Operation & Maintenance Manual

PTF20–25
PTP20–25S
PTP20–25R
(1PT)

Keep this manual in your lift truck as a ready reference Original instructions
Pub no.: OM21GB1PT0T5
The content of this manual is protected by copyright law and may not be copied, fully or in
part, without written permission.
The material has undergone careful examination with regard to correctness. We reserve
the right to make changes.
© Copyright MLE AB (556083–6461), 2021
 TABLE OF CONTENTS

1 INTRODUCTION .................................................... 1 Trucks equipped with folding platform.................. 10

Operation and Maintenance Manual...................... 1 Options......................................................... 11
2 TRUCK MODIFICATION .......................................... 2 Additional equipment ................................. 11
Additional equipment, overview.................... 12
Truck modification ............................................. 2 Battery lock, quick lock (option).................... 13
3 ENVIRONMENTAL CONSIDERATIONS ..................... 3 Load backrest (option) ............................... 13
5V USB-power supply socket (option) ........... 13
We respect the environment................................ 3 12V power supply socket (option) ................. 14
4 THE SUPERVISOR................................................. 4 Equipment bar, multi-purpose tray, writing
surface ................................................... 14
Foreman’s responsibility..................................... 4
Work light (option) ..................................... 14
5 TRUCK OPERATOR ............................................... 5 Closed Pallet Entry and Exit (option) ............. 14
Authorization to operate a truck............................ 5 Platform damping - adjustable, controls
(option) ................................................... 14
Operator requirements ....................................... 5 Foot protection (option) .............................. 14
Inspection of the truck ........................................ 5 Increased drive speed, 10.5/12.5 km/h
(option) ................................................... 15
6 MACHINE PLATES................................................. 6
Lift stop, low battery voltage (option) ............. 15
Machine plates ................................................. 6 Low battery voltage level (option) ................. 15
Location of machine plates.................................. 6 8 BATTERY ........................................................... 16
7 DESCRIPTION OF THE TRUCK................................ 7 Battery specification ........................................ 16
Low lifter with foldable platform ............................ 7 Battery charging Lead/Acid batteries ................... 16
Low lifter with rear entry ..................................... 7 Maintaining the battery..................................... 18
Low lifter with, fixed side entry platform.................. 8 Battery replacement (with rollers) ....................... 19
Operator environment ........................................ 8 Battery servicing ............................................. 20
Functions .................................................. 8 Battery charging Li-Ion ............................... 21
 TABLE OF CONTENTS

9 DISPLAY ............................................................ 30 11 GENERAL LOADING AND UNLOADING

Simple display................................................ 30 INFORMATION .................................................... 48
Simple display general ............................... 30 Responsibility for the load ................................. 48
Simple display.......................................... 30 Responsibility for others ................................... 48
Warnings ................................................ 31
Maximal load ................................................. 48
Advanced display (option)................................. 32
Advanced display...................................... 32 Picking up a load ............................................ 48
Overview of Advanced display ..................... 33 12 MAINTENANCE OF THE TRUCK ............................ 49
Start the truck by logging on using the
Daily inspection (before each shift) ..................... 49
advanced display ...................................... 33
Operational screen.................................... 34 Daily inspection (after each shift)........................ 49
Battery discharge indicator (BDI) .................. 35 Weekly inspection ........................................... 49
Centre indicator ........................................ 35
Symbols in the display ............................... 35 Preventive maintenance ................................... 50
Audible alert ............................................ 37 13 SERVICING AND MAINTENANCE .......................... 51
Menu screen advanced display .................... 37 Service technician........................................... 51
Advanced display warnings......................... 40
Safety instructions for maintenance .................... 51
10 DRIVING INSTRUCTIONS ..................................... 43 Working at height ...................................... 51
Starting the truck ............................................ 43 Precautionary measures during
Getting in and out............................................ 43 repairs.................................................... 51
Drive mode.................................................... 43 Maintenance intervals ...................................... 51
Recommended replacements ...................... 51
Driving instructions.......................................... 44 Servicing, type and frequency...................... 52
High visibility fork tips and Crossway pallet Lubrication chart, rear entry......................... 56
handling indication .......................................... 46 Lubrication chart, side entry ........................ 57
Lubrication chart, foldable platform .............. 58
Switching off the truck ...................................... 47
Symbol key, lubrication chart ....................... 58
 TABLE OF CONTENTS

Fuses ..................................................... 59 Direction of travel when driving on

Maintenance instructions .................................. 60 slopes .................................................... 69
Genuine replacement parts ......................... 60 Awareness! ............................................. 70
Basic troubleshooting ................................ 60 Transportation security..................................... 70
Covers and panels .................................... 62 Moving an inoperable truck ............................... 72
Dismantling and assembling wheels.............. 63
Towing/moving inoperable truck ......................... 73
14 SAFETY REGULATIONS....................................... 66
When lifting the truck ....................................... 75
The authority and obligations of the truck General .................................................. 75
operator........................................................ 66 When lifting the truck ................................. 76
Driving the truck ............................................. 66 Exceptional operating conditions ........................ 77
Driving in public areas................................ 66
Distance between vehicles.......................... 66 Work in hazardous environments ....................... 78
Pinch risk ................................................ 66 Parking ......................................................... 78
Passengers ............................................. 66 Assembling and putting into service .................... 78
Clearance height ...................................... 66
The truck in an industrial lift ......................... 66 Subsequent mounting of radio equipment ............ 78
Floor load................................................ 67 Temporarily taking the truck out of service ............ 79
Signalling ................................................ 67 Storage .................................................. 79
Reduced vision......................................... 67 Actions before storage ............................... 79
Transports............................................... 67 Actions during storage ............................... 79
Speed .................................................... 68 Putting back into service after storage ........... 79
Driving space ........................................... 68 Hanging load ................................................. 79
Trucks equipped with a folding
platform .................................................. 68 In the event of accidents ................................... 79
Risk zones .............................................. 69 Noise levels ................................................... 80
Overturning ............................................. 69
Vibrations...................................................... 80
Trucks on another vehicle's loading
platform or on a ramp................................. 69 Climatic conditions .......................................... 80
 TABLE OF CONTENTS

Protective shoes ............................................. 80

Work Light..................................................... 81
Additional units/Trailers .................................... 81
Safety and warning signs.................................. 81
General .................................................. 81
Explanation of symbols .............................. 81
Locations of safety and warning signs ........... 81
15 DIMENSIONS ...................................................... 83
Dimensions Foldable platform ........................... 83
Dimensions Rear entry..................................... 84
Dimensions Side entry ..................................... 85
16 WEIGHT ............................................................. 87
Weights ........................................................ 87
17 ORDERING HANDBOOKS AND MANUALS ............. 89
Replacement Parts Manual ............................... 89
 1 INTRODUCTION 1

Introduction Directives 2006/42/EC and 2014/30/EU. The risk analysis is

based on ISO 3691. The Declaration of conformity certificate
Operation and Maintenance Manual accompanies every machine. This should always be kept with the
truck.
These original instructions contains information that you, as user
of the truck, must be aware of in order to avoid/minimise the risk
of injury/damage to yourself or the truck. You are also responsible
to the company management, other people and objects in your
environment. You should therefore carefully read all the way
through this manual before starting the truck for the first time.
The Operation and Maintenance Manual describes a truck with
standard equipment, customer modifications may have been fitted.
All options that are described in the operation and maintenance
manual are not suitable for all truck variants. Contact your truck
supplier for information.
Our products are continuously being improved, we therefore
reserve the right to make alterations without prior notice.
Quality, operational safety and innovation have given us a
prominent role as a truck supplier across the globe.
Thank you for choosing us as your truck supplier.
Genuine Parts
The reliability that we promise is contingent upon using our
original spare parts. Only our genuine replacement parts
guarantee correct operation, long life and the right to a warranty.
Declaration of conformity
MLE AB (556083– 6461), SE-435 82 Mölnlycke, Sweden,
declares under its sole responsibility that the supplied products
are in compliance with the relevant safety requirements of
 2 TRUCK MODIFICATION 2

Truck modification • approves and makes appropriate changes to the capacity plate
(s), decals, tags and Instruction Handbook.
Truck modification • affixes a permanent and readily visible label to the truck stating
the manner in which the truck has been modified or altered,
NOTE together with the date of the modification or alteration, and the
Unauthorized truck modification is not permitted. name and address of the organization which performed the task.

No modifications or changes to powered industrial trucks that can

affect areas such as capacity, stability or safety requirements for
the truck may be made without advance written authorisation from
the manufacturer, its authorised representatives or a successor to
these. Contact your local authorised dealer before any
modification or change is made to your industrial truck that may
affect, for example, braking, steering, visibility and connection of
separate load aggregates. Once permission has been granted by
the manufacturer, authorised representative thereof or successor
to these, the plate indicating the truck's capacity, decals, labels
and operating and operation and maintenance manual must also
be changed accordingly.
Only in the event that the manufacturer is no longer in business
and there is no successor to the company's stakeholders may the
user implement a modification or alteration to a powered industrial
truck. This applies on condition that the user:
• arranges for the modification or alteration to be designed, tested
and implemented by one or more engineers who are experts in
industrial trucks and their safety.
• maintains a permanent record of the design, test (s) and
implementation of the modification or alteration.
 3 ENVIRONMENTAL CONSIDERATIONS 3

Environmental considerations
We respect the environment
The majority of our products consist of steel, and can be
completely recycled.
Environmental impact
All products have an impact on the environment throughout their
entire life cycle.
We strive to minimise total energy consumption during production
and recycling. This is done throughout the process, e. g. through
design and choice of components.
Waste
Waste material in conjunction with repairs, maintenance, cleaning,
or scrapping, must be collected and disposed of in an
environment-friendly way and in accordance with local directives.
Such work should only be carried out in areas intended for this
purpose.
Recyclable material should be taken care of by specialised
authorities.
Environmentally hazardous waste, such as oil filters, hydraulic oil,
batteries and electronic equipment, can, if handled incorrectly,
have a negative effect on the environment and human health.
 4 THE SUPERVISOR 4

The supervisor Conditions of use

The truck is designed to be driven under the following conditions:
Foreman’s responsibility
• indoors
1. It is the responsibility of the supervisor, on behalf of the
company management, to ensure that the truck is operated • on a flat, hard and smooth surface
and used correctly.
• with the maximum floor loading checked and not exceeded
2. The supervisor is responsible for compliance with the
• normal operating temperature, see section Climatic conditions
requirements placed on the operator, refer to Operator
page 80.
requirements page 5.
• good visibility, adequate lighting and approved routes.
3. It is the duty of the supervisor to instruct and to ensure that
operator instructions are followed. • driving with the load lowered
4. The supervisor must supply, and the truck operator must sign
for, the following relevant operation and maintenance manual. WARNING
The supervisor must also read and be familiar with the Do not drive the truck over wet or dusty floors. Unclean
appropriate operation and maintenance manual. floors covered with screws, nuts, bits of packaging etc.
constitute a risk area.
The fork lift truck must be insured with at least third party
insurance if this is a national authority requirement.
Maintenance personnel WARNING
A truck operating in an area where there is a risk of fire,
explosion, or in any other high risk area, must be
NOTE specially equipped for the purpose. Trucks are not
The daily maintenance and certain service is to be normally equipped for these situations.
carried out by the operator after he/she has received
sufficient training in the construction and maintenance
of the truck. Continuous regular servicing should be
performed by an authorized servicing organization. To
ensure efficient and satisfactory servicing of the truck,
please contact an authorized dealer who can offer a
service agreement for continuous maintenance.
 5 TRUCK OPERATOR 5

Truck Operator • North America: Users shall follow the requirements of the
applicable part of ANSI/ITSDF B56.
Authorization to operate a truck
The employer must ensure that the employee has the required Inspection of the truck
training and knows what must be observed in order to avoid risks
while working. The employer must take into consideration an • The operator of the truck is responsible to the supervisor, for
employee's suitability for the work in question. It is therefore ensuring that the truck is kept in good working order.
necessary that a person engaged as an operator completes the
appropriate truck driver training, both theoretical and practical, • Daily maintenance shall be carried out carefully before the start
that corresponds to the work assignments the operator is of each shift. See section 12 Maintenance of the truck page 49.
expected to undertake after training. Further training may be • Any faults must be reported to the supervisor immediately.
required in the event of major changes in work assignments. The
employer should give the employee written authorization to • The truck must be kept clean and maintained so that it is always
operate the truck - as well as a written outline of the extent of his/ in good working order. It must be checked at regular intervals in
her duties. accordance with the service instructions.
• Check that no safety equipment has been modified or put out of
service.
Operator requirements
For optimum performance and so as not to invalidate the warranty,
The truck operator shall have the mental and physical capacity use only genuine replacement parts!
required for the job. The operator shall also be aware of
everything that is relevant to the handling and manoeuvring of the
truck, traffic regulations and any other relevant instructions. The
operator shall have the permission of the supervisor to drive the
type of truck in question and be specially trained for the work and
the traffic conditions involved.
The responsibilities of the operator in specific markets
The following apply in respect of the operator's responsibilities
concerning the use of fork lift trucks:
• Australia: Users shall follow the requirements of AS 2359.2.
 6 MACHINE PLATES 6

Machine plates WARNING

Machine plates The load capacity and load centre distance given on
the plate must be respected to keep the machine
The Machine plate contains important information. Read it within safe limits.
carefully! The permitted load shall not be exceeded. The stated
load limit assumes that the load is evenly distributed over the forks.

Location of machine plates

1 Model brandmodel

2 Type model The image shows where the machine plate is located. The
3 Serial no. sno
location is the same for the foldable platform, as well as the side
4 Year of manufacturing year

5 Load capacity cap and rear entry variants.

6 Load center distance tp

7 Weight without battery wwob

8 Battery weight min. bwmin

9 Battery weight max. bwmax

10 Battery voltage bv A
11 Reference number ref

Fig. 1. Machine plates

1 Model designation 7 Weight without battery

2 Type designation 8 Minimum battery weight
3 Type Serial No./Version (S= 9 Maximum battery weight
Special version)
4 Year of manufacture 10 Battery voltage
5 Permitted load 11 Reference number (year and
month of manufacture)
6 Load centre distance
Fig. 2. Location of machine plate

A Machine plate
 7 DESCRIPTION OF THE TRUCK 7

Description of the truck Low lifter with rear entry

Low lifter with foldable platform

Fig. 3. Low lifter with foldable platform Fig. 4. Low lifter with rear entry

This truck is an electric low lifter for ride-on or walking operators, This truck is an electric low lifter for ride-on operators, specially
which is made possible by the folding platform and the movable adapted for transport and handling at loading bays. The truck has
side guards. The truck is specially adapted for transport and a fixed platform with entrance from the rear. A low lifter with rear
handling at loading bays. A low lifter with foldable platform can be entry can be equipped with long forks for transport of several
equipped with long forks for transport of several loads. Usual loads. Usual loads are pallets or roller containers.
loads are pallets or roller containers.
 7 DESCRIPTION OF THE TRUCK 8

Low lifter with, fixed side entry platform Operator environment

Functions
Controls
Controls on tiller head
On the tiller head there are a number of controls for operating the
truck, see image 6. Controls, tiller head page 8.

C B A
D
B
Fig. 5. Low lifter with side entry

A E
This truck is an electric low lifter for ride-on operators, specially
adapted for transport and handling at loading bays. The truck is
F
equipped with a fixed platform with an entrance from the side. A
low lifter with side entry can be equipped with long forks for the E
transport of several loads. Usual loads are pallets or roller
containers. Fig. 6. Controls, tiller head

A Lower D Low speed/Tiller up drive

(option)
B Lift E Speed Control
C Horn F Belly safety switch/Maximum
brake switch, depending on
configuration, see braking
instructions in Driving
instructions.
 7 DESCRIPTION OF THE TRUCK 9

Dashboard, components
A
B
On the dashboard there is a display and a key switch. In addition, C
the truck can be equipped with additional optional controls/sockets.

Fig. 8. Key switch entry

A Ignition off C Power mode

B B Eco-mode
C1 A
C2 C3

For starting and shutting down the truck, and for operating
instructions, see chapter 10 Driving instructions page 43.
Controls and outlets (option)
C
The dashboard can be equipped with extra controls and power
supplies (option). At most, the dashboard can be equipped as in
Fig. 7. Controls, dashboard with simple display image 9. Dashboard with a USB - socket page 9 or image 10.
Dashboard with a 12V - socket page 10. Note that you can have
A Key switch entry C Example of a switches/sockets either a 5V USB-power supply socket or a 12V-power supply
(option) socket on the dashboard.
B Display

A D
For a description of the display, see section Simple display page B C
E
30. 0
1/2
1

The positions of the key switch

The key switch has three different positions, see image 8. Key
switch entry page 9. Fig. 9. Dashboard with a USB - socket
 7 DESCRIPTION OF THE TRUCK 10

• In the case of a fixed platform (option), lifting and lowering of the

D
B C
E
forks are also prevented if there is no operator standing on the
A
0
1/2
1
platform.
• On foldable platform variant, automatic reversing if the driver
becomes trapped between the tiller arm and an obstacle (belly
safety switch).
Fig. 10. Dashboard with a 12V - socket
• Automatic stop if a fault is detected in the truck.

Table 1. The dashboard's controls, outlets and display

Trucks equipped with folding platform
A 5V USB - (power supply) socket (option) / 12V - (power
supply) socket (option) If the machine is to be used as a pedestrian truck, the platform
must be folded up and the side guards folded down manually.
B Work light (option)
Platform
C Platform damping, adjustable (option)
A number of safety functions have been built into the truck to
D Display avoid accidents:

E Key switch entry

For a description of an optional control/power supply socket, see

section Options page 11.

Safety functions
The truck is equipped with a number of safety functions to
minimise the risk of accidents.
• Driving and hydraulic functions are inactivated if the platform is
down and there is no operator standing on it.
 7 DESCRIPTION OF THE TRUCK 11

A B Options
Additional equipment
The truck may be equipped with additional equipment. Platform
C D
configurations (F) foldable platform, (R) rear entry and (S) side
entry. Among other things, there are the following possibilities:
X Option available
O Standard
E F

Additional F F R R S S
equipment 200 250 200 250 200 250
Steel battery X X X X X X
rollers
Fig. 11. Built in safety functions
Battery lock, quick X X X X X X
A Platform folded down without D Platform folded down with lock
operator standing on it: The operator on it and side guards
truck cannot be driven. down: The truck can be driven Load wheel, bogie, X O X O X O
at reduced speed. 85 mm
B Platform folded down and side E Platform folded up and side
guards up, without driver guards down: The truck can be
Load wheel, bogie, X X X X X X
standing on it. The truck cannot driven at reduced speed. 80 mm
be driven. Climbing wheel X X X X X X
C Platform folded up and side F Platform folded down with
guards up: The truck cannot be operator on it and side guards Pivot arm (Short X X X X
driven. up: The truck can be driven at
normal speed.
maneuver arm
with a fixed length)
Drive wheel X X X X X X
Vulcollan 93
7 DESCRIPTION OF THE TRUCK 12

Additional F F R R S S Additional F F R R S S
equipment 200 250 200 250 200 250 equipment 200 250 200 250 200 250
Drive wheel X X X X X X Cold store design X X X X X X
Tractothan 93
Cross way pallet X X X X X X
Drive wheel Super X X X X X X handling -
grip 93 indication
Platform damping, X X X X Increased drive X X X X X X
adjustable with a speed (10.5/12.5
switch km/h)
Power steering X X O O O O Tiller up drive X X
Load backrest X X X X X X Foot protection X X
1350 mm
Active spin X X X X X X
12 V - socket X X X X X X reduction
5 V USB - socket X X X X X X Closed Pallet X X X X X X
Equipment bar X X X X X X Entry and Exit

Equipment holder, X X X X X X Advanced display X X X X X X

RAM System C
Equipment holder, X X X X X X Additional equipment, overview
RAM System C, 2
pcs. In the image there is an example of additional equipment.
Equipment holder, X X X X X X
RAM System D
Multi-purpose tray X X X X X X
Work light X X X X X X
 7 DESCRIPTION OF THE TRUCK 13

F A C D1 D2 D3 Battery lock, quick lock (option)

The battery is attached with a manual lever as in image Battery
replacement page 19. This variant of the battery lock requires no
tool to attach and release the battery. The quick lock indicates
B visually if the battery is correctly attached or not, since the lever
prevents the battery closure from closing if the battery is not
correctly installed.

Load backrest (option)

E The truck may be equipped with a load backrest to offer support to
the load and protect the operator and the truck from objects that
are at risk of falling down from the load carrier and injuring the
operator or the truck when handling the load. See Additional
Fig. 12. Additional equipment equipment, overview. page 12 (pos. A).
A Load backrest D Switches/sockets
B Equipment bar E Load wheel, climbing WARNING
C Work light F Load wheel, Bogie Remember that the load guard requires extra lifting
space!

Table 2. Switch/socket d
D1 5V USB-socket. May be replaced with a 12V- 5V USB-power supply socket (option)
socket
The truck can be equipped with a 5 V USB - outlet designed for
D2 Work light power supply or charging of external equipment. The socket is
D3 Platform damping, adjustable placed on the dashboard and is marked with a 5V/USB - symbol
on the cover. See image Additional equipment, overview page 12
(pos. D3). The truck can only have one type of power socket at a
time. .
 7 DESCRIPTION OF THE TRUCK 14

12V power supply socket (option) enable this function, the truck is equipped with climbing wheels
and slide plates.
The truck can be equipped with a 12 V-outlet designed to supply
power or charge external equipment. The socket is placed on the
dashboard and is marked with a 12 V-symbol on the cover. See Platform damping - adjustable, controls (option)
Controls page 8 The truck can only have one type of power socket
at a time.. With this function, the truck operator has the possibility to adapt
the hardness of the floor damping according to individual
preference. The adjustment is done with a control on the
Equipment bar, multi-purpose tray, writing surface dashboard. See image Additional equipment, overview page 12
(pos. D1). A protection plate between the floor and the fixed
The truck can be equipped the an equipment bar that enables structure that adjusts with the floor movement is installed with this
multiple attachments. Attachments that can be equipped are option to avoid injury to feet.
writing surfaces and multi-purpose trays. Multi-purpose trays can
for example mount tablets and computers. See Fig. 12. Additional
equipment, page 13(Pos B) Foot protection (option)

Work light (option)

The truck can be equipped with work lights in order to improve the
field of vision and working environment for the truck operator in
the fork direction. The option consists of two lights mounted on
the equipment holder, see Fig. 12. Additional equipment, page 13
(pos B). The function is activated by a switch on the dashboard
that is marked with a light symbol, see Fig. 12. Additional
equipment, page 13 (pos. D2).

Closed Pallet Entry and Exit (option)

The function of the Closed Pallet Entry and Exit feature is to
facilitate the entrance and withdrawal of the load carrier forks from Foot protection is an option to help safeguard the operator. If the
standard pallets when handled in crossways direction (closed truck is stationary and light beam is broken the truck will not able
pallets). See Additional equipment, overview page 12 (pos. E). To to be driven. If the truck is in motion and the light beam is broken
the truck will, after a short delay, brake and come to a complete
 7 DESCRIPTION OF THE TRUCK 15

stop. A visual indication will show in the advanced display until the
light beam is unobstructed. Only available for rear entry truck
versions.

Increased drive speed, 10.5/12.5 km/h (option)

Allows an increased drive speed up to 12.5 km/h. Only applies to
trucks with both servo-steering and bogie wheel.
Trucks with single load wheels and/or mechanical steering are
restricted up to 10 km/h.

Lift stop, low battery voltage (option)

Activates when the battery charge is at a critical level and
deactivates the lift function. The lowering function is always active,
even with low battery voltage.

Low battery voltage level (option)

Activates when the battery's charge is at a critical level. The
driving performance is reduced to force the truck operator to
change/charge the battery before it is completely discharged.
 8 BATTERY 16

Battery Requirements of EN 50272-3 must be met. See the battery

supplier's instruction book and the instruction handbook for the
Battery specification battery charger.
Comply with local legislation and safety instructions when
Chassis type Battery Capacity Weight min/ charging batteries. Areas where batteries are charged should be
voltage and (kWh) max (kg) signposted and have good ventilation. An eye douche, washing
capacity (V/ facilities, fire extinguisher and protective glasses should be
Ah) available.
MN (BS cell) 24/300 7.2 250/300
WARNING
JN (BS cell) 24/300-400 7.2-9.6 285/350
Specific gravity checks should only be performed by
JN (DIN cell) 24/270-375 6.48-9 285/350 an authorised service technician.

SN (BS cell) 24/450-600 10.8-14.4 350/470

MN=Mini,
WARNING
JN=Junior, Always use protective glasses. Acid can cause serious
SN=Senior burn injuries.

Battery charging Lead/Acid batteries WARNING

Explosive gas is generated during battery charging!
Battery servicing should only be carried out by specially trained Smoking or a naked flame may cause an explosion!
personnel. Batteries may, however, be charged by other
personnel provided that a battery plug is used to connect the
battery to the charging unit. The battery is charged in accordance WARNING
with the recommendation from the battery manufacturer, with a
charger that is suitable for the battery. The truck is designed for Remove all rings, bracelets, necklaces and similar
use with lead/acid batteries. Only fully automatic charging units items before handling batteries.
should be used.
 8 BATTERY 17

2. Remove any battery covers to gain access to the battery plug

WARNING and to permit the heat generated during charging to be
The battery charger may only be connected to a ventilated away.
grounded socket. 3. Pull the battery plug out from the truck using the battery plug
handle.

WARNING CAUTION
Disconnect the battery and mains connection prior to Do not pull out the battery plug by pulling on its
maintenance, troubleshooting or cleaning of the cables.
battery charger.
4. Ensure that the electrolyte level is correct, as per battery
supplier instructions. The battery may be damaged if the cell
plates are dry during charging. The battery electrolyte may
overflow when charging if its level is too high.

NOTE
This does not apply to gel batteries.

Before charging, ensure that the plates are covered with

battery acid, but not over the edge of the plates. The space
above the plates is needed for charging as the fluid increases
in volume.

NOTE
If the battery water needs to be filled more than
Before charging once a week, it generally indicates that something
is wrong. This applies to normal environment and
1. Switch off the truck. normal use.
 8 BATTERY 18

5. Connect the battery plug to the charger's connector. Maintaining the battery
6. Set the charging switch on the battery charger to on.
7. Check that the charging indicator gives a normal reading. A B
Report otherwise as an error.
After charging
1. Check that charging is completed.
2. Set the charging switch to off.
3. Disconnect the battery charger connector.
4. Check the battery water and, if necessary, fill to the correct
level as per the battery manufacturer’s instructions.
5. Connect the battery plug.
6. If there is a battery cover, close it. Fig. 13. Maintaining the battery

A. Standard lock
B. Quick lock

1 Switch off the truck.

2 Open the battery cover.

3 Pull out the battery plug.

4 Release the battery lock according to the image 13.

Maintaining the battery page 18.
 8 BATTERY 19

5 Roll out the battery slightly. 10 Connect the battery plug.

11 Carefully close the battery cover.

WARNING
There is a risk of crushing injury. Do not insert a 12 Check the battery voltage on the battery indicator.
hand between the battery and the chassis. Use
gloves.
Battery replacement (with rollers)
WARNING
Be careful to avoid splashing waste acid or oxide A B
from the battery. Use protective glasses.

WARNING
There is no battery stop when it is rolled sideways.

6 Check, and if necessary:

• clean.
• top up the battery fluid.
• Perform a battery inspection in accordance with 12 Fig. 14. Battery replacement
Maintenance of the truck. page 49

7 Repeat on the other side to gain access to the other cells. A. Standard lock
8 Roll in the battery after completed service. B. Quick lock

9 Secure the battery using the battery lock. 1 Switch off the truck.
2 Open the battery cover.
 8 BATTERY 20

3 Pull out the battery plug. 9 Lift in the new battery.

4 Release the battery lock according to the image 14. Battery

replacement page 19. NOTE
Ensure that the new battery is correctly oriented.
5 Roll out the battery slightly.
10 Secure the battery using the battery lock.
WARNING
There is a risk of crushing injury. Do not insert a 11 Connect the battery plug.
hand between the battery and the chassis. Use
gloves. 12 Carefully close the battery cover.

13 Check the battery voltage on the battery indicator.

WARNING
Be careful to avoid splashing waste acid or oxide Battery servicing
from the battery. Use protective glasses.

WARNING
WARNING Battery and battery charger servicing may only be
There is no battery stop when it is rolled sideways. carried out by specially trained personnel.

6 Secure with suitable lifting devices, always comply with the WARNING
recommendations of the battery manufacturer when lifting
Avoid short circuits, which can cause explosion or fire.
batteries.
7 Lift slightly and pull the battery all the way out of the truck.

8 Check that the new battery complies with the specification for
the truck, in respect of voltage, capacity and weight.
 8 BATTERY 21

Battery charging Li-Ion

General information WARNING
Disconnect the battery and mains connection prior to
• Battery service should only be carried out by specially trained maintenance, troubleshooting or cleaning of the
personnel. battery.
• Different battery types are not interchangeable. The battery type
the truck was supplied with is the only battery type possible to
use. For example, if a truck is equipped with a Lithium-Ion NOTE
battery system (LBS) it is not possible to exchange with a lead- Only use original lithium ion batteries. Please contact
acid battery, and vice versa. the truck manufacturer or authorised dealer for more
• Only fully automatic charging units must be used. Charge the information.
battery in accordance with this manual, with a certified charger
suitable for the battery. Nameplate
• Charging stations must comply with all standards, legislation Each battery system is fitted with a corresponding nameplate
and local regulations which may vary from region to region. For containing the typical battery performance data and serial number.
example, it is usually prescribed that safety equipment must be Always give the serial number when making inquiries.
available.

WARNING
Only a certified charger installed by an authorized
service technician should be used.

WARNING
The battery charger may only be connected to a
grounded outlet.
8 BATTERY 22

Safety instructions
Read and follow the instruction and safety
manual for the truck and battery provided.
Both the instruction and safety manual
should always be accessible to the operator
in their work area, for when questions arise.
The battery system must not be dismantled
or modified. Maintenance on the battery
system may only be carried out by your
local service partner or supplier.
Do not operate the battery system in
potentially explosive zones. Do not allow it
to come in contact with fire or be short-
circuited. The system may only be charged
with an approved charger.
If these regulations are not followed,
escaping liquid or gas, a fire hazard or
excessive heat generation can occur.
WARNING
Do not remove the nameplate. The terminals of the battery may be live.
There is a short-circuit risk.
The battery system must be kept dry at all
times.
Never attempt to open or dismantle the
battery system. Doing so risks the
possibility of coming into direct physical
contact with the electrolyte, which is very
caustic and is to be avoided at all times.
 8 BATTERY 23

If electrolyte substance comes in contact D B

with your skin or eyes, rinse with plenty of
water and consult a doctor immediately. If
your clothing becomes contaminated,
remove without delay.
C
The battery system must not be discarded
with household or industrial waste.
Esc

Li-Ion Enter

Return the battery system to the

A
manufacturer for free of charge recycling, or
certified recycling company. Fig. 15. Operating and display unit of the charger.

A. Pause button C. Battery LED indicator

B. Graphic display D. Warning symbol
Do not lift the battery system diagonally or
unevenly. The battery must always remain
upright.
Always use a battery lifting beam when To interrupt the charging process, press the pause button .
lifting the battery system. Unplug the
battery/load and charger connectors before
lifting.

Description of the operating and display unit of the charger

The operating and display unit of the charger is equipped with a
battery LED indicator, symbols, a graphic display and pause button.
 8 BATTERY 24

Table 3. Indication of the operating state via the battery LED indicator. Table 3. Indication of the operating state via the battery LED indicator.
(cont'd.)
Battery LED indicator Operating state during
charging Battery LED indicator Operating state during
charging
No battery connected
Wrong battery connected, too
high voltage for this charger
(yellow LED flashes)

Main charge
Pause mode (LEDs flashing
alternately)

Back-up charge
Indication of the operating state via graphic display
The graphic display of the charger has a few different operating
states, primarily:
End of charge • The start display — indicates the set charging parameters.
• Battery charging indicator — this display is shown during the
entire charging process.

End of charge/Balancing
 8 BATTERY 25

1 2 WARNING
Before charging ensure that there is no damage to
either the battery, mains connector, the housing,
3
58.OV 4:30 4
charging and power cables, the charging plug and all
exterior screw connections.

6O.OA 465.5 Ah 5
WARNING
Detected defects must be reported to a supervisor
immediately. The defective charger must then be
6
marked and decommissioned until rectified.
Fig. 16. Example of graphic display during charging.

1. Current battery voltage 4. Charging time of the entire WARNING

charger
A damaged or otherwise defect charger may cause
2. Battery charge indicator 5. Charged Ampere hours
personal injury and/or damage to property.
3. Graph display for charging
current (0–100%)

Charging
The LBS should be fully charged at least once a week and more
often if possible, see .
The every day procedure for charging the LBS is referred to as
”Opportunity charging” and is designed to benefit from intermittent,
sporadic charging, at any given opportunity; even if only for a
short time.
 8 BATTERY 26

Start of charging
WARNING
There is a risk of severe personal injury and/or
damage to property, when a running charging
process is interrupted by pulling out the charging
plug.

2. Disconnect the charger plug from the battery.

3. Start the truck using the normal log-in procedure, see Starting
the truck page 43.
Discharging
If the battery is not used for a long period of time (>2 hours), the
battery automatically switches to Sleep Mode. The battery can be
reactivated by pressing the On-button on the battery display.
At a discharged level of 15% (85% of the battery system’s
capacity spent), the integrated alarm horn briefly sounds once.
The battery should be charged as quickly as possible.
1. Connect the charger plug to the battery plug, located on the
At a discharged level of <10%, the integrated alarm sounds,
side of the battery.
pulsing steadily. The battery has to be charged immediately.
2. Check that the charger activates, on either the battery LED
At a discharged level of 0%, the battery is turned off.
indicator or the graphic display.
After charging
WARNING
This should be avoided at all costs as the sudden
1. Stop the charger using the charger pause button.
cutoff of the battery can lead to damage and hazards.
 8 BATTERY 27

After one minute the battery can be activated by pressing the On- Battery service
button one more time in order to directly drive to the charger. After
that, the battery remains turned off in order to avoid further damage.
NOTE
Only clean the battery system when the system is
WARNING switched off.
If the battery has shut off due to a low discharge level it
must be charged immediately, as it can lead to If it’s necessary to clean the battery tray, use a soft, clean cloth,
permanent damage to the battery system. Long times but never use liquids (acidic or abrasive cleaning products).
at a fully discharged level must be avoided at all costs.

CAUTION
Battery maintenance and inspection Never use a pressure washer or steam to clean the
outside of the battery.
Battery balancing
At least once a week (more often preferably) the LBS need to Before each use, check the battery system for damage (loose
perform a battery balancing. This is done through allowing the plug-in connections, defective cables, etc.). If a defect exists,
battery to charge to full. contact your local service partner or supplier.
To start the charging, follow the procedure of Charging page 25
and let the battery remain charging until the battery LED indicator CAUTION
and the graphic display states 100%. The battery balancing Battery and battery charger service may only be
should be left charging for a minimum of one hour. The certified carried out by specially trained personnel. Do not
chargers are designed to control and terminate the charging cycle under any circumstances attempt to repair the battery
automatically, once complete. on your own.
The battery system can become permanently damaged if it sits
discharged for a lengthy period of time. The fully charged system Service and repair
can be put into storage for up to 6 months, before it must be
recharged. The battery system require regular service inspections and
maintenance as performed through an authorized service partner.
If any errors are displayed or the unit malfunctions, immediately
contact your local service partner or supplier.
 8 BATTERY 28

Error Messages • The battery does not switch on — possibly no communication

with the charger or vehicle.
When errors occur an error menu is accessible.
Necessary Action: Check the plug and cable (contact
• The battery system will not start or it shuts down. problems).
Necessary Action: Contact your service provider. • External display does not respond.
• The horn is pulsing steadily: maximum discharge of 90% was Necessary Action: Check the plug and cable (contact
reached (10% remaining). problems).
Necessary Action: Charging is required. Any other errors or faults, the service partner or supplier must
• The battery system shuts down: 100% discharge has been be notified immediately.
reached (0% remaining). Technical specifications
Necessary Action: Acknowledge that the battery is in a state of Further performance data of the battery system is given on the
deep discharge. After one minute, press the ON/OFF button respective nameplate, that can be found on the battery and in the
and immediately drive slowly back to the charging station and operation and maintenance manual for the truck.
put the battery on charge to prevent battery damage.

WARNING
WARNING The Li-Ion battery system is not compatible with cold
This should be avoided at all costs as the sudden store environments.
cutoff of the battery can lead to damage and
hazards.
Operating temperature range
–27° C to + 55° C (discharge)
WARNING –27° C to + 55° C (charge)
If the battery has shut off due to a low discharge
level, it must be charged immediately. Long sitting Nominal operating temperature
times of discharged batteries are to be avoided at
25° C
all costs. Nonobservance can lead to battery
damage.
8 BATTERY 29

Storage temperature
-20° C to + 45° C
Self-discharging
< 3 % per month at 25° C
 9 DISPLAY 30

Display Battery indicator

The battery’s charge is indicated with a bar diagram (A). The
Simple display number of lit and off fields indicates the battery charge. When the
Simple display general battery charge reaches a level that requires charge of the battery,
the battery icon lights (B). The level at which the warning starts to
The truck can be equipped with a simple display showing indicate is adjustable between 10% and 50% but requires
information on battery status, driving status and warnings. aftermarket tool setup.
Graphic symbol field
Simple display
There a graphic symbol fields in the display. The following
The simpler type of display consists of a battery indicator, graphic appears:
symbol field and an alphanumeric display.
• Battery (B): Displayed with a low battery level.
Alphanumeric display
The alphanumeric display indicates the following:
1/2
0 1 • Parking brake (C): If the parking brake is active, the letter P
A appears on the display, otherwise nothing is shown in this
G
B position.
• Low speed (D): If low speed is active, the letter L appears on the
F
display. At normal speed, nothing is shown in this position. Low
C E speed/normal speed is activated/deactivated with a button on
D the tiller head, see Controls page 8 (D). If the truck is operating
Fig. 17. Simple display in tiller up drive the letter L will blink.
A Battery discharge indicator E Error code prefix (E or U) • Error code prefix (E): At this position the letter E appears for a
B Battery icon F Numeric code (Operating time system based error and U for a user based error. If there are no
or error code) error codes, operating time is shown in this position on the
C Parking brake, activated G Warning lamp display. For system based errors that requires contact with a
D Low speed, active service technician, the red warning lamp also lights up (G).
 9 DISPLAY 31

• Numeric three position code (F): This displays the truck's Table 4. Warning messages in the display
operating time or error/warning code. Operating time is shown
as standard. Warning (Error Descriptions Operator actions
code)
• Warning lamp (G): The red warning lamp lights up for a system
based error (Error code with prefix E). U001 Operator is not in Step onto the
correct position for platform or fold it
For a description of the error codes which are a warning for the truck operation. up.
truck operator, see section Warnings page 31. (Note: Includes
platform and left
foot, not seat, side
Warnings guards nor foot
There are a number of different warnings used to attract the protection sensor).
operator’s attention in the case of e.g. an operational error. Some
U002 Incorrect start Release the
of the truck’s systems will also not be operable until the operator
sequence throttle and retry
has followed the command on the display. Other warning
(accelerator when in correct
messages are displayed if a system in the truck is not working or
activated prior to operator position.
starts to overheat. If the warnings do not disappear even though
operator presence
the driver has followed the instructions in this manual, contact an
or accelerator
authorised service technician. For a list of warning messages
active at logon).
shown in the display, see table Warning messages in the display .
U003 Incorrect start Release the
sequence (load controls and retry
handling control when in correct
activated prior to operator position.
operator presence
or load handling
control active at
logon).
 9 DISPLAY 32

Table 4. Warning messages in the display (cont'd.) Advanced display (option)

Warning (Error Descriptions Operator actions Advanced display
code)
The truck can be equipped with an advanced display that enables
U010 Side guards are Make sure the side the operator to interact with the control system and receive
not in correct guards are not in relevant information, see Fig. 18. Advanced display, page 32.
position for truck an intermediate
operation. position. If the
platform is up, then
fold the side
guards down to be
able to drive.
U011 Traction is not Make sure the feet
allowed due to that are not on the
the foot protection edge.
sensor is active.
U012 The Active Spin No operator action
Reduction is active, required.
which limits the
travel speed for a
short period of time. Fig. 18. Advanced display
E015, E205, E206, Limp Home: A Drive to service
E304 system error has area and contact
caused the truck to service technician.
enter Limp Home
mode. Driving
performance is
reduced.
 9 DISPLAY 33

Overview of Advanced display Start the truck by logging on using the advanced
display
After the initialization is finalized and the display is ready to
receive operator authentication data the logon screen is displayed,
see Fig. 20. Logon screen, page 33.

A P E
B 4657 F

C G

D
B 1 2 3 4

Fig. 19. Advanced display, overview

C
A. Display area C. Function keys
D
B. Function key identifier row D. Dedicated keys

Fig. 20. Logon screen

The display can be divided into sections according to Fig. 19. A. Parking brake icon E. Time field
Advanced display, overview, page 33: B. Function key identifier row F. Operator ID input field
The dedicated keys are from left to right, arrow left, arrow right, C. Function keys G. Operator password input field
backspace, enter. D. Dedicated keys

Start the truck by logging on:

1. Enter Operator ID by entering numbers with the function keys
(pos C) corresponding to numbers in the function key identifier
 9 DISPLAY 34

row (pos B). When the correct operator ID has been entered Operational screen
the cursor will automatically move to the operator code input
box. It is an option to not have the operator ID as a required
input field and only use Operator password. This is available If the operator is identified and the password combination is valid,
as an option when ordering the truck or by a service technician. the main screen is presented and the truck starts, see Fig. 21.
The default function key set-up is [1 2 3 4]. Press the “Arrow Operational screen, page 34.
right” key to change function key set-up to [ 5 6 7 8] then [8 9
menu.i]. To reverse press the left arrow.
To change digits that has been entered, use the “Back space” D
key to erase one position with each activation.
2. Enter Operator password by entering numbers with the
function keys (pos C) corresponding to numbers in the A
function key identifier row (pos B). If incorrect code is entered E
a red X will appear over the logon screen. B F
The default function key set-up is [1 2 3 4]. Press the “Arrow C
right” key to change function key set-up to [ 5 6 7 8] then [8 9 G
menu.i]. To reverse press the left arrow.
To change digits that has been entered, use the “Back space”
key to erase one position with each activation. Fig. 21. Operational screen
If the truck is equipped with a key switch and advanced display A. Battery discharge indicator E. Multi-purpose indicator
then the key switch acts as logon and start function, see Controls (BDI)
page 8. The menu screen is accessible from the logon screen B. Function key identifier row F. Log on/off button
See Menu screen advanced display page 37. C. Performance category G. Menu button
D. Centre indicator

The operational screen consists of a battery discharge indicator

A), a centre indicator (D) and a truck status indicator. Different
functions can be shown in the function key identifier row (B)
 9 DISPLAY 35

depending on how the truck is configured. In this example the instructions page 44. If the “No hands” icon is shown in the centre
following functions are shown: indicator then the operator should release the controls.
• Press function button (C) to change Performance category(not
available if truck has a Key switch). From left to right , Power Symbols in the display
mode, Eco mode, Easy mode (reduced performance can be
set as only option for specific operators).
• The multi-purpose indicator shows operating temperature, The truck uses various symbols, colours and error codes in the
energy consumption (power) or hydraulic pressure. Select display to communicate with the operator. Examples of symbols in
which is shown in the menu screen. the display are shown in Fig. 22. Symbols in the display, page 35.

• Press the Log off button (F) to log off.

• Press the menu screen button (G).to open the menu screen.
1

Battery discharge indicator (BDI)

This function presents the power remaining in the battery, see Pos
A in figure Operational screen page 34. If the truck is configured
with a standard battery, the colour of the bar graph is white. If the
truck is configured with a litium-ion battery, the graph is blue.
When Eco mode is selected, BDI is in eco green and with a eco
leaf, see Symbols in the display page 35.

Centre indicator
Fig. 22. Symbols in the display

1. Icon row
The centre indicator shows the trucks status regarding driving
mode and safety features, such as side guards and platform
position. If operator or truck is in a position that stops the truck Icons and positions may differ between different truck types.
from moving it will be shown in the centre indicator. See , Driving
Symbols that can be displayed are:
9 DISPLAY 36

Symbol Description Eco mode is active.

Tiller up drive/Low speed. Yellow tortoise
indicates the truck is in Tiller up drive and
has markedly reduced speed and
performance for precision handling. Green
tortoise indicates low speed is activated. Temperature warning.
Low speed is activated by pressing the
button on the tiller head, see the Instruction
handbook. The performance category can
be changed by pressing the left most
function key, provided that the maximum
category is Power mode or Eco mode.
Service alarm. When the service interval is
According to a legal requirement, the truck reached, the wrench symbol pops up. The
speed is limited to max 6 km/h when the service interval is set in the TruckTool
operator is walking with the truck or Settings menu. Two service intervals can be
standing on the foldable platform with the selected: active use of truck in hours and
side guards lowered. calender time in months.
The truck is equipped with regenerative
Indicates that drive stop is active. braking. When the brake system is charging
the battery, the arrow symbol is displayed.

Parking brake is active.

 9 DISPLAY 37

System error. Menu screen advanced display

Release controls.

Audible alert
In the menu screen, use the arrow keys to choose one of the four
The display features a buzzer to call attention of the operator to icons and select by pressing the enter key. The screen
the HMI, when significant information is shown, such as error corresponding to the selection is displayed. The options available
codes. are Brightness adjustment, Hour/Trip meter, Time/Date, Operator
session log and Versions. Exit the menu screen by pressing the
back button.
 9 DISPLAY 38

Brightness adjustment Hour/Trip meter

Change the brightness with the arrow keys, to increase brightness

by moving the cursor to the right and to decrease the brightness
by moving the cursor to the left. Save and exit to menu by
pressing the back button.

• A.Trip screen
• B.Reset trip meter
 9 DISPLAY 39

The hour screen shows total accumulated operating time. The trip Operator session log
screen shows the current operating time. To reset the trip meter
press and hold the reset trip meter function key for one second.
Exit to menu by pressing the back button.
Change time/date

In the operator session log is a list of dates and times of when

operators were logged on. Exit to menu by pressing the back
button.
Versions
Highlight the desired section by pressing the arrow key. To
activate edit mode, press the enter key. The numbers can then be
increased or decreased with the arrow keys. When the desired
number is reached, press the enter key to save and exit edit mode.
12/24 h format can be changed with external service tool. Exit to
menu by pressing the back button.

A
 9 DISPLAY 40

The versions screen shows the current software versions installed Table 5. Warning messages in the display
on the trucks electric system devices. C shows the credits screen.
Exit to menu by pressing the back button. Warning Descriptions Operator actions
Truck won’t drive. To drive the truck
Advanced display warnings Platform folded up with foldable
and side guards in platform up the
raised position. side guards must
be in a lowered
There are a number of different warnings used to attract the truck position. Only
operator’s attention in the case of e.g. an operational error. Some applicable to
of the truck’s systems will also not be operable until the operator foldable platform
has followed the instructions on the display. Other warning truck variant.
messages are displayed if any system in the truck is not working
or starts to overheat. An audible alert will sound if there is a Truck won’t drive. To drive the truck
system error or warning. If the warnings do not disappear even Driver not standing without standing on
though the operator has followed the instructions on the display, on foldable the platform the
contact an authorised service technician. For a list of warning platform in lowered platform must be in
messages shown in the display, see table 5. Warning messages position. the raised position.
in the display page 40. Only applicable to
foldable platform
truck variant.
Truck wont drive. If Make sure the side
a stop sign is guards are
visible and the completely lowered.
operator standing Only applicable to
on the platform foldable platform
with side guards in truck variant.
neither fully
lowered or raised
position.
 9 DISPLAY 41

Table 5. Warning messages in the display (cont'd.) Table 5. Warning messages in the display (cont'd.)

Warning Descriptions Operator actions Warning Descriptions Operator actions

Truck won’t drive. Lower the side Temp warning. Reduce drive
The side guards guards and raise speed or stop the
are in a raised the foldable truck to allow the
position and platform or make temperature to
platform is in a sure the foldable decrease.
lowered position platform is
and the operator is completely lowered. Service due. Contact authorized
not standing on the Only applicable to service engineer.
platform. foldable platform
truck variant.
Truck won’t drive. Place feet fully on
Operators foot is platform so that the
not in correct foot protection Low battery. Charge the battery.
placement. sensor is not Warning indication Critical level may
activated. Only and low battery damage the battery.
applicable to truck indicated in battery
variant with fixed discharge indicator.
rear entry platform. Low battery is
indicated by the
No Hands symbol. Release all hand bar changing
controls. colour to orange
and when a critical
level is reached, to
red.
 9 DISPLAY 42

Table 5. Warning messages in the display (cont'd.) Table 5. Warning messages in the display (cont'd.)

Warning Descriptions Operator actions Warning Descriptions Operator actions

Active Spin No operator action Limp home. A Drive to service
Reduction (ASR) is required. system error has area and contact
active. This caused truck to service technician.
function reduces enter Limp Home
spinning of the mode. Driving
drive wheel. A performance is
reduction of reduced.
performance may
be noticed
temporarily.
System error In the event of a
warning. There are persistent warning
two levels of triangle, cut power
system error to the truck by
warnings, yellow disconnecting the
and red. Yellow: battery or press the
System error that emergency stop
may impede some button. Restart
functions. Red: after 10 seconds. If
system error that error message
will impede normal remains contact
truck operation. service technician.
 10 DRIVING INSTRUCTIONS 43

Driving instructions To select ECO mode if the truck is equipped with a with key switch
entry,see Starting the truck page 43.
Starting the truck If the truck is equipped with an advanced display see Start the
truck by logging on using the advanced display page 33 how to
1 Connect the battery plug and check that the emergency stop select Eco mode.
function is disengaged.
If the truck is equipped with an advanced display (option) and the
2 Turn the start key to the position “ignition on”, see image truck is operating in eco mode, the colour of the battery discharge
Controls page 8 (pos. B). indicator (BDI) is in eco green with a eco leaf symbol, see Fig. 22.
Symbols in the display, page 35.
Power mode
Getting in and out
This mode gives powerful, dynamic response and should only be
Be careful when getting in and out. Pay attention to the difference
used by experienced operators. Use the key switch/start switch to
in height between the floor and the truck.
select the operation mode, see Fig. 8. Key switch entry, page 9. If
the truck is equipped with an advanced display see Start the truck
WARNING by logging on using the advanced display page 33 for how to
It is not permitted to climb on to the truck. select Power mode.
Easy mode
Easy mode is suited for inexperienced drivers, but may also be
used if sensitive goods are handled or to reduce risks in confined
Drive mode spaces. See Operational screen page 34 for how to select Easy
The truck can be operated in several operation modes. mode. Easy mode is only available with the Advanced display.
Economy mode (ECO) Low speed
Eco-mode is an economic drive mode that provides slightly Low speed has reduced performance for pedestrian use. To
reduced performance in combination with lower energy activate low speed press the low speed button on the tiller head.
consumption. This is an easy truck operation mode for occasional See Controls page 8.
truck operators, for training and for long truck operation periods.
Acceleration, breaking and max speed are reduced.
 10 DRIVING INSTRUCTIONS 44

Tiller up drive A B
Tiller up drive is used for precision driving at greatly reduced
performance. To activate Tiller up drive press the low speed
button with the tiller in an upright position. See Controls page 8.

Driving instructions
The truck is either equipped with a pivot arm or tiller arm, see
image 23. Truck with pivot arm or tiller arm page 44. Both control
arms have different characteristics.
Pivot arm:
Fig. 23. Truck with pivot arm or tiller arm
• functions as fixed steering,
A Truck with pivot arm B Truck with tiller arm
• may be set in vertical position.
Tiller arm:
The truck has either mechanical or power steering. Mechanical
• may be angled during use,
steering is only available for the foldable platform variant and is
• returns automatically to the folded up position, standard. All variants can have power steering.
• brakes are activated in folded up/folded down position. • Tiller power is available for the foldable platform and rear entry
variant.
• Pivot power is available for the side entry and rear entry variant.
Driving the truck:

1 Start the truck in accordance with Starting the truck page 43.

2 Truck with tiller arm: Angle down the tiller arm to make
driving possible.
 10 DRIVING INSTRUCTIONS 45

3 4 There are several ways to brake the truck:

• Brake by moving the speed controller back to its neutral
position. This ensures smooth braking and should be the
method generally used.
• Brake the truck by reversing, i.e. changing the direction of
travel.

NOTE
The further the speed controller is moved the
greater the braking capacity.

Fig. 24. Speed control • Truck with tiller arm: Brake by moving the tiller arm up or
down to its end position. Only used when maximum
braking is required.
The truck begins to drive when the tiller arm's speed control is
• Truck with pivot arm: Brake by pressing the belly safety
turned forward/back. The further the speed controller is
switch, see image Fig. 6. Controls, tiller head, page 8 (pos
moved the faster the truck will move. When using the Tiller-up
F). Only used when maximum braking is required.
drive option driving is possible with the tiller in an upright
position, at greatly reduced performance for precise handling.
NOTE
The brakes work regardless whether the speed
control is affected or not.

5 If the main power needs to be disconnected in an emergency,

press the emergency stop button or pull out the battery plug.
The emergency stop button is on the left side in the driver cab
facing the forks.
 10 DRIVING INSTRUCTIONS 46

6 In order to avoid crushing injuries during driving, there is a High visibility fork tips and Crossway pallet
belly safety switch at the end of the tiller arm. handling indication
• Truck with tiller arm: When the belly safety switch is
pressed in the truck will slow down and then move, with
maximum power, in the direction the forks are pointing.

7 It is possible to manually activate low speed during operations

by pressing in a button on the tiller head, see image Controls A
page 8 (pos. D).

8 Switch off the truck in accordance with Switching off the truck
page 47. B

Fig. 25. High visibility fork tips and crossway pallet handling indication

The truck is equipped with a High visibility fork tips. See Fig. 25.
High visibility fork tips and crossway pallet handling indication,
page 46(pos. A). The aim of this function is to give the operator a
visual aid to make it easier to identify the position of the forks. The
fork tips are equipped with high contrast markings, which lie on a
recessed surface to minimise wear. The function is especially
advantageous in environments with poor or reduced lighting, such
as containers and trailers without lighting.
The truck is also equipped with an indication for Crossway pallet
handling. See Fig. 25. High visibility fork tips and crossway pallet
 10 DRIVING INSTRUCTIONS 47

handling indication, page 46(pos. B). This function is a visual aid

for the truck operator to correctly place the pallet crossways on
the forks to avoid:
• The fork tips extending beyond the outer pallet's side, that isn’t
within the vision field of the truck operator. This reduces
possible risks that can occur when a load is crosswise and not
transported correctly.
• The pallet is crushed. The load wheels are placed in the correct
position to prevent them from damaging the pallet when the
forks are lifted and lowered.

Switching off the truck

1 Turn the start key to the position “Ignition off”, see image
Controls page 8 (pos. A).

2 In the case of a lengthy stop, pull out the battery plug.

NOTE
Emergency stop must not be used to switch off the
truck.
 11 GENERAL LOADING AND UNLOADING INFORMATION 48

General loading and unloading CAUTION

information Check the load centre distance of the load.
Responsibility for the load
The operator of the truck is responsible for the load that is being
carried during transport. There must not be any risk of the load CAUTION
tipping or sliding off during transport. The operator of the truck has Do not drive with the load lifted.
the right and duty to refuse to carry any load that is a clear safety
hazard. Refer to the load limit plate to see the permitted maximum
load for the truck.

Responsibility for others

Operate the truck so that there is no risk of an accident. No one
may pass or stand under the raised forks, whether they are
carrying a load or not. The truck operator has the right and duty to
see that these directives are followed.

Maximal load
The maximum lifting capacity of the truck must not be exceeded
(refer to the fork lift truck machine plate). Note the effect of the
load centre distance on the lifting capacity.

Picking up a load
Always pick up a load so that it comes to rest as close to the mast
as possible.
 12 MAINTENANCE OF THE TRUCK 49

Maintenance of the truck Daily inspection (after each shift)

Responsibility: Truck operator
Daily inspection (before each shift)
Battery charging
Responsibility: Truck operator
Check the battery voltage on the battery indicator.
CAUTION Charge the battery as necessary. Only an original charger suited
Naked flames or smoking are prohibited when working to the battery may be used.
on or near to the battery.
Refer to section Battery charging page 16 for the charging
procedure.

CAUTION If there is damage

Loading ergonomics must be observed during battery Any damage that has occurred must be reported to the supervisor.
change or battery check.

1 Check that the battery cables, connections and plugs are Weekly inspection
connected correctly and not damaged. Responsibility: Truck operator
2 Check that the battery is properly secured in its compartment. 1 Clean the battery; see the battery manufacturer's maintenance
instructions.
3 Check that the truck is not leaking oil.
2 Check the oil level in the hydraulic system by pushing all the
4 Check the signal horn by activating the controls while the truck hydraulic cylinders to their end positions. Then, control that
is switched on. the fork assembly reaches the maximum lifting height without
5 Check the braking capacity on the main brake and parking the pump sucking air.
brake.
3 Check that the wheel is intact.
6 Check for external damage or excessive wear on the wheels.

7 Check that there are no error messages or warnings on the

truck computer display.
 12 MAINTENANCE OF THE TRUCK 50

4 The outside of the truck should be cleaned. Vacuum clean, and

wipe with moist cloth in the operator cab. Electrical panels and
printed circuit boards must always be protected from liquids.
Damage to the truck caused by liquids in contact with
electrical components is not covered by the manufacturer's
warranty.

Preventive maintenance

NOTE
Preventive maintenance must be carried out by
specially appointed and trained personnel with a good
working knowledge of the function and maintenance of
the truck.
 13 SERVICING AND MAINTENANCE 51

Servicing and maintenance WARNING

Service technician Do not touch non-insulated electrical connections
without the battery being disconnected for at least two
minutes.
NOTE
Servicing and maintenance must be carried out by a
specially appointed and trained technician with a good • Ensure that the drive wheel is off the ground before
working knowledge of the truck's function and troubleshooting. Secure the truck with blocks.
maintenance. • To prevent crushing injuries, the battery plug should always be
removed when working on and around the mast and hydraulic
To achieve the best result from your truck investment, we unit.
encourage you to contact your service organisation to sign an
• When dismantling parts of the hydraulic system, the system
active maintenance agreement with continuing service.
must not be pressurised, e.g. the pump motor must be shut off
and the forks down.
Safety instructions for maintenance • The battery should always be protected during grinding work.
Working at height • When changing a fuse, the controllers must be thoroughly
discharged. (Remove the battery plug and wait for two minutes
Comply with local safety instructions when working at height. before fuses are changed, otherwise there a risk of arcing.)
• Great caution must be observed when removing gas springs.
Precautionary measures during repairs They contain compressed gas and may explode.
Utmost importance must be placed on precautionary measures to
avoid accidents during all work on the truck.
Maintenance intervals
WARNING Recommended replacements
The battery plug should be pulled out before working
on the truck. NOTE
To ensure correct operation, use only original spare
parts.
 13 SERVICING AND MAINTENANCE 52

• Air filters for the hydraulic oil tank must be checked and cleaned • Check of lifting devices.
or replaced as needed but no later than after each 600th
operating hours. • Check of component attachments.

• The hydraulic oil must be changed annually or every 1200 hours • Check of the horn.
of operation. • Operation test front, back and steering.
• Check of the drive unit.
CAUTION
If the hydraulic oil has been heated to over 60°C, • Check of all the wheels.
the oil and the filter must be replaced immediately, • Test of the brake function.
since the chemical properties of the oil may have
changed. • Change the oils in accordance with instructions.
• Check for oil leakage.
• Gearbox oil must be changed at first service and then every • Check of the hydraulic unit, pipes and hoses.
1800 hours of operation.
• Check of the cylinders.
Servicing, type and frequency • Function test, lifting and lowering.
General • Lubrication in accordance with lubrication chart.
Before service, the truck should be test driven, in order to test its • Measurement and check of the battery and charging function.
functions. Any errors should be corrected before servicing the truck.
Service intervals
First service (200 hours)
Service must be carried out regularly, once a year or after 600
This service has the purpose of ensuring the operation of the hours of operation with normal use of the truck. The planned
truck and its component parts. The gearbox oil must be changed servicing includes operations such as test driving, functional tests,
and a functional test carried out in accordance with the following list. and the changing of filters and oils, etc.
• Check for external damage on chassis.
• Check of weld joints at vital points.
 13 SERVICING AND MAINTENANCE 53

Table 6. F, R and S stand for foldable platform, rear entry and side entry
NOTE variant respectively (cont'd.)
In the case of demanding and/or dusty environments Chassis
with humid or corrosive air, it is advisable to perform
maintenance more often. Your authorised service Description F R S
organisation can help you assess this.
Link system X X X
Castor wheel X X X
Service points Micro switches X X X
Planned service inspections are implemented in accordance with Pivot points X X X
the following points:
Operator’s platform X X X
X Obligatory
O Not obligatory Side guards X X X
Machine plate X X X
Table 6. F, R and S stand for foldable platform, rear entry and side entry
variant respectively
Drive unit
Chassis
Description F R S
Description F R S
Gearbox (oil level/oil X X X
Signs/Decals X X X leakage)
Covers and panels X X X Traction motor X X X
Load wheels X X X Drive wheel X X X
Battery lock, rollers X X X Drive shaft X X X

Rubber mat X X X
Chassis X X X
Lubrication X X X
 13 SERVICING AND MAINTENANCE 54

Mast system Hydraulic system

Description F R S Description F R S
Forks, fork carriage X X X Pump motor X X X
Bearings/Rollers X X X On/off valve X X X
Lubrication X X X Friction force X X X
Pull rods X X X
Lift cylinders
Steering Description F R S
Description F R S Cylinders X X X
Servomotor X1 X X
Electrical system
Tiller foot X X X
Description F R S
Steering Bearing X2
Cables, Switches X X X
Steering chain X2
Contactors X X X
1. Option
2. Mechanical steering Battery X X X

Hydraulic system Traction motor X X X

controllers
Description F R S
Horn X X X
Hydraulic oil level X X X Speed Controller X X X
Hoses X X X Fuses X X X
Couplings X X X Battery plug X X X
13 SERVICING AND MAINTENANCE 55

Electrical system Consumable materials

Only consumables (oils, grease, lubricants, etc.) that have been
Description F R S approved by our genuine spare parts department may be used for
Cooling fan X X X servicing and maintenance of the truck. See Genuine
replacement parts page 60.
Truck computer X X X
Belly safety switch X X X
button
Emergency stop X X X
Lift switches X X X
Hour meter X X X
Operator presence X X X
sensor
Battery indicator X X X
Key switch O O O

Brake system
Description F R S
Brake function X X X
Parking brake X X X
Brake disc X X X
 13 SERVICING AND MAINTENANCE 56

Lubrication chart, rear entry Components to lubricate, rear entry

Location Explanation
A Fork carriage, 4 pcs. grease
nipples
B Hydraulic oil
C Steering bearing, 1 pc. grease
nipple
D Gearbox oil
A
E Castor wheel
B

A C

E D

200h
600h
1200h
1800h

Fig. 26. Lubrication chart, rear entry

 13 SERVICING AND MAINTENANCE 57

Lubrication chart, side entry Components to lubricate, side entry

Location Explanation
A Fork carriage, 4 pcs. grease
nipples
B Hydraulic oil
C Steering bearing, 1 pc. grease
nipple
D Gearbox oil
A
E Castor wheel
B

A C

E D

200h
600h
1200h
1800h

Fig. 27. Lubrication chart, side entry

 13 SERVICING AND MAINTENANCE 58

Lubrication chart, foldable platform Components to lubricate, foldable platform

Location Explanation
A Fork carriage, 4 pcs. grease
nipples
B Hydraulic oil
C Steering bearing, 1 pc. grease
nipple
D Gearbox oil
A
E Castor wheel
B

A C
Symbol key, lubrication chart
E Table 7. Symbols in the lubrication chart
E D
Symbol Explanation Symbol Explanation
Hydraulic oil (level Hydraulic oil,
check). change.
200h
600h Air filter, control/ Air filter, control/
1200h cleaning. cleaning.
1800h
Gearbox oil (level Gearbox oil,
Fig. 28. Lubrication chart, foldable platform check). change.
Grease. Chain spray.

Chain spray/oil. Only cold store

version.
 13 SERVICING AND MAINTENANCE 59

Applicable in general for the symbols: Fuses

• Unfilled symbol - Control lubrication and lubricate as required. Designations Heavy current (A) Use
• Filled symbol - Change. F1 250 Combi controller;
Power supply
Fuses F3 5 Truck computer,
General HMI and key
switch
WARNING F4 7.5 Combi controller
Fuses should be changed by an authorised service and EPS; Logic
technician. supply
F5 10 Combi controller
outputs, Power
WARNING supply
Always switch off the current by pulling out the battery
plug when changing fuses. F6 10 Options, power
supply + extra
power outlet
WARNING F7 10 12V option
Do not touch non-insulated electrical connections until
F19 40 EPS; Power supply
the battery as been disconnected for at least two
minutes.
 13 SERVICING AND MAINTENANCE 60

Maintenance instructions Truck condition Possible cause Action

Genuine replacement parts The truck does not The battery plug Insert the battery
start has not been plug
Genuine Parts
inserted
The reliability that we promise is contingent upon using original
Emergency Stop Close the
spare parts. Only our genuine replacement parts guarantee
Switch emergency stop
correct operation, long life and the right to a warranty.
switch
Battery level too low Charge the battery
Basic troubleshooting
Defective fuse Change the
If the truck does not work after action has been taken in
defective fuse
accordance with the following table, contact an authorised service
technician. Further action should only be carried out by specially The key switch is Turn the key
assigned and trained service technicians. If an error code is set to "0" or the switch to position
shown on the operator's display, this must be reported to an truck is not logged "I" or enter the
authorised service technician. on appropriate
Operator ID and
password
The truck cannot The truck is not Carry out all the
be driven ready for use actions under the
heading "The truck
will not start"
Operator not Pull down the tiller
standing on arm and stand on
platform the platform
Change the
Defective main fuse defective main
fuse
13 SERVICING AND MAINTENANCE 61

Truck condition Possible cause Action Truck condition Possible cause Action
The truck will not The truck is not Carry out all the Steering damper is Change defective
lift the load ready for use actions under the worn out/defective steering damper
heading "The truck
will not start" Truck cannot be Fuse F19 is Change defective
steered defective fuse
Operator not Stand on the
standing on platform Power steering Connect power
platform system incorrectly steering system
connected correctly
The hydraulic oil Check the level
level is too low and top up the Power steering Fit/connect sensor.
hydraulic oil system sensor Calibrate power
incorrectly fitted/ steering system
Battery level under Charge the battery connected according to
20 % service manual
Defective main fuse Change the Truck will not steer Power steering Calibrate power
defective main straight system incorrectly steering system
fuse calibrated according to
service manual
The load is too Reduce the load
heavy Refer to the Fuse F19 blows Something is Check that all
maximum when steering preventing drive moving parts in the
permitted weight wheel from turning power steering
on the load limit system (gear
plate wheel, chain, gear
box) can move
Power steering is Steering damper is Unscrew the freely
too light/heavy not sufficiently steering damper
applied or is worn screw.
out/defective
 13 SERVICING AND MAINTENANCE 62

Covers and panels 3 Remove the cover by pulling it straight out and downwards.
General
4 Install in the reverse order.
WARNING
Removal and installation of the machine front cover, rear and
The removal and refitting of panels and covers should
side entry
be carried out by an authorised service technician.
1 Remove the securing screws.

WARNING 2 Remove the cover by pulling it straight out and downwards.

Disconnect the main power circuit by pulling out the 3 Install in the reverse order.
battery plug before the covers are removed.
Removal and installation of top cover
WARNING 1 Disconnect the cable connections to the tiller arm.
Take great care in the machinery compartment, e.g. in
2 Remove the tiller foot from the steering shaft by loosening the
respect of hot surfaces.
screw.
3 Disconnect the cable connections to the dashboard.
WARNING 4 Remove the screws for the top cover.
Use of the truck with covers and panels removed is not
permitted. 5 Remove the top cover.

6 Refit in the reverse order.

Removal and installation of machine front cover, foldable
platform Removal and installation of the dashboard
1 Remove the securing screws. 1 Disconnect the connections to the dashboard.

2 Raise the gates. 2 Remove the screws to the dashboard.

3 Remove the dashboard.
 13 SERVICING AND MAINTENANCE 63

4 Refit in the reverse order.

WARNING
Ensure that the truck is unable to move while work is in
Dismantling and assembling wheels progress.
Safety regulations concerning wheel change
1 Remove the lock nuts and screws.
WARNING 2 Remove the castor wheel.
For safety reasons, we recommend that wheel
changes only be carried out by an authorised service 3 Install in the reverse order.
technician.
TORQUE
The lock nut should be tightened with 81 Nm.
WARNING
For optimum performance and so as not to invalidate
the warranty, use only our genuine replacement parts!
Otherwise, we are unable to guarantee stability and Dismantle and assemble the drive wheel
brake function.
Pull out the battery plug.

1 Loosen the drive wheel nuts, without removing them.

WARNING
Take care while lifting and securing the truck with a 2 Lift the drive wheel off the ground and secure the truck with
block, as there is a risk of crushing injury. blocks.

WARNING
Dismantle and assemble the castor wheel Ensure that the truck is unable to move while work
is in progress.
Lift the load wheel off the ground and secure the truck with blocks.

3 Remove the wheel nuts and remove the drive wheel.

 13 SERVICING AND MAINTENANCE 64

4 Install in the reverse order. Dismantle and assemble the load wheel (Bogie)
1 Lift up the truck, and secure it with blocks.
TORQUE
Tighten the wheel nuts crosswise, to 84 Nm. 2 Remove the screws from the wheel ends.
3 Lift off the wheels with their axles and spacers.
Start the truck and test drive in both directions. The wheel must
4 Inspect, and replace all damaged parts.
not catch or jam.
5 Refit in the reverse order.
Dismantle and assemble the load wheel, (Single)
1 Lift up the truck, and secure it with blocks. Dismantle and assemble the front climbing wheel
1 Remove the bolts from the wheel forks.
2 Drive out the retaining pin for the wheel axle, and then the
wheel axle, by means of a drift. 2 Remove the holder with the climbing wheel and secure the
assembly in a vice.
3 Remove the wheel.
3 Remove the bolts securing the wheel bearing.
4 Inspect, and replace all damaged parts.
4 Remove the climbing wheel.
5 Lubricate the holes and wheel axle with grease.
5 Inspect, and replace all damaged parts.
6 Position the wheel correctly in the wheel fork and drive in the
wheel axle through the wheel fork and the wheel centre. 6 Refit in the reverse order.
7 Tap in the retaining pin.
TORQUE
Tighten the bolts to 47 Nm.
CAUTION
Ensure that the hole for the retaining pin is located
so that the pin can be inserted.
Dismantle and assemble the back climbing wheel
1 Lift up the truck, and secure it with blocks.
 13 SERVICING AND MAINTENANCE 65

2 Remove the screw.

3 Remove the wheel axle and the locking washer.

4 Remove the climbing wheel.

5 Refit in the reverse order.

TORQUE
Tighten to 47 Nm.
 14 SAFETY REGULATIONS 66

Safety Regulations Distance between vehicles

Remember that the vehicle in front of you may stop suddenly.
The authority and obligations of the truck Keep a reasonable distance. Remember that any load on the
operator forks affects the braking distance.
The truck operator has the authority and the responsibility to
refuse to drive the truck in the following cases: Pinch risk
• The truck constitutes a clear safety hazard.
WARNING
• The load constitutes a clear safety hazard.
Always be careful when using the truck to be aware of
• The truck has been repaired, altered or adjusted without the the risk of pinching, both in respect of the truck
changes being approved by the supervisor. operator and adjacent people.
• The truck operator’s physical or psychological condition is such
that they can be considered a safety hazard.
Passengers
The operator has the authority to:
Passengers are not permitted.
• prevent unauthorised persons from using the truck for which
they are responsible. An unauthorised person is someone who
has not received permission from the supervisor and/or Clearance height
someone who lacks training.
Bear in mind that the truck cannot be used where the clearance
• prevent anyone from walking or standing under a raised lift, height of an opening is less than the height of the operator, the
whether this is loaded or unloaded. overhead guard, the load or the mast.

Driving the truck The truck in an industrial lift

Driving in public areas The truck can only be driven into an industrial lift if this has been
authorised. Make sure that the capacity of the industrial lift is
The truck must not be driven on public roads outside a private never exceeded (the total weight of the truck including the weight
area. of the truck operator). The operator must be able to escape. Park
inside the lift so that the operator is beside the door. Never place
 14 SAFETY REGULATIONS 67

the truck or the load within the industrial lift's risk zones. Ensure Transports
that the truck's brakes have been engaged before the industrial lift
is started!

Floor load
Carefully check notices or other instructions concerning the
maximum floor load or maximum wheel pressure to ensure that
these are not exceeded. For the truck's total weight, see the
machine plate.

Signalling
Use the signal horn to attract attention.

Reduced vision Fig. 29. Transport mode

Slow down when approaching crossings and other places where

the line of vision is reduced. Avoid driving in the same direction as
the forks if the load in front of you obstructs your sight. Engage a
helper if free vision cannot be attained.

NOTE
Accessories on the truck may restrict the view.

Fig. 30. Transport mode

 14 SAFETY REGULATIONS 68

Driving space
Ensure that you have sufficient space for the truck – both the
operator and the load – in narrow aisles. Narrow door openings
that will not permit two-way traffic must be entered through the
centre of the opening. Follow the truck paths marked within the
driving area. Remember to keep your whole body inside the truck
perimeter to avoid crushing injuries.

Fig. 31. Transport mode

WARNING
The pushing of material that is on the floor out of the
During normal driving, the direction of travel must be taken into way using the truck's chassis is not permitted.
account. Driving with the forks raised is forbidden except whilst
lifting or lowering a load. Always drive the truck with forks as low
as possible with consideration to the floor, ramps, etc to avoid injury.
Trucks equipped with a folding platform
When transporting loads, the truck should, if possible, be driven in
the opposite direction to the direction the forks are pointing. This
ensures that the driver has a better view if the load is high, and
WARNING
makes the truck easier to manoeuvre. When driving in the Use great caution while operating a truck with a
direction of the forks the truck is sensitive to sharp turns (compare foldable platform, as the operator risks being caught
with reversing a car.) Only drive the truck with covers and between the truck and objects in the vicinity.
housings closed and secured in place.

Speed
Adjust the speed according to the floor conditions, the line of sight
and operational safety. Avoid rapid acceleration, sudden braking
and cornering at speed; there is a risk for overturning or that the
load will fall off.
 14 SAFETY REGULATIONS 69

Overturning
Foldable platform
Truck with lowered side guards: If the truck overturns, get out and
keep away from it.
Trucks with raised side guards: Keep hold of a handle if the truck
overturns. Do not jump!
Rear and Side entry
Keep hold of a handle if the truck overturns. Do not jump!
WARNING
Place your feet correctly on the platform, to avoid injury. Trucks on another vehicle's loading platform or on a
ramp
Before the truck is driven from a loading bay and onto the platform
of a lorry or trailer you must always check the maximum load
capacity of the ramp. There must also be devices that prevent the
ramp from sliding. You must also remember to check the
maximum load capacity of any vehicle that you intend to drive
onto. There must also be devices (e.g. brake chocks) that prevent
Fig. 32. Correct placement Fig. 33. Incorrect placement movement of the vehicle being driven on to. For information on
the total weight of the truck, refer to the machine plate.

Risk zones
Direction of travel when driving on slopes
Do not drive near the edges of loading bays, gangways, etc.
where there is a risk of the truck going over an edge. Be careful Outrigger trucks
when operating close to colour marked risk zones. Always drive with the forks facing towards the top of an incline
 14 SAFETY REGULATIONS 70

Awareness!
Always be aware of personnel in the vicinity when operating the
truck.

Transportation security A
Trucks with a fixed platform
During transport, the truck should be placed on a long pallet and C
secured with load securing straps. If the truck is transported with a
battery, a strap will be pulled through the hole in the battery as in B
the following images.
Fig. 34. Transportation security rear entry with a battery

NOTE
The battery must be disconnected if it is sent together
with the truck.

Fig. 35. Transportation security side entry with a battery

 14 SAFETY REGULATIONS 71

If the truck is transported without a battery, a strap should be

pulled through the battery space as in the following images.

C
A
B
C
Fig. 37. Transportation security side entry without a battery
B

Fig. 36. Transportation security rear entry without a battery A spacer (pos. A) is placed under the forks. Wedges are placed
as in the images to prevent rolling/sliding:
• A wedge (pos. B) is placed on the back edge of the truck.
• Wedges (pos. C) are placed against the chassis on the right and
left sides.
Truck with a foldable platform
When a truck is to be transported, it must be placed on a pallet
and secured with load securing straps. If the truck is transported
with a battery, a strap will be pulled through the hole in the battery
as in the following image.
 14 SAFETY REGULATIONS 72

NOTE
The battery must be disconnected if it is sent together
with the truck.

C
B

Fig. 39. Transportation security foldable platform without a battery

A
A spacer (pos A) is placed under the forks. Wedges are placed as
C in the images to prevent rolling/sliding:
B • A wedge (pos B) is placed on the back edge of the truck.
• Wedges (pos. C) are placed against the chassis on the right and
Fig. 38. Transportation security foldable platform with a battery
left sides.

If the truck is transported without a battery, a strap shall be pulled

through the battery space as in the following image. Moving an inoperable truck
If the truck is out of action and cannot be operated from the
operator's compartment using normal driving controls, contact the
supervisor immediately.
If the truck is inoperable and needs to be moved to a safer
location see Towing/moving inoperable truck page 73
 14 SAFETY REGULATIONS 73

In consultation with the authorised service organisation, the 5 Remove cover, see Covers and panels page 62.
responsible supervisor must ensure that the move of the truck can
take place in a controlled manner so that there is no risk of an
accident. The truck is to be moved with the aid of another truck
which has sufficient capacity to a suitable location where it can be
repaired. The truck should be lifted by the specified lifting points,
see section When lifting the truck page 76.

WARNING
Ensure that the truck cannot fall over or slide off the
forks while being moved.

Towing/moving inoperable truck

This description shows how to move a truck in case it has become
inoperable.

1 Remove load from forks.

2 Lower the forks to the bottom position if not already lowered.

3 Disconnect the battery.

4 Ensure that the truck cannot move while work is in progress. If

the truck has stopped on an incline, chock the drive wheel to
ensure the truck cannot move whilst work is in progress.

NOTE
Chock the wheels if necessary.
 14 SAFETY REGULATIONS 74

6
NOTE
Reassembly in the reverse order. Remember to
remove the two release screws.
1

Fig. 40. Release electrical brake

Release the parking brake by screwing in two screws in the

holes on top of the electrical brake as indicated in Fig. 40.
Release electrical brake, page 74. Use DIN 912 M5x45
screws. Locking the driving wheel in place is not possible.

CAUTION
The truck can not be braked if it starts rolling when
brake is disengaged.
 14 SAFETY REGULATIONS 75

7 Lift up the truck with a jack or appropriate truck. Lift

inoperable truck at the place shown in the image with suitable
equipment.

NOTE
Make sure the lifting equipment is certified to lift
the weight of the inoperable truck. Make sure not
to hit the castor wheels, drive wheel or drive unit
when lifting the truck with a forklift.

8 Tow slowly to secure location.

When lifting the truck

General
The truck must only be lifted using the lifting eyes intended for this
purpose. The figure shows where the permitted lifting points are
located on the truck. The lower lifting points must be used when
lifting a truck with jacks. The lifting points are marked with a decal
representing a lifting hook. When lifting the truck with a traverse or
similar, the upper lift points should be used, which are marked
with lifting straps in the image. If the truck has bogie wheels make
sure both bogie wheel brackets are in a correct horizontal position
level to the ground. If the bogie wheel brackets are in an incorrect
position they may be damaged when he truck is lowered to the
ground. For correct position see Fig. 41. Bogie wheel bracket
position, page 76
 14 SAFETY REGULATIONS 76

When lifting the truck

Fig. 41. Bogie wheel bracket position

When the truck is to be lifted using a jack, make sure it is secured

by blocks. The truck must not rest on the jack while work is carried
out.

WARNING A
Ensure that all lifting aids are classed for the intended
weight. Weights are specified under section Weight
page 87.
Fig. 42. Foldable platform

A Lifting point for jack B Lifting the entire truck

WARNING
Lifting the truck should only be carried out by an
authorised service technician.

WARNING
If the truck is lifted incorrectly, parts may be damaged
by being subjected to excessive force.
 14 SAFETY REGULATIONS 77

B B

A A

Fig. 43. Rear entry Fig. 44. Side entry

A Lifting point for jack B Lifting the entire truck A Lifting point for jack B Lifting the entire truck

Exceptional operating conditions

When the operating conditions differ from normal conditions , the
following steps must be taken:
• If the working conditions are of a permanent nature, an
agreement must be drawn up with the supervisory authority
and any other party concerned.
• If the working conditions are of a temporary nature, take suitable
measures such as using a larger truck or reducing the load
correspondingly.
 14 SAFETY REGULATIONS 78

Work in hazardous environments Assembling and putting into service

A truck operating in an area where there is a risk of fire, explosion,
or in any other high risk area, must be specially equipped for the WARNING
purpose. Assembling/dismantling and putting the truck into
service may only be carried out by an authorised
WARNING service technician.
A truck is not normally equipped for these situations.
The following actions are to be taken in order to make the truck
ready for use.
• Charge the battery.
Parking
• Perform an inspection in accordance with Daily inspection
The truck must not be left unattended other than in specified (before each shift) page 49.
parking areas. Parking must always be done on a level floor. The
forks must be lowered to their lowest position, so that no one can • Visually inspect the truck, including the forks, for signs of
accidentally trip over them. Always shut down the truck so that it damage.
cannot be operated. If the truck is equipped with a key-operated • Check that the safety and warning signs are in place and are
ignition switch, the key must be taken out when leaving the truck legible. See Safety and warning signs page 81.
so that unauthorised persons cannot use it. At the end of the shift,
the conditions of the local fire insurance determine whether the
key is removed from the ignition or not. Check!
Subsequent mounting of radio equipment
If the truck is left unused for a prolonged period without it being
recharged, e. g. between two shifts, the battery plug must be If equipment emitting an electromagnetic field, such as radio
disconnected. transmitters, RFID readers or data collection systems, are
connected after delivery, all such equipment must be CE marked.
Carefully follow warnings and installation instructions from the
CAUTION equipment manufacturer. If there is a risk that the equipment can
Do not block access to fire fighting equipment or fire harm people, e. g. with medical implants, the machine must be
doors by parking the truck or placing goods in front of fitted with decals warning of this hazard. See also section Truck
them. modification page 2.
 14 SAFETY REGULATIONS 79

Temporarily taking the truck out of service 2 Clean and charge the battery in accordance with Battery
charging page 16.
Storage
If the truck is to be taken out of service for more than a month, it 3 Check the gearbox and hydraulic oil levels.
should be stored indoors in dry and frost-free premises.
4 Lubricate the truck in accordance with the lubrication chart.

Actions before storage 5 Connect the battery plug.

1 Clean the truck. 6 Carry out a weekly inspection in accordance with Weekly
inspection page 49.
2 Clean and charge the battery in accordance with the battery
manufacturer's maintenance instructions.
WARNING
3 Check the oil level in the hydraulic system by looking at the The truck should only be put back into service by an
markings on the truck, or alternatively by pushing all the authorised service technician.
hydraulic cylinders to their fully extended positions. Top up
the oil if necessary.

4 Check the braking effect on the main brake and parking brake. Hanging load
5 Lubricate the truck in accordance with the lubrication chart. The truck is not intended for hanging loads that may swing.
6 Disconnect the battery plug.
In the event of accidents
Actions during storage Report all accidents or incidents immediately to the supervisor. If
1 Charge the battery and check the cell electrolyte levels about possible, leave the truck where it is. If possible, take action to
every second month. lessen the damage or harm, especially if there are people hurt.
Avoid actions that might hinder accident investigation. In general,
you must await the decision of the supervisor.
Putting back into service after storage
1 Clean the truck.
 14 SAFETY REGULATIONS 80

Noise levels Climatic conditions

Noise levels at the driving position are lower than 70 dB (A) The normal operating temperature for which the truck is intended
measured in accordance with European standard EN 12053. is within the range of +1° C to +25° C in humidity up to 95% ,
provided non-condensing conditions. If temperatures exceeding
+25° C are combined with long term heavy duty operation,
Vibrations overheating tendencies may gradually increase up to the
maximum ambient temperature of +40° C . If the truck is used
Vibration data for truck models (tested in accordance with EN below +1° C, condensation, ice and thawing risks may
13059+A1:2008). consequently increase. If condensation occurs, the truck must be
allowed to fully dry. If condensation is avoided, -10° C is
permissible. A truck kept at working temperature can be used
NOTE short term down to -25° C. Special equipment is required if the
The average magnitude of hand-arm vibration during truck is used continuously in environment with extreme
operation of industrial trucks, operated in the specified temperature or condensing air conditions.
conditions, will stay below 2.5 m/s2.
If the truck is specified for use in refrigerated rooms, without
shutting off, it can be used at temperatures down to -30°C, but it
Foldable āw,z F= 0.57 m/s², measuring accuracy Cv = may not be left unused in temperatures below zero. Charging or
platform 0,02 long-term parking must be at temperatures of a minimum of +1°C.
Fixed āw,z F= 0.66 m/s², measuring accuracy Cv =
platform, Std 0,02 NOTE
damping The operation and characteristics of the truck can be
negatively affected by starting in temperatures below
Fixed āw,z F = 0.59 m/s², measuring accuracy Cv = zero. Bear in mind that the truck may still be frozen,
platform, 0,021 even if the ambient temperature has risen above zero.
Adjustable
damping

Protective shoes
Protective shoes must be worn when working with trucks
according to applicable national standards.
 14 SAFETY REGULATIONS 81

Work Light Explanation of symbols

Work lights facilitate work in poor light conditions. Work lights are
available as accessories for many models.

Additional units/Trailers
If, after delivery, it is decided to equip the truck with additional
units, towing hitch equipment for trailers or other accessories Read and follow the operation
which could influence the stability or braking capacity of the truck, and maintenance manual
an authorised representative of the truck manufacturer must be before the truck is put in use.
contacted. Before the truck is assembled, it must have been
approved by its manufacturer, see 2 Truck modification page 2.
Locations of safety and warning signs

Safety and warning signs

General

NOTE
There are a number of warning signs on the truck.
Always replace signs that are damaged or missing.

Fig. 45. Foldable platform

 14 SAFETY REGULATIONS 82

Fig. 46. Rear entry

Fig. 47. Side entry

15 DIMENSIONS 83

Table 8. Truck type and dimensions in mm, Foldable platform

Dimensions
F 200/250
Dimensions Foldable platform
Measurements MN JN SN
x (Load wheel 913/975 913/975 913/975
raised/lowered)
y (Load wheel 1375/1437 1455/1517 1519/1581
raised/lowered)
h3 135 135 135
h14 max

h7 Platform Without Without

height, operator: operator:
h14 min

without 219 219

1063

operator: With With

219

s
operator*: operator*:

h3
Platform 171 171
m2

H
h7

height, with

h13
y operator*:
l1 171
h14 (min/max): Tiller Mech: Tiller Mech: Tiller Mech:
441 l2 l
x
1100/1463 1100/1463 1100/1463
Tiller Power: Tiller Power: Tiller Power:
1108/1381 1108/1381 1108/1381
h13 85 85 85
497
b1

b5

l1 (Platform 1880/2256 1960/2336 2024/2400

e

folded up/
folded down)
Wa
 15 DIMENSIONS 84

Table 8. Truck type and dimensions in mm, Foldable platform (cont'd.) Dimensions Rear entry
F 200/250
Measurements MN JN SN
l2 (Platform 730/1106 810/1186 874/1250
folded up/
folded down)
b1 740 740 740

h14 max
l/e/s 1150/175/60 1150/175/60 1150/175/60

h14 min
1150
b5 520-640 520-640 520–640
m2 25 25 25

h3
m2
Wa (Platform 1666/2019 1746/2099 1810/2163

H
h7
folded up/

h13
y
folded down)
l1

* = Average weight, 74 kg
l2 l
x

b1

b5
e
Wa
 15 DIMENSIONS 85

Table 9. Truck type and dimensions in mm, Rear entry Dimensions Side entry
R 200/250
Measure- MN JN SN
ments
x (load wheel 913/975 913/975 913/975
lifted/lowered)
y (load wheel 1375/1437 1455/1517 1519/1581

h14 max
lifted/lowered)

h14 min
1262
h3 135 135 135
h7 Stand height, Platform Platform

s
no operator: height, no height, no

h3
m2

H
170 operator: 170 operator: 170

h7

h13
y
h14 (min/max) Tiller Power: Tiller Power: Tiller Power:
l1
1108/1381 1108/1381 1108/1381
Pivot Power: Pivot Power: Pivot Power: l2 l
1175/1250 1175/1250 1175/1250 x

h13 85 85 85
l1 2292 2372 2436

b1

b5
l2 1141 1221 1285

e
l/e/s 1150/175/60 1150/175/60 1150/175/60
b5 520-640 520-640 520–640
Wa
m2 25 25 25
Wa 2059 2139 2203
 15 DIMENSIONS 86

Table 10. Truck type and dimensions in mm, Side entry

S200/250
Measure- MN JN SN
ments
x (Load wheel 913/975 913/975 913/975
raised/
lowered)
y (Load wheel 1375/1437 1455/1517 1519/1581
raised/
lowered)
h3 135 135 135
h7 Stand height, Platform Platform
no operator: height, no height, no
170 operator: 170 operator: 170
h14 (min/max) Pivot Power: Pivot Power: Pivot Power:
1175/1250 1175/1250 1175/1250
h13 85 85 85
l1 2292 2372 2436
l2 1141 1221 1285
l/e/s 1150/175/60 1150/175/60 1150/175/60
b5 520-640 520-640 520–640
m2 25 25 25
Wa 2059 2139 2203
 16 WEIGHT 87

Table 12. Axle pressure, with load (cont'd.)

Weight
Truck Axle pressure, drive wheel side/load wheel
Weights side, including battery with a load (kg)
Table 11. Service weight
MN JN SN
Truck Service weight with/without battery (kg)
Foldable 1128/2129 1131/2184 1165/2252
MN JN SN platform 250

Foldable 750/500 790/505 860/510 Rear entry 1207/2110 1211/2165 1245/2232

platform 250

Rear entry 820/570 880/595 980/630 Side entry 1193/2107 1197/2162 1230/2230
250
Side entry 800/550 860/575 960/610
Battery 250 kg 285 kg 350 kg
Battery 250 kg 285 kg 350 kg weight
weight
Table 13. Axle pressure, without load
Table 12. Axle pressure, with load
Truck Axle pressure, drive wheel side/load wheel
Truck Axle pressure, drive wheel side/load wheel side, including battery, without load (kg)
side, including battery with a load (kg)
MN JN SN
MN JN SN Foldable 570/187 588/227 640/277
Foldable 1015/1742 1018/1797 1052/1865 platform 200/
platform 200 250

Rear entry 1216/1691 1221/1744 1255/1812 Rear entry 648/169 666/210 717/260
200 200/250

Side entry 1202/1688 1207/1742 1241/1809

200
 16 WEIGHT 88

Table 13. Axle pressure, without load (cont'd.)

Truck Axle pressure, drive wheel side/load wheel

side, including battery, without load (kg)
MN JN SN
Side entry 634/166 651/207 702/258
200/250
Battery 250 kg 285 kg 350 kg
weight
 17 ORDERING HANDBOOKS AND MANUALS 89

Ordering Handbooks and Manuals

Replacement Parts Manual
The parts manual can be downloaded via the WebShop by
locating the truck model and selecting download. If you have any
questions regarding the parts manual, please contact your local
distributor.
last page

MLE AB (556083-6461)
SE–435 82 Mölnlycke
Sweden
+46 (0)31-98 40 00
info@unicarrierseurope.com
www.unicarrierseurope.com
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