Manual Tr. Ameise PTE 1.1-1.5

PTE 1.
1 Li-Ion /
PTE 1.5 Li-Ion
Operating instructions
en-GB
51780448
09.19
06.21
PTE 1.1 Li-Ion
PTE 1.5 Li-Ion
2
Declaration of Conformity
Manufacturer
Noblelift Intelligent Equipment Co., Ltd., No. 528 Changzhou Road, 313100
Changxing, Huzhou, Zhejiang, People's Republic of China
Imported by (for all countries except China)/approved by (for China)
Jungheinrich AG, Friedrich-Ebert-Damm 129, 22047 Hamburg, Germany
Description
Industrial truck
Type Option Serial no. Year of

manufacture
PTE 1.1 Li-Ion
PTE 1.5 Li-Ion
Additional information
On behalf of
Date
EU DECLARATION OF CONFORMITY
The undersigned hereby declares that the power-operated forklift truck described in
detail satisfies the current versions of the applicable European directives
2006/42/EG (Machinery Directive) and 2014/30/EU (Electromagnetic Compatibility
Directive (EMC)). The manufacturer is authorised to compile the technical
documentation.
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4
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Foreword
Notes on the operating instructions
The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide

sufficient instruction for the safe operation of the industrial truck. The information is
presented in a precise and clear manner. The chapters are arranged by letter and
the pages are numbered continuously.
The operating instructions detail different industrial truck models. When operating
and checking the industrial truck, make sure that the particular section applies to
your truck model.
Our industrial trucks are subject to ongoing development. We reserve the right to
alter the design, features and technical aspects of the equipment. No guarantee of
particular features of the equipment should therefore be assumed from the present
operating instructions.
Safety notices and text mark-ups
Safety instructions and important explanations are indicated by the following

graphics:
DANGER!
Indicates an extremely hazardous situation. Failure to comply with this instruction will
result in severe irreparable injury and even death.
WARNING!
Indicates an extremely hazardous situation. Failure to comply with this instruction
may result in severe irreparable injury and even death.
CAUTION!
Indicates a hazardous situation. Failure to comply with this instruction may result in
slight to medium injury.
NOTICE
Indicates a material hazard. Failure to comply with this instruction may result in
material damage.
Z Used before notices and explanations.
t Indicates standard equipment

o Indicates optional equipment
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Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.

Jungheinrich Aktiengesellschaft
Friedrich-Ebert-Damm 129
22047 Hamburg - Germany
Tel: +49 (0) 40/6948-0
www.jungheinrich.com
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Contents
.
A Correct Use and Application 11
.
1 General 11
2 Correct application 11
3 Approved application conditions 11
4 Proprietor responsibilities 12
5 Adding attachments and/or optional equipment 13
6 Removal of components 13
7 Wind loads 13
.
B Truck Description 15
.
1 Application 15
2 Truck models and rated capacity 15
3 Travel direction definition 16
4 Assemblies and Functional Description 17
4.1 Assembly Overview 17
4.2 Functional Description 19
5 Technical Specifications 21
5.1 Dimensions 21
5.2 Performance data 24
5.3 Battery 25
5.4 Battery charger 26
5.5 Weights 26
5.6 Tyre type 26
5.7 EN norms 27
5.8 Electrical Requirements 27
6 Identification points and data plates 28
6.1 Data plate 30
.
C Transport and Commissioning 31
.
1 Lifting by crane 31
2 Transport 33
3 Using the Truck for the First Time 34
4 Changing the Access Code 35
5 Mounting the tiller 36
.
D Battery - Servicing, Recharging, Replacement 39
.
1 Description of the lithium-ion battery 39
2 Battery Decals 40
2.1 Battery data plate 41
2.2 Battery serial number 41
3 Safety Instructions, Warning Indications and other Notes 42
3.1 Safety regulations for handling lithium-ion batteries 42
3.2 Potential hazards 44
3.3 Battery lifetime and maintenance 51
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3.4 Charging the battery 52

3.5 Storage / safe handling / faults 53
3.6 Disposal and transport of a lithium-ion battery 54
7
4 Charging the battery 57
4.1 Correct Use and Application 57
4.2 Charge Status Indicator 58
4.3 Charging the Battery with External Charger 60
5 Battery removal and installation 62
5.1 Removing the battery 62
5.2 Battery installation 63
.
E Operation 65
.
1 Safety Regulations for the Operation of Forklift Trucks 65
2 Displays and Controls 67
2.1 Controls 67
2.2 Display symbols 71
3 Starting up the truck 72
3.1 Checks and operations to be performed before starting daily operation 72
3.2 Preparing the truck for operation 73
3.3 Parking the truck securely 75
4 Industrial Truck Operation 76
4.1 Safety regulations for truck operation 76
4.2 Emergency Disconnect 78
4.3 Brakes 79
4.4 Travel 81
4.5 Slow travel 82
4.6 Steering 83
4.7 Lifting, transporting and depositing loads 84
5 Troubleshooting 88
6 Operating the truck without its own drive system 90
.
F Truck maintenance 91
.
1 Spare Parts 91
2 Operational Safety and Environmental Protection 91
3 Maintenance Safety Regulations 93
3.1 Working on the electrical system 93
3.2 Consumables and used parts 94
3.3 Wheels 94
3.4 Hydraulic system 94
3.5 Energy saving components 94
4 Lubricants and Lubrication Schedule 95
4.1 Handling consumables safely 95
4.2 Lubrication Schedule 96
4.3 Consumables 97
5 Maintenance and repairs 98
5.1 Preparing the truck for maintenance and repairs 98
5.2 Lifting and jacking up the truck safely 99
5.3 Removing the Covers 101
5.4 Cleaning 103
5.5 Checking the drive wheel and load wheels 105
5.6 Checking the hydraulic oil level 106
5.7 Checking electrical fuses 107
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6 Restoring the truck to service after maintenance and repairs 108

7 Decommissioning the industrial truck 108
7.1 Prior to decommissioning 108
8
7.2 Action to be taken during decommissioning 109
7.3 Restoring the truck to service after decommissioning 109
8 Safety tests to be performed at intervals and after unusual incidents 109
9 Final de-commissioning, disposal 109
.
G Maintenance, Inspection and Changing of Maintenance
Parts Requiring Replacement 111
.
1 Maintenance Contents PTE 1.1 112
1.1 Owner 112
1.2 Customer Service 115
2 Maintenance Contents PTE 15N 118
2.1 Owner 118
2.2 Customer Service 119
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A Correct Use and Application
1 General
The truck must be used, operated and serviced in accordance with the present
instructions. All other types of use are beyond its scope of application and may result
in damage to personnel, the industrial truck or property.
2 Correct application
NOTICE
The maximum load and load distance are indicated on the capacity plate and must
not be exceeded.
The load must rest on the load handler.
The load must be fully raised, see page 84.
The following operations are in accordance with regulations and are permitted:
– Lifting and lowering loads.
– Transporting lowered loads.
The following operations are prohibited:
– Carrying and lifting passengers.
– Pushing or pulling loads.
3 Approved application conditions
WARNING!
Operation under extreme conditions
Using the truck in extreme temperatures or conditions can result in malfunctions and
accidents.
uUsage under extreme conditions, in particular in very dusty or corrosive
environments, is not permitted.
uThe truck must not be used in areas at risk of explosion.
uIn adverse weather conditions (thunder, lightning), the truck must not be operated
outside or in hazardous areas.
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The following operating conditions apply for PTE 1.1 Li-Ion and PTE 1.5 Li-Ion:
– Operation in industrial and commercial environments.

– Use only on secure surfaces with sufficient capacity.
– Do not exceed the permissible surface and point load limits on the travel paths.
– Use only on travel paths that are visible and approved by the operating company.
– Slopes of max. 6 % may be negotiated with load, and 16 % without load.
– Do not travel across or at an angle on inclines. Travel with the load facing uphill.
– Minimum illumination level of the traffic lanes 50 Lux.
There are differences with the following operating conditions:
Operating conditions PTE 1.1 Li-Ion PTE 1.5 Li-Ion

Use indoors Yes Yes
Use outdoors No Yes
Use on level surfaces Yes Yes
Use on uneven surfaces No Yes
Temperature range +5 °C to +40 °C
Minimum temperature for brief outdoor - -20 °C
use (max. 30 minutes)
4 Proprietor responsibilities
For the purposes of the present operating instructions the “operating company” is
defined as any natural or legal person who either uses the industrial truck himself, or
on whose behalf it is used. In special cases (e.g. leasing or renting) the proprietor is
considered the person who, in accordance with existing contractual agreements
between the owner and user of the industrial truck, is charged with operational
duties.
The proprietor must ensure that the industrial truck is used only for the purpose it is
intended for and that danger to life and limb of the user and third parties are
excluded. Furthermore, accident prevention regulations, safety regulations and
operating, servicing and repair guidelines must be followed. The operating company
must ensure that all users have read and understood these operating instructions.
NOTICE
Failure to comply with the operating instructions invalidates the warranty. The same
applies if improper work is carried out on the truck by the customer or third parties
without the permission of the manufacturer.
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5 Adding attachments and/or optional equipment
The mounting or installation of additional equipment which affects or enhances the
performance of the industrial truck requires the written permission of the
manufacturer. Local authority approval may also need to be obtained.
Local authority approval however does not constitute the manufacturer’s approval.
6 Removal of components
It is forbidden to modify or remove truck components, particularly protective and
safety equipment.
Z If in doubt, contact the manufacturer's customer service department.
7 Wind loads
Wind forces can affect the stability of a truck when lifting, lowering and transporting
loads with large surface areas.
Light loads must be especially secured when they are subjected to wind forces. This
will prevent the load from sliding or falling.
Stop the truck in both cases.

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B Truck Description
1 Application
The PTE 1.1 Li-Ion / PTE 1.5 Li-Ion is designed to transport goods. It can lift open-
bottom or stringer-board pallets beyond the area above the load wheels, as well as
roll cages. The capacity is shown on the capacity plate, Qmax.
Z The truck is designed for light-duty applications; the maximum battery charge at
PTE 1.1 Li-Ion is approx. 2,5 hours and at PTE 1.5 Li-Ion is approx. 3,5 hours.
2 Truck models and rated capacity

The rated capacity can be derived from the model name.
PTE 1.1 Li-Ion / PTE 1.5 Li-Ion: 1100 / 1500 kg
The rated capacity does not generally match the permissible capacity. The capacity
can be found on the capacity plate attached to the truck.
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3 Travel direction definition
The following determinations have been made for travel direction specification:
2 3
Item Travel Direction

1 Left
2 Drive direction
3 Load direction
4 Right
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4 Assemblies and Functional Description
4.1 Assembly Overview
PTE 1.1 Li-Ion
7
8
9
10 11
12
13
14 15 16 17
Item Description Item Description

5 Collision safety switch 12 Cover for the hydraulic unit and
the electrical system
6 Charge status indicator 13 Drive unit
7 Magnetic lock 14 Bumper
8 Load wheels 15 Drive wheel
9 Tiller 16 Load section
10 Emergency disconnect switch 17 Load handler
11 Battery
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PTE 1.5 Li-Ion
11
18
19 8
9
10
12
13
14 15 16 17

5 Collision safety switch 14 Bumper
8 Load wheels 15 Drive wheel
9 Tiller 16 Load section
10 Emergency disconnect switch 17 Load handler
11 Battery 18 Keypad
12 Cover for the hydraulic unit and 19 Display unit
the electrical system
13 Drive unit
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4.2 Functional Description
PTE 1.1 Li-Ion: Magnetic lock
The truck is equipped with a magnetic lock that can be used to start the truck
immediately.
PTE 1.5 Li-Ion: Keypad
The truck is equipped with a keypad. The truck can only be started if the correct
access code is entered via the keypad. This prevents any unauthorised use of the
truck.
Safety equipment
An enclosed, smooth truck geometry with rounded edges ensures safe handling of
the truck. The wheels are surrounded by a solid skirt offering collision protection.
When released, a gas strut pushes the tiller up and activates braking.
When travelling in the drive direction in pedestrian mode, the red collision safety
switch changes the travel direction if the truck comes into contact with a person. The
truck brakes, travels away from the operator and stops. This prevents the truck
driving into the operator.
Activating the emergency disconnect switch rapidly cuts out all electrical functions in
hazardous situations.
Emergency disconnect switch
The truck is equipped with an emergency disconnect switch. When it is pressed, all
lifting and lowering operations are stopped and the fail-safe electromagnetic brake is
activated, see page 78.
Operator position
All travel and lift operations can be performed without having to reach.
Hydraulische Anlage
Pressing the “Lift” button starts the pump unit, supplying hydraulic oil from the oil
reservoir to the lift cylinder. The load handler is raised at even speed. Pressing the
“Lower” button lowers the load handler.
Drive system
An electric motor actuates the drive wheel directly. The electric traction controller
ensures smooth drive motor speed control and hence smooth travel, powerful
acceleration and electrically controlled braking.
Steering
The driver steers with an ergonomic tiller. The drive system can be pivoted +/- 90°.
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curveCONTROL (PTE 1.5 Li-Ion)
The curveCONTROL function assists the driver in operating the truck safely and with
due regard for the safety regulations. When cornering, the maximum travel speed is
adapted to the steer angle.
Electrical system
The truck has an electronic traction controller. The truck electrical system operates
with a rated operating voltage of 24 V.
Controls and displays
Ergonomic controls ensure fatigue-free operation for sensitive application of the

travel and hydraulic operations.
The display unit shows the operator key information such as operating hours, battery
capacity and event messages.
Service hours are counted while the truck is operational and one of the following
operations is performed:
– Lifting
– Lowering
– Travel
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5 Technical Specifications
Z Technical data specified in accordance with VDI 2198.

Technical modifications and additions reserved.
5.1 Dimensions
PTE 1.1 Li-Ion

h14
c Q
628
h3
m2
144 y h13
l1
l2 l
100 x
e
b11
b1
800
b5
Wa
1200
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Ast
21
PTE 1.1 Li-Ion
Designation
520 x 1150 685 x 1150
c Load centre distance with standard fork
600 mm
length
x Load distance 942 mm
y Wheelbase 1185 mm
b10 Track width, front 420 mm
b11 Track width, rear 360 525 mm
h3 Lift 115 mm
h14 Tiller height in the travel position min./
700/1160 mm
max.
h13 Load handler lowered 80 mm
l1 Overall length 1537 mm
l2 Length to fork face 387 mm
b1 Fork width 520 685 mm
s/e/l Fork dimensions 48/160/1150 mm
b5 Width across forks 520 685 mm
m2 Ground clearance, centre of wheelbase 32 mm
Ast Working aisle width, pallets 800x1200
2007 mm
length
Wa Turning radius 1337 mm
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PTE 1.5 Li-Ion
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PTE 1.5 Li-Ion
Description
540x1150 685x1150
c Load centre distance with standard fork
600 mm
length
x Load distance 947 mm
y Wheelbase 1185 mm
b10 Track width, front 420 mm
b11 Track width, rear 380 525 mm
h3 Lift 115 mm
h14 Tiller height in the travel position min./
700/1160 mm
max.
h13 Load handler lowered 80 mm
l1 Overall length 1530 mm
l2 Length to fork face 380 mm
b1 Fork width 540 685 mm
s/e/l Fork dimensions 47/160/1150 mm
b5 Width across forks 540 685 mm
m2 Ground clearance, centre of wheelbase 33 mm
Ast Working aisle width, pallets 800x1200
2000 mm
length
Wa Turning radius 1330 mm
5.2 Performance data

Designation PTE 1.1 Li-Ion PTE 1.5 Li-Ion
Rated capacity Q 1100 1500 kg
Travel speed 4.6/4.8 4.6/4.8 km/h
with/without rated load
Lift speed 0.031/0.037 0.020/0.025 m/s
Lowering speed 0.069/0.051 0.05/0.04 m/s
Drive motor S2 60 min 0.65 kW
Lift motor S3 15% 0.50 kW
Max. gradeability 4/16 6/16 %
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5.3 Battery
The battery used in this truck is a lithium-ion model. This is an environmentally
friendly battery without chemical mercury or cadmium.
The truck must only be operated with an approved lithium-ion battery.
Technical parameter Battery specification

24 V 20 Ah 1) 24 V 36 Ah 2)
Nominal voltage 24 V
Rated capacity 1) 20 Ah 36 Ah
Weight 5,0 kg 7,0 kg
Dimensions 380 x 250 x 71 mm
Standard charging current 5A 8A
Charging temperature +5 °C to +40 °C
Discharge temperature -20°C 3) to +50°C
Storage temperature range +5 °C to +40 °C
1)Standard for the PTE 1.1 Li-Ion. For the PTE 1.5 Li-Ion, only available in the APEC
region (Asia-Pacific Economic Cooperation).
2) PTE 1.5 Li-Ion only
3) Briefly up to 30 minutes
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5.4 Battery charger
Model Specification Input Output
SSLC165V29 1) 24 V 180 V AC - 240 V AC 29.4 V
5A ~ 3.0 A max 5.0 A
24 V 180 V AC - 240 V AC 29.4 V
SSLC300V29 2)
8 A (EU) ~ 3.0 A max 8.0 A
1) For PTE 1.1 Li-Ion

2) For PTE 1.5 Li-Ion
The permissible temperature range for charging the battery is between +5 °C and
+40 °C.
5.5 Weights
PTE 1.1 Li-Ion
Designation
520 x 1150 685 x 1150
Net weight 124 129 kg
Axle load, laden
355/972 425/908 kg
front/rear
Axle load without
load 101/27 106/27 m/s
front/rear
PTE 1.5 Li-Ion

Description
540 x 1150 685 x 1150
Net weight 123 126 kg
Axle load, laden
623/1000 626/1000 kg
front/rear
Axle load without
load 96/27 99/27 m/s
front/rear
5.6 Tyre type

PTE 1.1 Li-Ion /
Description
PTE 1.5 Li-Ion
Tyre size, front ø 210x70 mm
Tyre size, rear ø 80x93 (ø 80x70) mm
Additional wheels (dimensions) ø 80x30 mm
Wheels 1x / 2(1x/4) or
Number front / rear (x = driven) 1x +2 / 2(x +2/4)
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5.7 EN norms
Continuous sound pressure level
– PTE 1.1 Li-Ion / PTE 1.5 Li-Ion: < 70 dB(A)

in accordance with EN 12053 as harmonised with ISO 4871.
Z The continuous sound pressure level is calculated according to standard procedures

and takes into account the sound pressure level when travelling, lifting and idling.
The sound pressure level is measured at the operator's ear.
Z Noise levels can fluctuate depending on the floor composition and wheel lining.
Electromagnetic compatibility (EMC)
The manufacturer confirms that the truck adheres to the limits for electromagnetic
emissions and resistance as well as the static electricity discharge test in
accordance with EN 12895 as well as the standardised instructions contained
therein.
Z No changes to electric or electronic components or their arrangement may be made

without the written agreement of the manufacturer.
WARNING!
Damage to medical equipment due to non-ionising radiation
Electrical equipment on the truck carrier emitting non-ionising radiation (e.g. wireless
data transmission) can affect operators' medical equipment (pacemakers, hearing
aids Etc.) and result in malfunctions. Consult a doctor or the manufacturer of the
medical equipment to clarify whether it can be used near the industrial truck.
5.8 Electrical Requirements

The manufacturer certifies compliance with the requirements for the design and
manufacture of electrical equipment, according to EN 1175 "Industrial Truck Safety -
Electrical Requirements", provided the truck is used according to its purpose.
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6 Identification points and data plates
PTE 1.1 Li-Ion
Type XXX XX Option xx X xxxx
Serial No. XXXXX Year of Manuf. MM/YYYY

Load center
Rated capacity XXXX kg distance XXX mm
System voltage XX V Nominal power XXX kW
20
Net weight Battery mass
XXX kg XXX /XXX kg
without battery min/max
23 21 24 22 26 25
XXXX XXXC
XXXXXXXX xx
XXXXX / XXXXX
26
xxxx
27
28

20 Data plate 25 Decal: "Add hydraulic oil"
21 Sign: "Risk of trapping" 26 Serial number
22 Attachment point 27 Sign: "Capacity Qmax"
23 Sign: "Observe operating 28 Sign: "Observe the operating
instructions" instructions before performing
maintenance work"
24 Prohibition plate: "No
passengers"
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PTE 1.5 Li-Ion
Type XXX XX Option xx X xxxx
Serial No. XXXXX Year of Manuf. MM/YYYY

Load center
Rated capacity XXXX kg distance XXX mm
System voltage XX V Nominal power XXX kW

XXX kg XXX /XXX kg
without battery min/max
23 24 22 20 26 25
XXXX XXXC
XXXXXXXX xx
XXXXX / XXXXX
xxxx
27

20 Data plate 25 Decal: "Add hydraulic oil"
22 Attachment point 26 Serial number
23 Sign: "Observe operating 27 Sign: "Capacity Qmax"
instructions"
24 Prohibition plate: "No
passengers"
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6.1 Data plate
29 Type XXX XX Option xx X xxxx 30

31 Serial No. XXXXX Year of Manuf. MM/YYYY 32
Load center
33 Rated capacity XXXX kg distance XXX mm 34
35 System voltage XX V Nominal power XXX kW 36
37 without battery
XXX kg
min/max
XXX /XXX kg 38
39 XXXX XXXC 40
XXXXXXXX xx
XXXXX / XXXXX

29 Type 35 Battery voltage [V]
30 Option 36 Rated power [kW]
31 Serial number 37 Net weight excl. battery [kg]
32 Year of manufacture 38 Min./max. battery weight [kg]
33 Rated capacity [kg] 39 Manufacturer and manufacturer
address
34 Load centre distance [mm] 40 CE mark
Z For queries regarding the truck or when ordering spare parts, always quote the serial
number (31).
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C Transport and Commissioning
1 Lifting by crane
WARNING!
All persons involved in loading by crane must be trained
Incorrect crane loading procedures due to untrained personnel can cause the truck
to fall. There is a risk of injury to personnel and a risk of material damage to the
truck.
uLoading must only be performed by specialist personnel trained for this purpose.
The specialist personnel must be instructed in securing loads on road vehicles and
handling load securing devices. In each case correct measurements must be
taken and appropriate safety measures applied.
WARNING!
Improper loading by crane can result in accidents
Improper use or use of unsuitable lifting gear can cause the truck to fall when being
loaded by crane.
uPrevent the truck from hitting other objects during lifting, and avoid uncontrolled
movements. If necessary, secure the truck with guide ropes.
uLoading by crane may only be performed by persons who have been trained in the
use of the lifting accessories.
uWear personal protective equipment (e.g. safety shoes, hard hat, hi-vis jacket,
protective gloves) when loading by crane.
uDo not stand under suspended loads.
uDo not enter or stand in the hazardous area.
uAlways use lifting gear with sufficient capacity (observed truck weight in
accordance with truck data plate – see page 30).
uAlways secure crane lifting gear to the prescribed attachment points and prevent it
from slipping.
uUse the lifting accessories only in the prescribed load direction.
uLifting slings should be fastened in such a way that they do not come into contact
with any attachments when lifting.
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PTE 1.1 Li-Ion PTE 1.5 Li-Ion
41
41
Loading the truck by crane

Requirements
– Truck parked securely, see page 75.
Tools and Material Required
– Lifting gear
– Crane lifting gear
Procedure
• Attach the crane lifting gear to the attachment points (41).
The truck can now be loaded by crane.
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2 Transport
WARNING!
Uncontrolled movement during transport
Improper fastening of the truck and mast during transport can result in serious
accidents.
uLoading is only to be carried out by specially trained staff. The specialist personnel
must be instructed in the securing of loads on road vehicles and in the use of load-
securing equipment. When securing the truck, the appropriate measures must be
determined and applied for each individual case.
uThe truck must be securely fastened when transported on a lorry or a trailer.
uThe lorry or trailer must have lashing rings.
uUse wedges to prevent the truck from moving.
uUse only lashing straps with sufficient load rating.
uUse anti-slip material to secure loading aids (pallets, wedges,...), e. g. anti-slip
mats.
42
42
42
42
Securing the truck for transport

Requirements
– The truck is loaded.
– The truck is parked securely, see page 75.
– Lashing straps
Procedure
• Attach the lashing straps (42) to the industrial truck and the transport vehicle and
tension sufficiently.
The truck can now be transported.

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3 Using the Truck for the First Time
WARNING!
The use of unsuitable energy sources can be hazardous
Rectified AC current will damage the assemblies (controllers, sensors, motors etc.)
of the electronic system.
Unsuitable cable connections (too long, insufficient wire cross-section) to the battery
(tow cables) can overheat, setting the truck and battery on fire.
uThe truck must only be operated with battery current.
Procedure
• Check the truck for completeness, see page 17.
• Check the tiller, see page 36.
• If the tiller is fitted: verify correct assembly of all electrical and mechanical
components.
• If the tiller was supplied separately: Fit the tiller.
• Insert the battery, see page 62.
• Check the battery charge status, see page 57.
• Visual inspections and operations to be performed before starting daily operation,
see page 72.
The truck can now be started, see page 72.
Wheel flattening
If the truck has been parked for a long period, the wheel surfaces may tend to
flatten. This flattening has a negative effect on the safety and stability of the truck.
Once the truck has covered a certain distance, the flattening will disappear.
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4 Changing the Access Code
PTE 1.5 Li-Ion
1 2 18
3 4
X 43
Z The truck can only be started with the correct access code.
The truck is delivered with the access code 1234, which can be used for immediate
start. A new access code can be generated using the administrator password 3232.
The code is entered via the keypad (18).
Changing the access code

Requirements
Procedure
• Enter access code 3232 and press the RETURN key (43).
• Enter the previous access code and press the RETURN key.
• Enter the new access code and press the RETURN key.
The access code has been changed.
Resetting the access code

Requirements
Procedure
• Enter access code 123 and press the RETURN key.
• Enter access code 123 once more and press the RETURN key.
The access code has been reset to 1234.

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5 Mounting the tiller
Z If the tiller is supplied separately, the tiller must be installed by authorised and trained
personnel prior to commissioning.
44
9
45
46 46
Fitting the tiller

Requirements
– Circlip pliers
– Tyre lever
– Screwdriver, PH2
– The following materials are supplied with the truck:
– King pin (46)
– Retaining ring (44)
Procedure
• Position the tiller (9) vertically to the tiller mount (45) and fit the king pin (46).
• Secure the tiller in this vertical position until the gas strut has been fitted.
• Fit the retaining ring (44).
The tiller has been fitted and is ready for the gas strut assembly.
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47 45 47 48
Fitting the gas strut

Requirements
– Tiller has been fitted.
– Allen key, key width 6 mm
– Tyre lever
– Screw and washer for gas strut (48)
Procedure
• Use the tyre lever and the screwdriver to position the strut (47) such that the hole
on the strut (47) is aligned with the threaded hole on the tiller mount (45).
Z Risk of trapping: The gas strut is placed under tension during this process. Hold
the gas strut in this position until final assembly.
• Fit the gas strut with the screw and washer such that the front face of the screw
thread is flush with the outside of the tiller mount.
• Press the tiller down and check for freedom of movement.
• Test the function of the gas strut.
Z When the tiller is released, the gas strut must return the tiller to its vertical
position.
The gas strut has been fitted. The electrical connection of the tiller can be
established.
06.21 en-GB
37
49 50 49
Establishing the electrical connection of the tiller

Requirements
– The tiller and gas strut have been fitted.
– Plastic clamp (50) with screw and washer
Procedure
• Press the tiller (9) down and hold it in this position.
• Before assembly, align the plug connections (49) such that the arrows on both
parts are in line.
• Establish the connection (49).
• Align and install the plastic clamp (50) as shown.
The electrical connection has been established. The tiller assembly process is
completed.
06.21 en-GB
38
D Battery - Servicing, Recharging,
Replacement
1 Description of the lithium-ion battery
The lithium-ion battery is a battery with rechargeable high-performance energy cells.
The battery is designed for industrial trucks and can withstand heavy vibrations and
knocks.
The battery features special connections for charging and discharging in order to
prevent the use of incorrect batteries and chargers.
The battery has an intelligent battery management system, which includes safety
functions such as voltage, temperature detection, undervoltage, overvoltage,
overtemperature, overcurrent and short-circuit.
The internal resistance of the battery is very low, which minimises heat generation
and maximises the power available to the truck.
Temperatur range for using the battery
Optimum battery useful life is achieved at the battery temperatures of +5 °C to

+40 °C.
Low temperatures reduce the available battery capacity, high temperatures reduce
the batteries useful life.
50 °C is the maximum temperature for batteries, at which point the truck can be
operated.
Temperature differences on both sides of the battery must not exceed 5 °C.
Battery chargers
Only approved battery chargers must be used to charge the lithium-ion battery, see
page 26.
06.21 en-GB
39
2 Battery Decals
51
52
53
54
55
56

51 Sign: "Capacity and nominal 54 Safety information
voltage"
52 Data plate 55 Battery
53 Warning notice: "Avoid collision" 56 Serial number
06.21 en-GB
40
2.1 Battery data plate
XXXXX XX XXX XXXXXXX

57
xxVxxAh XXXXX XXXXXXXXX

Rate Voltage: xx V 35
Rate Capacity: xx Ah 58
Model: x-xxx-xx-xx-xxx 59
40
Battery Voltage: xx V - xx V 60
Weight: xx kg 61
Operation Temperature: xx°C - xx°C 62
63 Manufacturer: xxxx xxxxx xxxxxxxxx xxxxxxxxxxxxxxxxx

64 Adress: xxxxx xxxxxxxxxxxxx xxxxxxxxx xxx xxxx

35 Rated voltage 60 Voltage range
40 CE mark 61 Battery weight
57 Manufacturer logo and type 62 Operating temperature range
designation
58 Battery capacity 63 Battery manufacturer
59 Model designation 64 Manufacturer address
2.2 Battery serial number
65
YYMMDDxxxx
XXXXxxxx
66 67 68

65 Barcode 67 Month of manufacture
66 Year of manufacture 68 Day of manufacture
06.21 en-GB
41
3 Safety Instructions, Warning Indications and other Notes
3.1 Safety regulations for handling lithium-ion batteries
Do not carry out any repairs on the lithium-ion battery.
Replace defective lithium-ion battery by customer service.
WARNING!
Risk of electric shock and burning
Damaged and unsuitable cables can cause electric shocks and can overheat,
resulting in fires.
uAlways use mains cables with a maximum length of 30 m.
Local regulations must be observed.
uUnwind the cable reel fully when using it.
uAlways use original manufacturer’s mains cables.
uInsulation safety, acid and caustic ratings must comply with the manufacturer's
mains lead.
uThe charging connector must be dry and clean when used.
WARNING!
Unsuitable batteries that have not been approved by the manufacturer for the
truck can be hazardous
The design, weight and dimensions of the battery have a considerable effect on the
operational safety of the truck, in particular its stability and capacity. The use of
unsuitable batteries that have not been approved for the truck by the manufacturer,
can lead to a deterioration of the braking characteristics of the truck during energy
recovery, causing considerable damage to the electric controller and resulting in
serious danger to the health and safety of individuals.
uOnly manufacturer-approved batteries may be used on the truck.
uBattery equipment may only be replaced with the agreement of the manufacturer.
uWhen replacing/installing the battery make sure the battery is securely located in
the battery compartment of the truck.
uDo not use batteries that have not been approved by the manufacturer.
WARNING!
Any damage and other defects to the charger can result in accidents.
If any safety-related modifications, damage or other defects are discovered on the
charger or during operation, the charger must be taken out of service until it has
been repaired.
uReport any defects immediately to your supervisor.
uTag out and decommission a faulty charger.
uOnly return the charger to service when you have identified and rectified the fault.
06.21 en-GB
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NOTICE
Risk of material damage due to improper charging
Improper use of external charger can cause material damage
uIt is necessary to apply the lithium-ion charger of our company.
uThe operation voltage of the charger is 24 V; the maximum charging voltage is
29,4 V, the charging current is 5,0 / 8,0 A.
uThe charger must only be used for batteries supplied by the manufacturer or other
approved batteries provided it has been adapted by the manufacturer’s service
department.
uReverse charge of the battery is prohibited.
uIf the battery is heated obviously during charging, stop charging immediately.
Charge again after it has been cooled down.
uHold the puller when pulling the connectors. It is not allowed to pull the wires
directly.
NOTICE
Intermediate charging of the lithium-ion battery
Lithium-ion battery intermediate charging is possible. A battery that is not fully
discharged can be partially or fully charged at any time.
uThe lithium-ion battery must be fully charged before first use.
uTo ensure reliable operation, a lithium-ion battery that undergoes frequent
intermediate charging must be fully charged at least once a week.
uTurn off the battery charger before disconnecting the lithium-ion battery from the
battery charger.
06.21 en-GB
43
3.2 Potential hazards
No hazards are anticipated if the equipment is used correctly.
The following hazards can arise in the event of improper use:
– Physical damage:
This can occur if a battery falls or is deformed through pressure (e.g. truck forks
penetrate the battery housing).
Mechanical damage includes cracks, breakage, splinters or holes in the battery
housing. This type of damage may be caused by a short circuit inside the battery,
which may result in harmful materials leaking, fire or battery explosion.
– Short circuits:
These may be caused by connecting the two battery terminals (e.g. battery
immersed in water)
– Temperature effects:
High temperatures caused for example by sunlight or being store in warm
locations (e.g. near ovens) can result in harmful materials leaking, fire or battery
explosion.
In order to avoid fire, explosion and leakage of harmful materials, a safe place for
storing batteries until the manufacturer's customer service department arrives on site
must satisfy the following criteria:
– Do not store in places often frequented by personnel.
– Do not store in places where valuable objects (e.g. cars) are stored.
– A PM12i burning metal fire extinguisher or a Co2 fire extinguisher must be
available to put out any fires.
– There should not be any fire or smoke detectors in the vicinity in order to ensure
that an automatic fire detection system is only activated in the event of actual
danger (e.g. naked flames).
– Small amounts of discharge from a single battery are not critical to the
environment. Above-average natural ventilation is required in this case.
– No ventilation intake pipes should be in the vicinity, as discharged content could
spread within a building.
Examples of where to store a non-functional battery:
– Roofed outdoor position.

– Ventilated container.
– Covered box with pressure and smoke discharge option.
06.21 en-GB
44
3.2.1 Symbols - Safety and Warnings
Used lithium-ion batteries must be treated as hazardous waste.

Lithium-ion batteries marked with the recycling symbol and the sign showing a
crossed-out waste bin must not be disposed of with ordinary household waste.
Buy-back terms and type of recycling are to be agreed with the manufacturer in
example to accordance with the Battery Directive 2006/66/EG, for example.
Avoid fire and short circuits due to overheating.

Do not ignite or position an open flame, glowing embers, or sparks near the
lithium-ion battery.
Keep lithium-ion batteries away from strong heat sources.
Hot surfaces.
Battery cells can generate very high short-circuit currents, causing them to
become hot.
Dangerous electrical voltage!
Battery cells can generate very high short-circuit currents, causing them to
become hot.
Caution!
The metal parts of the battery cells are constantly under voltage, so do not
place any foreign objects or tools on the lithium-ion battery.
Observe the accident prevention regulations and EN 50272-3.
Wear personal protective equipment (e.g. safety goggles and safety gloves)
when handling damaged battery cells and lithium-ion batteries. Use only
insulated tools.
If the contents leak out, do not inhale the fumes.
Always wash your hands after completing the work.
Do not mechanically machine the lithium-ion battery, strike, crush, compress,
notch, dent or modify it in any way.
Do not open, damage, penetrate, bend, heat the lithium-ion battery or allow it to
become hot, do not throw it into a fire, short circuit it or immerse it in water. Do
not store it or operate it in pressurised containers.
Follow the operating instructions and keep them in a visible position in the
charging area.
If any faults are found on the lithium-ion battery, contact the manufacturer's
customer service department immediately.
Do not carry out any actions on your own.
Do not open the lithium-ion battery.
Protect the lithium-ion battery from solar radiation or other forms of heat
radiation.
+ -
Do not expose the lithium-ion battery to heat sources.
06.21 en-GB
45
3.2.2 Marking of packages with lithium-ion batteries
The lithium-ion battery is a hazardous material. The applicable ADR regulations

must be observed during transport.
Z ADR = Accord européen relatif au transport international des marchandises

Dangereuses par Route
69
70
UN 3171
Item Description
69 Danger label class 9A for lithium-ion batteries
Marking of packages with lithium-ion batteries in accordance with the
70 dangerous goods regulations GGVS/ADR appendix 9 for the transport of
hazardous goods
06.21 en-GB
46
3.2.3 Explosion and fire hazard
WARNING!
Physical damage, thermal effects or incorrect storage in the event of a defect can
result in explosions or fire.
The battery materials can be flammable.
06.21 en-GB
47
3.2.3.1 Particular hazard from combustion products
The lithium ion battery may be damaged by a fire in the vicinity of the lithium ion
battery. When fighting a lithium-ion battery fire, the following dangers and information
must be taken into consideration.
WARNING!
Risk due to contact with combustion products
Combustion is a chemical process by which a flammable material combines with
oxygen under heat and light (fire). The resulting combustion products can occur in
the form of smoke, through leaking fluids, escaping gases, debris as well
decomposition products of certain chemicals. These combustion products are
substances that enter the body through the respiratory tract or skin, where they can
produce adverse effects such as choking.
uAvoid contact with combustion products.
uUse protective equipment.
– Hydrogen fluoride (HF) Hydrofluoric acid = extremely corrosive

– Risk of toxic substances produced by pyrolysis
– Risk of highly flammable gas mixtures.
– Other combustion products: Carbon monoxide & -dioxide, manganese, nickel and
cobalt oxides.
06.21 en-GB
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3.2.3.2 Special fire fighting protective equipment
– Use self-contained breathing apparatus.
– Wear protective overalls.
3.2.3.3 Additional fire fighting instructions
To prevent secondary fires from occurring, the lithium-ion battery must be cooled
from the outside. Fluids or solids must never be directed into the lithium-ion battery.
Suitable extinguishing agents

– Carbon dioxide extinguisher (CO2)
– Water (not on mechanically opened or damaged batteries!)
Unsuitable extinguishing agents
– Foam
– Grease fire extinguishing agents
– Powder extinguishers
– Metal fire extinguishers (PM 12i extinguishers)
– Metal fire powder PL-9/78 (DIN EN 3SP-44/95)
– Dry sand
3.2.3.4 Instructions for cooling an overheated, non physically damaged battery
This type of damage may be caused by a short circuit inside the battery, which may
result in harmful materials leaking, fire or battery explosion.
Endangered unopened batteries can be cooled using a water
jet.
06.21 en-GB
49
3.2.4 Material discharge
WARNING!
Risk due to electrolyte fluid escaping from the battery
Electrolyte fluid can escape from the battery if it suffers mechanical damage.
Electrolyte fluid is hazardous to health. If the electrolyte fluid comes into contact with
the skin or eyes, this can result in chemical burns and visual impairment. Inhaling the
contents of electrolyte fluid can lead to respiratory illness.
uIn the case of contact with the skin or eyes, rinse the affected areas with plenty of
water and seek medical assistance immediately.
uIf contents have been inhaled, seek medical assistance immediately. The affected
person should also be taken to the fresh air.
uCordon off the affected area.
uEnsure there is adequate ventilation.
uRemain upwind of the area.
uKeep persons away.
3.2.4.1 Precautionary measures for personnel

– Keep personnel away and facing the wind.
– Block off the affected area.
– Ensure there is adequate ventilation.
– Wear personal protective equipment.
– If vapours / dust / aerosols are present, use self-contained
breathing apparatus.
3.2.4.2 Precautionary measures for the environment
Do not allow spilled fluids to enter the water system, drainage system or the
underground
water.
3.2.4.3 Cleaning measures
The leaked fluid must be removed professionally by the operating company on the
basis of a risk assessment and disposed of in the correct manner. The fire brigade,
the Agency for Technical Relief or similar institutions must be used. Absorb residues
with liquid-absorbent material (such as vermiculite, sand, universal binders and
pebble grain).
06.21 en-GB
50
3.2.5 Touch voltage hazard
WARNING!
Risk of Accident due to Contact Voltage
Hazardous contact voltages may occur in the event of a technical or mechanical
defect on the battery. This may also be the case on an apparently discharged
battery.
uTag out the faulty battery and take out of service.
uDo not touch faulty batteries and do not allow them to come into contact with
metallic objects – see page 44.
uNotify the customer service department.
With this kind of defect the battery must not be touched and must not come into
contact with metal objects see page 44.
3.3 Battery lifetime and maintenance

The lithium-ion battery is wear-free. The components are maintenance-free, as a
result there are no maintenance intervals planned for this battery.
06.21 en-GB
51
3.4 Charging the battery
DANGER!
Explosion risk when charging unsuitable battery types
Charging a battery that is not suitable for this charger can result in damage to the
charger and battery. The battery could expand or burst.
uThe lithium-ion battery must only be charged with the battery charger provided for
this battery.
WARNING!
Warning: hazardous electrical voltage!
The charger is an electric component conducting voltages and currents that are
hazardous to people.
uThe charger must only be operated by trained technicians.
uDisconnect the mains supply and the battery connector before carrying out any
work on the charger.
uThe charger should only be opened and serviced by trained electricians.
WARNING!
The use of a different charger can result in overheating, fire or a battery explosion.
NOTICE
Full discharge can damage the battery
Self-discharge can cause the battery to fully discharge. Full discharge shortens the
service life of the battery.
uBefore a long period of inactivity, the battery must be fully charged.
uCharge the battery at least every 12 weeks, see page 52.
Z If the battery is deeply discharged or if the battery temperature is below the

permissible level (+5 °C), the battery will not charge. Deeply discharged batteries
cannot be charged by the operator (faulty). Contact the manufacturer's customer
service department.
Z Due to the risk of condensate formation, batteries that have been stored at
temperatures below +5 °C must only be charged after spending at least 4 hours in a
warm environment.
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3.5 Storage / safe handling / faults
3.5.1 Storing the battery
NOTICE
Discharge can damage the battery
If the battery is not used for a long period of time, it can become damaged through
discharge.
uTo ensure a long battery life, we recommend checking and charging the battery
every 4 weeks when it is not being used.
The temperature range for storing the battery is +5 °C to +40 °C.
3.5.2 Instructions for safe handling
NOTICE
New lithium-ion batteries are transported and stored with a charge status of at least
<100 %.
– Do not physically machine or modify the battery.

– Do not open, damage, penetrate or bend the battery.
– Do not throw the battery into a fire.
– Protect the battery from high temperatures and overheating.
– Protect the battery from solar irradiation.
– Keep the battery away from radiant sources and strong heat sources.
– The specified charging, operating and storage temperature ranges must be
observed.
Failure to comply with these safety instructions can result in fire and explosion or the
leakage of harmful materials.
3.5.3 Faults
If any damage is found to the battery or battery charger contact the manufacturer's
customer service department immediately. The operating company must not carry
out any remedial work on its own.
Independent attempts to tamper with or repair the battery may invalidate the
warranty. A service agreement with the manufacturer will help identify faults.
WARNING!
Do not open the battery.
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3.6 Disposal and transport of a lithium-ion battery
3.6.1 Instructions for disposal
NOTICE
Lithium-ion batteries must be disposed of in accordance with the relevant national
environmental protection regulations.
uFor lithium-ion battery disposal, contact the manufacturer's customer service
department.
Used lithium-ion batteries are recyclable commodities. These batteries must be

treated as hazardous waste.
Lithium-ion batteries marked with the recycling symbol and the sign showing a
crossed-out waste bin must not be disposed of with ordinary household waste.
Return or recycling of batteries must be ensured, for example, in accordance with

the Battery Directive 2006/66/EG. Buy-back terms and the manner of recycling must
be agreed with the manufacturer.
06.21 en-GB
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3.6.2 Shipping information
The lithium-ion battery is a hazardous material. The applicable ADR regulations

must be observed during transport.
Z ADR = Accord européen relatif au transport international des marchandises

Dangereuses par Route
3.6.2.1 Shipping functional batteries

Functioning batteries can be shipped in accordance with the following regulations:
Classification according to UN 3480 lithium-ion battery class 9

ADR (road transport)
- Classification code M4 lithium battery
- Danger label
UN 3480
LITHIUM-IONEN-BATTERIEN
- ADR limited quantity LQ:0
IMDG classification (sea UN 3480 lithium-ion battery class 9

transport)
- EMS F-A, S-I
- Danger label
UN 3480
- IMDG limited quantity LQ: -

06.21 en-GB
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IATA classification (air UN 3480 lithium-ion battery class 9
transport)
- Danger label
UN 3480
Exposure scenario Not specified.

Substance safety rating Not specified.
Product does not require marking under EC Directive /
Marking
HazMatR.
NOTICE
New lithium-ion batteries are transported with a charge status of at least <100 %.
3.6.2.2 Shipping faulty batteries

To transport these faulty lithium-ion batteries, contact the manufacturer's customer
service department. Faulty lithium-ion batteries must not be transported
independently.
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4 Charging the battery
4.1 Correct Use and Application
The operating instructions are a major component of the charger.
The owner shall ensure that the operating instructions are kept permanently in the
vicinity of the charger, and that operating personnel shall be aware of the guidelines
mentioned in the instructions.
The owner shall add further instructions regarding national accident prevention and
environmental protection regulations to the operating instructions, including
information on supervisory and reporting obligations, taking into account particular
company practices e.g. in terms of work organization, work processes and the
personnel employed.
Apart from the operating instructions and the current accident prevention regulations
in force in the country and place of use, generally recognised technical regulations
for safe and proper use shall be observed.
Charging the battery
Z The lithium-ion battery may only be charged with an approved charger within the
permissible temperature range,see page 25.
The truck should not be stored without battery compensation charge for more than
12 weeks.
NOTICE
Damage to the lithium-ion battery due to improper connection
Unsuitable connector plugs of industrial trucks or battery chargers used with the
lithium-ion battery can damage the battery connector.
uOperate the lithium-ion battery only with appropriate trucks and battery chargers.
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4.2 Charge Status Indicator
PTE 1.1 Li-Ion
71
72 73 74 75
The charge status indicator (6) is located on the tiller head (71). The charge status is
indicated by four LEDs of different colour, which mean the following:
Item LED Charge status

72 Green LED lit 75% to 100%
73 Blue LED lit 50 % to 75 %
74 Yellow LED lit 25 % to 50%
75 Red LED lit 0 % to 25%
PTE 1.5 Li-Ion
0% 100%
1 2
3 4
19 X
0% 100%
71
The charge status indicator of the battery is integrated in the display unit (19) on the
06.21 en-GB
tiller head (71).
The charge status is displayed in ten increments. Each is represented by a rectangle

that corresponds to 10% of the battery charge.
58
The rectangles gradually disappear as the battery discharges. Special statuses
appear in the display unit as error codes.
Code The error code appears if ... Effect

0 The battery charge is too low. Lift function is deactivated.
91 Operation of the truck continues Travel speed is reduced.
without first charging the battery.
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4.3 Charging the Battery with External Charger
Maintenance personnel
Batteries may only be charged, serviced or replaced by trained personnel. These

operating instructions and the battery manufacturer's instructions must be observed
when performing these operations.
Park the truck securely before carrying out any work on the batteries (see page 75).
General information
Z The charge status of the battery is indicated by LEDs on the battery charger.
Z The charging time depends on the battery charge status. The time it takes to charge
an almost fully depleted battery depends both on the battery capacity and the charge
current. The approximate duration can be calculated as follows:
Charging time = capacity of battery / charge current of battery charger.
Z The lithium-ion battery can also be used when not fully charged. In this case, the
remaining operating time is reduced.
Z Charging continues automatically after a mains failure. Charging can be interrupted

by pulling out the mains connector and continued as a partial charge.
NOTICE
The battery temperature rises by approx. 13 °C during charging. Battery charging
should only start when the battery temperature is below 50 °C. The battery
temperature before charging should be at least +5 °C as otherwise it will affect the
charge.
Meaning of the LEDs on the battery charger
When the battery charger is connected to the battery and to the power supply, the
LEDs on the charger indicate the following:
LED lit Meaning

Green The battery is fully charged
Red Battery is charging
If the green LED does not light up or if the red LED lights up permanently or not at
all, this indicates a fault, see page 88.
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76 77 78
79
79 76 11 77 78
11
Z The graphic shows the PTE 1.1 Li-Ion as an example.
Charging the battery

Requirements
– The battery charger is approved for the battery type, see page 26.
– Battery charger
Procedure
• Expose the charging socket (79) of the battery and start by connecting it to the
charge connector (76) of the battery charger (77).
• Then connect the mains plug (78) of the battery charger (77) to the power supply.
Z The charging process is indicated by the illumination of the red LED.

• Check the charge status; also refer to the instructions on the battery charger (77).
Z The charging process is completed when the green LED lights up.
• Once the battery (11) is charged, disconnect the battery charger (77) from the
power supply before unplugging it from the battery.
• Close the charging socket (79)with the cap.
Battery is charged.
Z Alternatively, the battery can also be charged outside the truck, see page 62. The
process for charging the battery remains the same.
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5 Battery removal and installation
5.1 Removing the battery
80
81
11
Removing the battery

Requirements
– The emergency disconnect switch is actuated, see page 78.
Procedure
• Unlock the battery latch (80).
• Lift the battery (11) up by the battery handle (81).
The battery has been removed.

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5.2 Battery installation
80
11
82
Installing the battery

Requirements
Procedure
• Insert the battery (11) into the battery compartment.
Z The plug connection (82) between the battery and truck must be fully connected.
• Lock the battery latch (80).
• Release the emergency disconnect switch, see page 78.
The battery is now installed.

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64
06.21 en-GB
E Operation
1 Safety Regulations for the Operation of Forklift Trucks
Driver authorisation
The truck may only be used by suitably trained personnel, who have demonstrated
to the proprietor or his representative that they can drive and handle loads and have
been authorised to operate the truck by the proprietor or his representative.
Operator’s rights, responsibilities and rules of conduct
The driver must be informed of his duties and responsibilities and be instructed in
the operation of the truck and shall be familiar with the operating instructions. Safety
shoes must be worn on pedestrian-operated trucks.
Unauthorised use of truck
The operator is responsible for the truck during the time it is in use. The operator
must prevent unauthorised persons from driving or operating the truck. Do not carry
passengers or lift other people.
Damage and defects
The supervisor must be informed immediately of any damage or faults to the truck or
attachment. Trucks which are unsafe for operation (e.g. wheel or brake problems)
must not be used until they have been rectified.
Repairs
The operator must not carry out any repairs or alterations to the truck without
authorisation and the necessary training to do so. The operator must never disable
or adjust safety mechanisms or switches.
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65
Hazardous area
WARNING!
Risk of accidents/injury in the hazardous area of the truck
A hazardous area is defined as the area in which people are at risk due to travel or
lifting operations of the truck, its load handler or the load. This also includes the area
within reach of falling loads or lowering/falling operating equipment.
uInstruct unauthorised persons to leave the hazardous area.
uIn case of danger to third parties, give a warning signal in good time.
uIf unauthorised persons are still within the hazardous area, stop the truck
immediately.
Safety devices, warning signs and warning instructions
Safety devices, warning signs (see page 28) and warning instructions in the present
operating instructions must be strictly observed.
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2 Displays and Controls
2.1 Controls
PTE 1.1 Li-Ion
5
83
84
85 84
6 86
87
10
06.21 en-GB
67
Item Description Function
5 Collision safety switch Safety feature
When the collision safety switch is
activated, the truck travels a short
distance away from the operator in
load direction, thus protecting the
operator. The truck is then braked,
see page 19.
6 Charge status indicator Shows the battery charge status,
see page 58.
7 Magnetic lock Starts the truck – see page 73.
9 Tiller Steers the truck via corresponding
movements, see page 83.
10 Emergency disconnect switch Stops all electrical functions (travel,
lifting, lowering) and activates the
electromagnetic brake, see
page 78.
83 Warning signal button Activates an audible signal.
84 Travel switch Controls the travel direction and the
travel speed, see page 81.
85 Slow travel button Toggles between slow travel and
travel at normal speed. Switches to
slow travel when the tiller is in
vertical position, see page 82.
86 Lift button Raises the load handler, see
page 84.
87 Lower button Lowers the load handler, see
page 84.
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PTE 1.5 Li-Ion
5
83
84
85 84
86
18
1 2
3 4
X
87
19
10
06.21 en-GB
69
Item Description Function
5 Collision safety switch Safety feature
When the collision safety switch is
activated, the truck travels a short
distance away from the operator in
load direction, thus protecting the
operator. The truck is then braked,
see page 19.
9 Tiller Steers the truck via corresponding
movements, see page 83.
10 Emergency disconnect switch Stops all electrical functions (travel,
lifting, lowering) and activates the
electromagnetic brake, see
page 78.
18 Keypad Entry of access code for starting the
truck, see page 35.
19 Display unit Displays various truck data, see
page 71.
83 Warning signal button Activates an audible signal.
84 Travel switch Controls the travel direction and the
travel speed, see page 81.
85 Slow travel button Toggles between slow travel and
travel at normal speed. Switches to
slow travel when the tiller is in
vertical position, see page 82.
86 Lift button Raises the load handler, see
page 84.
87 Lower button Lowers the load handler, see
page 84.
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2.2 Display symbols
PTE 1.5 Li-Ion
0% 100%
6
1 2
3 4
X
19
88 89 90 91
Item Designation Function

6 Charge status indicator Shows the battery charge status –
see page 58.
19 Display unit Displays symbols for:
- Battery charge status
- Slow travel
- Hour meter
- Service and fault messages.
88 Hourglass Flashes when the hour meter is
active.
89 Tortoise Only appears when slow travel mode
is active.
90 Number field Displays operating hours or fault
codes.
91 Service symbol Only appears when scheduled
maintenance is required or if faults
exist.
Fault codes are displayed in the
number field.
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71
3 Starting up the truck
3.1 Checks and operations to be performed before starting daily
operation
WARNING!
Truck damage or defects can result in accidents
If damage or other truck defects are discovered during the following checks, the
truck must be taken out of service until it has been repaired.
uTag out the defective truck and take it out of service.
uDo not return the truck to service until you have identified and rectified the fault.
Inspection before daily operation
Requirements
Procedure
• Check the entire truck from the outside for damage and leaks.
• Check the load handler for visible signs of damage such as cracks, bent or
severely worn forks.
• Check the hydraulic system for leaks, see page 106.
• Check the battery attachment and cable connections for damage and make sure
they are secure.
• Check the drive wheel and load wheels for damage and freedom of movement,
see page 105.
• Check that the markings and labels are all present and legible, see page 28.
• Check that the controls automatically return to the neutral position after use, see
page 81.
• Switch on the truck, see page 72.
• Check the battery charge status, see page 58.
• Test the warning signal, see page 67.
• Test the brakes, see page 79.
• Test the travel functions, see page 81.
• Test the lifting and lowering functions, see page 84.
• Test the emergency disconnect switch, see page 78.
• Test the collision safety switch, see page 19.
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72
3.2 Preparing the truck for operation
PTE 1.1 Li-Ion
83
02
10
92
Switching on the truck

Requirements
– Checks and operations before starting daily work have been completed, see
page 72.
– Load is correctly palletised and secured, see page 84.
Procedure
• Release the emergency disconnect switch (10), see page 78.
• Insert the magnetic key (92) into the magnetic lock (7).
• Press the warning signal button (83).
The truck is ready for operation.

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73
PTE 1.5 Li-Ion
83
1 2
3 4 43
X
10
Switching on the truck

Requirements
– Checks and operations before starting daily work have been completed, see
page 72.
– Load is correctly palletised and secured, see page 84.
Procedure
• Release the emergency disconnect switch (10), see page 78.
• Switch on the truck. To do this:
• Enter the access code, see page 35.
• Press the RETURN key (43).
• Press the warning signal button (83).
The truck is ready for operation.

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74
3.3 Parking the truck securely
WARNING!
An unsecured truck can cause accidents
Parking the truck on an incline, without the brakes applied or with a raised load or
load handler is dangerous and is strictly prohibited.
uPark the truck on a level surface. In special cases the truck may need to be
secured with wedges.
uFully lower the load handler.
uSelect a place to park where no other people are at risk of injury from the lowered
load handler.
uIf the brakes are not working, place wedges underneath the wheels of the truck to
prevent it from moving.
9
10
15
Parking the truck securely

Procedure
• Park the truck on a level surface.
• Fully lower the load handler, see page 84.
• Turn the drive wheel (15) to the straight-ahead position using the tiller (9).
• Press the emergency disconnect switch (10).
Truck is parked securely.

06.21 en-GB
75
4 Industrial Truck Operation
4.1 Safety regulations for truck operation
Travel routes and work areas
Only use lanes and routes specifically designated for traffic. Unauthorised third
parties must stay away from work areas. The load may only be stored in the
designated locations.
The truck must only be operated in work areas with sufficient lighting to avoid danger
to personnel and materials.
DANGER!
Do not exceed the permissible surface and point loading on the travel lanes.
At blind spots get a second person to assist.
The driver must ensure that the loading dock /dock leveller cannot be removed or
come loose during loading/unloading.
Conduct while travelling
The operator must adapt the travel speed to local conditions. The operator must
drive slowly e.g. on corners and in narrow spaces, when driving through swinging
doors, in blind spots. The operator must always observe an adequate braking
distance between the forklift truck and the vehicle in front and must be in control of
the truck at all times. Abrupt stopping (except in emergencies), rapid U turns and
overtaking at dangerous or blind spots are not permitted.
Travel visibility
The operator must look in the direction of travel and must always have a clear view
of the route ahead. If the truck is carrying loads that affect visibility, the truck must
travel against the load direction. If this is not possible, a second person must walk
alongside the truck as a lookout to observe the travel route while maintaining eye
contact with the operator. Proceed only at walking pace and with particular care.
Stop the truck as soon as you lose eye contact.
Negotiating slopes and inclines
Negotiating slopes and inclines up to 16 % is only permitted when they are

recognised lanes. The slopes and inclines must be clean, have a non-slip surface,
and negotiating them safely must be within the technical specifications of the truck.
The truck must always be driven with the load facing uphill. The industrial truck must
not be turned, operated at an angle or parked on inclines or slopes. Inclines must
only be negotiated at slow speed, with the driver ready to brake at any moment.
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76
Negotiating lifts, loading ramps and docks
Lifts may only be negotiated if they have sufficient capacity, are suitable for driving
on and authorised for truck traffic by the owner. The driver must satisfy himself of the
above before entering these areas. The truck must enter lifts with the load in front
and must take up a position which does not allow it to come into contact with the
walls of the lift shaft. Persons riding in the lift with the forklift truck must only enter
the lift after the truck has come to a rest and must leave the lift before the truck. The
driver must ensure that the loading ramp / dock cannot move or come loose during
loading / unloading.
Type of loads to be carried
The operator must make sure that the load is in a satisfactory condition. Loads must
always be positioned safely and carefully. Use suitable precautions to prevent parts
of the load from tipping or falling down. Prevent liquid loads from sloshing out.
WARNING!
Electromagnetic influence can result in accidents
Strong magnets can cause electronic components such as Hall sensors to become
damaged, resulting in accidents.
uDo not use magnets in the operating area of the truck. Exceptions to this rule are
commercial, weak clamping magnets for attaching notices.
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77
4.2 Emergency Disconnect
10
Pressing the Emergency Disconnect switch

Procedure
• Press the Emergency Disconnect (10).
All electrical functions are deactivated. The truck brakes to a halt at maximum brake
force.
Releasing the emergency disconnect switch

Procedure
• Turn the emergency disconnect switch (10) to unlock it.
All electrical functions are enabled and the truck is operational again (assuming the
truck was operational before the emergency disconnect switch was pressed).
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78
4.3 Brakes
WARNING!
Risk of collision due to a defective tiller
Operating the truck with a defective tiller can lead to collisions with persons or
objects.
uIf the tiller returns to the brake position slowly or not at all, the truck must be taken
out of service until the cause of this fault is be rectified.
uContact the manufacturer's customer service department.
84 5
84
10
The braking behaviour of the truck largely depends on the ground conditions and the
truck load. The operator must take this into account.
06.21 en-GB
79
The truck can brake in different ways:
Braking type
Action Effect
Service brake
Set the travel switch (84) to the The regenerative brake is activated.
neutral "0" position. The truck brakes to a halt.
Travel switch reverse
Turn the travel switch (84) in the The regenerative brake is activated.
opposite direction. The truck brakes and begins travelling
in the opposite direction.
Coasting brake
Move the tiller (9) to the brake zone The truck brakes to a halt.
"B".
Z When the tiller is released, it
automatically returns to vertical
position.
Safety brake
Operate the collision safety switch (5). The truck brakes and travels a short
distance in the opposite direction to
Z This function is also active if protect the operator.
the truck is stationary and the
tiller is in the travel zone "F".
Emergency brake
Press the emergency disconnect The truck brakes to a halt at the
switch (10). maximum rate.
Z Only do this in an emergency,
as damage to the drive wheel
may occur.
06.21 en-GB
80
4.4 Travel
WARNING!
Risk of injury or trapping from the truck
Be extremely careful when driving and steering, especially if parts of your body
extend beyond the truck. The operator's legs and feet could get injured or trapped.
uWear personal protective equipment (e.g. safety shoes, ...).
uIn pedestrian mode make sure you have sufficient distance from the truck.
uMake sure there is nobody between the truck and any obstacles.
84
84
A L
Requirements
– Commissioning carried out – see page 72.
Procedure
• Set the tiller (9) to the travel zone (F).
• Control the travel direction with the travel switch (84):
• Slowly turn the travel switch in the load direction (L):
Travel in load direction.
• Slowly turn the travel switch in the drive direction (A):
Travel in drive direction.
• Control the travel speed with the travel switch (84):
• The further the travel switch is turned, the higher the speed.
The brake is released and the truck moves in the selected direction.
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81
4.5 Slow travel
84 84
85 85
1 2
3 4
19
9
0% 100%
93
75
Operating the truck at slow speed

Requirements
– Truck prepared for operation, see page 73.
Procedure
• Slow travel with tiller (9) in travel zone "F":
• Press the slow travel button (85).
• Press the travel switch (84) in the desired direction.
• Press the slow travel button again to resume travelling at normal speed.
• Slow travel with tiller (9) in vertical position in confined spaces:
• Press the slow travel button (85) for approx. 2 seconds.
• Press the travel switch (84) in the desired direction.
• Press the slow travel button again to resume travelling at normal speed.
The truck can be steered with precision at slow speed and in tight spaces.
Z PTE 1.1 Li-Ion: Slow travel is indicated by illumination of the red LED (75).
Z PTE 1.5 Li-Ion: Slow travel is indicated on the display unit (19) by the tortoise symbol
(93).
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82
4.6 Steering
Procedure
• Move the tiller (9) to the left or right.
The truck is steered in the required direction.

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83
4.7 Lifting, transporting and depositing loads
WARNING!
Unsecured and incorrectly positioned loads can cause accidents
Before lifting a load unit, the driver must make sure that it has been correctly
palletised and does not exceed the truck’s capacity.
uInstruct other people to move out of the hazardous area of the truck. Stop working
with the truck if people do not leave the hazardous area.
uOnly carry loads that have been correctly secured and positioned. Use suitable
precautions to prevent parts of the load from tipping or falling down.
uDamaged loads must not be transported.
uNever exceed the maximum loads specified on the load chart.
uDo not stand on the load handler.
uDo not lift other people on the load handler.
uInsert the load handler as far as possible underneath the load.
CAUTION!
uDo not lift longitudinal goods (e.g. pipes) from the side.
NOTICE
Adapt a slower speed when stacking and retrieving.
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84
4.7.1 Raising a load
86
87
Requirements
– Load correctly palletised.
– Load weight matches the truck's capacity.
– Forks evenly loaded for heavy loads.
Procedure
• Drive the truck carefully up to the pallet.
• Slowly insert the forks into the pallet until the fork shank touches the pallet.
Z The load must not extend by more than 50 mm beyond the fork tips.
• Press the “Lift” button (86) button until you reach the desired lift height.
The load is raised.
CAUTION!
Release the button as soon as the load handler reaches its end stop.
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85
4.7.2 Transporting a load
Last transportieren
Requirements
– Last ordnungsgemäß aufgenommen.
– Einwandfreie Bodenbeschaffenheit.
Procedure
• Accelerate and decelerate with care.
• Adapt your travel speed to the conditions of the route and the load you are
transporting.
• Travel at a constant speed.
• Be prepared to brake at all times.
• Brake gently in normal circumstances.
• Only stop abruptly in hazardous situations.
• Watch out for other traffic at crossings and passageways.
• You must use a lookout at blind spots.
• Do not travel across or at an angle on inclines. Do not turn on slopes and inclines,
and always drive with the load facing uphill.
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86
4.7.3 Depositing a load
86
87
CAUTION!
Loads must not be deposited on traffic lanes or escape routes, in front of safety
equipment or in front of operating equipment that must be accessible at all times.
Deposit the load
Requirements
– Lagerstelle für Lagerung der Last geeignet.
Procedure
• Drive carefully up to the storage location.
• Press the “Lower” button (87).
• Carefully lower the load handler so that the fork arms are clear of the load.
• Carefully remove the fork arms from the pallet.
The load is deposited.

06.21 en-GB
87
5 Troubleshooting
This chapter enables the operator to localize and rectify basic faults or the results of
incorrect operation himself. When trying to locate a fault, proceed in the order shown
in the remedy table.
Z If, after carrying out the following remedial action, the truck cannot be restored to
operation or if a fault in the electronics system is displayed with a corresponding
error code, contact the manufacturer’s service department.
Troubleshooting must only be performed by the manufacturer’s customer service
department. The manufacturer has a service department specially trained for these
tasks.
In order for customer services to react quickly and specifically to the fault, the
following information is essential:
- Truck serial number
- Event message from the display unit (if applicable)
- Error description
- Current location of truck.
Load cannot be lifted

Cause Remedy
Load weight too high. Only lift loads up to the maximum capacity, as
specified on the type plate, see page 30.
Charge status of the Charge the battery, see page 60.
battery is low.
Contactor is faulty. Contact the manufacturer's customer service
department.
Hydraulic oil level is too Check the hydraulic oil level and top up if
low. necessary, see page 96.
Leak in hydraulic system. Contact the manufacturer's customer service
department.
Hydraulic oil leaking from the breather filter

Cause Remedy
Hydraulic oil level too Check the hydraulic oil level and drain if necessary,
high. see page 96.
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88
Truck does not start
Cause Remedy
Battery still connected to Fully charge the battery and disconnect the charger
the battery charger. from the battery, see page 57.
Battery is not connected Check that the battery is correctly attached and
correctly. locked in place and adjust if necessary, see
page 63.
Fuses faulty. Check the fuses and replace if necessary, see
page 107.
Battery charge status is Charge the battery, see page 57.
too low.
Emergency disconnect Release the emergency disconnect switch, see
switch activated. page 78.
Tiller in travel zone "F". Move tiller to brake zone "B", see page 81.
Z Do not use the emergency disconnect switch as a service brake; otherwise, wear of
the drive wheel will increase significantly.
06.21 en-GB
89
6 Operating the truck without its own drive system
WARNING!
Accidental truck movement
When the brakes are de-activated the truck must be parked on a level surface, since
the brakes are no longer effective.
uDo not release the brake on slopes or inclines.
uDo not park the truck with the brake released.
uApply the brake again when you reach your destination.
Recovering the truck
The truck can be moved without its own drive system only when the drive wheel
brake is disassembled.
The brake may be disassembled and assembled only by authorised service

personnel.
Requirements
– Truck cannot be moved with its own drive system.
– The emergency disconnect switch is actuated, see page 78.
– Working area is secured.
– Lifting gear
– Crane lifting gear
Procedure
• Unload the truck.
• Secure the lifting gear to the attachment points, see page 31.
• Load the truck onto a suitable transport aid, secure it and transport it away, see
page 33
Truck has been recovered.
06.21 en-GB
90
F Truck maintenance
1 Spare Parts
To ensure safe and reliable operation, use only the manufacturer's original spare
parts.
The manufacturer’s original spare parts are consistent with the manufacturer’s
specifications and guarantee the highest possible quality of safety, size accuracy
and material.
The installation or use of non-original spare parts can negatively affect the specified
properties of the product and impair safety. The manufacturer cannot be held liable
for damage caused by the use of non-original spare parts.
The product-related electronic spare parts catalogue can be found at

(www.jungheinrich.de/spare-parts-search) by entering the serial number.
Z The serial number can be found on the data plate, see page 30.
2 Operational Safety and Environmental Protection

The inspections and maintenance tasks listed in chapter "Maintenance, Inspection
and Changing of Maintenance Parts Requiring Replacement" must be performed
according to the defined service intervals (see page 111).
The manufacturer recommends the replacement of the maintenance parts also listed
in chapter "Action to be taken during decommissioning" according to the specified
replacement intervals (see page 111).
WARNING!
Risk of accidents and component damage
Any modification to the truck, in particular the safety mechanisms, is prohibited.
Exception: Operating companies should only make changes or have changes made
to powered industrial trucks if the manufacturer is no longer operating in the field and
there is no successor to the business; operating companies must however:
– Ensure that the changes to be made are planned, tested and performed by a
specialist engineer in industrial trucks taking safety into account.
– Keep permanent records of the construction, tests and completion of changes
– Carry out and have authorised the respective changes to the capacity data plates,
decals and stickers as well as the operating instructions and workshop manuals
– Attach a permanent and clearly visible marking to the truck indicating the types of
06.21 en-GB
changes made, the date of the changes and the name and address of the
organisation responsible for the work.
91
Z On completion of inspection and service work, carry out the operations listed in the
“Recommissioning the truck after cleaning or maintenance work” section (see
page 108).
06.21 en-GB
92
3 Maintenance Safety Regulations
Maintenance and repair personnel
Z The manufacturer has a customer service department specially trained for these
tasks. A maintenance contract with the manufacturer will support trouble-free
operation.
Truck maintenance, repair work and changing of parts requiring replacement must
only be carried out by specialist personnel. The activities to be carried out are
divided into the following target groups.
Customer Services
Customer Services are specially trained in the use of the truck and are able to carry
out maintenance and repairs independently. Customer Services are aware of the
relevant standards, guidelines and safety regulations as well as potential risks.
Operating company
The maintenance personal of the operating company has the technical expertise and
experience to perform the activities in the maintenance check list for the operating
company. The maintenance and repair work to be performed by the operating
company are also written down, see page 91.
3.1 Working on the electrical system
WARNING!
Electrical current can cause accidents
Make sure the electrical system is voltage-free before starting work on it. The
capacitors in the controller must be completely discharged. The capacitors are
completely discharged after approximately 10 minutes. Before starting maintenance
on the electrical system:
uOnly suitably trained electricians may operate on the truck's electrical system.
uBefore working on the electrical system, take all precautionary measures to avoid
electric shocks.
uPark the truck securely (see page 75).
uDisconnect the battery.
uRemove any rings, metal wrist bands etc.
06.21 en-GB
93
3.2 Consumables and used parts
CAUTION!
Consumables and used parts are an environmental hazard
Used parts and consumables must be disposed of in accordance with the applicable
environmental-protection regulations. Oil changes should be carried out by the
manufacturer's customer service department, whose staff are specially trained for
this task.
uNote the safety regulations when handling these materials.
3.3 Wheels
WARNING!
The use of wheels that do not match the manufacturer's specifications can
result in accidents
The quality of wheels affects the stability and performance of the truck.
Uneven wear reduces truck stability and increases the stopping distance.
uAfter replacing wheels, make sure the truck is not skewed.
uAlways replace wheels in pairs, i.e. left and right at the same time.
Z When replacing wheels fitted at the factory, only use the manufacturer’s original
spare parts. Otherwise the truck's rated performance cannot be ensured, see
page 91.
3.4 Hydraulic system
WARNING!
Leaky hydraulic systems can result in accidents
Hydraulic oil can escape from leaky and faulty hydraulic systems.
uMark defective truck and take out of service.
uDo not return the industrial truck to service until you have identified and rectified
the fault.
uRemove any spilled hydraulic immediately with an appropriate bonding agent.
uThe bonding agent / consumable mixture must be disposed of in accordance with
regulations.
3.5 Energy saving components
CAUTION!
Risk of accidents due to energy saving components
The tiller contains components that store mechanical energy. Improper opening may
result in an accident.
uDo not dismantle the tiller.
uThe tiller may only be dismantled by authorised service personal.
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94
4 Lubricants and Lubrication Schedule
4.1 Handling consumables safely
Handling consumables
Consumables must always be handled correctly. Follow the manufacturer’s

instructions.
WARNING!
Improper handling is hazardous to health, life and the environment
Consumables can be flammable.
uKeep consumables away from hot components and naked flames.
uAlways keep consumables in prescribed marked containers.
uAlways fill consumables in clean containers.
uDo not mix up different grades of consumable. The only exception to this is when
mixing is expressly stipulated in the Operating Instructions.
CAUTION!
Spilled consumables can cause slipping and endanger the environment
Risk of slipping from spilled consumables. The risk is greater when combined with
water.
uDo not spill consumables.
uSpilled consumables must be removed immediately with an appropriate bonding
agent.
uThe bonding agent / consumable mixture must be disposed of in accordance with
regulations.
WARNING!
Improper handling of oils can be hazardous
Oils (chain spray / hydraulic oil) are flammable and poisonous.
uDispose of used oils in accordance with regulations. Store used oil safely until it
can be disposed of in accordance with regulations.
uDo not spill oil.
uSpilled oils must be removed immediately with an appropriate bonding agent.
uThe mixture consisting of the bonding agent and oil must be disposed of in
accordance with regulations.
uObserve national regulations when handling oils.
uWear safety gloves when handling oils.
uPrevent oil from coming into contact with hot motor parts.
uDo not smoke when handling oil.
uAvoid contact and digestion. If you swallow oil do not induce vomiting but seek
medical assistance immediately.
uSeek fresh air after breathing in oil fumes or vapours.
uIf oil has come into contact with your skin, rinse your skin with water.
06.21 en-GB
uIf oil has come into contact with your eyes, rinse them with water and seek medical
assistance immediately.
uReplace oil-soaked clothing and shoes immediately.
95
CAUTION!
Consumables and used parts are an environmental hazard
Used parts and consumables must be disposed of in accordance with the applicable
environmental-protection regulations. Oil changes should be carried out by the
manufacturer's customer service department, whose staff are specially trained for
this task.
uNote the safety regulations when handling these materials.
4.2 Lubrication Schedule
94
A, B
95
96
97
98
99
100
C
Item Component Item Component

94 Lift cylinder (s) 98 Lift kinematics (s)
95 Filler plug for hydraulic oil (S) 99 Transmission (s)
96 Load wheel bearing (s) 100 Tiller bolt (s)
97 Tiller bearing (s)
Lubricate the truck according to the lubrication schedule

Requirements
– Truck is prepared for maintenance and repair work, see page 98.
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– Maintenance interval has been reached, see page 111.

– Lubricants according to lubrication schedule, see page 97
96
Procedure
• Lubricate the lubrication points (s) according to the lubrication schedule.
Z Some lubrication points are only lubricated when required.

• Check the hydraulic oil level and top up if necessary (S), see page 106.
• Start up the truck, see page 108.
Truck is lubricated.
4.3 Consumables
Code Order no. Description Used for Volume
A 51207593 Hydraulic oil Hydraulic system 0.4 l
HVLP 32, -5°C to 25°C 1)
DIN 51524
B 50459855 Hydraulic oil Hydraulic system 0.4 l
HLP 46, > 25°C 1)
DIN 51524
C 29200430 Lubricating Various bearing As required
grease points
DIN 51825
1) Ambient temperature
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97
5 Maintenance and repairs
5.1 Preparing the truck for maintenance and repairs
Procedure
• Unload the truck.
• Park the truck securely, see page 75.
• Disconnect the battery, see page 62
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98
5.2 Lifting and jacking up the truck safely
WARNING!
Risk of accidents when working under the load handler and lift truck
uWhen working under a raised load handler or a raised truck, secure them to
prevent the truck from lowering, tipping or sliding away.
uWhen raising the truck, follow the instructions, see page 31. When working on the
parking brake, prevent the truck from accidentally rolling away (e.g. with wedges).
WARNING!
Lifting and jacking up the truck safely
In order to raise the truck, the lifting gear must only be secured to the points
specially provided for this purpose.
In order to raise and jack up the truck safely, proceed as follows:
uJack up the truck only on a level surface and prevent it from moving accidentally.
uAlways use a jack with sufficient capacity. When jacking up the burden carrier, take
appropriate measures to prevent it from slipping or tipping over (e.g. wedges,
wooden blocks).
uIn order to raise the truck, the lifting accessories must only be secured to the
points specially provided for this purpose, see page 31.
Raising and jacking up the truck securely

Requirements
06.21 en-GB
– Prepare the truck for maintenance and repairs (see page 98).
99
– Jack
– Hard wooden blocks
Procedure
• Place the jack against the contact point.
Z For jacking the truck, make sure to use the structural parts of the truck as contact
point for the jack (e.g. truck chassis).
• Raise the truck.
• Support the truck with hard wooden blocks.
• Remove the jack.
The truck is now securely raised and jacked up.
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100
5.3 Removing the Covers
101
10 102
Removing the cover for the hydraulic unit and electrical system
Requirements
Procedure
• Remove the 2 Allen screws (101).
• Lift off the cover (102) over the emergency disconnect switch (10) and set it down
securely.
Cover for the hydraulic unit and electrical system has been removed.
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101
103
14
Removing the bumper

Requirements
Procedure
• Remove the 2 Allen screws (103) on both sides of the bumper (14).
• Lift off the bumper and set it down securely.
Bumper has been removed. 06.21 en-GB
102
5.4 Cleaning
5.4.1 Cleaning the truck
CAUTION!
Fire hazard
Do not use flammable liquids to clean the industrial truck.
uAlways disconnect the battery before starting cleaning work.
uCarry out all necessary safety measures to prevent sparking before cleaning (e.g.
by short-circuiting).
Z Cleaning tasks may only take place in the designated locations, which adhere to the
stipulations of the country of use.
Cleaning the truck
Requirements
– Truck prepared for maintenance and repair work, see page 98.
– Water-based solvents
– Sponge or cloth
Procedure
• Clean the surface of the truck with water-based solvents and water. Use a sponge
or cloth to clean.
• Dry the truck after cleaning, e.g. with compressed air or a dry cloth.
• Carry out all the tasks in the section "Recommissioning the truck after cleaning or
maintenance work" (see page 108).
The truck is now clean.

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103
5.4.2 Cleaning the electrical system assemblies
NOTICE
Risk of electrical-system damage
Cleaning the electronic system assemblies (controllers, sensors, motors etc.) with
water can damage the electrical system.
uDo not clean the electrical system with water.
uClean the electrical system with weak suction or compressed air (use a
compressor with a water trap) and a non-conductive, anti-static brush.
Cleaning the electrical system assemblies
Requirements
– Truck prepared for maintenance and repair work (see page 98).
– Compressor with water separator
– Non-conductive, antistatic brush
Procedure
• Expose the electrical system, see page 101.
• Clean the electrical system assemblies with weak suction or compressed air (use
a compressor with a water separator) and a non-conductive, anti-static brush.
• Fit the electrical system panel, see page 101.
• Carry out all the tasks in the section "Recommissioning the truck after cleaning or
maintenance work" (see page 108).
The electrical system assemblies are now clean.
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104
5.5 Checking the drive wheel and load wheels
Z Wheels must only be replaced by authorised service personnel.
14
15
Procedure 15
• Remove the bumper (14), see

(6,5 mm)
page 101.
• Check the drive wheel (15) and
load wheels (8) for wear, damage
and freedom of movement. 210
mm
Z A new drive wheel has a diameter
of 210 mm. The drive wheel must
mm
be replaced when it has reached a 197
diameter of 197 mm or a residual
thickness of 6.5 mm.
Z The wheels must be round and

must not have excessive abrasion.
• Fit the bumper.
06.21 en-GB
105
5.6 Checking the hydraulic oil level
104
105
Checking the hydraulic oil level and replenishing if necessary

Requirements
– Load handler is fully lowered.
Procedure
• Remove the cover for the hydraulic unit, see page 101.
• Check the oil level in the hydraulic reservoir (105).
Z When the load handler is fully lowered, the hydraulic oil level must be between the
min and max markings.
• Add hydraulic oil if necessary:
• Unscrew the cap (104) from the hydraulic reservoir (105).
• Add hydraulic oil of the correct grade until the hydraulic oil level lies within the
target range (see page 97).
• Screw the cap (104) onto the hydraulic reservoir (105).
• Fit the cover onto the hydraulic unit, see page 101.
• Restore the truck to service after maintenance and repairs, see page 108.
The hydraulic oil level is correct.
Z If a leak is detected in the hydraulic system, the truck must be decommissioned and
repaired by specialist personnel.
06.21 en-GB
106
5.7 Checking electrical fuses
106
11
107
108
105
Fuse Rating Installation location

FU1 (106) 10 A Between hydraulic reservoir (105) and
Control circuit controller (107)
FU 01 (108) 70 A On the reverse of the battery (11)
Battery
Checking electrical fuses

Requirements
– Cover for the hydraulic unit and electrical system has been removed, see
page 101.
Procedure
• Check fuse FU1 (106) for correct rating and condition, and replace if necessary.
• Fit the cover.
• Remove the battery (11), see page 62.
• Check fuse FU01 (108) for correct rating and condition, and replace if necessary.
• Install the battery, see page 63.
The fuses have been checked.

06.21 en-GB
107
6 Restoring the truck to service after maintenance and
repairs
Procedure
• Thoroughly clean the truck, see page 103.
• Lubricate the truck according to the lubrication diagram, see page 96.
• Charge the battery, see page 57.
7 Decommissioning the industrial truck

If the truck is to be out of service for more than a month, it must be stored in a frost-
free and dry room. All necessary measures must be taken before, during and after
decommissioning as described hereafter.
When the truck is out of service it must be jacked up so that all the wheels are clear
of the ground. This is the only way of ensuring that the wheels and wheel bearings
are not damaged.
Z Jack up the truck, see page 99.
If the truck is to be out of service for more than 6 months, agree further measures
with the manufacturer's customer service department.
7.1 Prior to decommissioning

Procedure
• Park the truck securely, see page 75.
• Clean the truck, see page 103.
• Check the hydraulic oil level and replenish if necessary, see page 106.
• Apply a thin layer of oil or grease to any non-painted mechanical components.
• Drive the truck to the storage location and jack it up, see page 99.
• Remove the battery, see page 109.
• Check the battery charge at regular intervals, see page 109.
Z Final de-commissioning or disposal of the truck in must be performed in accordance

with the regulations of the country of use. In particular, regulations governing the
disposal of batteries, consumables and electronic and electrical systems must be
observed.
The truck must only be disassembled by trained personnel in accordance with the
procedures as specified by the manufacturer.
06.21 en-GB
108
7.2 Action to be taken during decommissioning
NOTICE
Full discharge can damage the battery
Self-discharge can cause the battery to fully discharge. Full discharge shortens the
service life of the battery.
uCharge the battery at least every 12 weeks, see page 57.
7.3 Restoring the truck to service after decommissioning

Procedure
• Thoroughly clean the truck, see page 103.
8 Safety tests to be performed at intervals and after unusual

incidents
The truck must be inspected at least annually (refer to national regulations) or after
any unusual event by a qualified inspector. The manufacturer offers a safety
inspection service which is performed by personnel specifically trained for this
purpose.
A complete test must be carried out on the technical condition of the truck with
regard to safety. The truck must also be examined thoroughly for damage.
The operating company is responsible for ensuring that faults are rectified
immediately.
9 Final de-commissioning, disposal
Z Final de-commissioning or disposal of the truck in must be performed in accordance

with the regulations of the country of use. In particular, regulations governing the
disposal of batteries, consumables and electronic and electrical systems must be
observed.
The truck must only be disassembled by trained personnel in accordance with the
procedures as specified by the manufacturer.
06.21 en-GB
109
110
06.21 en-GB
G Maintenance, Inspection and Changing of
Maintenance Parts Requiring
Replacement
WARNING!
Lack of maintenance can result in accidents
Failure to perform regular maintenance and inspections can lead to truck failure and
poses a potential hazard to personnel and equipment.
uThorough and expert maintenance and inspections are among the most important
requirements for the safe operation of the industrial truck.
NOTICE
The application conditions of an industrial truck have a considerable impact on
component wear. The following service, inspection and replacement intervals are
based on single-shift operation under normal operating conditions. The intervals
must be reduced accordingly if more stringent requirements are placed on the
equipment, e.g., use in conditions of extreme dust, temperature fluctuations or
multiple shifts.
uTo prevent damage due to wear, the manufacturer recommends an on-site
application analysis to agree on appropriate intervals.
The following chapter defines the tasks to be performed, the respective intervals to
be observed and the maintenance parts for which replacement is recommended.
06.21 en-GB
111
1 Maintenance Contents PTE 1.1
Issued on: 2021-06-23 13:00
1.1 Owner
To be performed every 50 service hours, but at least once a week.
06.21 en-GB
112
1.1.1 Maintenance contents
1.1.1.1 Standard equipment
Brakes
Test the brake.
Hydraulic operations
Correct the hydraulic-oil level.
Steering
Test the tiller return function.
06.21 en-GB
113
1.1.2 Inspection contents
The following points must be checked:
Electrical system
Warning and safety equipment in accordance with the operating instructions
Functionality of display and controls
Test emergency disconnect switch and check for damage
Power supply
Check battery and battery components for damage
Battery connector for secure fit, functionality and damage
Chassis/structure
Check labels for legibility, completeness and plausibility
Check doors or covers for damage
Test hydraulic system
Check fork arms or load handler for wear and damage
1.1.2.2 Optional equipment

06.21 en-GB
114
1.2 Customer Service
In accordance with the PTE 1.1 service interval, to be performed every service
hours, but at least once a year.
Brakes
Test the brake.
Adjust the air gap of the magnetic brake.
Measure the air gap of the magnetic brake.
Electrical system
Adjust the microswitches.
Test key switch or alternative access system including the access rights.
Test the contactors and/or relays.
Clean the motor with compressed air.
Carry out a frame leakage test.
Power supply
Measure the battery voltage.
Adjust the lift mechanism.
Test and adjust the pressure relief valve.
Agreed services
Carry out a test run with the rated capacity or a customer-specific load.
Lubricate the truck according to the lubrication schedule.
Demonstration after maintenance.
Steering
Battery charger
Test the immobiliser on trucks with an on-board charger.
Carry out a potential measurement on the chassis while charging is in progress.
06.21 en-GB
115

Electrical system
Cables and motor for secure fit and damage
Test microswitches and check for damage
Contactors and/or relays for wear and damage
Check electrical wiring for damage (insulation damage, connections) and check whether
the fuse ratings are correct
Check carbon brushes for wear
Check connections and cables are securely attached and check for insulation damage
and other signs of damage
Power supply
Battery latch and battery attachment for correct function and damage
Travel
Drive system bearings for wear and damage
Transmission for noise and leaks
Check wheels for wear, damage and secure mounting
Check wheel bearings and mounting of wheels for wear and damage
Chassis/structure
Check chassis connections and screw connections are securely attached and check for
damage
Test hydraulic controls and check their labels for legibility, completeness and plausibility
Lift mechanism for wear, functionality and damage
Check cylinders and piston rods are securely attached and check for damage
Check hydraulic connections, hoses and pipes are securely attached and check for leaks
and damage
06.21 en-GB

Tie/plunger rods for uniform adjustment, wear and damage
116
Steering
Check the mechanical parts of the steering column for wear and damage
1.2.3 Maintenance parts
The manufacturer recommends the replacement of the following maintenance parts

at the specified intervals.
maintenance part service hours months

Hydraulic system breather filter 2000 12
Hydraulic oil 2000 12
06.21 en-GB
117
2 Maintenance Contents PTE 15N
Issued on: 2021-06-23 13:00
2.1 Owner
To be performed every 50 service hours, but at least once a week.

Brakes
Test the brake.
Steering

Electrical system
Power supply
Chassis/structure
2.1.2.2 Optional equipment

06.21 en-GB
118
2.2 Customer Service
In accordance with the PTE 15N service interval, to be performed every 1000
service hours, but at least once a year.
Brakes
Test the brake.
Adjust the air gap of the magnetic brake.
Measure the air gap of the magnetic brake.
Electrical system
Adjust the microswitches.
Test key switch or alternative access system including the access rights.
Test the contactors and/or relays.
Clean the motor with compressed air.
Carry out a frame leakage test.
Power supply
Measure the battery voltage.
Adjust the lift mechanism.
Test and adjust the pressure relief valve.
Agreed services
Carry out a test run with the rated capacity or a customer-specific load.
Lubricate the truck according to the lubrication schedule.
Demonstration after maintenance.
Steering
Battery charger
Test the immobiliser on trucks with an on-board charger.
Carry out a potential measurement on the chassis while charging is in progress.
06.21 en-GB
119

Electrical system
Cables and motor for secure fit and damage
Test microswitches and check for damage
Contactors and/or relays for wear and damage
Check electrical wiring for damage (insulation damage, connections) and check whether
the fuse ratings are correct
Check carbon brushes for wear
Check connections and cables are securely attached and check for insulation damage
and other signs of damage
Power supply
Battery latch and battery attachment for correct function and damage
Travel
Drive system bearings for wear and damage
Transmission for noise and leaks
Check wheels for wear, damage and secure mounting
Check wheel bearings and mounting of wheels for wear and damage
Chassis/structure
Check chassis connections and screw connections are securely attached and check for
damage
Test hydraulic controls and check their labels for legibility, completeness and plausibility
Lift mechanism for wear, functionality and damage
Check cylinders and piston rods are securely attached and check for damage
Check hydraulic connections, hoses and pipes are securely attached and check for leaks
and damage
06.21 en-GB

Tie/plunger rods for uniform adjustment, wear and damage
120
Steering
Check the mechanical parts of the steering column for wear and damage
2.2.3 Maintenance parts
The manufacturer recommends the replacement of the following maintenance parts

at the specified intervals.
maintenance part service hours months

Hydraulic system breather filter 2000 12
Hydraulic oil 2000 12
06.21 en-GB
121

Manual Tr. Ameise PTE 1.1-1.5

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PTE 1.

Imported by (for all countries except China)/approved by (for China)

Jungheinrich AG, Friedrich-Ebert-Damm 129, 22047 Hamburg, Germany

Type Option Serial no. Year of

The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide

Safety instructions and important explanations are indicated by the following

Z Used before notices and explanations.

t Indicates standard equipment

Copyright of these operating instructions remains with JUNGHEINRICH AG.

Tel: +49 (0) 40/6948-0

3.4 Charging the battery 52

6 Restoring the truck to service after maintenance and repairs 108

3 Approved application conditions

– Operation in industrial and commercial environments.

Operating conditions PTE 1.1 Li-Ion PTE 1.5 Li-Ion

Z If in doubt, contact the manufacturer's customer service department.

Stop the truck in both cases.

2 Truck models and rated capacity

Item Travel Direction

PTE 1.1 Li-Ion

Item Description Item Description

Item Description Item Description

PTE 1.1 Li-Ion: Magnetic lock

Ergonomic controls ensure fatigue-free operation for sensitive application of the

Z Technical data specified in accordance with VDI 2198.

PTE 1.1 Li-Ion

5.2 Performance data

Technical parameter Battery specification

1) For PTE 1.1 Li-Ion

PTE 1.5 Li-Ion

5.6 Tyre type

– PTE 1.1 Li-Ion / PTE 1.5 Li-Ion: < 70 dB(A)

Z The continuous sound pressure level is calculated according to standard procedures

Electromagnetic compatibility (EMC)

Z No changes to electric or electronic components or their arrangement may be made

5.8 Electrical Requirements

PTE 1.1 Li-Ion

Type XXX XX Option xx X xxxx

Serial No. XXXXX Year of Manuf. MM/YYYY

System voltage XX V Nominal power XXX kW

Item Description Item Description

Type XXX XX Option xx X xxxx

Serial No. XXXXX Year of Manuf. MM/YYYY

System voltage XX V Nominal power XXX kW

Item Description Item Description

29 Type XXX XX Option xx X xxxx 30

Item Description Item Description

Loading the truck by crane

The truck can now be loaded by crane.

PTE 1.1 Li-Ion PTE 1.5 Li-Ion

Securing the truck for transport

The truck can now be transported.

The truck can now be started, see page 72.

PTE 1.5 Li-Ion

Changing the access code

The access code has been changed.

Resetting the access code

The access code has been reset to 1234.

Fitting the tiller

Fitting the gas strut