that the fork tine can be pushed onto the fork carriage. – Extension safety mechanism (172) disassembled. Procedure • Carefully push the fork tines (23) onto the fork carriage (171). •...
Page 192: Lifting, Transporting And Depositing Loads
Lifting, transporting and depositing loads WARNING! Unsecured and incorrectly positioned loads can cause accidents Before lifting a load unit the driver must make sure that it has been correctly palletised and does not exceed the truck’s capacity. uInstruct other people to move out of the hazardous area of the truck. Stop working with the truck if people do not leave the hazardous area.
Page 193 5.3.1 Raising a load unit from the side Requirements – Prepare the truck for operation, see page 139 or see page 140. – Load unit correctly palletised. – Fork spread for the pallet checked and adjusted if necessary, see page 184. –...
Page 194 5.3.2 Raising a load unit from the front (standard attachment only) Requirements – Prepare the truck for operation, see page 139 or see page 140. – Load unit correctly palletised. – Fork spread for the pallet checked and adjusted if necessary, see page 184. –...
Page 195 5.3.3 Transport the load unit. WARNING! Ensure there are no other people standing underneath the raised load and driver's cab. uDo not stand on the load handler. uDo not lift other people on the load handler. uInstruct other people to move out of the hazardous area of the truck. uNever stand underneath a raised and unsecured load handler / driver's cab.
Page 196 5.3.4 Depositing a load unit from the side WARNING! Depositing loads can be hazardous A storage location that is unsuitable for the load can become damaged when depositing the load. Neighbouring rack components can also be damaged. uDeposit the load only in locations that are suitable for storage (in terms of dimensions and capacity).
Page 197 Procedure • Press the deadman button. • Drive carefully up to the storage location. • Raise the load handler so that the load can enter the storage location without striking any objects. • Do not press the deadman button. • Carefully set the load into its storage location. •...
Page 198 5.3.5 Depositing a load unit from the front WARNING! Depositing loads can be hazardous A storage location that is unsuitable for the load can become damaged when depositing the load. Neighbouring rack components can also be damaged. uDeposit the load only in locations that are suitable for storage (in terms of dimensions and capacity).
Page 199 Procedure • Press the deadman button. • Drive carefully up to the storage location. • Set the attachment to the "front lifting" position: 90˚ • Do not press the deadman button. • Traverse the attachment to the centre position, see page 174.
Page 200: Troubleshooting
Troubleshooting Troubleshooting This chapter enables the user to identify and rectify basic faults and the effects of incorrect operation. When trying to locate a fault, proceed in the order shown in the table. If, after carrying out the following remedial action, the truck cannot be restored to operation or if a fault in the electronics system is displayed with a corresponding error code, contact the manufacturer’s service department.
Page 201 Fault Possible Cause Remedial Action Truck does – Battery connector – Check battery connector and plug it in if not start not plugged in necessary. – Emergency – Unlock Emergency Disconnect switch Disconnect pressed (see page 150). – Key switch turned off – Turn on key switch (see page 139). –...
Page 202 Fault Possible Cause Remedial Action Truck cannot – Truck not operational – Carry out all remedial measures listed be steered under “Truck does not start”. – Automatic guidance – Press the “Switch automatic guidance switched on on/off” button and switch off "Travelling in narrow aisle".
Page 203: Emergency Stop Device
Emergency stop device When the automatic emergency stop device applies (e.g. if the wire is abandoned, electrical steering fails) the truck brakes to a halt. Determine the cause of the fault and eradicate it before starting up the truck again. When starting the truck again, follow the manufacturer's instructions as indicated in the present operating instructions (see page 134).
Page 204 WARNING! Lowering the load handler can result in injuries The hazardous area is defined as the area in which a person is at risk due to the mast or load handler (e.g. forks or attachments) or the load itself. This also includes areas which can be reached by falling loads or lowering operating equipment.
Page 205 Load handler emergency lowering Requirements – Load handler is not in the rack. Tools and Material Required – Allen key (key width 7) to undo the lowering valve (174). Procedure If necessary, the load handler can be lowered from the ground by the driver or an auxiliary person.
Page 206 The load handler is lowered. WARNING! Only return the truck to service when you have identified and rectified the fault.
Page 207: Travel Cutout Override (O)
Travel cutout override (o) The “travel cutout override" symbol (175) is illuminated in the driver's display whenever further travel is inhibited beyond a certain lift height or range. If however the position of the truck needs to be adjusted with respect to the rack in order to stack or retrieve a load, proceed as follows: WARNING! The truck can cause accidents...
Page 208 Driving the truck in the event of a travel cutout Procedure • Press the deadman button (18). • Press and hold down on the button (104) under "Travel cutout override" symbol (175). • Determine the travel direction: • Push the travel direction switch (105) right = Travel in load direction •...
Page 209: Lift Cutout Override (O)
Lift cutout override (o) If local conditions require, an automatic lift cutout can be installed to be activated from a given lift height. The automatic lift cutout prevents the Main Lift from raising. The driver's display shows the "Lift cutout override" symbol (153). CAUTION! An extended mast can cause accidents The lift cutout is an auxiliary function designed to support the operator which...
Page 210 Lift cutout override Procedure • Press the deadman button (18). • Press and hold down on the button (104) under "Lift cutout override" symbol (153). • Turn the "Hydraulic functions" control lever (113) clockwise. The Main Lift is raised. Lift cutout is deactivated.
Page 211: Lower Cutout Override (O)
Lower cutout override (o) If local conditions require, an automatic lower cutout can be installed to be activated from a given height. The automatic lower cutout prevents the Main Lift from being lowered. The driver's display shows the "Lower cutout override" symbol (176). CAUTION! Accident risk due to setting down the driver's cab or load handler The lower cutout is an auxiliary function designed to support the operator which...
Page 212 Lower cutout override Procedure • Press the deadman button (18). • Press and hold down on the button (104) under "Lower cutout override" symbol (176). • Turn the "Hydraulic functions" control lever (113) anti-clockwise. The Main Lift is lowered. The lower cutout is deactivated.
Page 213: End Of Aisle Safety Device (O)
End of aisle safety device (o) Trucks with the end of aisle safety device brake before the aisle exit or in the transfer aisle. There are two basic versions for this: 1. Braking to a halt 2. Braking to 2.5 km/h Other variants (affecting the subsequent travel speed, lift height etc.) are available.
Page 214 2. Braking up to 2.5 km/h When the truck passes over the aisle end safety devices (route measurement, magnets, ...) in the direction of the end of the aisle, it brakes to 2.5 km/h and can be driven out of the narrow aisle at this speed. WARNING! The stopping distance depends on the travel speed.
Page 215: Wg Emergency Operation (Event Messages 3670 / 3752)
WG emergency operation (event messages 3670 / 3752) In a wire guidance system if the truck's antenna extends beyond the pre- determined range of the guide wire, an emergency stop is immediately induced. The driver's display flashes the "Wire guidance fault" symbol and displays the event messages "3670"...
Page 216: Recovering The Truck From A Narrow Aisle / Moving The Truck Without A Battery
If you cannot start the truck again after an automatic or manual Emergency Stop, despite having rectified the problem, turn the truck off and on again with the key switch. Then perform a reference run (see page 144) and carry out the above items again. The truck is now operational again.
Page 217 6.9.1 Release and activate the drive wheel brake WARNING! Uncontrolled truck movement When the brakes are de-activated the truck must be parked on a level surface, since the brakes are no longer effective. uDo not release the brake on slopes or inclines. uApply the brake again when you reach your destination.
Page 218 • Disassemble the setscrews (177) from their bracket (178) above the magnetic brake (179). • Insert the setscrews (177) into the magnetic brake (179) above the drive motor (180) and tighten them with the two hex. nuts. The two setscrews (177) are used to tension (unlock) the compression springs which activate the parking brake, so that the truck does not brake when de- energised.
Page 219 WARNING! An unsecured truck can cause accidents Parking the truck on an incline or with a raised load handler is dangerous and is strictly prohibited. uAlways park the truck on a level surface. In special cases the truck may need to be secured with wedges.
Page 220 Activating the drive wheel brake Requirements – Drive wheel brake wheel. – Park the truck securely. Procedure • Use wedges to prevent the truck from moving. • Open the drive compartment cover (95), see page 330. • Remove the setscrews (177) from the magnetic brake (179). •...
Page 221 6.9.2 Releasing and applying the load wheel brake The load wheel brakes are fitted only on the ETX 515. WARNING! Uncontrolled truck movement When the brakes are de-activated the truck must be parked on a level surface, since the brakes are no longer effective. uDo not release the brake on slopes or inclines.
Page 222 • Use wedges to prevent the truck from moving. • Fit the panels (183) of the load wheels (24) on both sides: • Unscrew three Allen screws from each load wheel (24). • Remove the panels (183). The load wheel (24) has five notches (182) which are arranged so that for each position of the load wheel (24) at least three out of nine possible thread holes (181) can be accessed by the load wheel brake.
Page 223 WARNING! An unsecured truck can cause accidents Parking the truck on an incline or with a raised load handler is dangerous and is strictly prohibited. uAlways park the truck on a level surface. In special cases the truck may need to be secured with wedges.
Page 224 • Store the plastic bag and setscrews (93) in the drive compartment. • Open the drive compartment cover (95), see page 330. • Fix the plastic bag in the drive compartment with cable ties so that it does not come into contact with moving parts while the truck is moving. CAUTION! Open covers can cause injury and accidents uThe covers (battery cover, side panels, drive compartment cover etc.) must be...
Page 225 6.9.3 Steering the truck without its own drive system CAUTION! A non-steered truck can cause accidents It may not be possible to steer the truck if the steering system is damaged. The truck can only be steered without its own drive system when it is stationary. uDo not adjust the truck's steering angle during a recovery operation.
Page 226 Adjusting the steer angle Requirements – Fully lower the mast, see page 168 or see page 201. – Traverse the attachment to the home position (t), see page 182. – Traverse the telescopic table to the centre position (o), see page 183. –...
Page 227 6.9.4 Recovering the truck from a narrow aisle WARNING! Uncontrolled truck movement When the brakes are de-activated the truck must be parked on a level surface, since the brakes are no longer effective. uDo not release the brake on slopes or inclines. uApply the brake again when you reach your destination.
Page 228 NOTICE Risk of damage from the tow rope During recovery route the tow ropes to the front in such a way as to avoid damaging the hydraulic lines, the electric cables, the traverse/pivot frame, the fork carriage pivot joint, the telescopic table and / or the attachment. •...
Page 229 Truck with standard attachment recovery in load direction without load Requirements – Fully lower the mast, see page 168 or see page 201. – Traverse the attachment to the home position (t), see page 182. – Traverse the telescopic table to the centre position (o), see page 183.
Page 230 If the steering angle has to be changed during a recovery operation, brake until the truck comes to a halt. CAUTION! A non-steered truck can cause injury The truck can only be steered without its own drive system when it is stationary (see page 223).
Page 231 Truck with telescopic table - recovery in load direction with and without load Requirements – Fully lower the mast, see page 168 or see page 201. – Traverse the attachment to the home position (t), see page 182. – Traverse the telescopic table to the centre position (o), see page 183.
Page 232 If the steering angle has to be changed during a recovery operation, brake until the truck comes to a halt. CAUTION! A non-steered truck can cause injury The truck can only be steered without its own drive system when it is stationary (see page 223).
Page 233 Truck with standard attachment or telescopic table - recovery in drive direction Requirements – Fully lower the mast, see page 168 or see page 201. – Traverse the attachment to the home position (t), see page 182. – Traverse the telescopic table to the centre position (o), see page 183.
Page 234 If the steering angle has to be changed during a recovery operation, brake until the truck comes to a halt. CAUTION! A non-steered truck can cause injury The truck can only be steered without its own drive system when it is stationary (see page 223).
Page 235: Personal Safety System (O)
Personal safety system (o) Personal Protection System (PPS) The truck's integrated personal protection system (PSS) is designed to protect persons. The Personal Protection System (PSS) is used with industrial trucks in warehouse systems where pedestrians are not permitted to be in narrow aisles at the same time as industrial trucks.
Page 236: Functional Description
Functional description – Mobile personal protection system with laser scanner based obstacle detection. – Apron field protection. – Optimum integration in the truck. – Easy adjustment / settings to match warehouse environment. – Automatic speed reduction / stopping in front of obstacles / personnel / other industrial trucks.
Page 237: Environmental Awareness
7.2.2 Special functions depending on the ground conditions – Aisle type identification within a warehouse. – Speed reductions for escape routes within the lane. – Stopping for escape routes within the lane. – Zone change within a lane with short range recognition. –...
Page 238: Cleaning The Laser Scanner Front Screen
Cleaning the laser scanner front screen Requirements – Laser scanner under load axle: Prevent the attachment from accidentally lowering, see page 336. – Laser scanner in drive compartment: Open the drive compartment cover, see page 330. Procedure • Damp-clean the front screen. Dry cleaning carries the risk of static charge.
Page 239: Displays On The Seven Segment Display And Indicator Light (Led)
Displays on the seven segment display and indicator light (LED) The seven segment display and the indicator light (LED) on the laser scanner act as the display for the operator and the customer service engineer. Display LED signal Description – Protection field clear, no object in protection field –...
Page 240 Other seven segment and indicator light (LED) error displays are relevant only to the manufacturer’s service department. Troubleshooting must only be performed by the manufacturer’s specialist service engineers. The manufacturer has a service department specially trained for these tasks. In order for customer services to react quickly and specifically to the fault, the following information is essential: - Truck serial number - Error number on the seven segment display (if applicable)
Page 241: Daily Checks Before Starting The Personal Protection System
Daily checks before starting the Personal Protection System – Check the front screens of the Personal Protection System laser scanner for contamination and clean as required (see page 236). – Cycle test (see page 239) 7.6.1 Cycle test NOTICE To ensure the correct operation of the personal protection system a cycle test must be carried out after a 24 hour timer has expired or each time the truck is switched off and on again.
Page 242: Personal Safety System
Personal safety system 7.7.1 No obstacles and / or persons detected Provided there are no persons and / or obstacles in the PPS warning or protection fields, the truck can travel at the maximum speed setting. 7.7.2 Obstacles and / or persons in the warning field Requirements –...
Page 243 7.7.3 Obstacles and / or persons in the protection field Protection field infringements are displayed "protection field infringement" symbol (191). protection field infringements the truck also brakes to a halt. The obstacle or person are no longer in the protection field Requirements –...
Page 244 Travelling in the event of obstacles and / or persons located in the PPS protection field Requirements – Prepare the truck for operation, see page 139 or see page 140. – Drive the truck into the narrow aisle and establish automatic guidance, see page 156.
Page 245: Optional Equipment
Optional equipment Laser beam rack compartment display (o) CAUTION! Injury risk from the laser beam rack compartment display The laser beam rack compartment display emits class 2 laser radiation. This can damage the eyes or the retina if it comes into direct eye contact. uDo not look into the laser beam! The laser beam rack compartment display indicates the correct position of the truck with respect to the rack compartment.
Page 246: Telescopic Table (O)
Telescopic table (o) WARNING! Risk of accidents during lifting and lowering Other people can be injured in the truck's hazardous area. The hazardous area is defined as the area in which people are at risk from the truck movement, the load handler, attachments etc. This also includes areas which can be reached by falling loads or lowering operating equipment.
Page 247 WARNING! Trapping hazard when moving the telescopic forks of the telescopic table Other people can be injured in the truck's hazardous area. The hazardous area is defined as the area in which people are at risk from movement of the load handler, attachments etc. This also includes areas which can be reached by falling loads or lowering operating equipment.
Page 248 WARNING! A faulty attachment can be hazardous Check the attachment daily for external signs of damage or defects. Faulty attachments can cause the load to fall. uReport any defects immediately to your supervisor. uTag out and decommission a faulty lift truck. uOnly return the truck to service when you have identified and rectified the fault.
Page 249 8.2.1 Traversing the telescopic forks of the telescopic table (o) NOTICE Risk of material damage to the telescopic forks The telescopic forks must not be used to push or press loads. Requirements – Prepare the truck for operation, see page 139 or see page 140. Procedure •...
Page 250 8.2.2 Telescopic forks adjustment (o) WARNING! Trapping hazard and risk of material damage when adjusting the telescopic forks Other people can be damaged when the telescopic forks are adjusted. Apart from the operator (in the normal operating position) there should be no other people in the truck's hazardous area.
Page 251 8.2.3 Individual movement of the telescopic table fork tines (o) WARNING! The load can fall down if the telescopic forks do not traverse correctly If a single telescopic fork tine moves when the loads on the two telescopic forks are overlapping, this can cause the load to fall.
Page 252 Requirements – Prepare the truck for operation, see page 139 or see page 140. Procedure The choice of telescopic forks can only be made if both telescopic forks are in the centre position. • Do not press the deadman button (18). •...
Page 253: Sideshifter / Fork Positioner (O)
Sideshifter / Fork positioner (o) WARNING! A faulty attachment can be hazardous Check the attachment daily for external signs of damage or defects. Faulty attachments can cause the load to fall. uReport any defects immediately to your supervisor. uTag out and decommission a faulty lift truck. uOnly return the truck to service when you have identified and rectified the fault.
Page 254 8.3.2 Fork positioner (o) WARNING! Trapping hazard and risk of material damage when adjusting the forks Other people can be damaged when the forks are adjusted. Apart from the operator (in the normal operating position) there should be no other people in the truck's hazardous area.
Page 255 WARNING! Risk of injury and material damage when operating the symmetrical sideshifter with integrated fork positioner Due to the special design of the sideshifter with integrated fork positioner, the operator must ensure that the forks and sideshifter do not extend into the area of the operator position.
Page 256 Procedure The fork spread is changed when the two forks traverse simultaneously. The forks cannot be adjusted individually. • Do not press the deadman button (18). • Press and hold down on the button (104) under "Fork adjustment" symbol (198). •...
Page 257: Telescopic Forks (O)
Telescopic forks (o) WARNING! Loss of truck stability When the telescopic forks are extended and the load exceeds the weights specified on the capacity plate, there is a risk of the industrial truck tipping over. uWhen the telescopic forks are extended, do not lift any loads that exceed the weights specified on the capacity plate, see page 46.
Page 258 8.4.1 Single telescopic forks (o) Extending retracting single telescopic forks Requirements – Prepare the truck for operation, see page 139 or see page 140. Procedure • Do not press the deadman button (18). • Traverse the attachment to the right or left limit position of the traverse/pivot frame, see page 174.
Page 259 8.4.2 Double telescopic forks (o) Extending retracting double telescopic forks Requirements – Prepare the truck for operation, see page 139 or see page 140. Procedure • Do not press the deadman button (18). • Traverse the attachment left or right until the automatic stop, see page 174.
Page 260: Operator-Specific Settings (O)
Operator-specific settings (o) Select the "Operator-specific settings" menu Requirements – Prepare the truck for operation, see page 139 or see page 140. Procedure • Press the "Quit sub-menu" button (108). The "Warnings sub-menu" item (203) appears in the driver's display. Truck operations are inhibited in this menu.
Page 261 “Operator-specific settings” menu settings Procedure Truck operations are inhibited in this menu. • Press the "Select" button (147) in the cursor field. The “Travel acceleration” symbol appears in the driver's display (see table below). • The operator toggle between functions using cursor keys (146,148):...
Page 262 Order of "Operator-specific settings" functions: Functions Driver's display Travel Acceleration Apron speed Aisle Speed Main lift- raise speed Main lift – lower speed Sideshift speed Steering wheel transmission CAUTION! Altering travel parameters can cause accidents Increasing the settings for acceleration, steering, travel, lifting and lowering can result in accidents.
Page 263 Procedure • The operator cursor keys (156,157) to set the functions from 1 (weak) to 8 (strong). This allows individual settings to be made within a pre-defined area in the program. • Cursor key (156): strengthen the setting. • Cursor key (157): weaken the setting. •...
Page 264: Ism Access Module (O)
ISM access module (o) If the truck is equipped with an ISM access module or Can Code refer to the “ISM Access Module” operator manual. Rack Height Select (o) To lift or deposit loads in pre-selected storage locations, the truck must be adapted to the warehouse setup.
Page 265 8.7.1 Entering area recognition (zones) Area recognition can occur manually or automatically depending on the setting. Automatic area (zone) detection The area is automatically recognised by the truck. There is no requirement for the operator to make an entry. Manual area recognition (zone) entry Requirements –...
Page 266 8.7.2 Rack number entry (lift height) Requirements – Prepare the truck for operation, see page 139 or see page 140. – Drive the truck into the narrow aisle and establish automatic guidance, see page 156. Procedure • Using the numerical keypad (112) enter the rack number.
Page 267 8.7.3 Approaching the warehouse location with Rack Height Select Requirements – Prepare the truck for operation, see page 139 or see page 140. – Drive the truck into the narrow aisle and establish automatic guidance, see page 156. Procedure • Using the numerical keypad (112) enter the area (205), see page 263.
Page 268 Procedure In order to lift or deposit loads in pre- selected storage locations, the auxiliary lift must be fully lowered. The auxiliary lift height is irrelevant for stockpicking. • Approaching the warehouse location with Rack Height Select: • Press the deadman button. •...
Page 269 To reach the required height there are various operating modes depending on the parameter setting To approach the required height manually (t): The "Hydraulic functions" control lever (113) must be pressed and held down until the required height has been reached (automatic stop).
Page 270 "Jog mode" - To approach the required height automatically (o): Turn "Hydraulic functions" control lever (113) briefly in the desired direction. The desired height then automatically approached. The lift and lowering speeds are fixed and cannot be influenced. The warehouse location approach can be cancelled by pressing the “CE”...
Page 271 8.7.4 Stacking operation (o) General procedure: – Retrieval: • Extend the load handler, see page 174. • Raise the load handler, see page 168. • Retract the load handler, see page 174 – Stacking: • Extend the load handler, see page 174. •...
Page 272 Stacking operation not active / feedback to radio data transmission terminal – Press the deadman button (18). – When the selected height is reached, the Rack Height Select order disappears from the driver's display. – Do not press the deadman button (18). –...
Page 273 Manual stacking operation – Press the deadman button (18). – Stacking / retrieval can be performed when the selected nominal height has been reached. • Stacking and retrieval are prescribed to the driver in the driver's display via the load sensor. –...
Page 274 Automatic stacking operation with the "Hydraulic functions" control lever (version A) – Press the deadman button (18). – Stacking / retrieval can be performed when the selected nominal height has been reached. – Do not press the deadman button (18). –...
Page 275 Automatic stacking operation with the "Hydraulic functions" control lever (version B) – Press the deadman button (18). – Stacking / retrieval can be performed when the selected nominal height has been reached. – Do not press the deadman button (18). –...
Page 276 The following symbols appear in the driver's display “left” stacking operations:...
Page 277 Symbol Manual stacking operation Stacking Retrieval – Do not press the deadman button. – Traverse attachment to the left: • Press and hold down on the "Attachment traverse" button (120). • Turn the "Hydraulic functions" control lever (113) anti-clockwise. – Rest time active. –...
Page 278: Horizontal Positioning (O)
Horizontal positioning (o) Your truck may optionally be equipped with the “Horizontal Positioning (HozPos)” function. This function supports the owner in positioning (automatic, direct targeted positioning of the pallet location) the truck in the rack and at the transfer station. In conjunction with the integrated rack height select, this provides for consistent stopping and load collecting in the rack and at transfer stations with minor, monitored deviations.
Page 279 8.8.1 Storage mode (o) Warehouse mode: – In storage mode pallets can be stacked and retrieved, see page 172. – The vertical position of the warehouse location entered is the height of the forks. This ensures that the required pallet is stacked or retrieved. –...
Page 280 8.8.2 Driver's display The position of the symbols can be adapted to customer requirements. The setting is made by the manufacturer's customer service department. In this case the positions (rack row, location (marker), compartment (height) and zone) must be entered so as to match the symbol display.
Page 281 Item Symbol Function / Description The “lower” or “lift” symbols indicate that vertical adjustment runs are required to reach the storage location The "Order in memory" symbol indicates that in addition to the current order there is another order in the truck's memory Zone selection / area selection Zone display = different lift heights, only single digit entry allowed...
Page 282 8.8.3 Horizontal positioning error description Item Error Description Truck has entered the wrong – Enter the correct aisle. aisle. – The direction symbol flashes. – Set the forks / attachment to the home Forks / attachment are not in position shown. home position for the order –...
Page 283 Item Error Description Orders cannot be entered as – The order entry is blocked. there is already an order in the – Carry out the existing order. memory. – The order is not accepted. Faulty data transmission – The error number is issued. Data transmission not –...
Page 284 8.8.4 Storage mode symbols in the driver's display During storage mode following symbols (132) are shown in the driver's display: A load sensor between the forks detects whether there is a load on the forks. Symbols storage mode with attachment Symbol Function –...
Page 285 Symbols in storage mode with telescopic table Symbol Function – Telescopic forks in home position without load / with load – Telescopic forks in home position without load / with load – The telescopic forks can be extended to the left / right –...
Page 286 8.8.5 Warehouse target destination entry The destination for horizontal positioning can be entered in three different ways and can be adapted to customer requirements: – Manual destination input: the required destination is entered and confirmed manually. – Destination input with barcode scanner: The destination position is scanned in with a barcode scanner.
Page 287 Procedure • Press the "Select" button (147) in the cursor field. The background of the “rack row” field (217) goes dark. • Use the numerical keypad (112) to enter the rack row. Only single digit entries are allowed in the “rack row” field (217). •...
Page 288 A maximum of two orders can be stored in truck’s memory. destination entered first is shown on the driver's display current order. second destination entered is stored in the truck’s memory. In this case the "order in memory" symbol (215) is shown in the driver's display.
Page 289 Destination input with barcode scanner Requirements – Prepare the truck for operation, see page 139 or see page 140. – Drive the truck into the narrow aisle and establish automatic guidance, see page 156. Procedure • Scan in the label with the barcode scanner. •...
Page 290 Destination input via data radio transmission Requirements – Prepare the truck for operation, see page 139 or see page 140. – Drive the truck into the narrow aisle and establish automatic guidance, see page 156. Procedure • The destination transmitted by radio is received by the industrial truck and appears directly on the driver's display.
Page 291 8.8.6 Stacking / retrieval after target entry Automatic horizontal and manual vertical destination approach ( Requirements – Prepare the truck for operation, see page 139 or see page 140. – The attachment must be in the correct position. Note the symbols in the driver's display.
Page 292 Procedure • Press the deadman button (18). • Raise Main Lift "Lift" symbol (227) is displayed. • Turn the "Hydraulic functions" control lever (113) clockwise. • Lower the Main Lift if the "Lower" symbol (226) is displayed: • Turn the "Hydraulic functions" control lever (113) anti-clockwise.
Page 293 Automatic horizontal and vertical destination approach ( Requirements – Prepare the truck for operation, see page 139 or see page 140. – The attachment must be in the correct position. Note the symbols in the driver's display. If necessary push / turn the attachment to the correct home position. –...
Page 294: Weighing System (O)
Weighing system (o) The truck can be fitted optionally with a weighing system. When the load has been raised slightly with the Main Lift, the weight is shown on the driver's display in kg (131), see page 168. NOTICE The weighing system is not a substitute for a calibrated weigher.
Page 295 8.9.1 Tare function (o) The weighing system can optionally be equipped with tare function. The tare function sets the weigher display to zero. Display zero setting Requirements – Prepare the truck for operation, see page 139 or see page 140. Procedure •...
Page 296: Camera System
8.10 Camera system CAUTION! Accident risk from hidden work areas uThe camera system acts as an aid to assist safe operation. uPractice travelling and working with the camera system. uAlign the camera so that the hidden work area can be seen. When using the camera to reverse, the monitor automatically switches on when you set the travel direction switch to "travel in drive direction".
Page 297: Rear View Mirror (O)
8.11 Rear view mirror (o) NOTICE Use the mirror only to observe the traffic behind you. Should you need visibility aids (mirrors, monitors etc.) to ensure adequate visibility, practice working with them beforehand. The rear view mirror (235) is fitted with a swivel link. This allows the driver to adjust the rear view mirror (235) to his or her individual needs.
Page 298: Working Platform (O)
8.12 Working platform (o) The truck operator manual, in chapter E "Safety Regulations for the Operation of theForklift Truck" under the item "„Unauthorised use" specifically prohibits the carrying (travel / lift / lower) of one or more persons on the load handler. If the truck is equipped with a detachable, approved work platform, in exceptional cases a person authorised by the owner may be carried in the work platform.
Page 299 8.12.1 Work platform components Item Description Key to open the gate in emergencies Grab handles (two-hand compulsion) Connecting cable between work platform and truck Gate Operator platform Fork shoes Work platform for the standard attachment Work platform for the telescopic table Work platform lock Stop on the attachment of the truck...
Page 300 8.12.2 Lifting the work platform with the standard attachment exceptional circumstance approved by the owner, the work platform is to be raised and an operator carried in the work platform, proceed as follows: Requirements – Prepare the truck for operation, see page 139 or see page 140.
Page 301 • Carefully push the forks into the fork shoes (241) of the work platform. Raise the work platform securely: WARNING! Unsecured work platforms can be hazardous The work platform must be connected both physically and electrically to the truck at all times during operation.
Page 302 8.12.3 Lifting the work platform with the standard attachment exceptional circumstance approved by the owner, the work platform is to be raised and an operator carried in the work platform, proceed as follows: Requirements – Prepare the truck for operation, see page 139 or see page 140.
Page 303 • Carefully push the forks into the fork shoes (241) of the work platform. Raise the work platform securely: WARNING! Unsecured work platforms can be hazardous The work platform must be connected both physically and electrically to the truck at all times during operation.
Page 304 8.12.4 Operation in the work platform WARNING! Faulty work platform safety mechanisms can cause accidents Faulty work platform safety mechanisms (handles (two-hand compulsion), gate, "Work platform raised" sensors...) can cause the work platform and / or the person in the work platform to fall. Do not use the work platform if one of the safety mechanisms is not working.
Page 305 WARNING! Objects protruding or falling out of the work platform can be hazardous Objects protruding out of the perimeter of the work platform can collide with other components during operation (e.g. racking systems). This can cause the work platform to fall and injure people inside the work platform. Objects falling out of the work platform can injure the operator of the truck or damage the truck.
Page 306 Operating the work platform Requirements – Prepare the truck for operation, see page 139 or see page 140. – Work platform raised securely, see page 298 or see page 300. Procedure • Step on the work platform: • Press the "Gate opener" switch on the work platform. •...
Page 307 The travel and / or hydraulic operations are interrupted or cannot be performed as soon as the handles (237) (two-hand compulsion) of the work platform are released. WARNING! The driver must never leave the truck while there are people in the raised work platform.
Page 308 8.12.5 Lowering the work platform with the standard attachment Requirements – Prepare the truck for operation, see page 139 or see page 140. – Work platform raised securely, see page 298 or see page 300. – There are no people in the work platform.
Page 309 8.12.6 Lowering the work platform with the telescopic table Requirements – Prepare the truck for operation, see page 139 or see page 140. – Work platform raised securely, see page 298 or see page 300. – There are no people in the work platform.
Page 310: Floor-Spot (O)
8.13 Floor-Spot (o) 8.13.1 Description of the Floor-Spot The Floor-Spot serves as a visual aid and provides greater safety in the warehouse. When the load handler is lowered, the Floor-Spot projects a red or blue spot on the ground at a distance of approx. 5 m in front of or behind the industrial truck. The position of the projected spot is preset in the factory.
Page 311 Safety information for Floor-Spot with blue light CAUTION! Risk of retinal damage due to blue light The Floor-Spot on the truck is classified in risk group 2 according to the standard IEC 62471: medium risk. In the range of 400 nm to 780 nm, blue light can potentially damage the retina of the human eye.
Page 312 8.13.2 List of assemblies for Floor-Spot Item Description o Floor-Spot in the load direction o Floor-Spot in the drive direction...
Page 313 8.13.3 Activating the Floor-Spot outside of narrow aisles (free ranging truck) Truck stop Truck travel function Function of the Floor-Spot • Floor-Spot (247) and Floor-Spot (248) • Truck not travelling (stationary) are switched off. Truck travels in drive or load direction Truck travel function Function of the Floor-Spot •...
Page 314 8.13.4 Activating the Floor-Spot in narrow aisles (truck with rail or wire guidance) Truck stop Truck travel function Function of the Floor-Spot • Floor-Spot (247) and Floor-Spot (248) • Truck not travelling (stationary) are switched off. Narrow aisle entry (alignment) Truck travel function Function of the Floor-Spot •...
Page 315 Travel within narrow aisle (narrow aisle without end of aisle safety device) Truck travel function Function of the Floor-Spot • Floor-Spot (248) is switched on. • Guided truck travels in drive direction • Floor-Spot (247) is switched off. • Floor-Spot (247) is switched on. •...
Page 316: Fire Extinguisher (O)
8.14 Fire extinguisher (o) WARNING! The use of unsuitable extinguishing agents can cause fire to spread The extinguishing agents in a fire extinguisher are suitable only for certain types of fires, due to their extinguishing properties. The use of inappropriate extinguishing agents can cause fire to spread, and hence injure the operator.
Page 317: F Industrial Truck Maintenance
F Industrial Truck Maintenance Operational Safety and Environmental Protection The inspections and maintenance tasks listed in chapter "Maintenance, Inspection and Changing of Maintenance Parts Requiring Replacement" must be performed according to the defined service intervals (see page 359). The manufacturer recommends the replacement of the maintenance parts also listed in chapter "Maintenance, Inspection and Changing of Maintenance Parts Requiring Replacement"...
Page 318 NOTICE Only original spare parts have been certified by our quality assurance department. To ensure safe and reliable operation of the truck, use only the manufacturer's spare parts. For safety reasons, only components which have been specially agreed by the manufacturer for this truck may be installed near the computer, controllers and wire guidance sensors (antennae).
Page 319: Maintenance Safety Regulations
Maintenance Safety Regulations Maintenance and repair personnel The manufacturer has a customer service department specially trained for these tasks. A maintenance contract with the manufacturer will support trouble-free operation. Truck maintenance, repair work and changing of parts requiring replacement must only be carried out by specialist personnel.
Page 320 Lifting and jacking up WARNING! Lifting and jacking up the truck safely In order to raise the truck, the lifting gear must only be secured to the points specially provided for this purpose. You may only work under a raised load handler / raised cab if they have been secured with a sufficiently strong chain or the fastening bolt.
Page 321 Cleaning CAUTION! Fire hazard Do not use flammable liquids to clean the industrial truck. uAlways disconnect the battery before starting cleaning work. uCarry out all necessary safety measures to prevent sparking before cleaning (e.g. by short-circuiting). CAUTION! Risk of electrical system damage The electrical system can be damaged if it is cleaning with water.
Page 322 Electrical system WARNING! Accident risk uOnly suitably trained electricians may operate on the truck's electrical system. uBefore working on the electrical system, take all precautionary measures to avoid electric shocks. uAlways disconnect the battery before starting cleaning operations. WARNING! Electric currents can cause accidents Make sure the electrical system is voltage-free before starting work on it.
Page 323 Consumables and used parts CAUTION! Consumables and used parts are an environmental hazard Used parts, oils and fuels must be disposed of in accordance with the relevant environmental protection regulations. To change the oil contact the manufacturer's customer service department, who have been specially trained for this task. uNote the safety regulations when handling these materials.
Page 324 Wheels WARNING! The use of wheels that do not match the manufacturer's specifications can result in accidents. The quality of wheels affects the stability and performance of the truck. Uneven wear affects the truck's stability and increases the stopping distance. uWhen replacing wheels make sure the truck is not skewed.
Page 325: Lubricants And Lubrication Schedule
Lubricants and Lubrication Schedule Handling consumables safely Handling consumables Consumables must always be handled correctly. Follow the manufacturer’s instructions. WARNING! Improper handling is hazardous to health, life and the environment Consumables can be flammable. uKeep consumables away from hot components and naked flames. uAlways keep consumables in prescribed containers.
Page 326 WARNING! Oils (chain spray / hydraulic oil) are flammable and poisonous. uDispose of used oils in accordance with regulations. Store used oil safely until it can be disposed of in accordance with regulations. uDo not spill oil. uSpilled fluids must be removed immediately with an appropriate bonding agent. uThe bonding agent / consumable mixture must be disposed of in accordance with regulations.
Page 327: Lubrication Schedule
Lubrication Schedule Details of the correct lubricant to be used are given in the lubricant chart, see page 327. Outer mast: Grease nipple: Centre mast: Load handler: Inner mast: Load handler:...
Page 328 g Contact surfaces Hydraulic oil drain plug b Transmission oil filler neck Grease nipple a Transmission oil drain plug Hydraulic oil filler neck...
Page 329: Consumables
Consumables Package Code Order no. Capacity Description Application quantity 51 037 497 HLP D22 including 2% share of 51 037 494 approx. additive 68 ID – Hydraulic System 64 l Plantohyd 22 S 51 085 361* (BIO hydraulic oil) British Petroleum (BP) 51 179 177 6,6 l...
Page 330: Maintenance And Repairs
Maintenance and repairs Preparing the truck for maintenance and repairs All necessary safety measures must be taken to avoid accidents when carrying out maintenance and repairs. The following preparations must be made:...
Page 331 Procedure • Fully lower the load handler. • Park the truck securely, see page 180. • Switch off the truck, to do this: • Turn the key in the key switch (8) left as far as the stop and remove the key. •...
Page 332: Opening / Closing The Drive Compartment Cover
Opening / closing the drive compartment cover Open the drive compartment cover Requirements – Prepare the truck for maintenance and repairs (see page 328). Tools and Material Required – Allen key (key width 5) to undo the screws (94). Procedure •...
Page 333 Close the drive compartment cover Tools and Material Required – Allen key (key width 5) to undo the screws (94). Procedure CAUTION! Arm trapping hazard There is a risk of trapping when you close the drive compartment cover. uMake sure there is nothing between the cover and the truck when you close the cover.
Page 334: Checking Electrical Fuses
Checking electrical fuses WARNING! Only suitably trained electricians may carry out work on the electrical system. WARNING! Electric currents can cause accidents Make sure the electrical system is voltage-free before starting work on it. The capacitors built into the controller must be completely discharged. The capacitors are completely discharged after about 10 minutes.
Page 335 Procedure • Check all fuses (252-258) in accordance with the "fuse rating" table below and replace as required. • Using the slotted screwdriver turn each fuse (252-258) anticlockwise out of the controller (259). • Pull the fuses (252-258) and their brackets out of the controller (259). •...
Page 336 4.3.1 Fuse ratings Item Description Electric circuit Rating 10 A ISM data recorder control fuse (o) Options fuse (personal safety system scanner, barcode scanner, radio terminal 10 A etc.) F1.2 Control panel and horn control fuse 10 A Overhead guard control fuse (e.g. work 10 A lights, operator position lighting, fan etc.) F2.1...
Page 337 4.3.2 Controller display Display status when truck is switched off When the truck is switched off the displays indicated grey (A3, A4, A5, B4) are lit green. If one of these displays is not lit, replace the corresponding fuse. Controll switch F1.2 7F7 Batt...
Page 338: Prevent The Load Handler / Mast From Accidentally Lowering
Prevent the load handler / mast from accidentally lowering DANGER! Risk of accidents when working under an unsecured load handler When carrying out maintenance and repair work under the load handler, the load handler must be protected against accidental lowering. The load handler must not be secured with a load on the forks, in order to prevent people below the load handler from being injured by falling loads.
Page 339 • Open the drive compartment cover, see page 330. • Slowly lower the load handler using the lowering valve, see page 201. • Turn the lowering valve clockwise as far as it will go. • Close the drive compartment cover, see page 330. The load handler is now protected against accidental lowering.
Page 340 Remove the fastening bolt Tools and Material Required – Allen key (key width 22) to undo or tighten the screw (264) of the fastening bolt (263). Procedure • Re-connect the battery. • Turn EMERGENCY DISCONNECT switch (9) to unlock it. •...
Page 341 CAUTION! Hand / arm trapping hazard There is a risk of trapping when you close the battery cover and fit the side panels, battery retainers, battery locks and battery. uMake sure there is nothing between the parts mentioned above and the truck when you fit the battery, retainers and side panels.
Page 342: Lift Chain Servicing
Lift chain servicing WARNING! Non-lubricated and incorrectly cleaned lift chains can cause accidents Lift chains are safety-critical parts. They must not contain any serious contamination. Lift chains and pivot pins must always be clean and well lubricated. uLift chains should only be cleaned with paraffin derivatives e.g. petroleum or diesel fuels.
Page 343 Procedure WARNING! An extended mast can cause accidents Be aware of the ceiling when raising the load handler. Fully raise the load handler. • Switch off the truck and remove the key if applicable. • Disconnect the battery. WARNING! Risk of accidents when working under an unsecured load handler Do not place the work platform, lifting platform or safety ladder underneath an unsecured load handler.
Page 344: Lift Chain Inspection
Lift chain inspection Unauthorised wear and external damage: NOTICE In accordance with official regulations, a lift chain is considered to be worn if its length has increased by 2,9 % in the section which runs over the pulley. WARNING! Accident risk from damaged lift chains Replace a chain immediately if it shows external signs of damage.
Page 345 WARNING! If the truck is fitted with two lift chains, both chains must always be replaced. This is the only way to ensure even load distribution over the two chains. uWhen replacing chains the connecting bolts between the chain anchor and the chain must be replaced.
Page 346: Hydraulic System
Hydraulic system WARNING! Leaky hydraulic systems can result in accidents Hydraulic oil can escape from leaky and faulty hydraulic systems. uReport any defects immediately to your supervisor. uMark defective truck and take out of service. uDo not return the industrial truck to service until you have identified and rectified the fault.
Page 347 NOTICE Testing and replacing hydraulic hoses Hydraulic hoses can become brittle through age and must be checked at regular intervals. The application conditions of the industrial truck have a considerable impact on the ageing of the hydraulic hoses. uCheck the hydraulic hoses at least annually and replace if necessary. uIf the operating conditions become more arduous the inspection intervals must be reduced accordingly.
Page 348: Checking The Hydraulic Oil Level
Checking the hydraulic oil level CAUTION! The hydraulic oil is pressurised during operation and is a hazard to health and to the environment. uDo not touch pressurised hydraulic lines. uDispose of used oil in accordance with regulations. Store used oil safely until it can be disposed of in accordance with regulations.
Page 349 WARNING! Leaky hydraulic systems can result in accidents Hydraulic oil can escape from leaky and faulty hydraulic systems. uReport any defects immediately to your supervisor. uMark defective truck and take out of service. uDo not return the industrial truck to service until you have identified and rectified the fault.
Page 350 Checking the hydraulic oil level and replenishing if necessary Requirements – Park the truck on a level surface. – Fully lower the load handler. – Prepare the truck for maintenance and repairs (see page 328). – Open the drive compartment cover (95), see page 330. Procedure •...
Page 351 • If the hydraulic oil level is below the "MIN" mark on the dipstick (267), add approx. 3,5 l of new hydraulic oil in accordance with the consumables table to reach the upper "MAX" mark on the dipstick. The hydraulic reservoir (268) is now completely full.
Page 352: Restoring The Truck To Service After Maintenance And Repairs
4.10 Restoring the truck to service after maintenance and repairs The truck can only be restored to service after cleaning or maintenance after the following procedures have been carried out: Procedure • Thoroughly clean the truck. • Re-connect the battery (14). •...
Page 353 WARNING! Faulty brakes can cause accidents As soon as the truck has been started, test the brakes several times. uReport any defects immediately to your supervisor. uTag out and decommission a faulty lift truck. uOnly return the truck to service when you have identified and rectified the fault. Test the service and parking brakes.
Page 354: Decommissioning The Industrial Truck
Decommissioning the industrial truck If the truck is to be out of service for more than a month, e.g. for commercial reasons, it must be stored in a frost-free and dry room. All necessary measures must be taken before, during and after decommissioning as described hereafter. WARNING! Lifting and jacking up the truck safely In order to raise the truck, the lifting gear must only be secured to the points...
Page 355: Prior To Decommissioning
Prior to decommissioning Procedure • Thoroughly clean the truck. WARNING! Faulty brakes can cause accidents As soon as the truck has been started, test the brakes several times. uReport any defects immediately to your supervisor. uTag out and decommission a faulty lift truck. uOnly return the truck to service when you have identified and rectified the fault.
Page 356: During Decommissioning
During decommissioning NOTICE Full discharge can damage the battery Self-discharge can cause the battery to fully discharge. Full discharge shortens the useful life of the battery. uCharge the battery at least every 2 months. Charge the battery see page 80.
Page 357: Restoring The Truck To Service After Decommissioning
Restoring the truck to service after decommissioning Procedure • Thoroughly clean the truck. • Lubricate the truck according to the lubrication schedule, see page 325. • Clean the battery, grease the terminals and connect the battery. • Charge the battery, see page 80. •...
Page 358: Safety Tests To Be Performed At Intervals And After Unusual Incidents
Safety tests to be performed at intervals and after unusual incidents The truck must be inspected at least annually (refer to national regulations) or after any unusual event by a qualified inspector. The manufacturer offers a safety inspection service which is performed by personnel specifically trained for this purpose.
Page 359: Final De-Commissioning, Disposal
Final de-commissioning, disposal Final de-commissioning or disposal of the truck in must be performed in accordance with the regulations of the country of use. In particular, regulations governing the disposal of batteries, consumables and electronic and electrical systems must be observed.
Page 361: G Maintenance, Inspection And Changing Of Maintenance Parts Requiring Replacement
G Maintenance, Inspection and Changing of Maintenance Parts Requiring Replacement WARNING! Lack of maintenance can result in accidents Failure to perform regular maintenance and inspections can lead to truck failure and poses a potential hazard to personnel and equipment. uThorough and expert maintenance and inspections are among the most important requirements for the safe operation of the industrial truck.
Page 362: Maintenance Contents Etx
Maintenance Contents ETX 513-515 Issued on: 2019-04-23 12:00 Owner To be performed every 50 service hours, but at least once a week. 1.1.1 Maintenance contents 1.1.1.1 Standard equipment Brakes Test the function of the brakes Hydraulic operations Lubricate the load chains.
Page 363 1.1.1.2 Optional equipment JH personal protection system System components Clean the front screens of the PPS laser scanner. Telescopic forks Hydraulic operations Clean and lubricate the attachment. Aisle recognition System components Clean the magnetic switch and/or light switch for aisle recognition. Load sensing Hydraulic operations Clean the sensors.
Page 364 1.1.2 Inspection contents 1.1.2.1 Standard equipment The following points must be checked: Electrical system Warning and safety devices are in accordance with the operating instructions Function of display and controls The function of the emergency disconnect and for damage Electrostatic discharge strap or chain is present and for damage Power supply Battery and battery components for damage The function and secure seating of the battery connector and for damage...
Page 365 1.1.2.2 Optional equipment The following points must be checked: Mast bracing Hydraulic operations To ensure that the mast bracing is secure and check for damage Rail guidance Travel The rail guidance for wear and damage Fork adjuster Hydraulic operations The function of the fork positioner and for damage Work lights Electrical system The function of the lighting and for damage...
Page 366 Lead-acid battery, international Power supply Battery and battery components for damage Battery cable connections are secure Lead-acid battery Power supply Battery cable connections are secure...
Page 367: Customer Service
Customer Service 1.2.1 Maintenance contents In accordance with the ETX 513-515 service interval, to be performed every 1000 service hours, but at least once a year. 1.2.1.1 Standard equipment Brakes Note: Release drive wheel brake and load wheel brakes if applicable with set screws.
Page 368 Hydraulic operations Test and adjust the pressure relief valve. Lubricate the chain, rollers, guide rollers and swing bearings on the swivel-traverse forks. Clean and lubricate the gear racks. Measure lifting and lowering speeds, if necessary traversing/rotating speeds for the correct value. Agreed services Carry out a test run with the rated load or a customer-specific load.
Page 369 1.2.1.2 Optional equipment Wire guidance Electrical system Test two-hand operation in narrow aisles. System components Measure the wire guidance current and frequency in the guide wire. Test handling on the guide wire and maximum deviation and adjust if necessary. Test the truck's acquisition of the guide wire when it enters the aisle. Test the wire guidance system and clearance limits and adjust if necessary.
Page 370 End of aisle safety device - magnet System components Test the function of the end of aisle safety device. End of aisle safety device – transponder System components Test the function of the end of aisle safety device. Rack height select System components Test Rack Height Select.
Page 371 Video system System components Clean the camera. Clean the display. Weigher sensors / switches Electrical system Test the weighing system. Telescopic table Hydraulic operations Adjust the attachment. Clean and grease attachment bearings, guides and stops. Clean and lubricate the attachment. The axial play of the front and rear rollers.
Page 372 W&S on-board charger Battery charger Test the immobiliser on trucks with on-board chargers. Carry out a potential measurement on the chassis while charging is in progress. Personal protection system - stationary System components Test the functions of the external Personal Protection System, e.g. to ensure it is cut off by the activation frequency.
Page 373 1.2.2 Inspection contents The following points must be checked: 1.2.2.1 Standard equipment Brakes The secure seating and function of the microswitches and sensors and for damage The secure seating of the connections and cables and for damage Brake linings for wear and damage Electrical system Cables and engine are secure and for damage Warning and safety devices are in accordance with the operating instructions...
Page 374 Chassis/structure Doors and/or covers for damage The mast bearings for wear The secure seating of the mast Operator mat and steps are non-slip and free of damage Protective mechanism against trapping and shearing is present, secure, functions correctly and is free of dirt and damage The secure seating of the overhead guard and/or the cab for damage Hydraulic operations The function of the "hydraulic system"...
Page 375 1.2.2.2 Optional equipment JH personal protection system System components The secure seating of the laser scanner and for damage Electrolyte circulation Power supply The function of the hose connections and pump Aquamatik Power supply The function of the Aquamatik plug, hose connections and float and for leaks The function of the flow indicator and for leaks Mast bracing Hydraulic operations...
Page 376 Telescopic forks Hydraulic operations Attachment bearings, guides and stops for wear and damage Proper securing of the attachment to the truck and the load-bearing components for secure fit and damage The function of the attachment and for damage Cylinder seals for leaks and damage Hydraulic connections, hoses and pipes are secure, and for leaks and damage The pistons and piston rods for wear and damage Working platform...
Page 377 Video system System components The secure seating of the cables and for damage The function and secure seating of the camera and for damage The function and secure seating of the monitor and for damage Work lights Electrical system The function of the lighting and for damage Fire extinguisher Agreed services The fire extinguisher is present and secure and check the inspection interval...
Page 378 Swivel traverse frame Hydraulic operations The secure seating of the hydraulic connections, hoses and pipes and for leaks and damage Attachment bearings, guides and stops for wear and damage Proper securing of the attachment to the truck and the load-bearing components for secure fit and damage The function of the attachment and for damage Cylinder seals for leaks and damage...
Page 379 Audible warning devices Electrical system Buzzer/warning alarm is secure and functions correctly and for damage W&S on-board charger Battery charger The current collector contacts for wear and damage The function of current collector and for wear and damage The secure seating of the current collector and for damage The mains plug and mains cable for damage The current collectors and bus bar feed for damage The secure seating of the cables and electrical connections and for damage...
Page 380 1.2.3 Maintenance parts The manufacturer recommends the replacement of the following maintenance parts at the specified intervals. 1.2.3.1 Standard equipment maintenance part service hours months Hydraulic oil 2000 Hydraulic oil, additive 2000 Hydraulic system - breather filter 2000 Hydraulic oil filter 2000 Hydraulic oil filter, seal kit 2000...
Page 381 Foreword Notes to the operating instructions The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide sufficient instruction for the safe operation of the traction battery. The information is presented in a precise and clear manner. The chapters are arranged by letter and the pages are numbered continuously.
Page 382 Copyright Copyright of these operating instructions remains with JUNGHEINRICH AG. Jungheinrich Aktiengesellschaft Friedrich-Ebert-Damm 129 22047 Hamburg - Germany Tel: +49 (0) 40/6948-0 www.jungheinrich.com...
Page 383 Contents Traction battery ............... Correct Use and Application..............Data plate ....................Safety Instructions, Warning Indications and other Notes ....... Lead acid batteries with armour plated cells and liquid electrolyte..Description....................Operation....................Servicing lead-acid batteries with armour plated cells......PzV and PzV-BS lead-acid batteries with sealed armour plated cells..Description....................
Page 385 A Traction battery Correct Use and Application This appendix does not apply to trucks with lithium-ion batteries. Further documentation for lithium-ion batteries can be obtained from the supplied documents. Failure to observe the operating instructions, carrying out repairs with non-original spare parts, tampering with the battery or using electrolyte additives will invalidate the warranty.
Page 386 Safety instructions and warning information...
Page 387 Safety Instructions, Warning Indications and other Notes Used batteries must be treated as hazardous waste. These batteries are marked with the recycling symbol and the sign showing a crossed-out rubbish bin, and should not be disposed of with ordinary household waste. Buy-back terms and type of recycling are to be agreed with the manufacturer as described in §...
Page 388 Lead acid batteries with armour plated cells and liquid electrolyte Description Jungheinrich traction batteries are lead acid batteries with armour plated cells and liquid electrolyte. The names of the traction batteries are PzS, PzB, PzS Lib and PzM. Name Explanation –...
Page 389 4.1.1 Battery nominal data Product Traction battery Nominal voltage 2.0 V x number of cells Rated capacity C5 See data plate Discharge current C5/5h Nominal electrolyte density 1.29 kg/l Nominal temperature 30 °C System rated electrolyte level up to "Max" electrolyte level marking Limit temperature 55 °C 1.
Page 390 Operation 4.2.1 Commissioning unfilled batteries The operations required must be carried out by the manufacturer's customer service department or a customer service organisation authorised by the manufacturer. 4.2.2 Commissioning filled and charged batteries Battery cell cross section Top view of a battery cell Checks and operations to be performed before starting daily work Procedure •...
Page 391 4.2.3 Discharging the battery To achieve an optimum useful life avoid operational discharge of more than 80% of nominal capacity (full discharge). This corresponds to a minimum electrolyte density of 1.13 kg/l at the end of the discharge. Fully or partially discharged batteries must be re-charged immediately and not left unattended.
Page 392 The electrolyte temperature rises by approx. 10°C during charging. Charging should therefore only begin when the electrolyte temperature is below 45°C. The electrolyte temperature of batteries must be at least +10°C before charging. Otherwise the battery will not charge correctly. Below 10°C the battery is insufficiently charged with standard charging systems.
Page 393 Servicing lead-acid batteries with armour plated cells 4.3.1 Quality of Water for Adding Electrolyte The quality of the water used to add electrolyte must correspond to purified or distilled water. Purified water can be produced through distillation or ion exchangers and is then suitable for the production of electrolyte. 4.3.2 Daily Battery cell cross section Top view of a battery cell...
Page 394 4.3.3 Weekly – After re-charging, carry out a visual inspection for dirt and physical damage. – If the battery is charged regularly according to the IU characteristic, carry out a compensation charge. 4.3.4 Monthly – Towards the end of the charging process measure and record the voltages of all the cells with the charger switched on.
Page 395 PzV and PzV-BS lead-acid batteries with sealed armour plated cells Description PzV batteries are sealed batteries with fixed electrolytes, to which no water can be added over the entire lifespan of the battery. Relief valves are used as plugs which are destroyed when opened.
Page 396 Operation 5.2.1 Commissioning Checks and operations to be performed before starting daily work Procedure • Make sure the battery is in physically good condition. • Make sure the terminals are correct (positive to positive and negative to negative) and check that contacts on the battery terminal conducting system are secure. •...
Page 397 NOTE Charging the battery incorrectly can result in material damage. Incorrect battery charging can result in overloading of the electric wires and contacts, hazardous gas formation and electrolyte leakage from the battery cell. Always charge the battery with DC current. All DIN 41773 charging procedures are permitted in the format approved by the manufacturer.
Page 398 Charging the battery Requirements – Electrolyte temperature between +15°C and +35°C Procedure • Open or take off the tray lid or covers from the battery compartment. • Connect the battery to the switched off charger, ensuring the terminals are connect (positive to positive and negative to negative).
Page 399 Servicing PzV and PzV-BS lead-acid batteries with sealed armour plated cells Do not add water! 5.3.1 Daily – Charge the battery after each discharge. 5.3.2 Weekly – Visually inspect for dirt and physical damage. 5.3.3 Every three months – Measure and record the overall voltage. –...
Page 400 Aquamatik water replenishment system Water replenishment system design > 3 m Water container Tap connection with ball cock Flow indicator Shut-off cock Locking coupling Battery lock connector...
Page 401 Functional Description The Aquamatik water replenishment system is used to adjust the rated electrolyte level automatically on traction batteries for industrial trucks. The battery cells are interconnected through hoses and are attached to the water supply (e.g. water container) through a plug connection. When the shut-off cock is opened all the cells are filled with water.
Page 402 Filling time The filling time for a battery depends on the electrolyte level, the ambient temperature and the filling pressure. Filling ends automatically. The water supply line must be disconnected from the battery when the water has been filled. Water quality The quality of the water used to fill up electrolyte must correspond to purified or distilled water.
Page 403 Electrolyte circulation Functional Description Electrolyte circulation ensures the supply of air during charging to mix the electrolyte, thereby preventing any acid layer, shortening the charge time (charge factor approx. 1.07) and reducing the formation of gas during charging. The charger must be suitable for the battery and electrolyte circulation.
Page 404 NOTE If an installed electrolyte circulation system is seldom used or not used at all, or if the battery is subjected to severe temperature fluctuations, the electrolyte may flow back into the hose system. Attach a separate coupling system to the air inlet line, such as: locking coupling to the battery side and through-coupling to the air supply side.
Page 405 Cleaning batteries Batteries and trays must be cleaned in order to – Maintain cell insulation and protect cells from ground or external conductive parts. – Avoid damage from corrosion and stray currents. – Avoid excessive and varying automatic discharge of the individual cells or block batteries due to stray currents.
Page 406 Cleaning the battery with a high pressure cleaner Requirements – Cell connectors tight, plugged in securely – Cell plugs closed Procedure • Follow the high pressure cleaner's user instructions. • Do not use any cleaning additives. • Observe the permissible cleaning device temperature setting of 140°C. This generally ensures that the temperature does not exceed 60°C at a distance of 30cm behind the outlet nozzle.
Page 407 Storing the battery NOTE The battery should not be stored for longer than 3 months without charging as otherwise it will no longer be functional. If the battery is to be taken out of service for a long period, it should be stored fully charged in a dry room protected from frost.

This manual is also suitable for:

Etx 515

Jungheinrich ETX 513 Operating Instructions Manual

A Correct Use and Application

B Truck Description

C Transport and Commissioning

D Battery - Servicing, Recharging, Replacement

Operation

F Industrial Truck Maintenance

G Maintenance, Inspection and Changing of Maintenance Parts Requiring Replacement

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