Original instructions

Order picking truck

MX-X

2332 2334

5231 804 2502 EN - 04/2020

Table of contents

1 Foreword
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
EC declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Standard design and optional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Truck identification, Factory nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Product documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Accessories accompanying the product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Rules for the operating company of industrial trucks. . . . . . . . . . . . . . . . . . . . . . . . . . 6
Safe-keeping and passing on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Copyright and proprietary rights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Operator, Form of address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2 Safety
Working safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Vibrations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Medical equipment, implants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Special safety information about load pick up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Safe handling of operating media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Risk assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Regular testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Application area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Narrow aisle vehicles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Original parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Directives and guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Driver's licence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Alterations to industrial trucks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Personal protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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 Table of contents

3 Overview
Industrial-truck view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Standard design of labelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Labelling for special equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Description of truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Operating panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Operating the display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Swivel shift fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Other attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

4 Operation
General commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Initial commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Weights of the units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Transporting and loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Support screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Safe handling of the traction battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Battery compartment cover, Service flap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Installing the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Permitted batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Battery commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Replacing the battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Function checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Daily commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Checklist before starting work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Driver's compartment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Access to the driver's compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Operating devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Initial driving exercises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Adjusting the position of the operating panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Driver's seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Switching on the controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

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Table of contents

Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Braking, driving and steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Types of guidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Mechanical guidance MZF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Load pick up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Moving the load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Load capacity diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Fork arms, adjustable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Emergency operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Emergency lowering via the operating panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Emergency lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Securing the load support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Emergency operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Emergency abseil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Parking, decommissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Parking and leaving the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

5 Regular care and maintenance

Regular care and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Special versions, special equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Regular maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
1000-hour maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
2000-hour maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Battery maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
General information about fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Removing the control compartment hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

6 Technical data
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

7 Special equipment
Additional documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Enabling options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

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Optispeed versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Split operating panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Inductive guidance IZF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Automatic Floor Compensation AFC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Lift cut-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Traction cut-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Aisle entry assistant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Battery on a roller channel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Electronic access control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Automatic braking systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Personal protection system (MPSE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Safety laser scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Personal protection system, preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Tilt barrier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Mirror and lighting module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Camera system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Lift height preselection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Driver's cabs, special versions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Wind deflector cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Intercom system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Warm-air heating system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Protective roof cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Radio installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Overhead guard switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Working spotlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Safety Light safety headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Acoustic alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Antistatic version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Guard plate on rack rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Telescopic table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Other attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Trucks for use in cold storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

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Table of contents

Mounting system for auxiliary components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

USB charging station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
MMS interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Two-person cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Working platforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

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 1

Foreword
1 Foreword
General

General 

Our industrial trucks comply with applicable

European regulations. Any other applicable
country-specific regulations or operating con-
ditions for the use of industrial trucks must al-
so be observed.
The aim of this manual is to inform you about
how to safely handle your industrial truck and
how to keep it operational. It is therefore es-
sential that operators, operating personnel
and maintenance personnel familiarise them-
selves with, understand and adhere to the
contents of this manual. The operability, per-
formance and service life of the vehicle are
dependent on:
● Proper use
● A daily inspection by the operator and
● Regular, appropriate maintenance work

2 5231 804 2502 EN - 04/2020

Foreword 1
EC declaration of conformity

EC declaration of conformity

Declaration

STILL GmbH
Berzeliusstraße 10
D-22113 Hamburg Germany

We declare that the

Industrial truck according to these operating instructions

Model according to these operating instructions

conforms to the most recent version of EC Machinery Directive 2006/42/EC and the most re-
cent version of EMC Directive 2014/30/EU for industrial trucks implemented in accordance with
harmonised standard EN 12895:2015. Furthermore, we declare that any radio equipment con-
tained in this machine conforms with the most recent version of Radio Equipment Directive
2014/53/EU. The manufacturer is solely responsible for exhibiting this declaration of conformi-
ty.
Notified body in accordance with Annex
IX:
EU notified body no. 2140
Personnel authorised to compile the technical documents:

See EC compliance declaration

STILL GmbH

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1 Foreword
Safety instructions

Safety instructions
Explanations of the terms used in this manual:

DANGER
There is the risk of fatality to the operator.
The procedures indicated should be complied with in
full in order to avoid this danger.

WARNING
There is a hazard that could cause major damage to
property or to the health of the operator.
The procedures indicated should be complied with in
full in order to avoid this danger.

CAUTION
There is a risk of damage to property.
The procedures indicated should be complied with in
full in order to avoid this danger.

NOTE
Special attention is drawn to procedures and
technical requirements that must particularly
be observed.

Standard design and optional equipment

These instructions describe the Special versions and special equipment
● intended use (UPA)
● regular maintenance
For industrial trucks in a customer-specific
● and prescribed maintenance
special version or with special equipment, ad-
for industrial trucks in the standard design and ditional order-related documentation is created
for the optional equipment available at the and supplied if required.
time of going to print.

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Foreword 1
Truck identification, Factory nameplate

Truck identification, Factory

nameplate
The nameplate is fitted in the area of the driv-
ing seat and contains the following details:

Factory nameplate

1 CE symbol. The CE symbol confirms that 5 Nominal loading capacity

the EU machine guidelines and all the rele- 6 Unladen weight
vant guidelines, which are valid for this prod- 7 Battery voltage
uct, have been met. 8 Maximum battery weight
2 Truck type 9 Minimum battery weight
3 Truck serial number. This serial number 10 Rated drive power
must be given in the event of any queries. 11 Ballast weight
4 Year of manufacture 12 Name of manufacturer

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1 Foreword
Product documentation

Product documentation 

This includes:
● Spare parts list

● Operating and maintenance manual

● Any additional documentation for the driv-

er's seat
● Any additional documentation for an attach-

ment
● Any additional documentation for the bat-

tery
● Any additional order-related documentation

Accessories accompanying
the product
Each truck is supplied with a box of accesso-
ries upon delivery from the factory.
The contents differ depending on the truck
type and the order.
This includes, among other items, an adhesive
label that shows how to disable the magnetic
brake on the traction motor using mechanical
means. This adhesive label can be affixed in a
suitable position in the control compartment
near the magnetic brake.
This box also contains the documentation to
accompany the product, and the screws and
wrench that are required to disable the mag-
netic brake.
Depending on the type, additional lubricating
nipples may be included for maintenance.

Rules for the operating com-

pany of industrial trucks
In addition to these operating instructions, a
code of practice containing additional informa-
tion for the operating companies of industrial
trucks is also available.

6 5231 804 2502 EN - 04/2020

Foreword 1
Safe-keeping and passing on

This guide provides information for handling

industrial trucks:
● Information on how to select suitable indus-

trial trucks for a particular area of applica-

tion
● Prerequisites for the safe operation of in-

dustrial trucks
● Information on the use of industrial trucks

● Information on transport, initial commission-

ing and storage of industrial trucks

Internet address and QR code 

The information can be accessed at any time
by pasting the address https://m.still.de/vdma
in a web browser or by scanning the QR code.

Safe-keeping and passing on

● These operating and maintenance instruc-
tions must be kept safely so that the opera-
tor always has access to them.
● Documents can be ordered retrospectively.
Please give the ID or the order number.
● If the truck is sold on, the complete docu-
mentation should be passed on along with
the truck.

5231 804 2502 EN - 04/2020 7

1 Foreword
Copyright and proprietary rights

Copyright and proprietary 

rights
This manual - and any excerpts thereof - may
not be reproduced, translated or tansmitted in
any form to third parties without the express
written permission of the manufacturer.

8 5231 804 2502 EN - 04/2020

Foreword 1
Operator, Form of address

Operator,
Form of address
Our products are suitable for use by male or If these industrial trucks are operated by per-
female operators. However, these instructions sons who do not meet the criteria specified in
use only the masculine form of address, here- EN ISO 3411, the following effects must be
inafter "operator", to simplify the text. expected:
● The ergonomic conditions may be less fa-
Dimensions of the operator's compart- vourable
ment ● It may not possible for the operator to reach
the pedals and foot switches
The dimensions of the operator's compart- ● The useable height below the overhead
ment on our industrial trucks are designed in guard may be too low
accordance with standard DIN EN ISO 3411 ● The adjustment ranges for the steering-
and are accordingly constructed for both fe- wheel and operating panel adjuster may no
male and male operators. This standard also longer be sufficient
stipulates ranges within which the operator's ● The adjustment ranges for adjustable driv-
body weight and dimensions should lie. EN ers' seats may no longer be sufficient
ISO 3411 specifies 114.1 kg for the maximum ● There could be a negative effect on the
body weight for a large operator. load-bearing capacity of the industrial truck
Please be sure to consult your responsible au-
CAUTION
thorised service partner.
Reduction in the load capacity. Negative effect on
stability.
If the actual body weight of the operator exceeds
114.1 kg, the maximum load weight must be reduced
by the difference compared with the information on
the load capacity diagram.
Example
The actual body weight of the operator is 160 kg. In
this case, the maximum load weight must be reduced
by approx. 46 kg compared with the information on
the load capacity diagram.

5231 804 2502 EN - 04/2020 9

1 Foreword
Operator, Form of address

10 5231 804 2502 EN - 04/2020

 2

Safety
2 Safety
Working safely

Working safely
● The industrial truck must be operated exclu- Safe working environment
sively from the driver's compartment
● If industrial trucks are equipped for pedes-
● People must not encroach into the working
trian mode or with external operating pan- area (danger area) of the industrial truck; If
els, the industrial trucks may be operated a person does enter the danger area, all
using these features; for further safety infor- movements of the industrial truck must be
mation for this purpose, refer to the relevant stopped immediately and the person must
additional descriptions be directed away from the area
● When driving without a load, lower the fork
● If there are marked roadways, the industrial
to floor height truck must be moved only within these
markings for safety reasons
● When driving with a load, the load must be
lifted a few centimetres off the ground (clear
● It is never permitted for anyone to stand be-
of the ground, max. 500 mm) neath a raised load or driver's compart-
ment.
● The driver must keep all body parts within
the contours of the driver's compartment;
● The condition of the floor surface influences
the driver must refrain from sticking his the braking distance of the industrial truck.
head out to gain a better view and from The driver must take account of this in his
reaching into the area of the moving lift driving and braking style.
mast because doing this is highly danger- ● If the area of application and work situation
ous so require, the operating company must
● Aside from the driver, there must be no oth- evaluate the potential hazards and provide
er person present on the industrial truck un- appropriate personal protective equipment
less the industrial truck has additional such as safety shoes, a safety helmet, safe-
equipment to enable operation with two per- ty gloves or protection goggles: responsibili-
sons ty for the selection and provision lies with
the operating company; responsibility for
● Basically, it is the driver's duty to adapt his use of the equipment lies with the operator
driving speed to the local conditions and the
respective situation. When cornering in par-
ticular, attention must be paid to the overall Safe machine
height and the centre of gravity, which will ● Essentially, all safety information located on
be high as a result.
the industrial truck must be observed
● When cornering and driving past parts of ● Missing or illegible safety information must
buildings that restrict visibility, use the horn
be replaced
to warn others that the industrial truck is ap-
proaching. ● The openings in the area of the battery
where gas may be released must not be
● When driving through doorways and under
covered or sealed. To prevent the formation
ceiling joists, take the height of the industri-
of potentially explosive gas mixtures, an un-
al truck into consideration.
restricted air supply is required.
● Multiple operations or other types of opera- ● Under no circumstances should openings
tions not described here, especially the
be made in the battery's gassing area,
blocking or disabling of operating devices,
which could allow the gas created during
can cause damage to the industrial truck
charging to enter the area of the driver's
but also uncontrolled movements and are
compartment.
therefore prohibited
● The driver must secure the industrial truck Operational safety takes priority over working
against unauthorised use by removing and speed!
taking the switch key or by clearing the ac-
cess information on the electronic access
control system when leaving the industrial
truck.

12 5231 804 2502 EN - 04/2020

Safety 2
Vibrations

Vibrations
The vibrations of the machine must be deter- Tests have indicated that the amplitude of the
mined on an identical machine in accordance hand and arm vibrations on the steering wheel
with the EN 13059 standard "Vibration meas- or on the operating devices in the truck is less
urements on industrial trucks". than 2.5 m/s2. There are therefore no meas-
urement guidelines for these measurements.
Weighted effective
value of acceleration The personal vibration load on the driver over
to which the body < 0.6 m/s2 a working day must be determined by the op-
(feet or seat base) is erating company at the actual place of use in
subjected. accordance with Directive 2002/44/EC, in or-
der to consider all additional influences, such
Uncertainty K 0.3 m/s2 as driving route, intensity of use etc.

Medical equipment, implants

DANGER take it upon themselves to ensure that they
are not exposed to dangerous electromagnetic
Electromagnetic interference may occur on medical
devices! radiation. Ask your doctor or the manufacturer
of the medical equipment to confirm that the
Only use equipment that is sufficiently protected
against electromagnetic interference.
medical equipment is sufficiently protected
against electromagnetic interference.
Medical equipment, such as pacemakers or It is the responsibility of the company that op-
hearing aids, may not work properly when the erates the industrial truck to explain these
truck is in operation. Individuals with active or dangers to employees in detail.
non-active implanted medical devices must

5231 804 2502 EN - 04/2020 13

2 Safety
Special safety information about load pick up

Special safety information 

about load pick up
Recognising danger is half the battle!
● Before every load pick up, make sure that
the load to be picked up does not exceed
the load capacity of the truck (refer to the
load capacity diagram) or the maximum
permissible dimensions as specified on the
datasheet. This also includes, of course, the
accumulated weight of the picked goods
● Loads that are to be transported and stored
must be packed securely
● The centre of gravity of the load must not
change during acceleration, braking or dur-
ing transport
● No parts must be allowed to fall
● If loads cannot be transported with the nec-
essary level of safety, an appropriate con-
tainer or means of securing the load must
be employed to ensure safety
● Loads must always be transported in suita-
ble containers or secure packaging
● Loads comprising loose packages may not
be stacked higher than the top edge of the
cab rail
● If very high loads that block the view of the
roadway have to be transported, appropri-
ate safety measures must be put in place; if
necessary, a guide and traffic supervisor
must be used
● Hanging or swinging loads must not be at-
tached to and transported on the lifting ac-
cessories

14 5231 804 2502 EN - 04/2020

Safety 2
Safe handling of operating media

Safe handling of operating 

media
The following operating media are used in this
truck:
● Gear oill
● Hydraulic oil
● Battery acid
The handling of these materials is governed
by comprehensive safety regulations. The
most important points include:

For gear and hydraulic oil

DANGER
Danger to life or danger of injury from hydraulic flu-
id escaping under pressure.
If hydraulic fluid escapes under pressure, for exam-
ple from a damaged pipe or through leaks in a com-
ponent, it can easily penetrate the skin. By poisoning
the surrounding tissue this can lead to the loss of the
affected body part or even to death. Even if such in-
juries do not feel particularly painful or serious, a
doctor must be consulted immediately. The cause of
the injury must be described exactly and the treat-
ment started promptly.

ENVIRONMENT NOTE

● Oils pose a threat to the water supply, and

must accordingly always be transported and
collected in regulation containers.
● Do not spill oil. Bind any spillages using
suitable materials..
● Take care to dispose of oil-containing
wastes correctly.
● Dispose of used oil correctly.
Personal protective gear
● Avoid all skin contact. Pay particular atten-
tion to prevent contact with oil emerging un-
der pressure (hose breakage, leaks).
● Do not breathe in oil mist.

● If it is not possible to avoid contact with oils,

personal protective gear such as protective

gloves, protective goggles etc. must be
worn.

5231 804 2502 EN - 04/2020 15

2 Safety
Safe handling of operating media

For battery acid

DANGER
Danger of explosion
– When charging batteries, an explosive gas mix-
ture can be generated which can still remain
present for a long period after completion of the
charging process. Ensure adequate ventilation.
– Within a 2 metre area of charged batteries, smok-
ing, fires and open flames are strictly prohibited.

● Battery acid is poisonous. Always avoid

breathing in vapours.
● Battery acid is caustic. Take all necessary
precautions to prevent skin contact.
● Rinse off battery acid immediately using
plenty of clear water.
● When handling battery acid, wear personal
protective gear such as gloves and clothing
as well as facial protection.
● Should skin contact still take place, rinse
immediately using plenty of clear water and
consult a doctor.
● Comply with the additional operating in-
structions supplied by the battery and the
battery charger manufacturer.

16 5231 804 2502 EN - 04/2020

Safety 2
Risk assessment

Risk assessment
Within the scope of validity of the CE guide-
lines, the operating company must create op-
erating instructions on the basis of a risk as-
sessment. The purpose of the risk assess-
ment is to identify dangers and the associated
risks that could occur due to the product or the
application of the product in the specific place
of use and under the application conditions at
this place of use. We can help you to com-
plete the risk assessment. The operating in-
structions are intended to warn against the
identified dangers and provide information on
possible remedial actions.
We recommend integrating these operating in-
structions into the operating procedures for
the specific place of use.

Residual risks
Despite observation of all pertinent safety reg-
ulations for the design and construction of our
trucks and despite proper use by the operating
company, residual risks can occur during op-
eration. We refer to this specifically in the indi-
vidual chapters.
Please heed all provided safety warnings.

Regular testing
This industrial truck must be tested in accord-
ance with our specifications by a specialist
(expert) at least once per year or after any un-
usual incidents.
Our test instructions summarise all activities
that must be performed for the purposes of
detecting damage or defects that have an ef-
fect on safety. The requirements pursuant to
FEM 4.004 are included in these test instruc-
tions.
A log must be created for the tests.
If defects are found, they must be rectified be-
fore the truck is next commissioned. If serious
repairs are required (e.g. after an accident), it

5231 804 2502 EN - 04/2020 17

2 Safety
Application area

may be necessary for another test to be car-

ried out.
The operating company is responsible for
checking whether the country in which this in-
dustrial truck is used requires regular safety
checks to be carried out on the industrial truck
by a specialist.

Application area
The area of application must have sufficient
floor load capacity. Ask the responsible sales
representative about the relevant wheel loads
and specific floor loads for your industrial
truck. The floor must meet the guidelines
specified by us. The condition of the floor sur-
face influences the braking distance of the in-
dustrial truck. The driver must take account of
this in his driving and braking style.
The industrial trucks described here are de-
signed for the following application conditions
(VDI 2695 category 1):
● Smooth, level roadways without major gra-
dients up to a maximum of 3%
● normal work load, 50% capacity utilization;
full load and half shift or half load and full
shift.
Ambient temperature in accordance with EN
1175-1.
Series products in continuous operation are
designed for an average ambient temperature
range of +5°C to +25°C.
The maximum ambient temperature may in-
crease briefly (for up to one hour) to up to
+40°C.

18 5231 804 2502 EN - 04/2020

Safety 2
Narrow aisle vehicles

WARNING
Restrictions in the applicational area.
The industrial trucks described here must not be
used:
– in areas at risk from fire
– in areas at risk from explosions
– iin areas with atmospheres conducive to corrosion
– in atmospheres containing large amounts of dust
– In public road traffic
– In the cold store (see cold store special equip-
ment)
– On surfaces that are not horizontal

Observe the applicable national regulations.

Narrow aisle vehicles

Narrow aisle vehicles may only be operated in
narrow aisles in accordance with the intended
use, if suitable precautions have been taken
(e.g. mobile or stationary protective equipment
to EN 2006/42/EG and EN ISO 13849) which
prevent the possibility of collisions occurring
between persons and vehicles, or which pre-
vent persons and other vehicles also being
present at that time.
In Europe it is the owner's responsibility to en-
sure that EU guidelines and stipulations are
complied with. The owner must conduct a risk
analysis to prove that adequate protection is
provided. On the basis of our experience, we
offer to support the owner in this task.

Original parts
Our original parts and accessories are special-
ly designed for our vehicles. We would specifi-
cally point out that parts and accessories not
supplied by us have also not been tested and
approved by us. The incorporation and/or use
of such products can consequently adversely
affect the structurally predetermined proper-
ties of your vehicle and thus impair the active
and/or passive drivingsafety. The manufactur-
ers are in no way responsible for any damage

5231 804 2502 EN - 04/2020 19

2 Safety
Directives and guidelines

caused by the use of non-original parts and

accessories.

Directives and guidelines

In most countries, the national directives and
guidelines for proper usage of these trucks
must be observed. We therefore ask you to
please contact the relevant authorities or
speak to the authorised representatives for
more information. You as the operator are re-
sponsible for this.

Driver's licence
In most countries, a driver's licence is required
to operate these trucks.
Please check whether a driver's licence is re-
quired to operate this truck in your country.
This driver's licence serves as proof that com-
prehensive training has been completed. As
the operating company, you are responsible
for ensuring that this requirement is fulfilled.
We recommend that you contact your branch
or specialist representative. They will be able
to offer you the relevant training and tests re-
quired to obtain your driver's licence.

Alterations to industrial trucks

Operating companies may only make altera-
tions or arrange for alterations to be made to
self-propelled industrial trucks if the industrial
truck manufacturer has withdrawn from busi-
ness and there is no business successor.
However, operating companies must:
● Ensure that any alterations being made and
all associated safety issues are planned,
checked and performed by a specialist en-
gineer for industrial trucks
● Have permanent records of the construc-
tion, test(s) and execution of the alterations
● Make and approve corresponding altera-
tions to the signs stating the load capacity,
information signs and adhesive labels as

20 5231 804 2502 EN - 04/2020

Safety 2
Personal protective equipment

well as in operating manuals and workshop

manuals
● Mount a durable and easily visible label on
the industrial truck providing details of the
type of alteration or conversion, alteration or
conversion date and name and address of
the organisation entrusted with this task

Personal protective equip-

ment
For operation of our products, no personal
protective equipment is required under normal
application conditions.
However, it is possible that the use of person-
al protective equipment is required at the
place of use due to the on-site circumstances
or local or internal regulations.
The national regulations valid at the place of
use must be observed.

5231 804 2502 EN - 04/2020 21

2 Safety
Personal protective equipment

22 5231 804 2502 EN - 04/2020

 3

Overview
3 Overview
Industrial-truck view

Industrial-truck view 

(1) Overhead guard

(2) Operating panel
(3) Auxiliary lift mast
(4) Load forks
(5) Load wheel
(6) Front guide rollers
(7) Rear guide roller and support screws
(8) Battery compartment or battery compart-
ment doors*
(9) Barrier or cab doors*
(10) Control compartment
(11) Portable lamp*
(12) Rear-view mirror*
(13) Lift mast
(14) Lifting points for crane-loading
(15) Abseil system
(16) Hazard warning light
* Option

24 5231 804 2502 EN - 04/2020

Overview 3
Standard design of labelling

Standard design of labelling

1 Danger! High voltage c. It is not permitted for people to sit or stand

2 Foot switch on the load, on the load support, underneath
3 a. Do not transport people on the load or on a raised load or to be carried as passengers.
the load support. 4 Oil tank
b. The driver's compartment is approved for 5 It is not permitted for people to sit or stand
use by one person only underneath a raised load, or underneath a
raised driver's platform.

5231 804 2502 EN - 04/2020 25

3 Overview
Standard design of labelling

6 Lifting point for crane loading 9 Risk of crushing feet

7 The container is under hydraulic pressure, 10 Disconnect the battery male connector be-
hydraulic cylinder. fore removing the control compartment
8 Storage space for the abseil system hood. (Only for the 80-V version)

A number of information signs are fitted on ev-

ery industrial truck depending on the family to
draw attention to hazards, technical data or re-
quirements.
These signs must always be present in full
and must always be legible.

NOTE
The section entitled "Labelling for special
equipment" provides details of further informa-
tion signs that may also be required based on
the order.

26 5231 804 2502 EN - 04/2020

Overview 3
Labelling for special equipment

Labelling for special equipment

1 It is not permitted for people to sit or stand 4 Seat heater on/off switch
on the load or the load support, or to be car- 5 Switch in "switched off" position
ried as passengers 6 Switch in "switched on" position
2 It is not permitted for people to sit or stand 7 Switch in "automatic mode" position
underneath a raised load, or underneath a 8 The speed of the truck is limited based on
raised driver's compartment the order.
3 Risk of crushing hands

5231 804 2502 EN - 04/2020 27

3 Overview
Labelling for special equipment

9 Truck with customised software. Only the standard software may be installed in the
customer's special version and not the truck control unit.

The pictograms shown here replace the picto-

grams for the standard version or are fitted in
addition to the standard pictograms.

28 5231 804 2502 EN - 04/2020

Overview 3
Intended use

Intended use
The order picker truck is designed for narrow
aisle operation. It permits pallets to be entered
into and removed from storage, as well as or-
der picking from the rack compartments.
Observe the instructions in the paragraph
"safety".
The maximum load that can be lifted is speci-
fied on the loadbearing information plate (load
diagram) and must not be exceeded.
Use for other purposes is prohibited.
If this truck is to be used for work which is not
described in these instructions or does not ap-
pear in the guidelines for the specified and
proper use of industrial trucks, and if it has to
be converted and retrofitted for this purpose, it
is necessary to be aware that modifications to
the original construction can impair the driving
behaviour and stability of the truck and are
therefore not permitted without our agreement.
Add-on parts and modifications (e.g. the weld-
ing-on of parts or the creation of openings)
could weaken the supporting structure and are
therefore only permitted after acceptance by
our design department. Functional changes
through modifications to the electrical system
or the software also require our acceptance
and release.
Before any such work is done you should
therefore make contact with the branch office
or the specialist representative in your area.

Description of truck
Instructions on operation of the individual
functions are provided in the respective chap-
ters.

General information
The operator can put himself and the load
suspension device (swivel fork) into the most
suitable working height by raising the opera-
tor's cabin. The auxiliary lift can be used to
serve the highest rack level and to set a fa-
vourable deposit height when carrying out

5231 804 2502 EN - 04/2020 29

3 Overview
Operating panel

order picking work. The auxiliary lift must al-

ways remain in the lowest position when trav-
elling.
Outside the aisles (transfer aisle), the industri-
al trucks can be driven freely with the load
lowered (transportation mode). The load must
be lifted only sufficiently high (clear of the
ground) that no part of the load touches the
ground.
Within the aisles, the narrow aisle trucks are
guided mechanically or inductively*.
The steering of the truck is realized by a freely
programmable controller (CAN BUS). All
movements (driving, lifting/lowering the cab
lift, lifting/lowering the auxiliary lift, swivelling
the fork, pushing the fork) are infinitely adjust-
able. Operating errors can be prevented to a
large extent by means of safety circuits.
* Option

Operating panel

(1) Operating lever for hydraulics (in conjunc- (2) Horn

tion with the selection keys)

30 5231 804 2502 EN - 04/2020

Overview 3
Operating panel

(3) Enable button (e.g. for releasing the brake (15) Selection key for lifting or lowering the
in an automatic braking system or as bridging cab lift and auxiliary lift together, in connection
for the intermediate lift cut-out and for ac- with pulling or pushing the operating lever (1),
knowledging errors that can be acknowl- or the selection key for swivelling the fork syn-
edged)*. Flashes red when it needs to be ac- chronously 180° to the left or right in connec-
tuated tion with moving the operating lever (1) to the
right or left
(4) Manual-automatic two-way switch for in-
ductive guidance* (16) Selection of a menu display
(5) Selection keys for favourites (17) Selection within a menu
(6), (7), (8) Selection keys for additional hy- (18) Go back one step in the menu or cancel a
draulic functions* selection
(9) Emergency off switch (19) Return to main page
(10) Operating lever for driving (20) Light sensor for automatic control of the
display lighting
(11) Sensor surface for two-hand operation of
the main lift or shifting in the aisle (21) Steering knob or steering wheel
(12) Selection key for lifting or lowering the (22) Sensor surface for two-hand driving with-
auxiliary lift or swivelling the fork in the aisle
(13) Reserved for special functions * Optional functions
(14) Selection key for automatic functions, e.g.
fork cycle

5231 804 2502 EN - 04/2020 31

3 Overview
Displays

Displays

1.1 Emergency off switch pressed 4 Not used

1.2 Foot switch required 5.1 *MPSE in operation

Two-hand operation on the left re-
1.3 5.2 *MPSE has detected a fault
quired
Two-hand operation on the right re-
1.4 6 Not used
quired
1.5 Barrier open 7.1 *Navigation, combination operation
*Navigation, destination is located on the
1.6 PIN entry expected 7.2
left-hand side
*Navigation, located on the right-hand
1.7 RFID entry expected 7.3
side
2 Not used 8.1 Remove from stock with a fork cycle
3.1 Creep speed active 8.2 Place into stock with a fork cycle
3.2 Turret head not in the end position
3.3 Telescopic fork not in the end position

At points marked 1 - 8, the pictograms shown tions available.

appear depending on the situation and the op-
32 5231 804 2502 EN - 04/2020
Overview 3
Operating the display

Operating the display 

NOTE
To emphasise the functionality, the following
images have been simplified.

1 Display in the operating panel

2 Display in the case of split operation

Function 
Operating statuses and information relevant
for operation are shown on the display. Using
the display, it may be possible to switch func-
tions on and off or to switch between defined
statuses.
The display is presented in colour and is
graphical. The content is divided into four
parts:
● Left-hand menu bar (1)

● Right-hand menu bar (3)

● Top status bar (2)

● Central information area (4)

5231 804 2502 EN - 04/2020 33

3 Overview
Operating the display

Half of the display can be occupied by a mes- 

sage window (1). This window is automatically
inserted from the right-hand side. The informa-
tion which was previously displayed centrally
is then shown in the left-hand section of the
display. The elements may sometimes over-
lap.
This message window has various content:
● Messages relevant to operation

● Messages with error numbers

● Target position (drive order) and actual po-

sition for navigation

If the settings are modified, a special form of
the message window appears. This message
informs you that the changed settings are be-
ing saved. An acoustic signal accompanies
the display of this message. The message dis-
appears after four seconds.

Menu structure 
The ten membrane switches can be freely
configured to display your favourite functions
on the main page. As soon as the button (7) is
actuated, the menu bar (1) opens. From this
point the structure is always the same. There
is also no change to structure when you select
a different language. The symbols also remain
the same.
The menu levels are as follows:

Industrial truck (2)

Power-saving feature
Navigation
Lighting (3)
Life height preselection (4)
Used lift heights
Fans (5)
Settings (6)
Truck information
Production number
Display settings
Time
Date
Language
Status bar

34 5231 804 2502 EN - 04/2020

Overview 3
Operating the display

Left field
Centre field
Right field
Configure favourites
Truck settings
Lift height preselection
Approach lift heights
Enter lift heights
Clear lift heights
Service
Message list

Top status bar 

The status bar at the top of the display is divi-
ded into three fields:
● Left field (1)

● Centre field (2)

● Right field (3)

The status bar can display the following infor-

mation:

Display
Information
format
Battery charge level (charge Graphical
state) %
Operating hours h
Time hh:mm
Date dd.mm.yy
Next maintenance interval h

The status bar can be configured individually.

5231 804 2502 EN - 04/2020 35

3 Overview
Operating the display

Procedure 
– Push button (7). The menu in area (1)
opens.
– Press key sequence (6), (3) and (5).
– Select the status bar field using button (2),
(3) or (4).
– In the list, use buttons (2) to (6) to select the
desired information.
– Exit the list by pressing button (8).

Central information area 

The central information area simultaneously
shows four values that are relevant for opera-
tion:
● Weight (1):

The maximum permissible weight for the

current lift height. If the optional weight
measurement is available, the current
weight of the load being lifted.
● Lift height (2):

Current height of the fork arms (upper

edge)
● Type of guidance and steering angle (3)

● Driving speed (4)

This part of the display cannot be parameter-

ised.

Operation 
The display is operated using 15 membrane
switches. The function of buttons (2) to (4) is
fixed. Button (5) has two functions.

Item
Function
number
Changes the view back to the
2
main page
Changes the view back to the
3
next-highest menu
If the arrow is displayed at the up-
per or lower edge of the right-
4 hand menu bar, the content can
be changed using these two push
buttons.

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Overview 3
Operating the display

Changes the view to the main

page with the menu shown in the
5 right-hand menu bar.
If a settings page is displayed, the
current setting can be saved.

The function of membrane keys (1) to (10) is 

shown directly next to the keys in the display.
The function of the buttons changes depend-
ing on the menu that is displayed.
The layout of the main page is always the
same when the industrial truck is delivered ex
works.

Item
Function
number
The energy-saving mode of the
1 industrial truck is activated or de-
activated.
The navigation information is
shown or hidden. For this, the key
switch for the navigation must be
set to AUTO. Otherwise, the sym-
5 bol is greyed out and therefore
cannot be selected.*
If the button is pressed and held
when a drive order is active, the
drive order is deleted.*
The right-hand menu bar with the
available data regarding height
preselection opens. If the symbol
6 is greyed out, the industrial truck
is equipped with the navigation
option and the key switch for nav-
igation is set to AUTO.*
9 Switch the work light* on/off
10 Switch the fan* on/off
* Option

If a function or button is selected, this is indi- 

cated with a coloured bars (1) next to the but-
ton. If the function is deselected, this coloured
bar is no longer present.

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3 Overview
Operating the display

Scrolling through the menu bar 

If an arrow appears in area (1) or (2), then the
list contains additional entries. The arrow keys
(3) can be used to scroll through the menu. If
there is no longer an arrow in area (1), the
start of the list has been reached. If there is no
longer an arrow in area (2), the end of the list
has been reached.

Changing the language 

The texts are available in 25 languages. The
language can be set using a fixed key combi-
nation. This combination is the same for all
languages.
Procedure
– Push button (7). The menu in area (1)
opens.
– Press key sequence (6), (3) and (4).
– Use buttons (2) to (6) to select the desired
language in the list.

NOTE
Only five languages are shown here. The oth-
er 20 languages can be found by scrolling.
See "Scrolling through the menu bar"
– Exit the list by pressing button (8).

Favourites 
The ten membrane switches can be freely
configured to display your favourite functions
on the main page. The following functions are
available as favourites:
● Energy-saving mode

● Navigation

● Lighting

● Life height preselection

Complete, individual areas or individual

heights
● Fans

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Overview 3
Operating the display

Procedure
– Push button (7). The menu in area (1)
opens.
– Press key sequence (6) and (4).
– Use buttons (1)(10) to select the position for 
the favourite function.
– Select the desired function in the list using
buttons (6) to (10).

NOTE
On some buttons there is a sub-menu with ad-
ditional options.
– Exit the list by pressing button (11).

Message list 
Currently displayed error numbers can be hid-
den using push button (2). A warning symbol
(1) remains in the status bar with the number
of the current error. The hidden errors can be
displayed in the message list. The errors are
only displayed in the list until the cause is rec-
tified. All other errors can be read out using
the diagnostic software.

Procedure 
– Push button (7). The menu in area (1)
opens.
– Press key sequence (6), (6) and (2).
The message list shows all of the current error
numbers.
– Exit the list by pressing button (8).

5231 804 2502 EN - 04/2020 39

3 Overview
Operating instructions

Brightness setting 
The brightness is automatically adjusted by a
light sensor (1) below the display.

NOTE
For the automatic brightness feature to func-
tion correctly, the sensor must not be covered
or contaminated.

Operating instructions
The controller assists the operator in operating
the industrial truck effectively.
Operating instructions take the form of:
● Illuminated buttons

● Message in plain text

● Pictogram

● Error number

If a particular button needs to be actuated in

order to continue working, this button is illumi-
nated.
The messages in plain text provide direct in-
formation in the configured language.
Pictograms provide self-explanatory, lan-
guage-neutral information on the necessary
operating steps.
In the event of a fault or defect, one or more
numbers appear led by a pictogram of a warn-
ing triangle. Call the authorised service centre
and provide the authorised service centre with
these numbers.

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Overview 3
Swivel shift fork

Swivel shift fork 

The movements of the turret head are auto-

matically braked before the turret head rea-
ches its mechanical stop. The end positions
are signalled to the controller by switches. The
industrial truck drives at the maximum speed
approved for the lift height only if the turret
head is located in the right or left end position.
If either the swivel or reach movement does
not reach the end position, the industrial truck
drives only at positioning speed and the lifting
and lowering speed of the main lift is reduced.
The tortoise symbol appears in the display.
Once the turret head has reached one of the
two end positions, the operator is notified by
an acoustic signal.

Other attachments
Other attachments* can also be supplied in
place of the turret head.
These include:
● Telescopic tables

● Accessible pallets

● Order-picking platforms

● Customised structures

DANGER
Impairment of operational safety, danger to the op-
erator
Other than the attachments supplied by the manufac-
turer, only attachments tested and supplied by the
manufacturer are permitted. Unauthorised modifica-
tions are prohibited. See also "Alterations to industri-
al trucks".
Just as is the case with the industrial truck, attach-
ments must be serviced regularly and inspected
once a year by a specialist.

Other attachments differ from the standard de-

sign in terms of the method of operation as
well as in the type of hazards if safety informa-
tion is not observed. It is therefore important
for the operator to be familiar with and to ad-
here to the instructions for the particular at-
tachment that is fitted.

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3 Overview
Other attachments

Additional operating instructions and mainte-

nance instructions from our suppliers may also
apply.
*Option

42 5231 804 2502 EN - 04/2020

 4

Operation
4 Operation
General commissioning

General commissioning
Initial commissioning

NOTE
Observe the section entitled Safe handling of
consumables.
Prior to initial commissioning, make sure that
the entire industrial truck is properly assem-
bled. All electrical and hydraulic connections
must be checked. Mechanical connections
that were removed for transportation must be
reconnected with particular care. Check all
screw connections with the appropriate tor-
que. Commissioning can begin once the filling
levels for the hydraulic tank and for the gear-
box have been checked. The entire initial
commissioning process must be correctly per-
formed by our trained service personnel.

NOTE
During the daily commissioning process, work
through the Checklist before starting work.

Weights of the units

Industrial trucks are mainly transported in a
disassembled state and must be assembled
on site. You must ascertain the weight of the
individual units in order to assemble the truck
safely and to select a suitable harness. Our in-
dustrial trucks are constructed using a modu-
lar system. There are also many customised
specifications. For this reason, it is difficult to
specify the correct weight for each unit and for
each variant. The information and table for the
lift masts below provide rough guidelines. For
safety reasons, always add a generous mar-
gin when rounding up the determined value.

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Operation 4
General commissioning

Delivery in units 
Specified weights apply only to the standard
design. Determine or request the weights of
special designs.
Narrow aisle trucks can be disassembled into
the following units: attachment, driver's cab in-
cluding carriage, lift mast, battery and chassis.
When assemblies comprised of multiple com-
plete units are transported, the weights of the
individual units must be added together so
that a suitable hoist can be selected. When
hooking on the units, ensure that the overall
centre of gravity can be moved relative to the
individual units.

Weight of the attachment

A standard attachment (europallet) with a tur-
ret head weighs approximately 800 kg.
If another attachment is fitted, determine the
weight of the additional attachment, e.g. by
weighing the attachment.
1 Attachment
Weight of the driver's cab 2 Driver's cab incl. carriage
3 Lift mast
A standard driver's cab including carriage 4 Battery
5 Chassis
weighs approximately 660 kg. Take into ac-
count the additional weight of attachments, for
example the weight of order-picking platforms.
A standard cold store cab including carriage
weighs approximately 800 kg.
If another driver's cab is fitted, determine the
weight of the additional driver's cab, e.g. by
weighing the driver's cab.

Weight of the lift mast

The weight of the lift mast depends on its de-
sign and overall height. The following table
shows the expected maximum weights de-
pending on the overall height.

Overall mast height Weight

<3 m <1600 kg
<4 m <2,300 kg
<5 m <2,900 kg

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4 Operation
General commissioning

Overall mast height Weight

<6 m <3,500 kg
>6 m <4,300 kg

Weight of the battery

The weight of the battery is specified on the
nameplate on the battery.

NOTE
The installed battery must as a minimum
weigh the value stipulated on the nameplate
on the truck. Compare the information on the
nameplate on the battery with the information
on the nameplate on the truck. If ballast
weights are installed, the weight of the ballast
weights must be taken into account.

Weight of the chassis

The weight of the chassis depends on its de-
sign and the fitted equipment.

Transporting and loading

General 
Depending on the overall height, the industrial
truck can be delivered as a complete unit or
unassembled. In each case, determine the
weights of the components or the complete
truck (delivery papers) and provide suitable
hoists and harnesses.

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Operation 4
General commissioning

Hooking on the lift mast 

To hook the lift mast onto the crane hook, use
the bores intended for this purpose at the top
end of the lift mast (1). Harnesses suitable for
this purpose must be used (shackle or lifting
device). If necessary, the individual parts of
the lift mast must be lashed to each other dur-
ing this process to prevent them from separat-
ing unintentionally and thus shifting the centre
of gravity.

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4 Operation
General commissioning

Hooking the lift mast on horizontally 

If the lift mast needs to be crane-loaded in a
horizontal position (2), suitable shackles must
be used in the indicated bores at the top end
of the mast (3).

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Operation 4
General commissioning

Lift mast, lower lifting point 

At the lower end, a textile strap can be wound
around the middle crosspiece in the beam
support of the cab (4).

Loading the chassis

Electronic elements such as sensors and an-
tennas can be installed at different places in
the chassis according to the truck design. The
ground clearance of these elements is very
low. As a result, particularly when mounting
the chassis on a forklift truck fork and when fit-
ting supports, make sure that no pressure is
applied to these elements. Before mounting
on a forklift truck fork or before fitting a sup-
port, perform a visual inspection to determine
whether and where such elements should be
mounted on the industrial truck in question.

Hooking on the chassis 

The cross beams above the battery compart-
ment serve as lifting points for the chassis. To
protect the paintwork of your industrial truck,
we recommend that you always use textile
slings. Shims protect the harnesses against
sharp edges.

WARNING
If the chassis is to be moved using the crane, always
remove the battery.

NOTE
The chassis must always be mechanically
braked unless the industrial truck is actually in
operation.

WARNING
Hydraulic oil can escape through disconnected hy-
draulic connections.

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4 Operation
General commissioning

Transportation safety device on glass 

doors
Cab doors made of glass* are supplied with a
transportation safety device. This transporta-
tion safety device prevents the glass doors
from inadvertently opening during transporta-
tion and becoming damaged as a result.
– Remove and dispose of the transportation
safety device.
*Option

Mast bracing 
Mast bracing may be required depending on
the configuration of the order picking truck.
Once the mast bracing has been installed, it
must be adjusted according to factory specifi-
cations and tightened to the specified torque.
The screw connection at the upper mounting
position on the mast bracing must be tight-
ened to 195 Nm.
The lower mounting position is marked with a
label. This label specifies the torque as
50 Nm .

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Operation 4
General commissioning

Wheel nuts 

WARNING
Wheel nuts can loosen after initial commissioning.
After the first eight operating hours, tighten the wheel
nuts to 210 Nm.

Support screws 
The setting of the support screws must be
checked during initial commissioning and each
time maintenance is performed.
The setting dimension (1) is dependent on the
application of the truck and can be taken from
the load capacity diagram.

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4 Operation
General commissioning

Safe handling of the traction battery

The dangers described below can arise indi-
vidually or collectively depending on the type
of battery in use.

Batteries with liquid electrolyte

DANGER
Risk of explosion
– An explosive gas mixture can form when charging
batteries. This gas mixture can remain in the at-
mosphere for a lengthy period of time even after
the charging process has finished.
– The gas mixture formed when charging batteries
must not enter the driver's compartment.

● Pay particular attention to the risk of explo-

sion in the void above the battery when the
battery has been freshly charged.
● The openings in this void facilitate the ex-
change of air and these openings must not
be covered or be closed.
● Do not create any openings in the battery
compartment that allow the explosive gas
mixture to enter the driver's compartment.
● Ensure that the room or area in which the
battery is being charged is well ventilated.
● Smoking, fire and open flames are forbid-
den in an area of 2 m around the charged
battery.
● Battery acid is toxic. Do not inhale vapours.
● Battery acid is corrosive. Avoid skin contact.
● Rinse off spilled or splashed battery acid
immediately with plenty of clean water.
● When handling battery acid, wear personal
protective equipment such as protective
gloves and a protection suit as well as face
protection.
● If contact with acid is made despite these
measures, rinse immediately with plenty of
clean water and consult a doctor.
● Observe the additional operating instruc-
tions of the battery manufacturer and the
battery charger manufacturer.

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Operation 4
General commissioning

80-V version 

WARNING
In the 80-V version, there is risk of electric shock if
the live connections are touched.
Before removing the control compartment cover or
the battery compartment cover, disconnect the bat-
tery male connector.

Handling the battery

The installation, removal and transport of trac-
tion batteries always involves the handling of
heavy weights.

WARNING
Risk of crushing of fingers, risk of crushing of hands
and feet, risk of damage to property

● When heavy weights are being handled,

there is a risk of limbs or bodies becoming
trapped or crushed. To avoid this, operate
lifting gears and changeover frames with
the utmost care. Prevent heavy weights
from bumping against the machine or
equipment.
● Be aware of pinch points and shear points
when inserting the battery into or removing
the battery from the battery compartment.
Ensure that you keep your fingers, hands
and feet out of any areas where they could
be at risk from one of the abovementioned
points of constriction. These points of con-
striction occur regardless of the tool being
used (truck, crane or changeover frame).
● Provide support staff with accurate instruc-
tions.
● Remove passers-by and spectators from
the danger area.
● Set down the disconnected battery cable on
the battery in such a way that prevents the
cable from becoming trapped or torn off.

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4 Operation
General commissioning

Battery compartment cover, 

Service flap
The battery compartment cover covers the en-
tire battery compartment. The cover is held by
four clamping holders.
The cover can be removed by applying light
pressure from underneath near the corners.

NOTE
As an option, the industrial truck can be equip-
ped with lateral battery compartment doors.

Service flap 
All that is needed to operate the battery male
connector is to open the service flap.

Installing the battery

The battery must fill the installation space with
just a few millimetres of play. This will ensure
that the battery does not slip or tip over during
travel and that the function of the battery lock
is guaranteed. If a lighter battery is used tem-
porarily, you must compensate for the weight
difference using a fixed ballast, and the size
difference must be equalised using shims. In
this case, the specifications on the nameplate
of the industrial truck must be changed or

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Operation 4
General commissioning

updated. These narrow aisle trucks are equip-

ped with an integrated battery discharge indi-
cator that is set for normal wet lead batteries
(PzS) as standard. If a different battery type or
different battery capacity is used, the author-
ised service partner must adapt the battery
discharge indicator.

NOTE
The voltage and weight of the battery must
satisfy the requirements set out on the truck's
nameplate. Therefore, you need to compare
the nameplates on the truck and battery.

Battery type and battery charger

Wet lead batteries, gel batteries or lithium-ion
batteries can be used as traction batteries.
Because the various types have different
structures, suitable battery chargers must be
used.

NOTE
Batteries are subject to special charging,
maintenance and handling instructions. Ob-
serve the instructions from the respective
manufacturer.

DANGER
Risk to life
– Only use lithium-ion batteries in industrial trucks
that have a design and a controller intended for
use with such batteries.
– Lithium-ion batteries are lighter than lead-acid bat-
teries with the same capacity. Use an appropriate-
ly attached ballast weight to compensate for the
reduced weight.
– Check with the authorised service partner before
using a lithium-ion battery.

CAUTION
Danger of damage to property
Incorrect battery chargers can cause total battery
failure.

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4 Operation
General commissioning

Commissioning 
If your industrial truck is equipped with a Euro
battery male connector, make sure that the
voltage index pin is in the correct position. The
set voltage can be read through a display win-
dow (1).

WARNING
Risk of accident
Risk of injury from crushing zone and shearing zone

WARNING
Risk of short circuit
Do not clamp or crush battery cables.

Before starting each shift, check that the bat-

tery lock is in good working order and that it
functions correctly.
Before using the battery for the first time, a
proper commissioning procedure must be per-
formed. If the battery was obtained separately
to the industrial truck, check the following:
● The nominal voltage

● The minimum required weight

● The model and design of the battery male

connector fitted
● The minimum required cross-section and

the connection type of the battery cable

CAUTION
Danger of damage to property
Observe the information and guidelines from the bat-
tery manufacturer.

Permitted batteries
Only batteries with trays constructed in ac-
cordance with EN1175-1 may be used for op-
eration of the industrial trucks.

Battery commissioning
Proper commissioning must be performed if
the industrial truck was ordered without a

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Operation 4
General commissioning

battery or if it was supplied with a dry pre-

charged battery because it had to be transpor-
ted over a long distance (e.g. from overseas).
Observe the information and guidelines from
the battery manufacturer. If the battery was
obtained separately to the industrial truck, the
nominal voltage, the required minimum weight
and the attached battery male connector must
be checked particularly carefully.

WARNING

Observe the safety regulations for handling battery

acid.

CAUTION
Risk of short circuits
Take care not to jam or crush the battery cable.

Replacing the battery

Battery replacement using forklift truck 
The battery rests in a recess (1) as standard.
The battery is intended to be replaced using a
truck. The truck used must be suitable for this
purpose.
● The fork must be of sufficient length for the
prevailing load centre of gravity.
● The load capacity must correspond to the
weight of the battery fitted.
● The external width of the fork must be ad-
justed to the insertion opening.
● Adjust the fork tilt such that the battery does
not come into contact with the industrial
truck when the battery is removed.
● The battery is not provided with a latch.

WARNING
Risk of accident, risk of crushing
Observe the information in the section entitled Safe
handling of the traction battery.
Make sure that all four corners of the battery are
within the recess.

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4 Operation
General commissioning

Battery replacement with change frame

The industrial truck can be optionally equipped
with roller channels so that the battery can be
replaced using a crane or battery change
frame.
When using a battery change frame, observe
the corresponding operating instructions for
the change frame.

NOTE
If your industrial truck is equipped with roller
channels, the battery is secured in position
with a battery lock. Observe the information in
the section entitled Battery lock in particular.

WARNING
Risk of damage to property, risk of crushing
Observe the information in the section entitled Safe
handling of the traction battery.
Before starting each shift, check that the battery lock
is in good working order and that it functions correct-
ly.

Function checking
Before the truck is handed over to its destina-
tion, thorough function checking must be car-
ried out. Before starting work, the Checklist
before starting work must be completed.
If any defects that could influence operational
and road safety are determined during this
daily check, courses of action must be taken
immediately to ensure that appropriate repairs
are carried out. It is prohibited to continue op-
erating the industrial truck until the repairs
have been completed.
If your industrial truck is equipped with any
special equipment (order), this must also be
checked carefully. For a functional description
and any additional maintenance tasks re-
quired, see the chapter entitled Special equip-
ment or the additional documentation pre-
pared and provided by our suppliers.

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Operation 4
Daily commissioning

Daily commissioning
Checklist before starting work
Before starting work, the driver must make – Check that all the operating devices are op-
sure that the truck is in a safe operating con- erating correctly.
dition.
Checking the access control

CAUTION – Check that the switch key can be pulled out

when it is in the 0 position.
If any defects that could influence operational and
road safety are found during the daily pre-shift check, – Check that the industrial truck cannot be
a course of action must be taken immediately to en- operated when the switch key is removed.
sure that appropriate repairs are carried out. It is pro-
hibited to continue operating the truck until repairs – If electronic access control* is fitted: check
have been performed. for correct function.
Checking the lifting accessory
Function checking the brake system
– Visually check the forks for cracks.
– Check the brake function after releasing the
foot switch. – Visually check the forks for deformation.
– Examine the area around the foot switch for – Check the function of the fork safety de-
foreign objects. vice*.
– Check the brake function after activating the – Check that the locking pin moves easily and
emergency off switch. latches automatically.
– Check the function of the reverse brake. – Visually check the fork carriage for defor-
The braking and subsequent acceleration mation.
processes must be gentle and not subject
–
to jerky movements.
– Visually check the load chains for damage.
– Check the "end of aisle automatic braking"*
system function. Checking the overhead guard
– Perform further order-related brake function – Visually check the overhead guard for de-
checks. formation.
Function checking the steering system – Visually check the overhead guard cover*
for condition and contamination.
– Check that the steering turns freely.
Checking the wheels
– Check that the maximum steering angle of
approx. 90° to the left and right is achieved. – Examine the wheels for foreign objects.
Checking all operating devices – Check the condition of the drive wheel and
load wheels.
– Check that the levers and push buttons are
in good working order. Checking the cab doors, the barriers and the
emergency off switch
– Check that all operating levers and push-
buttons return automatically to the neutral – Make sure that when the emergency off
position. switch is actuated, neither the traction nor
any hydraulic function can be activated.
– Check that all the operating devices are in
good condition.

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4 Operation
Daily commissioning

– Make sure that when the barrier or cab – Check the function of the lighting devices.
door* is open neither the traction nor any
– Check that all covers and flaps are closed.
hydraulic function can be activated.
– Check that the battery lock is in perfect con-
Driver's cab with glass doors and front panel
dition and operates correctly (shut the truck
glazing or all-rounding glazing:
off if the lock is not correctly latched*).
– Check that there are no chips or cracks in
– Check special equipment and special func-
the glazing.
tions according to the order to make sure
– Check all parts of the glazing for contamina- they are in perfect condition and operate
tion. Clean the glazing if necessary. correctly.
Other checks * Option
– Check the function of the horn.
– Check the function of all other warning devi-
ces*.

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Operation 4
Driver's compartment

Driver's compartment
Access to the driver's compartment
Barriers 

DANGER
Risk of crushing
Only the area of the handle indicated must be used
for opening and closing the barriers.

WARNING
Risk of falling
When climbing in and out, it is important to note the
difference in height between the floor of the driver's
compartment and the ground.

NOTE
The barriers are monitored by electrical
means. The industrial truck is only ready for
operation when the barriers have been cor-
rectly closed.
The barriers comprise an upper section (stom-
ach bar), a centre section (knee bar) and a
lower section (foot bar). The three sections
are connected to each other by mechanical
means.
To open and close the barrier, use only the
section of the stomach bar that is furthest for-
ward.

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4 Operation
Driver's compartment

Doors 

DANGER
Risk of crushing
Only the area of the handle indicated may be used to
open and close the glass door.

WARNING
Risk of falling
When climbing in and out, it is important to note the
difference in height between the floor of the driver's
compartment and the ground.

The glass doors feature a recess on the inside

of the handle. Use only this area of the handle
to open and close the glass doors.
The glass doors feature a folding hinge in the
middle. To open the door, push the handle to-
wards the centre of the cab at the point
shown. The door is closed by performing the
action in the opposite direction.

NOTE
The glass doors are monitored by electrical
means. The industrial truck is only ready for
operation when the doors have been correctly
closed.

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Operation 4
Operating devices

Operating devices
Initial driving exercises
WARNING
Before starting work, the Checklist before starting
work must be completed.
Observe all safety instructions.

WARNING
Risk of accident
In order to become familiarised with the driving and
braking characteristics of these trucks, driving exerci-
ses must first be carried out in a flat, obstacle-free
area of the warehouse.

Speeds
The driver must adapt the driving speed ac-
cording to the situation. When cornering in
particular, attention must be paid to the overall
height and the centre of gravity, which will be
high as a result.

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4 Operation
Operating devices

Adjusting the position of the operat- 

ing panel

WARNING

The clamping device that is released for the settings

described below must be retightened before starting
work.

In order to be able to optimally adapt the oper-

ating panel to driver requirements, the panel
can be adjusted by height, by tilting the con-
sole and by tilting the operating panel. The po-
sition of the clamp lever can be changed by
means of an integrated latching mechanism.
To do this, pull out the handle of the clamp
lever (1) on its axle, turn it to the required po-
sition and allow it to engage again.
Adjustment
Release the clamp lever (1) by turning it to the
left. Keep hold of the operating panel with the
other hand while doing this. If the clamping
device comes loose, move the operating panel
into the required position with both hands and
hold it there. The setting is continuously varia-
ble. Retighten the clamp lever.
– Adjust height (2).
– Adjust tilt (3).

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Operation 4
Operating devices

Driver's seat 

NOTE
In addition to the standard driver's seat, sever-
al other models are available as options. The
corresponding original operating instructions
from the manufacturer are supplied with each
model. Observe these operating instructions.

WARNING
Risk of accident
Only apply settings in a stationary truck.

Adjusting the driver's seat, standard

version
Adjusting the seat height
– Place body weight on driver's seat.
– Pull the lever (1) and raise or lower the driv-
er's seat to the required height using your
body weight.
– Release the lever.
Adjusting the horizontal position
– Pull the handle (2) and move the seat into
the required position. The mechanism must
noticeably engage.
Tilting the seat surface
– Pull the handle (3) and move the seat base
into the required tilt position. The mecha-
nism must noticeably engage.
Folding up the seat base
If the seat base of the driver's seat (4) is in the
way when operating the industrial truck in a
standing position, it can be folded up and
away. The folded-up seat base is upholstered
and can be used to lean on.
– Reach under the seat base and fold it up-
wards.

Driver's seat, option

The driver's seats that are available as differ-
ent options vary considerably in terms of their

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4 Operation
Operating devices

design and operation. Observe the original op-

erating instructions supplied.
Optional versions
● Folding armrests

● Heatable

● 80 mm longitudinal adjustment

● Lumbar support

● Air suspension

● Leather upholstery

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Operation 4
Switching on

Switching on
Switching on the controller
Battery male connector 
To plug in the battery male connector, open
the service flap behind the lift mast.
Get into the cab and close the barriers/cab
doors.

NOTE
Barriers/cab doors are monitored by monitor-
ing switches to ensure that they are complete-
ly and correctly closed.

WARNING
High risk of injury
Never climb or jump on to a moving truck.

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4 Operation
Switching on

Emergency off switch, key switch 

Unlock the emergency off switch by turning it
clockwise.
Switch on the key switch or activate the elec-
tronic access control*.
If the truck is in an error-free state, the indica-
tor for normal operation appears on the opera-
tion status display (see "Operating status dis-
play").
The working spotlights* are switched on.

NOTE

If the controller is switched on when the

barriers are closed, the foot switch must
be actuated once to enable the functions.
To drive, the foot switch must be actu-
ated and held down so that the parking
brake is released.
If one of the barriers is opened and then
closed again when the controller is
switched on, the foot switch must be ac-
tuated again once.
This switching ensures that the industrial
truck can be operated only if the operator
is in the cab and all barriers are closed.
* Option

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Operation 4
Switching on

Electronic access control 

There is also the option to have these industri-
al trucks equipped with electronic access con-
trol (PIN code, RFID chip, magnetic card sys-
tem). See the section entitled "Special equip-
ment".

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4 Operation
Driving

Driving
Braking, driving and steering
Releasing the brake 
After entering the driver's cab, close the barri-
ers or cab doors. Pressing the foot switch (1)
once confirms your presence. If the drive
switch is also actuated when the foot switch is
actuated, the electromagnetic parking brake is
released.

NOTE
The foot switch must be pressed again after
each time the barriers or doors are opened
and closed. The ancillary movements can only
be used when the industrial truck is at a stand-
still and the foot switch is not actuated.

Braking
Releasing the foot switch while driving triggers
the electrical reverse current braking. The in-
dustrial truck is braked to a standstill. Then the
electromagnetic parking brake is activated.
Releasing the operating lever for driving or the
left-hand sensor surface while driving triggers
the electrical reverse current braking. The in-
dustrial truck is braked to a standstill.
There are functions that only work when the
industrial truck is at a standstill. Therefore, it
can be necessary to release the foot switch in
order to use these functions. The correspond-
ing pictogram appears on the display.

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Operation 4
Driving

Driving 
The drive direction and the driving speed are
selected using the right-hand operating lever.
Move the operating lever in the direction of the
fork (2) until the required driving speed in the
fork direction has been reached.
Move the operating lever in the direction of the
lift mast (3) until the required driving speed in
the direction of the lift mast has been reached.
If the operating lever is switched from one
drive direction directly to the other, the indus-
trial truck is braked and accelerated in the op-
posite direction.

Speed
The controller limits the driving speed depend-
ing on the driving situation and any options in-
stalled. It is always possible to have the speed
restricted by the authorised service centre, but
not to increase it. The operator can continu-
ously control the speed within the permitted
range.
The authorised service centre can configure
the acceleration and braking characteristics.

Steering 
The operator's left hand is used to actuate the
steering knob (4) and thus determines the
course the truck takes. The steering knob has
a mechanical detent in the straight-ahead po-
sition. From there, the steering knob can be
turned approx. 135° to the right and to the left.
The steering turntable rotates by 90°.
If the industrial truck is being directed by a
guidance function (MZF or IZF), the steering
knob must be in the straight-ahead position.

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4 Operation
Driving

Two-hand driving operation 

Operation of the industrial truck with two
hands is required within the aisles once the
controller has detected the corresponding sen-
sor system. To drive, you also need to touch
the sensor surface on the left-hand end of the
operating panel (5) with your left hand.

Simultaneous functions
Different functions can be combined. For this
purpose, more than two operating devices
may need to be actuated at the same time.

Driving and main lift 

In order to execute the two functions driving
and main lift simultaneously, both operating
levers must be moved accordingly. Moving the
left-hand operating lever in the direction of the
fork (6) activates lowering of the main lift.
Moving this operating lever in the direction of
the lift mast (7) activates lifting. The degree of
activation is always infinitely variable.
The drive direction and the driving speed are
selected using the right-hand operating lever.
Move the operating lever in the direction of the
fork (8) until the required driving speed in the
fork direction has been reached.
Move the operating lever in the direction of the
lift mast (9) until the required driving speed in
the direction of the lift mast has been reached.

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Operation 4
Driving

Driving and auxiliary lift 

In order to execute the two functions driving
and auxiliary lift simultaneously, both operat-
ing levers must be moved accordingly.
Press the button (10) to select the auxiliary lift.
The degree of activation is always infinitely
variable.

Driving, main lift and auxiliary lift

In order to execute the functions driving, main
lift lifting and auxiliary lift lifting, or driving,
main lift lowering and auxiliary lift lowering si-
multaneously, both operating levers must be
moved accordingly.
In addition, press the button (11) to select the
combination of main lift and auxiliary lift.
The degree of activation is always infinitely
variable.

Types of guidance
The industrial trucks can be designed for:
● Driving without guidance
● Driving with mechanical rail guidance*
● Driving with inductive guidance*
● And combinations* of these
*Option

Driving without guidance

In standard trucks, the operator's right hand
selects the driving speed and drive direction.
The operator's left hand is used for steering
and thus determines the course the truck
takes.

Mechanical rail guidance (MZF)*

The industrial trucks can be guided mechani-
cally when travelling within aisles. To achieve
this, a rail system is installed on the floor of
the warehouse. Two-hand operation is re-
quired to make use of the guidance system.
The operator's right hand selects the driving
speed and drive direction. The operator's left
hand is used to actuate a sensor or a function.

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4 Operation
Driving

More detailed information can be found in the

relevant dedicated chapter.

Inductive guidance (IZF)*

The industrial trucks can be guided inductively
when travelling within aisles. To achieve this,
a wire is embedded into the floor; this wire is
live with current. The magnetic field generated
by this wire is detected by sensors in the in-
dustrial truck and used to guide the truck.
Two-hand operation is required to make use
of the guidance system. The operator's right
hand selects the driving speed and drive di-
rection. The operator's left hand is used to ac-
tuate a sensor or a function.
More detailed information can be found in the
relevant dedicated chapter.
*Option

Mechanical guidance MZF

The mechanical guidance consists of one or
two rails on or between which the industrial
truck is guided with a maximum permissible
play of 5 mm. When guidance is active, the
controller automatically adapts the maximum
possible driving speed to match the lift height.

Entering the aisle

To enter rail guidance, the industrial truck
must be positioned as centrally as possible
and aligned with the aisle in front of the entry
funnel. The more accurate this positioning, the
faster and more precisely the industrial truck
will be led into the guide. Once the industrial
truck has entered the guide, the side rail
switches are activated. When the rail switches
detect the rail guidance, the MZF mode of op-
eration is automatically selected.
Instead of the "steering wheel" symbol, the
symbol for "guidance" appears in the display.

Exiting the aisle

The industrial truck must be driven completely
out of the aisle. The sensor system for the

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Operation 4
Driving

aisle detection recognises the location of truck

and re-enables the steering.

Changing the aisle 

If the industrial truck needs to be driven out of
one aisle and into another, the following notes
must be observed:
– Drive the industrial truck completely out of
the aisle.
– Slowly drive out of the aisle and beware of
any people or other industrial trucks in the
transfer aisle.
– Once the industrial truck is outside the rail,
the steering is reactivated by the rail switch.
– The industrial truck can then be turned 90°
on the spot and driven to the target aisle.

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4 Operation
Load pick up

Load pick up
Moving the load
Main lift and auxiliary lift 
The main lift and the auxiliary lift can be lifted
and lowered together. The lift height display
will be synchronised.
Pressing button (1) and moving the left-hand
operating lever in direction (2) or (3) triggers
the infinitely joint lifting or lowering of the main
lift and auxiliary lift.

NOTE
This combined hydraulic function can still be
combined with the driving function. To do this,
move the right-hand operating lever as well.

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Operation 4
Load pick up

Ancillary movements 
All movements of the load apart from the main
lift are categorised as ancillary movements.
Standard functions are:
● Sliding the fork.
● Swivelling the fork.
● Lifting the auxiliary lift.
Touch the right-hand sensor surface(4) and
move the left-hand operating lever in the di-
rection (5) or (6) to trigger the reach move-
ment to the left or right.
Pressing button (7) and moving the left-hand
operating lever in direction (8) or (9) triggers
the swivel-shift movement to the left or right.
Pressing button (10) and moving the left-hand
operating lever in direction (11) or (12) triggers
the lifting or lowering of the auxiliary lift.

Swivelling and sliding the swivel fork 

180° synchronously
Pressing selection key (13) and moving the
left-hand operating lever (14) to the right or left
triggers the synchronous movement. This
movement can be interrupted at any time or
continued in the opposite direction. To do this,
release the operating lever or the selection
key.

NOTE
The synchronous movement only starts when
the turret head is in one of its end positions.
When the synchronous movement reaches
the end, an acoustic signal is sounded. Al-
ways carry out the synchronous movement
until the end. The swivel fork is then in its right
or left end position.

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4 Operation
Load pick up

Swivelling and sliding the swivel fork

90° synchronously
This function moves the turret head to the
front position through a synchronised move-
ment involving shifting and swivelling. This
means that the swivelling function automati-
cally stops at a swivel angle of 90 and the
sideshift automatically stops in a central posi-
tion in front of the cab. This function makes it
easier to pick up loads at the front of the truck.
Option
See the chapter entitled "Special equipment".

Fork cycle
This function enables an increase in handling
performance through automation of load pick
up and load deposit. The details of the fork cy-
cle function depend on the design of the in-
dustrial truck.
Option
See the chapter entitled "Special equipment".

Hydraulic special functions 

Additional hydraulic functions are available as
an optional extras. Buttons (15)(16)(17) are
provided for operation of these additional func-
tions. See the chapter entitled "Special equip-
ment".

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Operation 4
Load pick up

Underside of the operating panel 

On the top of the operating panel, there are
four buttons on the right-hand end that are op-
erated using the thumb on your right hand.
There are also four buttons (18) and (19) on
the underside of the operating panel. These
buttons can operated using your other fingers
on the same hand. The functions of the but-
tons on the underside of the operating panel
are identical to the buttons directly above
them on the top of the operating panel. If the
button on the underside of the operating panel
is pressed, the illuminated ring for the button
above it on the top of the operating panel is
activated.

NOTE
The two lower buttons on the right-hand side
of the operating panel are primarily assigned
on an order-specific basis. If the industrial
truck is not equipped with options, the buttons
on the top and underside of the operating pan-
el (19) do not have a function.

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4 Operation
Load pick up

Load capacity diagram 

Depending on the job, a load capacity diagram
may be generated and mounted in the cab. To
ensure that the stability of the industrial truck
is not jeopardised in any way, the load capaci-
ty diagram and the load capacity restrictions
specified on this diagram for certain applica-
tion conditions must be observed.
This also applies to the increasing weight of
the commissioned goods.
Example for an industrial truck with a lift height
of 10280 mm (1)
Distance between the load centre of gravity
and the fork back

400 mm Max. load: 1500 kg

500 mm Max. load: 1285 kg
600 mm Max. load: 1125 kg

The load capacity of the truck decreases as

the lift height increases and the load centre of
gravity distance grows larger.
The data for the current situation must be tak-
en from the load capacity diagram.

NOTE
This industrial truck can also be equipped with
the intelligent load capacity diagram as an
option. Descriptions of this option can be
found in the chapter entitled Special equip-
ment.
The support screws may only be adjusted by
authorised service personnel. The setting di-
mension X on the load capacity diagram must
be observed.

WARNING
Risk of accident
The specified setting dimension X (2) for the support
screws must be checked every 6 months by author-
ised service personnel and adjusted if necessary

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Operation 4
Load pick up

Fork arms, adjustable 

The standard design features forged fork arms
that are manually adjustable. This allows dif-
ferent pallets and load supports with suitable
dimensions to be picked up.
As an option, these industrial trucks can also
be equipped with hydraulically adjustable fork
arms. The distance between the fork arms
must be sufficient so that the load cannot fall
and that there is constant support centrally be-
low the load centre of gravity. Adjust the fork
arms accordingly and lock in position.
– Lift the locking lever (1).
– Move the fork arms to the desired position
and allow the locking lever to engage again.

NOTE
If the locking lever is engaged, it is no longer
possible to move the fork arms laterally.

CAUTION
Risk of accident
– Use the industrial truck only if the side fork arm
locking device (2) is present and in perfect work-
ing order. Fork arms could slide off the fork car-
riage and fall down.
– Use only fork arms that are designed and ap-
proved for this industrial truck. See the order for
specifications.

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4 Operation
Emergency operation

Emergency operation
Emergency lowering via the operat- 
ing panel
In certain circumstances, the truck control unit
prevents further lowering of the cab. (chain
breakage or slack chain situation, or faults
with chain monitoring, faulty height measuring
system, faulty rev sensor on the pump motor).
In these situations, the operator can select the
emergency lowering function via the operat-
ing panel and the cab will lower to the ground
without further assistance.
– Do not actuate the foot switch.
– Push the operating lever for hydraulics (1)
forwards while touching the right-hand sen-
sor surface (3) (main lift lowering function).
– Wait six seconds. The enable button (2)
then flashes in red.
– Leave the main lift lowering function selec-
ted while pressing the enable button. The
main lift will slowly be lowered.

Emergency lowering
Emergency lowering function for the driver's
cab
If a technical defect causes the industrial truck
to shut down when the driver's cab is raised,
or if an operator in the raised cab becomes in-
capable of operating the industrial truck (e.g.
falls unconscious), the driver's cab can be
lowered by a second person on the ground us-
ing the hand-operated emergency lowering
valve.

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Operation 4
Emergency operation

Removing the control compartment 

hood

DANGER
Danger of electric shock (80-V version)
Disconnect the battery male connector
before removing the control compart-
ment hood.

– Open the two screw plugs (1).

– Hold the hood at the ventilation openings
(2), lift it off and then place it to one side.
The hood is very lightweight and can there-
fore be removed by hand without using any
tools.
– The emergency lowering valve (3) is loca-
ted in the control compartment and can be
accessed once the cowling has been
opened.

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4 Operation
Emergency operation

DANGER
Risk of physical injury
If the emergency lowering function has to be used
because the operator has fallen unconscious, make
sure that all parts of the operator’s body are fully
within the driver's cab so that there is therefore no
risk he may be injured during the lowering procedure.
The operator of the emergency lowering valve must
be certain that the moving components of the lift
mast are immediately set in motion on opening the
valve. Special attention must be given to the cab, the
chains and the inner masts of the lift mast. All of the
load chains in the lift mast must remain taut through-
out the whole of the lowering procedure. If the com-
ponents of the lift mast are not immediately set in
motion after opening the emergency lowering valve,
close the valve immediately.
If the view that the operator of the emergency lower-
ing valve has of the lift mast is obstructed, a third
person with full view of the lift mast must be involved.
This third person must be able to communicate clear-
ly with both the operator of the emergency lowering
valve and the operator of the industrial truck.
If a movement like the one described cannot be de-
tected immediately or if one of the chains has slack-
ened, a mechanical jam at the lift mast is suspected.
The emergency lowering procedure must then be
stopped immediately by closing the emergency low-
ering valve. The operator must then be retrieved
some other way. For example, a second turret truck
could be used if suitable, or an elevating work plat-
form. The authorised customer service team must
determine the cause of the fault and the means of
rectifying it.
If, as described above, it is suspected that the lift
mast is mechanically jammed, the abseil system
must not be used. The resulting vibrations could
cause the mechanical jam to be released, which
could create a further hazard should the cab subse-
quently drop.
– Apart from the emergency lowering valve, it is not
permitted to adjust any other screw.
– Close the valve again once the emergency lower-
ing process has been fully completed.

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Operation 4
Emergency operation

Securing the load support 

In order to secure the load support against
lowering during maintenance work, the lower-
ing movement can be locked by closing the
shut-off valves. A notch in the block section in-
dicates the valve position.
● The notch is pointing in the direction of the
connected line = flow open
● The notch is at a right angle to the direction
of the connected line = flow blocked

DANGER
Risk from lowering of the lift mast or driver's cab
– The pressure in the hydraulic system must be re-
leased before any work is carried out on it. The
load support must also be lowered to the ground.
– Before a person can go underneath the raised
driver's cab, an additional mechanical safety de-
vice must be installed. For example, fit a suitably
strong brace around the bridge pieces on parts of
the lift mast or place a suitably strong jack stand
underneath the driver’s cab.
– Lock all existing shut-off valves. There is a valve
for each main lift cylinder (1), one for each free lift
cylinder* (2) and two additional valves for the hy-
draulic lines for the attachment (3).

*Option

Emergency operation
If the entire truck control unit or part of it fails,
the industrial truck can be moved out of the
working area by means of the relevant emer-
gency operation mechanism.

WARNING

– Only tow at creep speed

– There must always be an operator in the industrial
truck that is being towed.
– There must not be anyone in the danger area of
the trailer train.
– In order to prevent strong lateral forces and there-
fore the risk of tipping, always leave plenty of
space when driving round corners.
– The vehicle used for towing must always be driv-
en carefully and be able to brake gently and in
good time.

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4 Operation
Emergency operation

Removing the control compartment 

hood

DANGER
Danger of electric shock (80-V version)
Before the control compartment hood is
removed, the battery male connector
must be disconnected.

– Rotate the two screw plugs (1) in a clock-

wise direction and remove them.
– Grasp the hood at the ventilation openings
(2) and lift it off. Put it aside.

Releasing the brake mechanically 

WARNING
If the brake (3) has been mechanically disabled as
described below, a suitable tow bar must be used for
towing or a second industrial truck must be coupled
to the industrial truck so that it can take over the
braking.
Before the truck is put back into service, restore the
brake system to perfect working order.

Traction motor brake

1. option
Disassemble the brake blocks. To do this, re-
move three mounting screws. Place the brake
blocks to one side.
2. option
Tighten the brake anchor plate. To do this,
screw two screws (M5X20) into the bores pro-
vided and tighten them.
Load wheel brake*
To release the load wheel brake, the hydraulic
line must be depressurised. To do this, open a
threaded pin on the valve block by turning it
anti-clockwise (three turns). This threaded pin
(4) is wrench size 4 mm.

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Operation 4
Emergency operation

NOTE
Once the hydraulic line to the load wheel
brake has been depressurised by turning the
threaded pin (4), no hydraulic functions may
be selected. If any hydraulic functions were to
be selected, an error message would appear
in the display.
* Option

Towing with operational steering

If the steering of the industrial truck is still op-
erational, once the brake has been released
the industrial truck can be towed either with a
rope or with the tow bar.

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4 Operation
Emergency operation

Towing with non-operational steering 

WARNING
Emergency steering movements may be carried out
only when the truck is at a standstill.
Make sure that the industrial truck is switched off.

These industrial trucks are equipped with a

mechanical emergency steering device. A
shaft with a pinion gear is provided for this
purpose.
– Perform the required steering movement
using a socket wrench or box-end wrench.
– Before the industrial truck is recommis-
sioned, the pinion shaft must be fixed back
in its original position.
Activating the emergency steering device
48-V version
– Using a suitable tool, e.g. a screwdriver, re-
move the lock washer (1). When doing so,
make sure that the lock washer does not
jump off.
– Insert the pinion shaft into the same bore
(2) from below. Insert the lock washer from
above into the shaft groove.
80-V version
– Remove the screw and the holding plate
(3).
– Insert the pinion shaft into the bore provided
from below and hold it in position with the
holding plate and screw (4).

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Operation 4
Emergency operation

Attachment points 
(5) for towing with the drive unit leading,
(6) for towing with the fork leading

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4 Operation
Emergency operation

Emergency abseil system

Exiting the raised driver's compartment 
in the event of an emergency

NOTE
An emergency abseil system is only required if
the driver's compartment can be raised higher
than 3000 mm above the ground.

NOTE
Two versions are available. As standard, a
system is supplied that includes a safety har-
ness designed for people up to a height of ap-
proximately 2 m. For larger operators, a var-
iant is available as an option that includes a
safety harness that can be adjusted up to size
XXL.
The storage location for the emergency abseil
system is marked with an adhesive label (1).

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Operation 4
Emergency operation

DANGER
Risk of falling
– Before using the very narrow-aisle truck, the oper-
ator must be instructed in using the abseil system
by a technical expert.
– The operating instructions located in the rucksack
must be read and followed.
– Before each use, the user must carry out a visual
inspection to make sure that the abseil system is
in a perfect condition and is ready to use.
– Before each use, the safety harness must be
checked to make sure it is in the initial position. In
addition, the free rope length between the lifting
point in the overhead guard and the safety har-
ness chest eyelet must be adjusted correctly. Only
a little slack rope is permitted between the lifting
point and the safety harness chest eyelet.
– If additional bores are created on the front edge of
the overhead guard, a redirecting point for the
rope can be provided. This redirecting point routes
the rope in a more favourable position for the per-
son abseiling. The carabiner, which is also inclu-
ded in the scope of delivery, is hooked into this
bore. The rope is then guided through this carabi-
ner. Carabiners must always be closed.
– Abseiling exercises are only permitted under the
supervision of an expert.
– In Germany, the abseiling procedure must be
practised at least once a year. We recommend
these practice exercises for other countries, even
if they have not explicitly been made compulsory.
– No changes may be made to the emergency ab-
seil system.
– Only abseil systems that meet the requirements of
the standards may be used.
– The emergency abseil system may only be used
for its proper purpose of rescuing a person from
the cab of a turret truck.
– Once the exercises are complete, the emergency
abseil system must be correctly repacked, sealed
and stowed away by a technical expert.
– See the operating instructions for the respective
abseil system for the maximum permissible serv-
ice life (replacement state of wear).
– At the end of the maximum permissible service life
(replacement state of wear), the abseil system
must be disposed of and replaced by a new sys-
tem.

The emergency abseil system is installed in

the driver's cab and is ready for use.
The safety harness, the descender device and
the rope are located in the rucksack.

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4 Operation
Emergency operation

The upper end is attached to the eyelet provi-

ded in the overhead guard via a carabiner.
The rucksack itself is sealed using a plastic
seal.
The original system must not be used for prac-
tice, because this causes a certain amount of
wear and the seal no longer serves as a moni-
toring element.
A figure-of-eight knot is tied on the other end
to protect it from unthreading. This knot is se-
cured with a cable tie.

Operating instructions
The rucksack contains the operating instruc-
tions for the system. These instructions must
be observed and must not be removed under
any circumstances.

Redirecting point for the rope 

In order to bring the person abseiling into a
more favourable position, the rope can be re-
directed with an additional snap hook in most
versions of the overhead guard. This addition-
al carabiner is attached to the safety harness
chest eyelet area. To redirect the rope, the
snap hook is detached from its original posi-
tion and reattached in a bore provided in a
strut on the overhead guard (2).

Testing
A technical expert must check the abseil sys-
tem at least once a year to confirm that it is in
perfect condition and functions correctly. To
perform this check, remove the seal to ensure
that the system can be removed. Once the
check has been successfully performed, seal
the rucksack using the next seal. The maxi-
mum number of seals required is included in
the rucksack.

Replacement state of wear

The maximum permissible service life for this
abseil system is restricted. During this time,
only minimal use is permitted and the system
must be stored in optimum conditions. See the
operating instructions for the respective abseil

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Operation 4
Emergency operation

system for the maximum permissible service

life (replacement state of wear).
Once the last numbered seal has been used,
the entire system must be replaced.

Two-person cab
Industrial trucks that feature a cab that permits
two operators must also be equipped with two
abseil systems.
In such trucks, it must be ensured that only
the lifting points approved by the manufacturer
are used.

Different operators
If an industrial truck is used by multiple per-
sons, e.g. in multi-shift use, it may be indica-
ted that several preset abseil systems must be
kept on hand. This is particularly sensible if
the different operators are of widely varying
heights and/or weights and the safety harness
would therefore have to be adjusted to a sig-
nificant degree.
In such trucks, it must be ensured that only
the lifting points approved by the manufacturer
are used.

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4 Operation
Parking, decommissioning

Parking, decommissioning
Parking and leaving the truck

NOTE

It is the operator's duty to remove the ignition

key when he leaves the truck, thus securing
the truck against unauthorised use. If the truck
is equipped with an electronic access control,
it must be reset and/or the device for control-
ling access must be removed. Where possi-
ble, the truck should be parked at the start of a
racking aisle or in a loading bay. If there are
parking spaces, the truck must be parked
there. The fork is to be lowered to the floor as
far as possible, and if there is one, the tilt at-
tachment must tilt towards the floor to reduce
the risk of stumbling.

Decommissioning
ponents are disposed of in accordance with
ENVIRONMENT NOTE
the valid guidelines. The used consumables in
particular are to be recycled or disposed of
If the industrial truck described here has to be correctly.
taken out of operation, make sure that all com-

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 5

Regular care and maintenance

5 Regular care and maintenance
Regular care and maintenance

Regular care and mainte- 

nance

NOTE
● The regular care and maintenance of the in-
dustrial truck will ensure that the truck is
ready for operation and will maintain its val-
ue.

WARNING
Risk of injury and damage to property
– Appropriate precautions for safe working must be
taken for all care and maintenance work.
– As well as the usual occupational safety regula-
tions, the safety information specifically outlined in
this brochure must also be observed.
– Whenever you are working on the hydraulic sys-
tem, ensure that the entire system is depressur-
ised. This is particularly important when working
on industrial trucks with built-in accumulators.
– For all care and maintenance work (except func-
tional tests), disconnect the battery male connec-
tor.
– Only electricians from the respective service part-
ner may perform work on the electrical system.

To ensure the safe operation of your industrial

truck over a long period of time, it is absolutely
essential that the machine is maintained reg-
ularly.
The activities listed in the maintenance
schedule must be performed thoroughly and
correctly at the specified intervals.
Our dedicated service partner will assist you
with any queries about care and maintenance.
We offer you the opportunity to take out main-
tenance contracts with us and to engage us to
perform regular testing (FEM).
Only regular maintenance and testing will ena-
ble you to make full use of the warranty.

Regular maintenance
Care work does not require special prior
knowledge or training and can be performed
by the operator or the workshop staff at the
operating company.

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Regular care and maintenance 5
Regular care and maintenance

Maintenance
In contrast, maintenance work must be per-
formed only by appropriately trained person-
nel. Special tools and the current service soft-
ware are required. Therefore, these activities
are described only briefly in the maintenance
schedule.

Original parts
We recommend that you use only genuine
spare parts. More information and the order
numbers can be found in the spare parts list.
The installation of other parts will invalidate
the warranty.

Maintenance frequencies and times

The maintenance activities are scheduled at
intervals of 1000 hours or 12 months. You can
use the maintenance schedule to determine
what work is required. The following mainte-
nance schedules are based on 10,000 operat-
ing hours. Once this number of operating
hours is reached, the cycle starts again from
the beginning. The intervals must be reduced
for trucks exposed to high levels of dust and
significant temperature fluctuations. A check
of the function and condition of the truck must
be carried out during each maintenance oper-
ation.

Type of stress
This maintenance schedule is valid for normal
stress for single-shift operation not within a
cold store. For heavy-duty and/or multi-shift
operation, reduce the intervals. Note the infor-
mation in the section entitled Area of applica-
tion.

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5 Regular care and maintenance
Special versions, special equipment

Replacement interval for lifting chains

CAUTION
Risk of accident
The main lift chains and the auxiliary lift chain must
be replaced when the wear limit is reached or if im-
permissible damage is present. The technical condi-
tion of the chains from a safety perspective must be
assessed by a competent person using the manu-
facturer's documentation. Observe the current
applicable guidelines for the cold store version of in-
dustrial trucks.

Special versions, special

equipment
The technology used in special versions of in-
dustrial trucks or in industrial trucks with spe-
cial equipment may mean that additional care
and maintenance work is required. In some
cases, the maintenance intervals will shorten
as a result.

NOTE
Observe additional operating instructions as
well as documentation from suppliers included
in the scope of delivery.

Regular maintenance
Maintenance work as required

Go through the checklist before starting work.

Keep the industrial truck clean and dry.

If damage becomes apparent on the industrial truck, have it repaired without delay.
Perform checks on the industrial truck after changes and damage.
Investigate any changes in the noise on the industrial truck.
Perform battery maintenance in accordance with the manufacturer's instructions.

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Regular care and maintenance 5
1000-hour maintenance schedule

1000-hour maintenance schedule

At operating hours Carried
1000 h 2000 h 3000 h 4000 h 5000 h out
6000 h 7000 h 8000 h 9000 h 10000 h  
Preparatory tasks
Industrial truck: clean or have it cleaned by the operating company.
Nameplate: identify the industrial truck.
Controller: read out the operating hours.
Gearbox
Gearbox: check for noise and leakages.
Gearbox: check the oil level, top it up if necessary.
Gearbox: first oil change after 1000 operating hours and every 4000 operating hours
thereafter.
Drive unit: check the tightness of the screw connection to the chassis (ensure the
appropriate torque).
Traction motor bearings: check for operating noise.
Traction motor bearings: replace if necessary.
Chassis, bodywork and fittings
Bearing points and joints: check and lubricate.
Doors, flaps and covers: check function.
Doors, flaps and covers: check the mounting and condition.
All moving parts: lubricate with a suitable lubricant.
Overhead guard: visually inspect the weld seams; use a dye penetrant procedure if
you suspect there are cracks.
Overhead guard: visually inspect for damage and deformations.
Rail switches: check the function and condition.
Support screws in the chassis: check the setting according to the specifications on
the nameplate. Adjust as necessary.
Battery compartment door and battery compartment hood: check and adjust as nec-
essary.
Battery compartment door and battery compartment hood: check and adjust as nec-
essary.
Battery compartment: check that the battery is securely positioned and check side
stops on the battery.
Chassis frame
Drive wheel: check the condition and check for wear and any foreign objects.

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5 Regular care and maintenance
1000-hour maintenance schedule

At operating hours Carried

1000 h 2000 h 3000 h 4000 h 5000 h out
6000 h 7000 h 8000 h 9000 h 10000 h  
Drive wheel, wheel nuts or wheel screws and cushion tyre: check for secure attach-
ment.
Load wheels: check the condition and mounting and check for wear and foreign ob-
jects.
Load wheels: check for ease of movement.
Antistatic belt: check the condition.
Antistatic chain: check the condition.
Active load wheel axle
Function: check while driving in the aisle.
Measurement units: check the condition.
Measurement units: clean, remove any foreign objects.
Measuring rollers, sensors, magnets: check the condition.
Measuring rollers, sensors, magnets: clean, remove any foreign objects.
Spur gears: check the condition of the lubrication and relubricate if necessary.
Steering system
Steering: function check outside the aisle.
Steering: check the steering angle (>90° on both sides).
Steering: check straight line travel.
Steering gears: lubricate with all-purpose grease.
MZF: function check.
IZF: check for central positioning and accuracy of the guidance in relation to the
guide wire.
Steering angle measurement: check the level of play and the condition.
Steering knob, steering wheel: check for ease of movement.
Live ring bearings: check for ease of movement and wear.
Live ring bearings: check the play of the gears.
Steering motor bearings: check for operating noise.
Brake system
Service brake: check for correct function.
Reverse brake: check for correct function.
Drive unit: check the thickness of the brake lining and check the condition. Replace
if necessary.

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Regular care and maintenance 5
1000-hour maintenance schedule

At operating hours Carried

1000 h 2000 h 3000 h 4000 h 5000 h out
6000 h 7000 h 8000 h 9000 h 10000 h  
Load wheels: check the brake clearance by freewheeling.
Load wheels: check the condition and thickness of the brake lining. Replace if nec-
essary.
Brake lining: blow out abrasion with oil-free air.
Brake retardation values: check after each adjustment (dynometer or retardation
measuring device).
Automatic braking: check the function as per the order.
Components for automatic braking (inductive switch/photoswitch/magnet-operated
switch): check the function, setting and condition.
Components of the RFID system: check the function, condition and setting.
Operating devices
Check that the service brake is working correctly.
Operating devices: check the function and condition.
Protective devices: check depending on the equipment. Repair if necessary.
Information signs, warning signs, load capacity diagram: check that they are present
and legible.
Information signs, warning signs, load capacity diagram: replace missing or illegible
labels.
Optional and additional equipment: check the function and condition according to
the order.
Electrics, electronics
Battery cables, battery connectors, battery male connectors: check the condition
and check for secure attachment.
Battery cables: visually check the insulation.
Battery: measure the battery voltage under load
Battery: measure the tray for short circuits.
Battery: check the electrolyte level.
Drive and pump controller: check the driving, acceleration, braking and reversing
functions.
Plugs and connections: check that they are securely attached.
Openly routed cables: visually inspect the insulation.
Contactor contacts: check the condition and check for erosion. Replace if necessa-
ry.
Visually check the condition of the fuses.

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5 Regular care and maintenance
1000-hour maintenance schedule

At operating hours Carried

1000 h 2000 h 3000 h 4000 h 5000 h out
6000 h 7000 h 8000 h 9000 h 10000 h  
Fuses: check the values.
Heat sink and fan: clean.
Height measuring system for the main lift: check the function and condition of the
measuring tape and check that the component is securely mounted.
Height measuring system for the auxiliary lift: check the condition of the magnetic
strip and protective tape and check that the components are securely mounted.
Displacement transducer for the load wheel: check for contamination, check the
condition and check that the component is securely mounted.
Displacement transducer for the load wheel: check the O-rings for contamination,
check the condition and check for wear. Replace if necessary.
Hydraulics
Check the oil level in the hydraulic system To do this, fully lower the load support.
The oil level must be between the minimum and maximum marking. The markings
on the hydraulic oil tank become visible once the control compartment hood is re-
moved.
Hydraulic system: check for leak tightness.
Hydraulic oil filter of the hydraulic oil tank: replace.
Air filter of the hydraulic oil tank: replace.
Pump motor: check for operating noise.
Hose lines: check the pre-load.
Load lift system
Stops and end lift cut-out: check the condition and function.
Lift cylinder: check the mounting.
Lift cylinder: visually check bearing points and their weld seams.
Main lift load chains: check the condition, lubrication and tension and check for
wear, elongation and damage.
Auxiliary lift load chains: check the condition, lubrication and tension and check for
wear, elongation and damage.
Main lift load chains: determine wear (maximum permissible wear is 2%)
Auxiliary lift load chains: determine wear (maximum permissible wear is 3%)
Load chains: lubricate with chain spray.
Chain rollers: check for ease of movement.
Mast channels: check the surfaces for wear.
Mast channels: lubricate the surfaces with grease.

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Regular care and maintenance 5
2000-hour maintenance schedule

At operating hours Carried

1000 h 2000 h 3000 h 4000 h 5000 h out
6000 h 7000 h 8000 h 9000 h 10000 h  
Lift mast rollers: lubricate with all-purpose grease. If necessary, install lubricating
nipples.
Lift mast rollers: check the condition and check the setting.
Guide elements: check the lateral play.
Guide elements: lubricate with all-purpose grease.
Load fork: check the condition and function of the latches.
Load fork: visually inspect for bends, measure if necessary.
Load fork: if you suspect there are cracks, check using the dye penetrant procedure.
Adjustable fork: lubricate sliding surfaces with all-purpose grease.
Swivel drive: check that the eight screws between the swivel drive and the front end
are securely fastened.

2000-hour maintenance schedule

At operating hours Carried
out
2000 h 4000 h 6000 h 8000 h 10000 h  
Gearbox
Gearbox: visually inspect the shaft/hub connection between the traction motor and
gearbox and clean the connection if necessary.
Gearbox: add new lubricant to the shaft/hub connection between the traction motor
and gearbox. Refer to the lubricant overview.
Gearbox: perform an oil change (every 4000 hrs).
Hydraulics
Hydraulic system: oil change.
Chassis, bodywork and fittings
M24 screw connection between the welded chassis, the rear of the cast and the col-
lision protection: check for secure attachment with a torque of Ma = 660 Nm.
Final tasks
Test drive: check all functions and special functions according to the order.
Service adhesive label: attach.

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5 Regular care and maintenance
Battery maintenance

Battery maintenance
DANGER instructions from the respective manufacturer
must be observed.
Incorrect handling or incorrect use of batteries and
chargers can cause serious damage. This can also
lead to serious hazards for the operator. Lithium-ion batteries
For each type of battery, the instructions provided by
the battery manufacturer regarding proper use, care To ensure safe operation, industrial trucks that
and maintenance, as well as the possible hazards for are powered by lithium-ion batteries must be
the operator, must be followed precisely. equipped with a battery management system.
The operators of such industrial trucks must
Lead-acid batteries, gel batteries and lithium- be instructed in the operation of lithium-ion
ion batteries are currently used. batteries and the charging systems for these
batteries.
NOTE
Battery maintenance
● Battery maintenance is not part of the regu-
lar maintenance. The battery is the energy source for the indus-
● Battery maintenance must be carried out trial truck. It must therefore be handled care-
according to the information provided by the fully!
relevant battery manufacturer
● If the battery male connector is disconnec- General daily maintenance tasks
ted while a consumer is switched on, the
contacts can combust Keep the battery clean and dry.
Charge the battery regularly.
Lead-acid batteries Avoid deep discharge.
Lead-acid batteries use liquid acid. The acid Visually check the insulation on the cable
can be easily accessed and can therefore be connections and battery female connector.
dangerous. Check the condition of the battery connection
assembly and check that it is working cor-
DANGER rectly.
The electrolyte (battery acid) is toxic and corrosive
on contact. For newly charged batteries in particu-
Additional maintenance work for lead-acid
lar, be aware of the risk of explosion in the area of
the battery where gas may be released. batteries
When handling battery acid, the specified safety Check the electrolyte level. If necessary, top
measures must be observed. up with demineralised water.
Spilt electrolyte must be siphoned off from
the battery tray using a siphon. Rinse the
Gel batteries
tray if necessary.
Gel batteries are a particular type of lead-acid
battery. The usage instructions and handling

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Regular care and maintenance 5
Lubricants

Lubricants
CAUTION
Danger of damage to property
Trucks for cold store operation must be lubricated
using different lubricants. Observe the operating in-
structions for cold-store trucks.

The following lubricants must be used:

Hydraulic system
● Hydraulic oil HLP DIN 51524/T2

● Mat. no. 7327 400 112

The tanks are labelled with a min/max mark-

ing. After the hydraulic oil has been topped up
or changed, the oil level must be between the
min marking and the max marking.
The filling quantity depends on the configura-
tion of the industrial truck. Maximum tank size
93 l.
Gearbox
● Castrol alphasyn EP150

● Fuchs Renolin Unisyn CLP150

● Mat. no. 7326 000 019 (200 l container)

● Mat. no. 7326 000 029 (5 l container)

Filling quantities for gearbox

● 2.9 l (48 V version)

● 7.1 l (80 V version)

Grease lubrication points

● Lithium soap grease multi-purpose grease

LITH-EP2
● Mat. no. 7337 500 200

● Mat. no. 0170761 (100 g tube)

Lubricant for load chains

● Chain spray Stabylan 2100

● Mat. no. 8010100

Lubricant for the shaft-hub connection

● Special grease Klüberplex BEM 34-132

● Mat. no. 7339 300 003

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5 Regular care and maintenance
General information about fuses

General information about 

fuses
If a fuse needs to be replaced:
● Disconnect the system by pulling out the
battery male connector
● Only use fuses that are identical in size and
type
● The correct fuse values can be found in the
truck-specific circuitry documents
(1) Control current fuse
(2) Primary current fuse

Removing the control com- 

partment hood
DANGER
Risk of electric shock
Before the control compartment hood is
removed, the battery male connector
must be disconnected.

The fuses are installed in the control compart-

ment.
To gain access to the control compartment,
the hood must be removed.
– Open the two screw plugs (1).
– Hold the hood at the ventilation openings
(2), lift it off and then place it to one side.
The hood is very lightweight and can there-
fore be removed by hand without using any
tools.
Proceed in the reverse sequence to fit the
hood. Place the hood carefully in its guide and
latch and tighten the plastic screws until they
are hand-tight only.

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 6

Technical data
6 Technical data
Technical data

Technical data
The technical data for this truck depends on
the order. You will therefore receive a data-
sheet specially prepared for your truck when it
is delivered. Please use this accompanying
datasheet to find all the technical data.
Sound level, driver’s ear 66dB(A)

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 7

Special equipment
7 Special equipment
Additional documentation

Additional documentation
Most of the options that can be ordered ac-
cording to the price list are described below.
Some options are self-explanatory and can be
operated intuitively and safely without a de-
scription.
Some options, on the other hand, require ex-
tensive documentation. If an industrial truck is
equipped with such options, the corresponding
documentation will also be supplied.
Such extensive options include:
● Navigation (iGo pilot navigation)

● Aisle safety assistant (GSA)

● On-board charging system

● Cold store version

● etc.

Industrial trucks in customised special ver-

sions (CO = customer options) will be supplied
with an additional description of these special
versions, if necessary.

Enabling options
Certain options can only be permanently acti-
vated at a later time by loading a new truck
configuration file.
A modified truck configuration file can be
made to order, supplied and invoiced by Serv-
ice Support.
The following options can be enabled:
● All options that generally do not require
hardware retrofitting
● Options that can be retrofitted with minimal
hardware costs

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Special equipment 7
Optispeed versions

Optispeed versions
"Optispeed" denotes the various versions of
the speed optimisation system. To make the
work processes more economical and reliable,
the industrial truck can be equipped in stages
with additional components. The result is a
considerable expansion of the range of func-
tions.

Version 3.0
Auxiliary equipment
● Advanced software functions

This version represents the basic equipment

of the "Optispeed" speed optimisation system.
The "intelligent load capacity diagram" tells
the operator what load weight can be lifted to
what lift height.
Automatic side shift limitation improves the po-
sitioning of the loads on the rack.

Version 3.1
Auxiliary equipment
● Load weight detection

● Advanced software functions

The "intelligent load capacity diagram" shows

the operator dynamically how high the load
that is currently on the load fork may be lifted.
Automatic side shift limitation improves the po-
sitioning of the loads on the rack.

Version 3.3
Auxiliary equipment
● Load weight measurement

● Physical load detection

● Advanced software functions

The "intelligent load capacity diagram" shows

the operator dynamically how high the load
that is currently on the load fork may be lifted.
If the limit values are exceeded, acoustic and
visual warnings are issued.
In addition, the driving and lifting functions can
be locked.

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7 Special equipment
Optispeed versions

Automatic side shift limitation improves the po-

sitioning of the loads on the rack.

Version 3.4
Auxiliary equipment
● Load weight measurement

● Physical load detection

● Advanced software functions

The "intelligent load capacity diagram" shows

the operator dynamically how high the load
that is currently on the load fork may be lifted.
If the limit values are exceeded, acoustic and
visual warnings are issued.
In addition, the driving and lifting functions can
be locked.
Automatic side shift limitation improves the po-
sitioning of the loads on the rack.
The load is stabilised as it is retrieved and
stored, with dynamic adaptation to the lift
height and the load weight. This enables sen-
sitive loads in particular to be positioned gen-
tly and precisely without jerking. These opera-
tor assistance functions accelerate work pro-
cesses in the storage area.

Version 4.0
Version 4.0 includes "iGo pilot navigation" fea-
tures. This extensive set of functions is descri-
bed in separate documentation.

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Special equipment 7
Split operating panel

Split operating panel 

(1) Operating lever for hydraulics (in conjunc-

tion with the selection keys)
(2) Horn
(3) Enable button (for example, as a brake re-
lease button in an automatic braking system,
as an override for the intermediate lift cut out
and to acknowledge errors that can be ac-
knowledged)*. Flashes red when it needs to
be pressed.
(4) Manual-automatic two-way switch for in-
ductive guidance*
(5) Selection keys for favourites
(6), (7), (8) Selection keys for additional hy-
draulic functions*
(9) Emergency off switch
(10) Operating lever for driving
(11) Sensor surface for two-hand operation of
the main lift or for shifting in the aisle
(12) Selection key for lifting or lowering the
auxiliary lift or for swivelling the forks
(13) Reserved for special functions
(14) Selection key for automatic functions, e.g.
fork cycle
(15) Selection key for lifting or lowering the
cab lift and auxiliary lift at the same time. Hold
this button while pulling or pushing the operat-
ing lever (1). The same button is used to se-
lect synchronously swivelling the forks 180° to
the left or right. Hold this button while simulta-
neously actuating the operating lever (1) to the
left or right.
(16) Selection of a menu display
(17) Selection within a menu
(18) Go back one step in the menu or confirm
a selection
(19) Back to the main menu
(20) Light sensor for automatically illuminating
the display lighting
(21) Steering knob or steering wheel

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7 Special equipment
Split operating panel

(22) Sensor surface for two-hand driving with-

in the aisle
*Option

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Special equipment 7
Inductive guidance IZF

Inductive guidance IZF 

System description
General
If an industrial truck is guided using inductive
steering control, the shift button (1) must be
pressed before the industrial truck is driven in-
to and out of the aisle. All other operation pro-
cesses correspond to the standard design.
A frequency generator (2) provides an AC
supply to a wire installed in the floor (3). This
AC supply is registered as a signal by anten-
nas that are installed in the industrial truck,
and is used to guide the industrial truck.
The IZF controller calculates a steering angle
based on the lateral deviation between the
centre of the antennas and the guide wire.
The steering angle is used to guide the indus-
trial truck along the wire groove.
The operating devices for inductive steering
control are integrated into the operating panel.
The display indicates the current operating
status. After the controller is switched on, a
self-test runs in the steering control system.
Switch (1) on the operating panel is used to
switch between manual driving mode and au-
tomatic driving mode.

Commissioning
Extensive safety circuits in the controller and a
diagnostic program simplify service work on
the system. When commissioning the industri-
al truck, the system must be configured for
and calibrated with the customer's guide sig-
nal. Afterwards, a function and safety test
must be carried out. Our diagnostic program
provides the specifications for this purpose.

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7 Special equipment
Inductive guidance IZF

Entering the aisle 

Guidance procedure
– Drive the industrial truck towards the wire
groove (induction track). Stop in front of the
wire groove.
– The angle of the industrial truck relative to
the wire groove must not be greater than
60°.
– Set the steering to the straight-ahead posi-
tion.
– Select automatic steering by pressing the
"Manual/Automatic" button (1). The wire
search starts.
– The coloured ring around the "guidance sta-
tus" symbol (4) goes red.
– Continue towards the wire groove. The driv-
ing speed is automatically reduced.
– When the controller detects the induction
track via the first antenna, the controller
switches to automatic mode.
– An acoustic signal will be heard.
– The coloured ring around the "guidance sta-
tus" symbol (4) changes colour from red to
yellow.
– Continue driving. The industrial truck is driv-
en automatically along the centre of the
wire groove.
– The steering function via the steering wheel
is now switched off.
– When both antennas detect the induction
track, the wire search is terminated. The
coloured ring around the "guidance status"
symbol (4) changes colour from yellow to
grey.
– Continue driving. After a short distance, the
industrial truck is now guided to the guide
wire. The coloured ring around the "guid-
ance status" symbol disappears. Now only
the guidance symbol (5) is visible.
– The truck can now be driven out of the rack-
ing at the permissible speed.

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Special equipment 7
Inductive guidance IZF

NOTE
The more precisely the driver drives the mid-
dle of the industrial truck onto the wire groove,
the faster the guidance procedure will be com-
pleted. This means that several of the above
steps can be skipped.
Entering the aisle
– Guide the industrial truck onto the induction
track and drive into the aisle in automatic
driving mode.
– When the sensor system of the industrial
truck has detected the aisle, the maximum
permissible speed within the aisle is possi-
ble.

CAUTION
Risk of collision with the racking
Entering the aisle by steering manually is not permit-
ted. If the industrial truck enters the aisle by manual
steering, the industrial truck is stopped immediately.
You can continue driving once you switch to auto-
matic mode.

Automatic driving within the aisle 

To operate the industrial truck in automatic
driving mode, the left-hand sensor surface for
two-hand operation (7) and the right-hand op-
erating lever (6) must be actuated. If the cab
lift needs to be lifted or lowered at the same
time as this, both operating levers must be ac-
tuated accordingly. If the steering knob is acci-
dentally turned to its straight-ahead position
(middle detent) during automatic driving mode,
the industrial truck is automatically braked to a
standstill.
Switching from automatic mode to manual
mode within the aisle
If the industrial truck is accidentally switched
to manual steering within the aisle, the indus-
trial truck is immediately braked to a standstill.
It is then only possible to continue at creep
speed.
Driving speed adaptation

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7 Special equipment
Automatic Floor Compensation AFC

The automatic speed adaptation feature ad-

justs the maximum possible driving speed ac-
cording to the current situation. If an unsafe
situation arises, for example an error occurs,
the driving speed is limited or the driving func-
tion is switched off completely.

Leaving the induction track 

– Drive the entire length of the industrial truck
out of the aisle.
– Turn off automatic steering by pushing the
"man/auto" (1) button again.
– The industrial truck is braked automatically.
– An acoustic signal sounds.
– Drive the industrial truck away from the wire
groove using manual steering. The maxi-
mum permissible speed outside of the aisle
is possible.
Changing the aisle
If the industrial truck is driven from one aisle to
another, it is essential that the notes in the
chapter "Changing the aisle" are observed.

Automatic Floor Compensa- 

tion AFC
Active load wheel axle
If an industrial truck is equipped with this op-
tion, additional sensor systems determine un-
evenness in the roadway while the truck is in
motion. Using these measured values, the
controller then actively intervenes in the posi-
tion of the load wheels and adjusts their axles
horizontally via an eccentric. This prevents the
lateral tilting response of the lift mast when
driving over uneven surfaces. A reduction in
the driving speed due to uneven surfaces is
not necessary and work safety is increased.
Industrial trucks with an active load wheel axle
can be recognised by the special design of the
bearing points on the load wheels. When the
system is working, the notch in the axle (1)
twists while the truck is in motion.

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Automatic Floor Compensation AFC

NOTE

● The system is active only if the industrial

truck moves under guidance
● Once the industrial truck is switched off, the
system goes into a rest position after a
short time. Reactions in the load wheel axle
can be felt by the operator
● The system is fully automatic. The operator
has no influence over the functions
● The parameterising of this function is based
on on-site measurements. If the conditions
change compared with these measure-
ments, correct functionality can no longer
be guaranteed

Error messages
Error message
In the event of a fault or defect, one or more
numbers appear led by a pictogram of a warn-
ing triangle. Call the authorised service centre
and provide the authorised service centre with
these numbers.

NOTE
See also the section entitled "Operating in-
structions".
Possible cause
● Defect in the sensor system
● Defect in the mechanism
Effect
● Lift height of less than 3 m -> speed limita-
tion to 1 km/h
● Lift height of over 3 m -> drive stop, bridg-
ing not possible
Remedy
Call the authorised service centre.

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7 Special equipment
Lift cut-out

Lift cut-out 

The lifting operation is stopped at a previously

determined lift height. The ring around the en-
able button (1) lights up. This cut-out can be
overridden once the enable button has been
pressed. This equipment is therefore necessa-
ry if the truck is used in two (or three) build-
ings of different height, for example.

NOTE
As an option, this function can also be modi-
fied so that it is necessary to press and hold
the enable button in order to continue lifting.

Traction cut-out
The traction cut-out can be combined with the
intermediate lift cut-out. The ring around the
enable button (1) lights up when the traction
function has been cut out. This cut-out can be
overridden once the enable button has been
pressed.

NOTE
As an option, this function can also be modi-
fied so that it is necessary to press and hold
the enable button in order to continue driving.
The traction cut-out can also be implemented
in designated areas of the storage area re-
gardless of the lift height. However, this re-
quires additional sensor systems. See the or-
der for customer-specific details.

Aisle entry assistant

General
The aisle entry assistant can be used to make
it easier to drive into an aisle when using me-
chanical guidance. To do this, the truck re-
ceives electrical and mechanical equipment,
like a truck with inductive guidance.
A storage area in which the aisle entry assis-
tant is to be used is therefore fitted with a

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Special equipment 7
Aisle entry assistant

guide wire for inductive guidance in the centre

of the aisle and with guide rails for mechanical
guidance. The induction guide extends ap-
prox. 5 m into the aisle. The trucks are also
equipped with the End of aisle slow down and
stop (ZAG) option.

Entering the aisle

The truck is driven along the guide wire out-
side of the racking, according to the End of
aisle slow down and stop information in the
chapter entitled Inductive guidance (IZF).
This means that the truck is aligned precisely
so that it can be driven into the guide rails.
Electrical aisle detection only occurs when the
truck is completely within the guide rails. Once
aisle detection has been successful, inductive
guidance is automatically turned off.

NOTE
If the man/auto button is not switched to auto-
matic, the truck behaves like a mechanically
guided truck. Switching from "auto" to "man-
ual" within the aisle has no effect.

Exiting the aisle

Switching from mechanical guidance to induc-
tive guidance takes place automatically when
exiting the aisle. To leave the guide wire, in-
ductive guide must be deselected by pushing
the man/auto button.

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7 Special equipment
Battery on a roller channel

Battery on a roller channel 

Description
The battery rests on roller channels and can
be installed and removed from the side of the
truck using a battery change frame*. The bat-
tery is secured with clamping devices on both
sides and held in position in this way.
Monitoring
The battery locks are electrically monitored. If
one of the locks is not correctly locked in place
an error message appears in the display and
the truck will stop.

WARNING 1 Knurled-head screw

Every time before starting work the battery locks (2) 2 Battery lock
must be checked for perfect condition and function. 3 Rubber buffer

* Option

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Special equipment 7
Battery on a roller channel

Setting the battery lock 

CAUTION
Risk of crushing and damage to property
An improperly fixed battery may fall out of the truck
when cornering and put people and property at risk.
If the battery cannot be clamped securely, the re-
sponsible service centre must be called. Further op-
eration with a faultily or improperly clamped battery is
dangerous.

To ensure the operational safety of this truck,

the traction battery must be securely fixed in
place in the battery compartment by means of
clamps. To achieve this, the truck is equipped
with an adjustable battery lock. The battery
lock can be adjusted by approx. 30 mm on
each side. Both locks must be adjusted sym-
metrically.

NOTE
When a battery is inserted into a chassis for
the first time, it is possible that the actions de-
scribed below may need to be repeated in
several steps. If the rubber buffer thread
(spring element) is not able to move smoothly,
this must be rectified before setting.
– Insert the battery approximately in the cen-
tre of the battery compartment. In doing so,
one of the battery locks will remain as a
stop in the truck.
– Rotate the knurled-head screw (1) and the
rubber buffer (3) all the way back (4) on
both locks (2).
– Insert the second battery lock into the truck.
– Unscrew both rubber buffers until they lie
against the battery. The visible thread
length should be roughly the same on both
sides of the battery. Gently move the bat-
tery to the side, if necessary The maximum
adjustment range for each rubber buffer is
approximately 20 mm.
– If the useable threads on both rubber buf-
fers are not long enough to fasten the buf-
fers to the battery, the knurled-head screws
must be screwed in to further increase the
adjustment range. At the same time, the

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7 Special equipment
Battery on a roller channel

rubber buffers must rotate with the knurled-

head screws.
– Tension can be increased by screwing one
of the two knurled-head screws in further.
Tighten the knurled-head screws hand tight.
The battery lock is clamped securely if the
rubber buffer is clearly deformed.
– If sufficient clamping is not achieved via
these steps, it is possible that a battery with
incorrect dimensions has been inserted.
The truck must not be used if the battery is
not securely locked. Doing so would result
in the risk of accidents and damage.
– When the clamping has been carried out, a
thread must still be visible at (5) and (6).

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Special equipment 7
Electronic access control

Electronic access control 

As an option, these industrial trucks can also

be equipped with electronic access control in
place of the key switch.
These systems are available as options:
● PIN code input

● RFID chip

● RFID card

Switching on the controller

Push the push button for approximately 2 sec-
onds. The controller is switched on. The dis-
play is activated and the working spotlights*
are switched on.
Once the industrial truck is switched on, all
functions are initially disabled. The functions
of the industrial truck are enabled only once
the electronic access control has been cor-
rectly activated.

PIN code 
The functions are enabled by entering a valid
five-digit number code using the keypad (see
also "factory setting").
– Press the F1 (1) button.
Depending on the language, the following dis-
play prompts the user to enter the specified
PIN code.
– Enter the five-digit code within 8 seconds.
– Press button (2). This confirms the entry.
When the PIN code is entered correctly, a
short acoustic signal will sound.
The display returns to the start screen.
The coloured bar in the display next to the F1
button (3) indicates that the functions of the in-
dustrial truck are now enabled.

Incorrect PIN code, input time elapsed

When an incorrect PIN code is entered or if
the input time of 8 seconds elapses:
– Press the F1 button (1) again.

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Electronic access control

– Enter the correct PIN code.

NOTE
● Each time the industrial truck is switched on
using the operator panel button, the PIN
code must be entered again.
● If the industrial truck cannot be switched on
using the PIN code, call the authorised
service centre.
Factory setting
The factory setting for this PIN code is
"11111".
PINcode change
Up to five different codes can be used. The
customer can select codes between 10000
and 99999 and these can then be program-
med into the controller by the authorised serv-
ice centre.
Switching off
– To switch off the industrial truck, push and
hold the operator panel button for approx.
2 seconds.

RFID chip, RFID card

If an industrial truck is equipped with this sys-
tem, a reading device for RFID chips or for
RFID cards will be located in the driver's cab
in the vicinity of the operating panel. RFID
chips and RFID cards are included in the
scope of delivery according to the order. How-
ever, the authorised service centre does not
program the system to the customer's specifi-
cations until it is on site. Assignment to differ-
ent operators is possible using the various
RFID chips or cards.
Factory setting
Standard chips and cards are supplied at the
factory.
Activating the system
– Switch on the controller by pressing the op-
erator panel button (see above).
An LED illuminates on the reading device.

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Special equipment 7
Electronic access control

– Hold the RFID chip or card in front of the

reading device.
The industrial truck is now ready for use.
Configuration levels
Additional configuration levels are available,
which are based on the electronic access prin-
ciple. These systems can be used to evaluate,
control and optimise the activities of entire
fleets of industrial trucks.
Additional configuration levels can
● Record the driving and idle times

● Determine empty runs

● Count lifting and lowering procedures

● Use a shock sensor to determine collisions

NOTE
Fleet management systems are described in a
separate set of operating instructions.

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7 Special equipment
Automatic braking systems

Automatic braking systems

Automatic braking systems ensure operational
safety. They make it easier for the operator to
pay better attention to on-site restrictions and
specifications due to the work process. Auto-
matic braking systems therefore also make an
important contribution to increasing handling
performance.
In principle, the design of the automatic brak-
ing systems can be adapted to the customer's
requirements. The exact function must there-
fore be obtained from the order.
A sensor system mounted on the industrial
truck forms the basis for reliable detection of
the areas (zones) in which the truck must
brake or stop. Also see the section entitled
Overview of sensors.

CAUTION

Automatic braking systems are assistance systems

for the operator. They do not exempt the operator
from a duty of care.

DANGER
Danger to life and risk of significant damage to
equipment due to malfunctions
Changes to the sensor system must only be carried
out by authorised service personnel. Every time the
racking is modified, assistance from authorised serv-
ice personnel is required. It is vital to check whether
the planned modifications have a negative impact on
the functionality of the automatic braking systems. In
particular, this includes changing the geometric di-
mensions, such as adding or removing uprights. Dur-
ing any repair work, it is vital to check whether the
sensor system for aisle detection or zone detection is
affected. The sensor system may need to be adap-
ted to the modified dimensions. To maintain the func-
tionality of these systems, it is important to observe
the information given in the system descriptions.

Aisle detection,
Zone detection,
Distance measurement

General
Sensors installed in the industrial truck are
used for aisle detection, zone detection and

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Special equipment 7
Automatic braking systems

distance measurement. In racking, there may

be areas in which the functions of the industri-
al truck need to be restricted or locked. Such
areas include those in which the truck must
brake or even stop for occupational safety rea-
sons, e.g.
● In the direction of the open or closed ends
of aisles
● Areas in the storage area with lower ceil-
ings (false ceilings, mezzanines)

Zones
A distinction is often made between the follow-
ing zones with different functions:
● Outside the aisles (transfer aisle)

● Braking zone before leaving an aisle. In the

case of aisles that are open at both sides,

there may be one of these zones at both
ends
● Braking zone before a wall if the aisles are

closed at one end

● Rapid travel zone. The area within an aisle

between the braking zones at the ends of

the aisles
By means of programming, the driving speed
can be limited to a different value in each of
the zones mentioned.
A waiting period can be programmed after
each braking (time stop).
In principle, enabling can be blocked for each
function.
The automatic braking systems are often com-
bined with lift height restrictions.

Zone detection
The zones are identified by a sensor system
that is either attached to the rack or embed-
ded in the hall floor. Optical, inductive, mag-
netic and radio-based systems are used.
In principle, the customer decides which sen-
sor system is best suited for the racking and is
therefore used.

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Automatic braking systems

RFID technology 
The RFID transponders are embedded in the
hall floor. They are located in approx. 10 mm
holes slightly outside the centre of the aisle at
different intervals. The RFID writing/reading
device is mounted to the load wheel axle un-
der the driver's cab. The RFID transponders
are maintenance-free.
– Keep the aisle clear of objects.
The RFID system is also used for distance
measurement in order to position the industrial
truck in the aisle.

Barcode 
Barcode scanners fitted on the industrial truck
read the barcode labels in both drive direc-
tions while the truck is in motion. The barcode
labels are attached to the uprights approx. 50
cm above the floor. The scanners can be at-
tached to the industrial truck and the labels to
the rack on one or both sides.
– Do not cover or adjust the barcode scan-
ners.
– Check the barcode scanners for contamina-
tion.
– Check the barcode labels for contamination
and legibility.
– Do not cover barcode labels, e.g. with loose
packing material.
The barcode system is also used for distance
measurement in order to position the industrial
truck in the aisle.

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Automatic braking systems

Reflective light switches and reflectors 

Reflective light switches attached to the indus-
trial truck detect the reflectors in both drive di-
rections while the truck is in motion. The re-
flectors are attached to the uprights approx.
170 – 200 cm above the floor. The reflective
light switches can be attached to the industrial
truck and the reflectors to the rack on one or
both sides. The number of reflectors is deter-
mined by the functionality in the industrial
truck.
– Do not cover or adjust the reflective light
switches.
– Check the reflective light switches for con-
tamination.
– Check the reflectors for contamination and
damage, such as scratches.
– Do not cover the reflectors, e.g. with loose
packing material.

Magnetic system 
The switching magnets are embedded in the
hall floor. They are located in approx. 35 mm
holes slightly outside the centre of the aisle at
different intervals. The magnet operated
switches are mounted to the load wheel axle
under the driver's cab. The number of switch-
ing magnets is determined by the functions in
the industrial truck. The switching magnets are
maintenance-free.
– Keep the aisle clear of objects.

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7 Special equipment
Personal protection system (MPSE)

Personal protection system 

(MPSE)
The purpose of mobile personal protection
systems is to protect people who have entered
the braking area of the truck without warning.
One safety laser scanner for each drive direc-
tion scans the braking area and triggers brak-
ing in the truck as soon as a person or object
is detected in this area (protective field).
As a rule, these personal protection systems
are active only with the guidance function. Op-
tionally, the functional range can also be ex-
panded to include front end monitoring.

CAUTION
Risk of accident
Even when a personal protection system is in use, ex
works we do not permit people and our very narrow
aisle trucks to be in the same aisle at the same time
in accordance with intended use. The manufacturer
provides a maximum of safety category 2.

NOTE
The makes of mobile personal protection sys-
tems approved by the truck manufacturer are
not identical in terms of functions and options.
For all information about operation and main-
tenance of the personal protection systems,
see the corresponding manufacturer's docu-
mentation.

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Special equipment 7
Safety laser scanner

Interface X99 
The plug X99 represents the interface be-
tween the truck control unit and the personal
protection system. All signals defined by us
are allocated in this plug. The scope of deliv-
ery of a very narrow aisle truck includes the
bridging plug X99, which can be fitted instead
of the MPSE connector plug if an internal de-
fect in the MPSE controller has caused failure
of the industrial truck.
The interface X99 is installed on man-down
trucks in the vicinity of the operating panel and
on man-up trucks in the control compartment

CAUTION
Risk of accident
When a bridging plug is fitted, all safety functions of
the MPSE are deactivated and the maximum driving
speed of the industrial truck limited to 2.5 km/h.
Therefore, the truck may only be operated with a
bridging plug during retrieval operations. This bridg-
ing plug must be kept locked away by the warehouse
manager responsible and its use is permitted only by
the instruction of this warehouse manager.

Safety laser scanner 

The laser scanners that are used in personal

protection systems are highly sensitive opto-
electronic sensors. They are well protected in
the contour of the industrial truck.
When the load-side scanner is covered by the
driver's cab when in the lowered position. For
this reason, the industrial truck drives at a
maximum speed of 2.5 km/h when the driver's
cab is lowered. Personal protection is ensured
by the low speed and the attention of the oper-
ator.
The drive-side scanner (picture) is located be-
hind the control compartment hood. The scan-
ner can monitor the roadway through a wide
slot. The diagnostic LEDs are visible through
the smaller, lower opening.

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7 Special equipment
Personal protection system, preparation

CAUTION
Functional impairment
– Observe the operating instructions provided by
the scanner manufacturer.
– Observe cleaning instructions.
– Do not adjust the scanner or cover the openings.

Personal protection system,

preparation
Preparation for immediate installation
With this option, industrial trucks are prepared
for installation of a personal protection system.
The customer will have already specified the
manufacturer of the MPSE. The brand-specific
cable harnesses and mechanical support
mountings will therefore be installed at the fac-
tory. The actual controller and sensor systems
must be completed at the customer's site in
time for commissioning. Until this point, the
driving speed is limited to 2.5 km/h. This limi-
tation is removed once the personal protection
system has been installed by the authorised
service centre.

CAUTION
Risk of accident
If the personal protection system is not fully installed
and commissioned, the "personal protection" and
"collision protection" functions are not enabled. In
this condition, the intended use of this industrial truck
is not possible or permissible.

Preparation for later installation

With this option, only the mechanical compo-
nents for installation of laser scanners are in-
cluded in the scope of delivery. The standard
interface in the X99 industrial truck for con-
necting a personal protection system is also
available. However, the functionality of the in-
dustrial truck corresponds to the standard ver-
sion.

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Special equipment 7
Tilt barrier

Tilt barrier
Description 
When in a reclined position, the tilt barrier
opens out to the side towards the racking.
This means that the distance to the racking is
reduced, which facilitates order picking. If the
operator releases the tilt barrier, it is automati-
cally returned to the initial position by spring
force.
The tilt barrier consists essentially of a mobile
upper part, a fixed bottom part and a hinge
connecting the upper and bottom parts. For
safety reasons, the tilt barrier is unlocked only
under certain conditions.

Function
The barrier can only be opened if:
● The truck is in an aisle
● The barriers are closed
● The two-hand sensors are not actuated
● The operating levers for driving/hydraulics
are in the neutral position
● The foot switch is not actuated
● The driving speed is v < 0.1 km/h
The barrier will be locked if:
● One of the barriers is opened
● The foot switch and the drive operating lev-
er is actuated
● The main lift function is selected
● The truck is not in an aisle

NOTE
If the truck is in an aisle and one of the two
barriers is opened and then closed again, the
tilt barrier is locked. It is unlocked again if the
foot switch is briefly actuated once and the re-
maining conditions are fulfilled for it to be un-
locked.

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7 Special equipment
Mirror and lighting module

Mirror and lighting module 

If an industrial truck is equipped with this mod-

ule, additional operating instructions are sup-
plied ex works. These instructions describe in
detail how to assemble and configure the
module.
This module can be supplied in various ver-
sions and combinations:
● As LED workplace lighting for illuminating
the racking next to the industrial truck
● With an integrated fan motor for circulating
air in the driver's compartment
● With an integrated parabolic mirror as a
rear-view mirror

CAUTION
Risk of accident
The curvature of the mirror surface significantly in-
creases the field of vision. As a result, objects ap-
pear further away than they actually are.

Adjusting the mirror

The mirror can be moved into the required po-
sition by pushing on the corresponding places.

CAUTION
Risk of damage to property
The adjustment range is mechanically limited. Push-
ing too hard on the mirror glass can cause the glass
to crack.

Switching on the fan

Press the corresponding push button on the
operating panel.

NOTE
Switch to fan level 2 using switch (1). A blind
plugs (2) is fitted on the other side of the fan.
Switching on workplace lighting
Press the corresponding push button on the
operating panel.

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Special equipment 7
Camera system

Camera system
Modern video cameras on the industrial truck
and colour monitors in the driver's cab provide
the operator with a better overview of the
working area.
The cameras can only perform the desired
function if they are set correctly. To achieve
an optimum image display, the cameras must
be adjusted individually. The system is activa-
ted as soon as the industrial truck is switched
on.

CAUTION
Assistance system
Camera systems are passive systems. They do not
interfere with the functionality of the industrial truck.
The operator is responsible for working in a safe
manner.
Before setting the truck in motion, the operator must
check that the camera system is functioning properly
and has the correct settings. If the camera system is
not functioning correctly, the system must be re-
paired or adjusted before setting off.

Rear view camera

One camera mounted centrally on the lift mast
facing towards the drive unit. One monitor in
the driver's cab.
This camera should be set in such a way that
the field of vision matches the braking area of
the industrial truck. If the operator sees an ob-
stacle on the monitor, there is enough time to
react and stop.

Rear view camera for entering aisles

Two cameras mounted on the rear of the driv-
er's cab with a view of the guide rollers (MZF)
and the roadway in the direction of the drive
unit. Two monitors in the driver's cab. This
version can also be used as a replacement for
rear-view mirrors in closed cabs (wind deflec-
tor, cold store).
These cameras should be set so that one of
the rail guide rollers (MZF) or the corner con-
tour of the chassis (IZF) is visible in each of

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7 Special equipment
Lift height preselection

the two monitors. This system therefore

makes it easier to enter the aisle guidance.

Camera system for monitoring the road-

way
One camera mounted on the load wheel axle
under the driver's cab. Shows the roadway in
the load direction. The driver's cab must be
raised by approximately 50 cm for this pur-
pose. A second camera installed centrally on
the lift mast with a view of the drive unit. One
monitor in the driver's cab. Switching takes
place depending on the drive direction.

Maintenance and cleaning

Camera systems are low-maintenance.
During regular maintenance or after particular
events:
– Check that the support mountings for cam-
eras and monitors are in perfect condition.
– Check the clamps for tightness.
– Check the camera settings.
– Clean the camera lenses using lens cloths.

Lift height preselection

NOTE

The optional "lift height preselection" function

is described in detail in separate operating in-
structions.
This function partially automates the approach
to the lift heights. The operator simply has to
enter the required lift height with a number.
The operator then actuates the operating devi-
ces accordingly and the system automatically
brings the load fork to the required height.
In a further configuration level, the controller
recognises whether or not there is a load on
the load fork. Accordingly, the load fork is
brought to the correct height for a storage or
retrieval process.

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Special equipment 7
Driver's cabs, special versions

Driver's cabs, special ver-

sions
Special versions of driver's cab are available
for special applications.
There are driver's cabs
● With safety glass all around below the rail

height
● With a windscreen made of safety glass or

plastic, fitted on the rail

● With a foil wind deflector with integrated foil

panels, fitted on the rail above the barriers

● With fixed plastic panels all around, fitted

on the rail

NOTE
Panels that are installed above the rail in the
load direction must either be removed or
pushed forward for the abseiling process. See
the section entitled "Emergency abseil sys-
tem". Zips and clamping screws that can be
opened by hand are used. Any panels that are
removed must be placed inside the cab.

Heating system
Driver's cabs can be equipped with a warm-air
heating system as an option.

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7 Special equipment
Wind deflector cab

Wind deflector cab 

The driver's cab is equipped with a removable

plastic panel on the load side. This panel must
be removed if the driver needs to abseil from
the cage in an emergency; see the section en-
titled "Emergency abseiling".
The driver's cab has plastic covers at the
sides with inspection windows. This side cover
features a zip (1) to enable entry. These cov-
ers can also be removed completely.

NOTE
The zip must be closed completely before re-
moving and fitting the side covers.

Removing the side covers

The side covers are held in position on the
long sides with Velcro strips (2) and on the top
in a keder rail (3). To remove, carefully loosen
the Velcro connection and then slide the cover
sideways out of the keder rail.

Fitting the side cover

To fit the side covers, follow the removal se-
quence in reverse order.

Cleaning
Clean plastic panels and plastic foils using on-
ly cleaners that are intended specifically for
this purpose and special cloths. Dirty and/or
scratched panels pose a safety risk.

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Special equipment 7
Wind deflector cab

Emergency abseiling 
Removing the windscreen
– Remove two knurled nuts (4) on both sides
and remove the clamping plates.
– Detach the windscreen from the Velcro
strips and bring it inside the cab.
– Stow it at the rear of the cab.
– Remove the abseil system from the storage
bag as described in the "Abseiling" section.
Installing the rope redirection
– An additional snap hook is hooked into the
chest eyelet of the safety harness. Remove
this snap hook.
– A snap hook is installed at the factory at the
front edge of the overhead guard (5).
– Hook the rope of the abseil system into this
snap hook. This snap hook thus serves as a
redirecting point for the rope.
– Screw on the screw fastening of the snap
hook.
– Carry out the abseiling process as descri-
bed in the "Abseiling" section.
– Only leave the cab once the abseil system
is correctly attached.
Inserting the windscreen
– First place the windscreen in the guide at
the bottom, align it in the centre and press it
into the Velcro strips.
– Fit the clamping plates and hand-tighten the
knurled-head screws (4).

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7 Special equipment
Intercom system

Intercom system 

If the ambient conditions in the storage area

make it necessary, closed driver's cabs can
be equipped with an intercom system.
– Press and hold down the red push button
(1) (audio out) on the console while speak-
ing.
– Release the push button in order to hear in
the driver's cab what is being said outside.
– Use the turning knob (2) to adjust the vol-
ume.

Warm-air heating system 

Closed driver's cabs can be equipped with a

warm-air heating system to make working in
the driver's cab more comfortable. This sys-
tem also provides a fan for air circulation.

CAUTION
Risk of overheating
Do not cover the inlets or vents for the heating sys-
tem.

1 Ventilation "On"
2 Ventilation blower level "1" or "2"
3 Heating system "On"
4 Heating level "1" or "2"

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Special equipment 7
Protective roof cover

Protective roof cover 

The standard overhead guard meets the cur-

rent standards in terms of stability and the dis-
tance between the roof struts. However, if
heavy objects that are small enough to fit
through the roof struts of the overhead guard
are transported in a storage area, there is a
danger that if they fall from a considerable
height, they may fall through the overhead
guard and injure the operator. To prevent this
danger, a cover made of high-strength plastic
can be fitted to the overhead guard at the fac-
tory.

NOTE
The protective roof cover must always be
clean so as not to obstruct the view upwards.

● Clean regularly.
● Use cleaning materials that are suitable for
plastics.
● Replace defective protective roof covers im-
mediately.

Radio installation 

Industrial trucks can be prepared in the facto-

ry for the installation of a car radio (1).
The preparation consists of:
● Console underneath the overhead guard

with two built-in loudspeakers.

● Standard installation slot for the installation

of commercially available car radios

● Rod antenna on the overhead guard

● 12 V voltage transformer

CAUTION
Risk of accident
The operator's attention may be limited by sound
from a radio or playback device, especially if the vol-
ume is particularly loud.
The use of sound devices is allowed only if permitted
or tolerated by the responsible operating company.

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7 Special equipment
Overhead guard switch

Overhead guard switch 

The overhead guard switch fitted on the over-

head guard can detect obstacles above the
overhead guard using its ultrasonic sensor. If
it detects an obstacle, further lifting and thus a
collision between the driver's cab and the ob-
stacle is prevented. It is not possible to over-
ride this function.
The ultrasonic sensor can be adjusted by the
authorised service centre.

NOTE
Only obstacles that are directly above the
overhead guard are detected. Obstacles in the
drive direction or to the side are not detected.

NOTE
The overhead guard switch is one of the oper-
ator's assistance systems. The operator is re-
sponsible for working safely with the industrial
truck.

Working spotlights 

Working spotlights are used to illuminate the

workplace outside the driver's cab. This can
include the storage spaces in the racking on
the right and left as well as the area in front of
the driver's cab where picked goods are stor-
ed. This makes working with the very narrow
aisle truck more effective and increases occu-
pational safety. The setting of the headlights is
customised. The headlights are switched from
the operating panel.

CAUTION
Impairment of occupational safety
Defective working spotlights must be repaired imme-
diately, as they help to improve occupational safety.

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Special equipment 7
Safety Light safety headlight

Safety Light safety headlight

Function 
The safety headlight is a device that can be fit-
ted to industrial trucks in order to give pedes-
trians sufficient warning of an approaching in-
dustrial truck. This function helps to improve
safety in storage areas, as it can prevent in-
dustrial trucks from colliding with pedestrians.
To prevent such accidents, the safety head-
light is fitted to the lift mast at a suitable height
so that it projects a powerful beam of light on-
to the ground a few metres in front of the in-
dustrial truck. If pedestrians notice this beam
of light, they have enough time to react ac-
cordingly. Safety headlights are available in
different colours.

DANGER
The driver of the industrial truck still has full duty of
care in relation to pedestrians and other industrial
trucks, regardless of whether this safety headlight
is fitted to their truck.
The driver cannot assume that pedestrians will notice
the beam of light in good time, interpret it correctly
and then react correctly.

NOTE
Industrial truck drivers and pedestrians must
be provided with instructions to advise them of
the safety headlight function and its use for
their protection.

Residual dangers
Due to the functionality and design of the sys-
tem, the safety headlight cannot provide com-
prehensive protection for other transport users
in the racking system.
The safety headlight cannot illuminate in the
direction of crossing traffic.
The customer can choose for the safety head-
light to be switched on:
● Depending on the drive direction

● Only at the point of moving off

● Only in predefined areas (zones)

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7 Special equipment
Safety Light safety headlight

It is therefore essential that the functionality

specified for the place of use is:
● Included in the operating instructions appli-
cable for the storage area
● Explained to the warehouse staff and
● That the warehouse staff are made aware
that they must comply with the operating in-
structions

Switching on and off

The safety headlight is switched on when the
key switch of the industrial truck is switched
on.
If the industrial truck is switched off using the
key switch, the safety headlight goes out.

NOTE
There is an option available to have the safety
headlight switch on or off only in specific areas
of the warehouse or during specific work pro-
cesses. For a description of these special ca-
ses, see the order.

Safety

NOTE
The safety headlight features extremely pow-
erful LEDs. Briefly looking directly into the
beam of light does not present a danger to
health, but is unpleasant due to the temporary
dazzling effect. However, looking into the
beam of light for longer periods must be avoi-
ded.

Maintenance
Before starting work, the driver must check
whether the distance between the beam of
light and the truck is correct.
Clean the lens of the safety headlight if it is
contaminated. Apart from these measures, the
safety headlight is maintenance-free.

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Special equipment 7
Acoustic alarm

Place of attachment and retrofitting 

Attach the safety headlight to the highest pos-
sible part of the industrial truck using the as-
sembly material supplied. During installation,
ensure that the safety headlight is located
within the truck contour. Because this safety
headlight can be fitted to industrial trucks with
a wide range of different designs, no precise
specifications can be provided here regarding
the ideal place of attachment. Raising the load
or the driver's cab can cause the safety head-
light to be temporarily covered. Careful selec-
tion of the place of attachment can reduce this
sometimes unavoidable situation to a mini-
mum. The supplied supports must be used
wherever possible.
The tilting support mounting must be used to
adjust the safety headlight so that the light
beam is projected onto the ground approxi-
mately 4 m in front of or behind the industrial
truck. When adjusting the safety headlight, the
front edge of the industrial truck or load must
be considered. Selecting a place of attach-
ment that is high up on the truck maximises
the tilt angle of the safety headlight and en-
sures that pedestrians and oncoming vehicles
are dazzled by the light beam as little as pos-
sible.

Technical data
Operating voltage 12 – 100 V
Power consumption 5W
Current draw 0.2 A at 24 V
Service life >20,000 hours

Protection class IP68 - IP69K

Operating temperature -40°C - +85°C

Acoustic alarm
Acoustic alarms can be issued automatically if
dangerous situations may arise between hu-
mans and machines during a racking work
procedure. This ensures that other people are

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7 Special equipment
Antistatic version

made aware of the industrial truck and can re-

act in good time.
As the work procedures can vary in every stor-
age area, the need for acoustic signals also
varies. For this reason, they are configured
according to the customer's specifications.

CAUTION
Risk of accident
When employees become used to certain acoustic
signals, they will rely on them more and more. That
is why acoustic signals are considered part of the
safety systems and must always be in working order.
See the "Checklist before starting work".

Antistatic version
Various components can be installed to pre-
vent or minimise static charging of the industri-
al truck. The customer must ensure that the
floor covering and/or racking permit the dis-
charge of electrical charge.
These include:
● Electrically conductive guide rollers for me-

chanical guidance
● Electrically conductive elements for induc-

tive guidance (chains, brushes)

● Electrically conductive load wheels

CAUTION
Danger of damage to property, loss of function
When replacing the elements for dissipating static
charge, use only elements that are electrically con-
ductive. We recommend using original parts.
Check the condition and functionality of the elements
each time maintenance is performed.

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Special equipment 7
Guard plate on rack rail

Guard plate on rack rail 

When goods are transported in sacks or bags,

they often protrude from the outer edge of the
pallet or load carrier.
There is therefore a danger of these sacks or
bags being damaged by the sharp edges of
the rack rail, e.g. when the sideshift is exten-
ded sideways. The goods may be lost or de-
stroyed as a result.
The guard plates on the rack rails minimise
this danger by covering the sharp edges of the
rack rail at the top and bottom.

Telescopic table 

Description

NOTE
To ensure proper use, the information in the
enclosed manufacturer's documents must be
observed.
The table unit is made up of two telescopic
fork arms, connected by a mechanical cou-
pling, and possibly a third fork, which is con-
nected via a universal drive shaft and an elec-
tromagnet disc coupling.
Each fork consists of a top table, middle table
and lower table as well as a drive gearbox.
The extending table profiles have a width of
180 mm and a height of only 60 mm (top and
middle part). The drive of the top and middle
profile is powered via a chain system.
WThe telescopic table has a high stability due
to it being maintenance-free and having very
large guide rollers and side cable guides. The
top table is driven to the middle table via 2
chains.
The telescopic table is a precise machine part.
The following information must therefore be
considered:

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7 Special equipment
Other attachments

● Do not subject to extreme atmospheric con-

ditions
● The inspection and maintenance intervals
are shortened in volatile and very damp en-
vironments.
● Do not subject to shear forces, e.g. shifting
of the load with the fork profile extended in
a longitudinal and lateral direction.

Maintenance of the telescopic table

NOTE
The information in the enclosed manufactur-
er's documents must be observed to ensure
proper maintenance of the telescopic table.

Other attachments
Other attachments* can also be supplied in
place of the turret head.
These include:
● Telescopic tables

● Accessible pallets

● Order-picking platforms

● Customised structures

DANGER
Impairment of operational safety, danger to the op-
erator
Other than the attachments supplied by the manufac-
turer, only attachments tested and supplied by the
manufacturer are permitted. Unauthorised modifica-
tions are prohibited. See also "Alterations to industri-
al trucks".
Just as is the case with the industrial truck, attach-
ments must be serviced regularly and inspected
once a year by a specialist.

Other attachments differ from the standard de-

sign in terms of the method of operation as
well as in the type of hazards if safety informa-
tion is not observed. It is therefore important
for the operator to be familiar with and to ad-
here to the instructions for the particular at-
tachment that is fitted.
Additional operating instructions and mainte-
nance instructions from our suppliers may also
apply.

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Special equipment 7
Trucks for use in cold storage

*Option

Trucks for use in cold storage 

Trucks for use in cold storage are provided

with extensive extra equipment, in order to
guarantee full functioning at low temperatures
(-30°C). Special instructions for the operation
of these trucks must be observed, which are
not contained in this operating manual Trucks
designed for operation in refrigerated environ-
ments are marked with the adjacent symbol.

CAUTION
Icy floors
Icy floors have a very negative effect on steering and
braking behaviour. In extreme cases steering and
braking potential may be lost completely. Therefore
the aisles must be kept free of ice at all times.

Mounting system for auxiliary 

components
The driver's cab can be equipped with a sys-
tem consisting of rods and support mountings
in order to mount additional components.
Additional components may include:
● Writing surface with paper clip (1)
● Storage area for barcode scanner gun (2)
● Support mounting for data terminal
● Support mounting for printer
● Support mountings for small load carriers

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7 Special equipment
USB charging station

CAUTION
Risk of accident due to the foot switch getting stuck
(service brake).
If your industrial truck is fitted with auxiliary equip-
ment for handling small load carriers, only the origi-
nal containers may be used in it. Other containers
cannot be held correctly and may fall to the floor.
This can result in the foot pedal being applied contin-
uously and the industrial truck no longer responding
to this brake signal.
The support mountings and clamping devices must
always be in perfect condition so that the auxiliary
components can be operated safely and do not move
from their positions during travel.

USB charging station 

This charging station can be used to charge

two consumers with USB charging cables at
the same time. Maximum charging power per
socket: 2 A.

NOTE
Protect against contamination and damage.
When the charging station is not in use, cover
the sockets with the hinged cover.
The support mounting also has space for hold-
ing drinks, pens and small items.

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Special equipment 7
MMS interface

MMS interface 

Additional components in the driver's cab re-

quire galvanically isolated power supplies.
Each power supply has a separate fuse.
The customer's printer or terminals can there-
fore be supplied with voltage. The mounting
position and number, as well as the voltage
supplied, are order-specific.

PIN 1 and PIN 2 +24 V

PIN 3 + 0 V
Max. 5 A

PIN 1 +12 V or +24 V

PIN 2 + 0 V
Max. 5 A

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7 Special equipment
Two-person cab

Two-person cab
Provided a driver's cab is equipped according-
ly, two people may be in it at the same time
during normal operation. The additional equip-
ment usually consists of:
● Key switch to switch from one-person oper-
ation to two-person operation
● Handholds
● Additional foot switches
● Lift ram protection against contact
● Protection against leaning out
● Other safety equipment may be available,
depending on the job.

CAUTION
Risk of accident
The additional safety equipment installed must not
be altered in any way. If safety equipment is defec-
tive or its function is impaired, the truck must not be
operated in ride on mode until it has been repaired
by a professional.

NOTE
If a truck is intended and equipped for normal
operation with two people (operator and pas-
senger), two abseil systems must also be kept
to hand in the driver's cab.

Operator and passenger

The dimensions of the operator's compart-
ment on our industrial trucks are designed in
accordance with standard DIN EN ISO 3411
and are accordingly constructed for both fe-
male and male operators. This standard also
stipulates ranges within which the operator's
body weight and dimensions should lie. EN
ISO 3411 specifies 114.1 kg for the maximum
body weight for a large operator.

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Special equipment 7
Two-person cab

CAUTION
Reduction in the load capacity. Negative effect on
stability.
If the actual body weight of the operator and passen-
ger combined exceeds 114.1 kg, the maximum load
weight must be reduced by the difference compared
with the information on the load capacity diagram.
Example
The actual body weight of the operator is 130 kg.
The actual body weight of the passenger is also 130
kg. Together, this makes 260 kg. In this case, the
maximum load weight must be reduced by approx.
146 kg compared with the information on the load ca-
pacity diagram.

Key switch 

CAUTION
Risk of accident
The truck operator is responsible for ensuring that
this key is actually switched to the appropriate posi-
tion when the truck is operated with two people. The
equipment described below is not activated until the
switching procedure has been carried out. The truck
operator must instruct the passenger regarding the
correct operation of the additional equipment and re-
garding safe conduct when travelling. If the passen-
ger does not comply with these instructions, the pas-
senger must not be transported.

The key for switching from one-person opera-

tion to two-person operation is installed in the
rear cab wall above the driver's seat. In the il-
lustration, the key switch (1) is set to one-per-
son operation (2).

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7 Special equipment
Two-person cab

Handholds 
Two handholds (3) are provided so that the
passenger is able to hold on with both hands
at all times, thus keeping the passenger's
body in a safe position. For monitoring purpo-
ses, the passenger must always actuate both
buttons (4). Only then are the truck functions
enabled. If the passenger releases one of the
buttons whilst travelling or during a hydraulic
movement, this function will stop immediately.

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Special equipment 7
Two-person cab

Foot switch 
One or two additional foot switches (5) force
the passenger to adopt a safe position. If the
passenger releases one of the foot switches
during travel, the truck will stop immediately.

Further equipment
Depending on the lift mast design and cab di-
mensions, protection against accidental con-
tact with the lift cylinder situated behind the
cab can be installed.
Protection against leaning out towards the
rack at the side may also be required. This
protection system can be installed on the bar-
rier and is moved with the barrier when it is
being opened.

Safety
The sensor system of the two-person cab is
monitored electronically. This prevents operat-
ing errors and means that any damage should
be detected.
Display 813
Cause
● Incorrect switching sequence. When the
key switch was set to ride on mode, one of
the enabling switches had already been ac-
tuated (manipulation of a switch or switch
defect)
● One of the foot switches was actuated for
longer than 5 seconds before the second
foot switch was actuated
● One of the enabling switches in the hand-
holds was actuated for longer than 5 sec-
onds before another switch was actuated
Effect
● Lifting and lowering of the main lift is disa-
bled. No enable possible
● Lifting and lowering of the auxiliary lift is dis-
abled. No enable possible
● Driving disabled. No enable possible
Remedy
Release all switches and actuate them in the
correct sequence.

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7 Special equipment
Working platforms

If this does not restore the correct function and

the error message disappears, call the author-
ised service centre.

Working platforms 

The use of working platforms in conjunction

with industrial trucks is regulated by national
law.
This legislation must be observed. The use of
working platforms is only permitted by virtue of
the legislation in the country of use. Before us-
ing working platforms, consult your national
regulatory authorities.

WARNING
High risk of accident
No one must ever stand on the forks to be raised or
transported!
Use only work platforms that have been supplied by
the manufacturer or approved work platforms from
other manufacturers.

If an industrial truck is equipped with a work-

ing platform at the factory, this special version
is accompanied by additional operating in-
structions. Detailed safety information can be
found within.

158 5231 804 2502 EN - 04/2020

Index

A Battery discharge indicator. . . . . . . . . . . . 54

Abseil system. . . . . . . . . . . . . . . . . . . . . . 154 Battery lock. . . . . . . . . . . . . . . . . . . . 57, 122
Acceleration behaviour. . . . . . . . . . . . 70, 76 Battery lock, setting. . . . . . . . . . . . . . . . . 122
Accessible pallet. . . . . . . . . . . . . . . . 41, 150 Battery maintenance. . . . . . . . . . . . . 54, 104
Accessories accompanying the product. . . 6 Battery management system. . . . . . . . . . 104
Acoustic alarm. . . . . . . . . . . . . . . . . . . . . 147 Battery on a roller channel. . . . . . . . . . . . 122
Active load wheel axle. . . . . . . . . . . . . . . 118 Battery type. . . . . . . . . . . . . . . . . . 52, 54, 55
Additional documentation. . . . . . . . . . 6, 110 Battery, weight. . . . . . . . . . . . . . . . . . . . . . 44
Additional hydraulic functions. . . . . . 30, 113 Blower. . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Adjusting the driver's seat. . . . . . . . . . . . . 65 Body weight. . . . . . . . . . . . . . . . . . . . . . . 154
Adjusting the position of the operating pan- Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
el. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Braking. . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
AFC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Braking characteristics. . . . . . . . . . 12, 70, 76
Aisle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 braking distance. . . . . . . . . . . . . . . . . . . . . 18
Aisle detection, barcode. . . . . . . . . . . . . 128 Braking zone. . . . . . . . . . . . . . . . . . . . . . 128
Aisle detection, magnet operated Bridging plug X99. . . . . . . . . . . . . . . . . . 132
switches. . . . . . . . . . . . . . . . . . . . . . . . 128
C
Aisle detection, reflective light switches. . 128
Cab doors. . . . . . . . . . . . . . . . . . . . . . 70, 76
Aisle detection, RFID. . . . . . . . . . . . . . . . 128
Camera system. . . . . . . . . . . . . . . . . . . . 137
Aisle entry assistant. . . . . . . . . . . . . . . . . 120
Camera system, maintenance. . . . . . . . . 137
Aisle safety assistant. . . . . . . . . . . . . . . . 110
Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Aisles, closed at one side. . . . . . . . . . . . 128
Care, special equipment. . . . . . . . . . . . . . 98
Aisles, open at both sides. . . . . . . . . . . . 128
Care, special versions. . . . . . . . . . . . . . . . 98
Alterations to industrial trucks. . . . . . . . . . 20
CD player. . . . . . . . . . . . . . . . . . . . . . . . . 143
Ancillary movements. . . . . . . . . . . . . . 70, 76
Changing the aisle. . . . . . . . . . . . . . . . . . . 74
Antistatic version. . . . . . . . . . . . . . . . . . . 148
Checking all operating devices. . . . . . . . . 59
application area. . . . . . . . . . . . . . . . . . . . . 18
Checking the access control. . . . . . . . . . . 59
Assistance system. . . . . . . . . . . . . . . . . . 144
Checking the cab doors. . . . . . . . . . . . . . . 59
Attachment. . . . . . . . . . . . . . . . . . . . . . . . . . 6
Checking the emergency off switch. . . . . . 59
Attachment points. . . . . . . . . . . . . . . . . . . 85
Checking the lifting accessory. . . . . . . . . . 59
Attachments. . . . . . . . . . . . . . . . . . . . . . . . 29
Checking the overhead guard. . . . . . . . . . 59
Attachments, other. . . . . . . . . . . . . . . 41, 150
Checking the wheels. . . . . . . . . . . . . . . . . 59
Automatic braking systems. . . . . . . . . . . 128
Checklist before starting work. . . . 44, 58, 59
Automatic driving within the aisle. . . . . . . 115
Climbing in. . . . . . . . . . . . . . . . . . . . . . . . . 61
Automatic floor compensation. . . . . . . . . 118
Climbing out. . . . . . . . . . . . . . . . . . . . . . . . 61
Auxiliary lift. . . . . . . . . . . . . . . 29, 70, 76, 113
Closing the barriers. . . . . . . . . . . . . . . . . . 61
B Closing the glass doors. . . . . . . . . . . . . . . 61
Ballast weight. . . . . . . . . . . . . . . . . . . . . . . 54 Cold-store operation. . . . . . . . . . . . . . . . 105
Barriers. . . . . . . . . . . . . . . . . . . . . 61, 70, 76 cold store. . . . . . . . . . . . . . . . . . . . . . . . . . 18
Battery acid. . . . . . . . . . . . . . . . . . . . . 15, 52 Colour monitor. . . . . . . . . . . . . . . . . . . . . 137
Battery change frame. . . . . . . . . . . . . 52, 54 Commissioning. . . . . . . . . . . . . . . . . . . . . 54
Battery charger. . . . . . . . . . . . . . . . . . . . . 55 Control current fuse. . . . . . . . . . . . . . . . . 106
Battery commissioning. . . . . . . . . . . . . . . . 56 Conversions. . . . . . . . . . . . . . . . . . . . . . . . 29
Battery compartment cover. . . . . . . . . . . . 54 Copyright and proprietary rights. . . . . . . . . 8
Battery compartment doors. . . . . . . . . . . . 54 Correct disposal. . . . . . . . . . . . . . . . . . . . . 94

5231 804 2502 EN - 04/2020 159

 Index

Counterweight. . . . . . . . . . . . . . . . . . . . . . 54 Entering the aisle. . . . . . . . . . . . . . . . . . . 115

Cup holder. . . . . . . . . . . . . . . . . . . . . . . . 152 Error message 813. . . . . . . . . . . . . . . . . 154
Customer option. . . . . . . . . . . . . . . . . . . 110 Error numbers. . . . . . . . . . . . . . . . . . . . . . 40
Customised special versions. . . . . . . . . . . . 4 Exiting the raised driver's compartment in
the event of an emergency. . . . . . . . 82, 90
D Expert. . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Danger area. . . . . . . . . . . . . . . . . . . . . . . . 12
Declaration of conformity. . . . . . . . . . . . . . . 3 F
Decommissioning. . . . . . . . . . . . . . . . . . . 94 Factory nameplate. . . . . . . . . . . . . . . . . . . . 5
Description of truck. . . . . . . . . . . . . . . . . . 29 Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Dimensions. . . . . . . . . . . . . . . . . . . . . . . 108 Fan module. . . . . . . . . . . . . . . . . . . . . . . 136
Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 FEM 4.004. . . . . . . . . . . . . . . . . . . . . . . . . 17
Distance measurement. . . . . . . . . . . . . . 128 Fleet management system. . . . . . . . . . . 125
Driver training. . . . . . . . . . . . . . . . . . . . . . 20 Floor height. . . . . . . . . . . . . . . . . . . . . . . . 12
Driver's cabs, special versions. . . . . . . . . 139 floor load. . . . . . . . . . . . . . . . . . . . . . . . . . 18
Driver's cab, closed. . . . . . . . . . . . . . . . . 139 Floor structure. . . . . . . . . . . . . . . . . . . . . . 12
Driver's cab, emergency lowering. . . . . . . 82 floor surface. . . . . . . . . . . . . . . . . . . . . . . . 18
Driver's compartment. . . . . . . . . . . . . . . . . 61 Foot switch. . . . . . . . . . . . . . . . . . . . . . 70, 76
Driver's licence. . . . . . . . . . . . . . . . . . . . . . 20 Fork arms, hydraulically adjustable*. . . . . 81
Driver's seat, option. . . . . . . . . . . . . . . . . . 65 Fork arms, latch. . . . . . . . . . . . . . . . . . . . . 81
Driver's seat, standard version. . . . . . . . . 65 Fork arms, manually adjustable. . . . . . . . . 81
Driving. . . . . . . . . . . . . . . . . . . . . . . . . 70, 76 Fork arms, specification. . . . . . . . . . . . . . . 81
Driving freely. . . . . . . . . . . . . . . . . . . . . . . 73 Fork cycle. . . . . . . . . . . . . . . . . . . . . . . . . 30
Drivingsafety. . . . . . . . . . . . . . . . . . . . . . . 19 Frequency. . . . . . . . . . . . . . . . . . . . . . . . . 13
Driving speed adaptation. . . . . . . . . . . . . 115 Front end monitoring. . . . . . . . . . . . . . . . 132
Function checking. . . . . . . . . . . . . . . . 58, 59
E Function checking the brake system. . . . . 59
EC declaration of conformity. . . . . . . . . . . . 3 Function checking the steering. . . . . . . . . 59
Electric field strength. . . . . . . . . . . . . . . . . 13 Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Electrolyte. . . . . . . . . . . . . . . . . . . . . . . . . 52
Electromagnetic radiation. . . . . . . . . . . . . 13 G
Electronic access control. . . . . . . 12, 67, 125 Gearbox oil. . . . . . . . . . . . . . . . . . . . . . . 105
Emergency abseil system. . . . . . . . . . . . . 90 Gearbox, filling quantities. . . . . . . . . . . . 105
Emergency abseil system for different op- Gearbox, lubricants. . . . . . . . . . . . . . . . . 105
erators. . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Gear oil. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Emergency lowering. . . . . . . . . . . . . . . . . 82 Gel batteries. . . . . . . . . . . . . . . . . . . . . . 104
Emergency lowering valve. . . . . . . . . . . . . 82 Gel battery. . . . . . . . . . . . . . . . . . . . . . . . . 54
Emergency lowering via the operating pan- General safety information. . . . . . . . . . . . . 12
el. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Glass doors. . . . . . . . . . . . . . . . . . . . . . . . 61
Emergency off switch. . . . . . . . . . 30, 67, 113 Guard plate on rack rail. . . . . . . . . . . . . . 149
Emergency operation. . . . . . . . . . . . . . . . . 85 Guidance. . . . . . . . . . . . . . . . . . . . . . . . . . 73
Emergency steering device. . . . . . . . . . . . 85 Guide rollers, electrically conductive. . . . 148
Emissions. . . . . . . . . . . . . . . . . . . . . . . . . 13
Enable button. . . . . . . . . . . . . . . . . . . 30, 120 H
Enabling options. . . . . . . . . . . . . . . . . . . 110 Hand and arm vibrations. . . . . . . . . . . . . . 13
Energy-saving mode. . . . . . . . . . . . . . . . . 33 Headlights. . . . . . . . . . . . . . . . . . . . . . . . 144
EN ISO 3411. . . . . . . . . . . . . . . . . . . . . . 154 Heating system. . . . . . . . . . . . . . . . . . . . 142

160 5231 804 2502 EN - 04/2020

Index

Hooking on the chassis. . . . . . . . . . . . . . . 46 Load stabilisation, dynamic. . . . . . . . . . . 111

Hooking on the lift mast. . . . . . . . . . . . . . . 46 Load weight detection. . . . . . . . . . . . . . . 111
Hooking the lift mast on horizontally. . . . . 46 Load weight measurement. . . . . . . . . . . 111
Horn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Load wheel brake. . . . . . . . . . . . . . . . . . . 85
Horn button. . . . . . . . . . . . . . . . . . . . . . . . 30 Load wheels, electrically conductive. . . . 148
Hydraulic oil. . . . . . . . . . . . . . . . . . . . 15, 105 Loudspeakers. . . . . . . . . . . . . . . . . . . . . 143
Hydraulic system, filling quantities. . . . . . 105 Lubricants. . . . . . . . . . . . . . . . . . . . . . . . 105
Lubricant, grease. . . . . . . . . . . . . . . . . . . 105
I Lubricant, load chains. . . . . . . . . . . . . . . 105
iGo pilot navigation. . . . . . . . . . . . . 110, 111 Lubricant, shaft-hub connection. . . . . . . . 105
Implants. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Inductive guidance. . . . . . . . . . . . . . . 73, 115 M
Industrial-truck view. . . . . . . . . . . . . . . . . . 24 Magnetic card system. . . . . . . . . . . . . . . . 67
Initial commissioning. . . . . . . . . . . . . . . . . 44 Main current fuse. . . . . . . . . . . . . . . . . . . 106
Initial driving exercises. . . . . . . . . . . . . . . . 63 Main lift. . . . . . . . . . . . . . . . . . . . 70, 76, 113
Installing the battery. . . . . . . . . . . . . . . . . . 54 Maintenance. . . . . . . . . . . . . . . . . . . . . 4, 96
Instruction. . . . . . . . . . . . . . . . . . . . . . . . . 90 Maintenance interval, shortened. . . . . . . . 98
Intelligent load capacity diagram. . . . . . . 111 Maintenance schedule, 1000-hr. . . . . . . . 99
Intended use. . . . . . . . . . . . . . . . . . . 4, 6, 29 Maintenance schedule, 2000-hr. . . . . . . 103
Intercom system. . . . . . . . . . . . . . . . . . . 142 Maintenance, special equipment. . . . . . . . 98
Interface X99. . . . . . . . . . . . . . . . . . . . . . 132 Maintenance, special versions. . . . . . . . . . 98
Intermediate lift cut-out. . . . . . . . . . . . . . 120 Mast bracing. . . . . . . . . . . . . . . . . . . . . . . 46
IZF. . . . . . . . . . . . . . . . . . . . . 70, 73, 76, 115 Maximum driving speed. . . . . . . . . . . . . . 128
Maximum service life. . . . . . . . . . . . . . . . . 90
K Maximum speed. . . . . . . . . . . . . . . . . 70, 76
Key switch. . . . . . . . . . . . . . . . . . . . . . . . . 67 Mechanical guidance. . . . . . . . . . . . . . . . . 74
L Mechanical rail guidance. . . . . . . . . . . . . . 73
Medical equipment. . . . . . . . . . . . . . . . . . . 13
Labelling for special equipment. . . . . . . . . 27
Microphone. . . . . . . . . . . . . . . . . . . . . . . 142
Laser scanner, Care. . . . . . . . . . . . . . . . 133
Mirror module. . . . . . . . . . . . . . . . . . . . . . 136
Laser scanner, Cleaning. . . . . . . . . . . . . 133
MMS interface. . . . . . . . . . . . . . . . . . . . . 153
Laser scanner, Maintenance. . . . . . . . . . 133
Modification. . . . . . . . . . . . . . . . . . . . . . . . 29
Lead-acid batteries. . . . . . . . . . . . . . . . . 104
Mounting system for auxiliary compo-
Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
nents. . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Leaving the induction track. . . . . . . . . . . 115
MPSE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Lift cut-out. . . . . . . . . . . . . . . . . . . . . . . . 120
MPSE, preparation. . . . . . . . . . . . . . . . . 134
Lift height preselection. . . . . . . . . . . . . . . 138
MZF. . . . . . . . . . . . . . . . . . . . . . . . 70, 73, 76
Lifting clear of the ground. . . . . . . . . . . . . 12
Lift mast, lower lifting point. . . . . . . . . . . . 46 N
Lighting. . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Narrow aisle vehicles. . . . . . . . . . . . . . . . . 19
Lighting module. . . . . . . . . . . . . . . . . . . . 136 Navigation. . . . . . . . . . . . . . . . . . . . . . . . . 33
Lithium-ion batteries. . . . . . . . . . . . . . . . 104 Non-ionising radiation. . . . . . . . . . . . . . . . 13
Lithium-ion battery. . . . . . . . . . . . . . . . . . . 54 normal work load. . . . . . . . . . . . . . . . . . . . 18
Load capacity. . . . . . . . . . . . . . . . . . . . . . . 12 Numerical code. . . . . . . . . . . . . . . . . . . . 125
Load capacity diagram. . . . . . . . . . . . . 29, 80
Load capacity, reduction. . . . . . . . . . . . . . . 9 O
Loading the chassis. . . . . . . . . . . . . . . . . . 46 Obligations of the operating company. . . . 13

5231 804 2502 EN - 04/2020 161

 Index

Occupational safety. . . . . . . . . . . . . . . . . 144 Plugging in the battery male connector. . . 67

Oil-containing wastes. . . . . . . . . . . . . . . . . 15 Product documentation. . . . . . . . . . . . . . . . 6
Opening the barriers. . . . . . . . . . . . . . . . . 61 Programming the display. . . . . . . . . . . . . . 33
Opening the glass doors. . . . . . . . . . . . . . 61 Protection against contact. . . . . . . . . . . . 154
Operating company. . . . . . . . . . . . . . . . . . 17 Protective roof cover. . . . . . . . . . . . . . . . 143
Operating instruction document. . . . . . . . . 17 PzS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Operating instructions. . . . . . . . . . . . . . . . 40
Operating instructions and maintenance in-
R
structions. . . . . . . . . . . . . . . . . . . . . . . . . . 6 Rack rail guard. . . . . . . . . . . . . . . . . . . . . 149
Operating lever for driving. . . . . . . . . . . . 113 Radio installation. . . . . . . . . . . . . . . . . . . 143
Operating lever for hydraulics. . . . . . 30, 113 Rapid travel zone. . . . . . . . . . . . . . . . . . . 128
Operating media. . . . . . . . . . . . . . . . . . . . 15 Rear view camera. . . . . . . . . . . . . . . . . . 137
Operating panel. . . . . . . . . . . . . . . . . . . . . 30 Recycling. . . . . . . . . . . . . . . . . . . . . . . . . . 94
Operating the display. . . . . . . . . . . . . . . . . 33 Reduction in load capacity. . . . . . . . . . . . 154
Operational safety. . . . . . . . . . . . . . . . . . . 12 Regular maintenance. . . . . . . . . . . . 4, 96, 98
Operator and passenger. . . . . . . . . . . . . 154 Regular testing. . . . . . . . . . . . . . . . . . . 17, 96
Operator's compartment, dimensions. . . . . 9 Releasing the brake mechanically. . . . . . . 85
Operator, body dimensions. . . . . . . . . . . . . 9 Removing the control compartment hood.
Operator, body weight. . . . . . . . . . . . . . . . . 9 82, 85, 106
Operator, female. . . . . . . . . . . . . . . . . . . . . 9 Replacement interval for lifting chains. . . . 96
Operator, form of address. . . . . . . . . . . . . . 9 Replacement state of wear. . . . . . . . . . . . 90
Operator, male. . . . . . . . . . . . . . . . . . . . . . . 9 Replacing the battery. . . . . . . . . . . 52, 54, 57
Options. . . . . . . . . . . . . . . . . . . . 4, 110, 151 Replacing the battery using a change
Optispeed, versions. . . . . . . . . . . . . . . . . 111 frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Replacing the battery using a truck. . . . . . 57
Order-picking platform. . . . . . . . . . . . 41, 150
Residual risks. . . . . . . . . . . . . . . . . . . . . . 17
Order-related documentation. . . . . . . . . . . . 6
Order picking truck. . . . . . . . . . . . . . . . . . . 29 Retrieval. . . . . . . . . . . . . . . . . . . . . . . . . . 132
RFID card. . . . . . . . . . . . . . . . . . . . . . . . 125
Original parts. . . . . . . . . . . . . . . . . . . . . . . 19
RFID chip. . . . . . . . . . . . . . . . . . . . . . 67, 125
Other checks. . . . . . . . . . . . . . . . . . . . . . . 59
Risk assessment. . . . . . . . . . . . . . . . . . . . 17
Overhead guard. . . . . . . . . . . . . . . . . . . . 143
Overhead guard switch. . . . . . . . . . . . . . 144 Risk of corrosion. . . . . . . . . . . . . . . . . 52, 54
Risk of explosion. . . . . . . . . . . . . . . . . 52, 54
P Roadways. . . . . . . . . . . . . . . . . . . . . . . . . 12
Parking brake. . . . . . . . . . . . . . . . . . . . 70, 76
S
Passenger. . . . . . . . . . . . . . . . . . . . . . . . 154
Safety category 2. . . . . . . . . . . . . . . . . . . 132
Pedestrian mode. . . . . . . . . . . . . . . . . . . . 12
Permitted batteries. . . . . . . . . . . . . . . . . . . 56 Safety headlight. . . . . . . . . . . . . . . . . . . . 145
Safety laser scanner. . . . . . . . . . . . . . . . 132
Personal protection. . . . . . . . . . . . . . . . . . 15
Safety laser scanners. . . . . . . . . . . . . . . 133
Personal protection system. . . . . . . 132, 133
Personal protection system, preparation. 134 Safety light. . . . . . . . . . . . . . . . . . . . . . . . 145
Safety light, maintenance. . . . . . . . . . . . 145
Personal protective equipment. . . . . . . . . 21
Safety light, retrofitting. . . . . . . . . . . . . . . 145
Personal protective gear. . . . . . . . . . . . . . 15
Pictograms. . . . . . . . . . . . . . . . . . . . . . . . . 40 Safety light, switching off. . . . . . . . . . . . . 145
Safety light, switching on. . . . . . . . . . . . . 145
PIN code. . . . . . . . . . . . . . . . . . . . . . 67, 125
Safety officer. . . . . . . . . . . . . . . . . . . . . . . 14
PIN code, a change. . . . . . . . . . . . . . . . . 125
PIN code, factory setting. . . . . . . . . . . . . 125 Scanners, cleaning. . . . . . . . . . . . . . . . . 133
Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Plain text messages. . . . . . . . . . . . . . . . . . 40

162 5231 804 2502 EN - 04/2020

Index

Securing the load support. . . . . . . . . . 82, 85 Traffic supervisor. . . . . . . . . . . . . . . . . . . . 12

Sensor surface. . . . . . . . . . . . . . . 70, 76, 113 Training. . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Sensor surface for two-hand operation. . . 30 Transfer aisle. . . . . . . . . . . . . . . . . . . . . . 128
Sensor system. . . . . . . . . . . . . . . . . . . . . 128 Transportation safety device on glass
Service flap. . . . . . . . . . . . . . . . . . . . . . . . 54 doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Shut-off valves. . . . . . . . . . . . . . . . . . . . . . 85 Transporting and loading. . . . . . . . . . . . . . 46
Side shift limitation, automatic. . . . . . . . . 111 Transport travel. . . . . . . . . . . . . . . . . . . . . 29
Small items. . . . . . . . . . . . . . . . . . . . . . . 152 Truck configuration file. . . . . . . . . . . . . . . 110
Sound level. . . . . . . . . . . . . . . . . . . . . . . 108 Truck identification. . . . . . . . . . . . . . . . . . . . 5
Spare parts list. . . . . . . . . . . . . . . . . . . . . . . 6 Turret head. . . . . . . . . . . . . . . . . . . . 41, 150
Special equipment. . . . . . . . . . . . . . . . . . . 58 Two-hand operation. . . . . . . . 30, 70, 76, 113
Special functions. . . . . . . . . . . . . . . . . . . . 30 Two-person cab. . . . . . . . . . . . . . . . . 90, 154
Specialist. . . . . . . . . . . . . . . . . . . . . . . . . . 17 Types of guidance. . . . . . . . . . . . . . . . . . . 73
Special safety information about load pick
up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
U
Special version, customised. . . . . . . . . . 110 Unauthorised use. . . . . . . . . . . . . . . . . . . . 12
Speed optimisation. . . . . . . . . . . . . . . . . 111 Underside of the operating panel. . . . . . . . 76
Speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Unevenness of the floor. . . . . . . . . . . . . . 118
Split operating panel. . . . . . . . . . . . . . . . 113 Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Stability. . . . . . . . . . . . . . . . . . . . . . . . . 9, 80 Units, delivery. . . . . . . . . . . . . . . . . . . . . . 44
Standard design. . . . . . . . . . . . . . . . . . . . . . 4 Units, weights. . . . . . . . . . . . . . . . . . . . . . 44
Standard labelling. . . . . . . . . . . . . . . . . . . 25 USB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Steering. . . . . . . . . . . . . . . . . . . . . . . . 70, 76 USB charging station. . . . . . . . . . . . . . . . 152
Steering knob. . . . . . . . . . . . . . . . . . . 30, 113 Use in cold storage. . . . . . . . . . . . . . . . . 151
Steering wheel. . . . . . . . . . . . . . . . . . 30, 113 Use in very narrow aisles. . . . . . . . . . . . . . 29
Support screws. . . . . . . . . . . . . . . . . . . . . 51 V
Support screws, setting dimension. . . . . . 80
VDE0117. . . . . . . . . . . . . . . . . . . . . . . . . . 18
Swinging loads. . . . . . . . . . . . . . . . . . . . . . 14
VDI2695. . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Switch-off functions. . . . . . . . . . . . . . . . . 120
VDMA (German Engineering Federation)
Switch-on push button. . . . . . . . . . . . . . . . 67 information booklet. . . . . . . . . . . . . . . . . . 6
Switching off. . . . . . . . . . . . . . . . . . . . . . 125 Ventilation. . . . . . . . . . . . . . . . . . . . . . . . 142
Switching on. . . . . . . . . . . . . . . . . . . 67, 125 Vibration load. . . . . . . . . . . . . . . . . . . . . . . 13
Swivel shift fork. . . . . . . . . . . . . . . . . . . . . 41 Vibrations. . . . . . . . . . . . . . . . . . . . . . . . . . 13
Synchronised fork movement. . . . . . . . . . 76 Video camera. . . . . . . . . . . . . . . . . . . . . . 137
T Voltage transformer. . . . . . . . . . . . . . . . . 143
Technical data. . . . . . . . . . . . . . . . . . . . . 108 Volume control. . . . . . . . . . . . . . . . . . . . . 142
Technicians. . . . . . . . . . . . . . . . . . . . . . . . 44 W
Telescopic table. . . . . . . . . . . . . 41, 149, 150 Warm-air heating system. . . . . . . . . . . . . 142
Tilt barrier. . . . . . . . . . . . . . . . . . . . . . . . . 135 Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . 96
Torque for wheel nuts. . . . . . . . . . . . . . . . 46 Wear limit for lifting chains. . . . . . . . . . . . . 96
Towing. . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Towing with non-operational steering. . . . 85 Weights, units. . . . . . . . . . . . . . . . . . . . . . 44
Towing with operational steering. . . . . . . . 85 Weight, attachment. . . . . . . . . . . . . . . . . . 44
Traction battery. . . . . . . . . . . . . . . . . . . . . 52 Weight, battery. . . . . . . . . . . . . . . . . . . . . . 44
Traction cut-out. . . . . . . . . . . . . . . . . . . . 120 Weight, chassis. . . . . . . . . . . . . . . . . . . . . 44
Traction motor brake. . . . . . . . . . . . . . . . . 85

5231 804 2502 EN - 04/2020 163

 Index

Weight, driver's cab. . . . . . . . . . . . . . . . . . 44 Working range. . . . . . . . . . . . . . . . . . . . . . 12

Weight, lift mast. . . . . . . . . . . . . . . . . . . . . 44 Working spotlights. . . . . . . . . . . . . . . . . . 144
Wet lead battery. . . . . . . . . . . . . . . . . . . . . 54 Work light. . . . . . . . . . . . . . . . . . . . . . . . . . 33
Wheel nuts. . . . . . . . . . . . . . . . . . . . . . . . . 46 Workplace, workplace. . . . . . . . . . . . . . . 144
Wind deflector cab. . . . . . . . . . . . . . 139, 140
Wind deflector cab, emergency abseiling.
Z
139, 140 Zone detection. . . . . . . . . . . . . . . . . . . . . 128
Working platform. . . . . . . . . . . . . . . . . . . 158 Zones. . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

164 5231 804 2502 EN - 04/2020

STILL GmbH

5231 804 2502 EN - 04/2020