Junghair

EKS 513 - 515 / EKX 410 - 515 05.
12 -
Operating instructions G
51255015
11.14
EKS 513
EKS 515k
EKS 515
EKX 410
EKX 513
EKX 515k
EKX 515
'HFODUDWLRQRI&RQIRUPLW\
-XQJKHLQULFK$*)ULHGULFK(EHUW'DPP+DPEXUJ*HUPDQ\
0DQXIDFWXUHURUDJHQWDFWLQJLQWKH(XURSHDQ8QLRQ
0RGHO 2SWLRQ 6HULDOQR <HDURI

PDQXIDFWXUH
$GGLWLRQDOLQIRUPDWLRQ
2QEHKDOIRI
'DWH
G(&'HFODUDWLRQRI&RQIRUPLW\
7KHXQGHUVLJQHGKHUHE\GHFODUHWKDWWKHSRZHUHGLQGXVWULDOWUXFNGHVFULEHGEHORZLQ
GHWDLOFRPSOLHVZLWKWKH(XURSHDQ'LUHFWLYHV(*0DFKLQHU\'LUHFWLYHDQG
(8(OHFWURPDJQHWLF&RPSDWLELOLW\(0&LQFOXGLQJDPHQGPHQWVDVZHOODV
WKHOHJLVODWLYHGHFUHHWRLQFRUSRUDWHWKHGLUHFWLYHVLQQDWLRQDOODZ7KHVLJQDWRULHVDUH
LQHDFKFDVHLQGLYLGXDOO\DXWKRULVHGWRFRPSLOHWKHWHFKQLFDOGRFXPHQWV
(1

4
11.14 EN
Foreword
Notes on the operating instructions
The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide

sufficient instruction for the safe operation of the industrial truck. The information is
provided clearly and concisely. The chapters are arranged by letter and the pages are
numbered continuously.
The operator manual details different industrial truck models. When operating and
servicing the industrial truck, make sure that the particular section applies to your
truck model.
Our trucks are subject to ongoing development. Jungheinrich reserves the right to
alter the design, equipment and technical features of the system. No guarantee of
particular features of the truck 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.
NOTE
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
11.14 EN
5
Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.

Jungheinrich Aktiengesellschaft
Am Stadtrand 35
22047 Hamburg - Germany
Tel: +49 (0) 40/6948-0

www.jungheinrich.com
11.14 EN
6
Table of contents
A Correct Use and Application ................................................... 11

1 General.................................................................................................... 11
2 Correct application................................................................................... 11
3 Approved application conditions.............................................................. 12
4 Proprietor responsibilities ........................................................................ 16
5 Adding attachments and/or accessories.................................................. 16
B Truck Description .................................................................... 17

1 Application ............................................................................................... 17
2 Travel direction definition......................................................................... 20
3 Assemblies and Functional Description................................................... 21
3.1 Functional Description ............................................................................. 21
3.2 Assembly Overview ................................................................................. 28
4 Technical Specifications .......................................................................... 30
4.1 Performance data .................................................................................... 30
4.2 Dimensions (as per data plate)................................................................ 38
4.3 Mast versions .......................................................................................... 54
4.4 Weights.................................................................................................... 56
4.5 Wheels, chassis....................................................................................... 59
4.6 Engine Data............................................................................................. 60
4.7 EN norms................................................................................................. 61
4.8 Conditions of use..................................................................................... 63
4.9 Electrical requirements ............................................................................ 63
5 Identification points and data plates ........................................................ 64
5.1 Data plate ................................................................................................ 66
5.2 Truck capacity plate................................................................................. 67
5.3 Attachment capacity plate ....................................................................... 68
5.4 Jack contact points .................................................................................. 68
5.5 "Residual capacity" tilt safety device notice (o) ...................................... 69
6 Stability .................................................................................................... 70
C Transport and Commissioning ................................................ 71

1 Transport ................................................................................................. 71
2 Lifting by crane ........................................................................................ 73
2.1 Lifting by crane with mast assembled...................................................... 74
2.2 Loading the basic truck by crane with mast tilted (EKX 410 only) ........... 76
2.3 Lifting the basic truck by crane ................................................................ 78
2.4 Lifting the mast by crane with the cab and load handler ......................... 80
2.5 Lifting the battery by crane ...................................................................... 82
3 Securing the truck during transport ......................................................... 84
3.1 Basic truck transport retainer................................................................... 84
3.2 Mast transport retainer ............................................................................ 86
11.14 EN
3.3 Transport retainer for basic truck with the mast assembled .................... 88
7
3.4 Transport retainer for basic truck with the mast tilted (EKX 410 only)..... 90
4 Using the Truck for the First Time ........................................................... 92
4.1 Moving the industrial truck without a battery ........................................... 92
4.2 Installing and removing the mast............................................................. 93
4.3 Commissioning ........................................................................................ 94
4.4 Tilt safety device...................................................................................... 96
D Battery - Servicing, Recharging, Replacement ....................... 97

1 Safety Regulations Governing the Handling of Lead-Acid Batteries ....... 97
1.1 General notes on handling batteries........................................................ 98
2 Battery types............................................................................................ 99
2.1 Dimensions of the battery compartment.................................................. 101
3 Exposing the battery................................................................................ 102
4 Charging the battery ................................................................................ 104
5 Battery removal and installation .............................................................. 108
5.1 Removing and installing the battery with a battery roller stand (single part
batteries).................................................................................................. 108
5.2 Battery assembly / removal using a fork lift truck (two part batteries) ..... 112
6 "Battery lock" sensors (o) ....................................................................... 116
E Operation ................................................................................ 119

1 Safety Regulations for the Operation of the Forklift Truck....................... 119
2 Displays and Controls.............................................................................. 121
2.1 Controls and displays on the control panel.............................................. 121
2.2 Driver's display ........................................................................................ 132
2.3 Hourmeter................................................................................................ 139
2.4 "Bar display" battery discharge indicator ................................................. 140
2.5 "Percentage display" battery discharge indicator (o).............................. 142
2.6 Driver's display function symbols............................................................. 144
3 Preparing the Truck for Operation ........................................................... 155
3.1 Checks and operations to be performed before starting daily operation . 155
3.2 Entry and exit........................................................................................... 160
3.3 Driver's seat removal and assembly........................................................ 162
3.4 Setting up the operator position............................................................... 164
3.5 Seat belt with safety rope (EKS without front guard or gate only) ........... 170
4 Industrial Truck Operation ....................................................................... 188
4.1 Safety regulations for truck operation...................................................... 188
4.2 Preparing the truck for operation ............................................................. 195
4.3 Preparing the truck for operation with an additional access code (o)..... 196
4.4 Date and time setting............................................................................... 200
4.5 Checks and operations to be carried out when the truck is operational .. 202
4.6 Referencing the main and auxiliary lift..................................................... 204
4.7 Emergency Disconnect............................................................................ 208
4.8 Travel....................................................................................................... 210
4.9 Steering ................................................................................................... 212
4.10 Brakes ..................................................................................................... 212
4.11 Negotiating narrow aisles ........................................................................ 214
11.14 EN
4.12 Diagonal travel......................................................................................... 225

4.13 Lifting / lowering – outside and inside narrow aisles ............................... 226
8
4.14 Traversing / rotating outside and inside narrow aisles ............................ 230
4.15 Simultaneous traversing - rotation outside and inside narrow aisles....... 234
4.16 Parking the truck securely ....................................................................... 239
5 Order picking and stacking ...................................................................... 243
5.1 Adjusting the forks ................................................................................... 243
5.2 Replacing the forks.................................................................................. 246
5.3 Lifting, transporting and depositing loads ................................................ 251
6 Troubleshooting....................................................................................... 260
6.1 Troubleshooting....................................................................................... 260
6.2 Emergency stop device ........................................................................... 264
6.3 Driver's cab emergency lowering............................................................. 265
6.4 Slack chain safety device override .......................................................... 269
6.5 Travel cutout override (o) ....................................................................... 270
6.6 Lift cutout override (o) ............................................................................ 271
6.7 Lower cutout override (o) ....................................................................... 273
6.8 End of aisle safety device (o) ................................................................. 275
6.9 WG emergency operation (event messages 3670 / 3752) ...................... 277
6.10 Recovering the truck from a narrow aisle / Moving the truck without a bat-
tery........................................................................................................... 278
7 Exiting the driver's cab with the rescue equipment.................................. 297
7.1 Rescue equipment storage compartment in the driver's cab................... 298
7.2 Rescue equipment testing / servicing...................................................... 299
7.3 Rescue equipment service life................................................................. 300
7.4 Rescue equipment storage and transportation........................................ 301
7.5 Description / use of rescue equipment (07.09 -)...................................... 302
8 Personal safety system (o)..................................................................... 321
8.1 Personal Protection System (PPS).......................................................... 321
8.2 Functional description.............................................................................. 322
8.3 Environmental awareness ....................................................................... 323
8.4 Cleaning the laser scanner front screen.................................................. 324
8.5 Displays on the seven segment display and indicator light (LED) ........... 325
8.6 Daily checks before starting the Personal Protection System ................. 327
8.7 Personal safety system ........................................................................... 328
9 Order picker - EKS .................................................................................. 331
9.1 Possible control panel arrangements ...................................................... 331
9.2 Controls on the two control panels .......................................................... 333
9.3 Height and angle adjustment of the two control panels ........................... 335
9.4 Truck with load guard and walk-on pallet ................................................ 337
9.5 Truck equipment - stockpicking platform without pallet lift option............ 338
9.6 Stockpicking platform with pallet lift option (not monitored, not locked) .. 340
9.7 Stockpicking platform with pallet lift option including pallet monitoring
and fixing ................................................................................................. 344
9.8 Display of stockpicking platform side and / or front gates and load direc-
tion gates ................................................................................................. 346
9.9 Additional symbols in driver's display ...................................................... 349
9.10 Lifting / depositing a load with a load lock (with / without load sensing) .. 351
9.11 Auxiliary Lift raise/lower (o) .................................................................... 360
10 Optional equipment ................................................................................. 361
10.1 Telescopic table (o) ................................................................................ 361
10.2 Sideshifter / Fork positioner (o) .............................................................. 373
10.3 Telescopic forks (o) ................................................................................ 383
11.14 EN
10.4 Operator-specific settings (o) ................................................................. 387

10.5 ISM access module (o)........................................................................... 394
9
10.6 Weighing system (o)............................................................................... 394
10.7 Rack Height Select (o) ........................................................................... 396
10.8 Horizontal positioning (o)........................................................................ 413
10.9 Passenger mode for a second person in the driver's cab (o)................. 435
10.10 Working platform (o)............................................................................... 437
10.11 Closed driver's cab (o) ........................................................................... 449
10.12 On-board charger (o).............................................................................. 458
10.13 Fire extinguisher (o) ............................................................................... 477
10.14 Rear view mirror (o)................................................................................ 478
10.15 Camera system ....................................................................................... 479
F Industrial Truck Maintenance .................................................. 481

1 Operational Safety and Environmental Protection................................... 481
2 Maintenance Safety Regulations............................................................. 483
3 Servicing and Inspection ......................................................................... 488
4 Maintenance checklist ............................................................................. 489
4.1 Owner ...................................................................................................... 489
4.2 Customer Service .................................................................................... 494
5 Lubricants and Lubrication Schedule ...................................................... 512
5.1 Handling consumables safely .................................................................. 512
5.2 Lubrication Schedule ............................................................................... 514
5.3 Consumables........................................................................................... 515
6 Maintenance and repairs ......................................................................... 516
6.1 Preparing the truck for maintenance and repairs .................................... 516
6.2 Drive compartment cover disassembly/assembly ................................... 518
6.3 Checking electrical fuses......................................................................... 522
6.4 Preventing the driver's cab from accidentally lowering............................ 527
6.5 Lift chain servicing ................................................................................... 532
6.6 Lubricate the lift chains, clean and grease the contact surfaces in the
mast sections........................................................................................... 532
6.7 Automatic Chain Lubrication (o) ............................................................. 534
6.8 Lift chain inspection ................................................................................. 540
6.9 Hydraulic hoses ....................................................................................... 540
6.10 Checking the hydraulic oil level ............................................................... 542
6.11 Restoring the truck to service after maintenance and repairs ................. 546
7 Decommissioning the industrial truck ...................................................... 548
7.1 Prior to decommissioning ........................................................................ 549
7.2 During decommissioning ......................................................................... 550
7.3 Restoring the truck to service after decommissioning ............................. 551
8 Safety tests to be performed at intervals and after unusual incidents ..... 552
9 Final de-commissioning, disposal............................................................ 553
10 Human vibration measurement ............................................................... 553
11.14 EN
10
Appendix
JH Traction Battery Operating Instructions

Z These operating instructions apply only to Jungheinrich battery models. If using
another brand, refer to the manufacturer's operating instructions.
0506.GB
1
2
0506.GB
A Correct Use and Application
1 General
The industrial truck described in the present operating instructions is designed for
lifting, lowering and transporting load units.
It must be used, operated and serviced in accordance with the present instructions.
Any other type of use is beyond the scope of application and can result in damage to
personnel, the industrial truck or property.
2 Correct application
NOTE
The maximum load and load distance are indicated on the load chart and must not be
exceeded.
The load must rest on the load handler or be lifted by an attachment approved by the
manufacturer.
The load must rest on the back of the fork carriage and centrally between the forks.
– Lifting, lowering and order picking of loads.

– Always transport a load outside the narrow aisle as low as possible, allowing for
ground clearance.
– Do not carry or lift passengers.
– Do push or pull load units.
– Do not negotiate slopes or inclines.
– Do not negotiate loading ramps / docks.
– Towing a trailer is prohibited.
– Do not transport suspended loads.
11.14 EN
11
3 Approved application conditions
DANGER!
Do not exceed the permissible surface and spot load limits on the travel routes.
At blind spots get a second person to assist.
NOTE
The industrial truck must not be used in fire or explosion endangered areas, or areas
threatened by corrosion or excessive dust. Furthermore, the truck must not be
operated in the vicinity of unprotected active components of electrical systems.
Z Special equipment and authorisation are required if the truck is to be used in

extreme conditions or areas at risk of explosion.
– Operation in industrial and commercial environments.
– Permissible temperature range +5°C to +40°C.
– Application only on level surfaces in accordance with VDMA guideline.
11.14 EN
12
WARNING!
An insufficient safety distance between the guided truck and the rack can
result in accidents
Failure to maintain the required and prescribed safety distance can result in collisions
between the guided truck and the rack.
XThe maximum travel speeds are reduced if the required and prescribed safety
distances are not maintained.
XYou must observe the minimum safety distance in accordance with EN 1726-2 item
7.3.2 90 mm. Do not operate the truck in these narrow aisles.
NOTE
Static charge can cause material damage to truck components
When the truck is operated on a surface with a shunt resistance in excess of 106ȍ,
static charge can result in damage to electric components (controller, control panel,
...).
XOperate the truck only on surfaces with a shunt resistance of less than 106ȍ.
XThe anti-static conductor must be in contact with the ground during operation.
11.14 EN
13
Safety distances (interpreted safety distance)
Z The racking systems must be set up for the EKS. The safety distances stipulated
by Jungheinrich (interpreted safety distance) must always be observed.
– For a rail-guided truck there must be a minimum safety distance on both sides
of100 mm between:
– the driver's cab and the rack, as well as the stored goods.
– the raised load and the rack, as well as the stored goods.
– For a wire-guided truck there must be a minimum safety distance on both sides of
125 mm between:
Z The safety distance may however be increased if special attachments are fitted.
11.14 EN
14
Z The racking systems must be set up for the EKX. The safety distances stipulated
– For a rail-guided truck there must be a minimum safety distance on both sides of
100 mm between:
– the swivel traverse frame and the rack, as well as the stored goods.
– the load handler and the rack, as well as the stored goods.
125 mm between:
11.14 EN
15
4 Proprietor responsibilities
For the purposes of the present operating instructions the “proprietor” is defined as
any natural or legal person who either uses the industrial truck himself, or on whose
behalf it is used. In special cases (e.g. leasing or renting) the proprietor is considered
the person who, in accordance with existing contractual agreements between the
owner and user of the industrial truck, is charged with operational duties.
The proprietor must ensure that the industrial truck is used only for the purpose for
which it is intended and that there is no danger to life and limb of the user and third
parties. Furthermore, accident prevention regulations, safety regulations and
operating, servicing and repair guidelines must be followed. The proprietor must
ensure that all users have read and understood these operating instructions.
NOTE
Failure to comply with the operating instructions shall invalidate 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.
5 Adding attachments and/or accessories

Adding accessories
The mounting or installation of additional equipment which affects or enhances the

performance of the forklift truck requires the written permission of the manufacturer.
Local authority approval may also need to be obtained.
Local authority approval does not however constitute the manufacturer’s approval.
11.14 EN
16
B Truck Description
1 Application
The EKS is an electric powered order picker.
The EKX with a standard attachment is an electric three-way order picker.
The EKX with a telescopic table is an electric two-way order picker.
The EKS / EKX is designed to transport and pick goods on level surfaces in
accordance with the VDMA directive.
It can lift open bottom or diagonal board pallets as well as roll cages beyond the area
of the load wheels. Loads can be stacked, unstacked and transported over long
distances.
The driver's cab rises together with the load handler to provide excellent visibility and
easy access to the various rack heights.
If the EKS / EKX is used for assembly work with an corresponding working platform,
the working platform must be supplied or approved in writing by the manufacturer.
11.14 EN
17
Z The racking systems must be set up for the EKS. The safety distances stipulated
– For a rail-guided truck there must be a minimum safety distance on both sides
of100 mm between:
125 mm between:
Z The racking systems must be set up for the EKX. The safety distances stipulated
– For a rail-guided truck there must be a minimum safety distance on both sides of
100 mm between:
125 mm between:
WARNING!
An insufficient safety distance between the guided truck and the rack can
result in accidents
Failure to maintain the required and prescribed safety distance can result in collisions
between the guided truck and the rack.
XThe maximum travel speeds are reduced if the required and prescribed safety
distances are not maintained.
XYou must observe the minimum safety distance in accordance with EN 1726-2 item
7.3.2 90 mm. Do not operate the truck in these narrow aisles.
Z The ground surface must comply with the VDMA guideline.

11.14 EN
18
Guide rails must be provided in the narrow aisles for the rail guidance system.
Vulkollan guide wheels attached to the truck chassis guide the truck between the
guide rails.
A guide wire must be routed in the ground for the wire guidance system. The signals
from the wire are received by sensors on the chassis and processed by the on-board
computer.
Z The capacity is shown on the data plate.
11.14 EN
19
2 Travel direction definition
The following determinations have been made for travel direction specification:
2 3
2 3
Item Travel direction

1 Left
2 Drive direction
3 Load direction
4 Right
11.14 EN
20
3 Assemblies and Functional Description
3.1 Functional Description
Safety mechanisms
– An enclosed truck geometry with rounded edges ensures safe truck handling. The
overhead guard protects the driver from falling objects.
– The drive wheel and the load wheels are protected by a solid skirt. A residual
danger remains for third parties, even when a skirt is used.
– The Emergency Disconnect immediately disables all truck functions in hazardous
situations.
– Gates on either side of the cab interrupt all truck operations as soon as they are
opened.
– The load direction gates disconnect all truck operations as soon as they are opened
(EKS with load backrest only).
– Line brake safety valves in the lift cylinders restrict the load lowering speed in the
event of a hydraulic system failure.
Deadman button
After the truck is ready for operation ((see "Preparing the truck for operation" on
page 195) or (see "Preparing the truck for operation with an additional access code
(o)" on page 196)) and the gates are closed, the deadman button in the footwell:
– t=
must be depressed once to allow the driver to work with the industrial truck. When
the travel control knob is released and the industrial truck is stationary, the parking
brake engages (prevents the truck from rolling away).
– o=
Depress and hold down to allow the driver to work with the industrial truck. Lifting
and travel are inhibited if the driver takes his foot off the foot switch. Steering and
braking remain enabled. When the deadman button is released and the industrial
truck is stationary, the parking brake engages (prevents the truck from rolling
away).
11.14 EN
21
Emergency Stop safety feature
– If an error is detected by the controller the truck automatically brakes to a halt.

Control indicators on the driver’s display indicate the emergency stop. Each time
the truck is switched on, the system performs a self test which only releases the
parking brake (emergency stop) if the functional test is positive.
Brake system
EKX 410 brake system:

– The electromagnetic spring pressure brake acting on the drive motor serves as
both parking and handbrake. The parking brake is electrically released and
actuated through spring pressure.
– The operator can brake gently and reduce brake wear by pulling back the travel
control button or by changing direction. This feeds energy into the battery (service
brake).
EKS 513 - 515 / EKX 513 - 515 brake system:
– Electronically controlled drive brake and wear-free electromagnetic multiplates
brake acting on the load wheels.
– The operator can brake gently and wear-free by pulling back the travel control
button or by changing direction. This feeds energy into the battery (service brake).
– The electromagnetic spring pressure brake acting on the drive motor serves as
both parking and handbrake. The parking brake is electrically released and
actuated through spring pressure.
– Depending on the lift height, the load wheel brake acting on the front axle (electro-
magnetic spring pressure brake) is only activated when the Emergency Disconnect
switch is pressed or if the truck is set to emergency stop. The load wheel brake is
electrically released and actuated through spring pressure.
11.14 EN
22
Drive system
– Vertically mounted, heavy-duty and maintenance-free threephase motor with no

wear parts. The motor is directly attached to the single-wheel driving gear, ensuring
rapid and trouble-free maintenance.
Steering
– Extremely smooth steering with threephase drive system (sturdy and maintenance-
free threephase motor with no wear parts).
– The steering wheel is integrated in the control panel. The position of the steered
drive wheel is shown in the driver's display. The maximum steer angle is ± 90°.
– In rail guidance mode the drive wheel is set to the straight-ahead position by
pressing a button. Manual steering is deactivated in this mode (o).
– When wire guidance mode is activated, the steering is assumed by the truck
controller when the guide wire is detected. Manual steering is deactivated in this
mode (o).
11.14 EN
23
Controls and displays
– Ergonomic controls ensure fatigue-free operation for sensitive application of the

travel and hydraulic operations.
– Soft keys to control functions (attachment traverse, fork carriage rotate ...) and
menus.
– Colour driver's display unit displays all important driver information such as steering
wheel position, overall lift, truck status reports (e.g. faults), service hours, battery
capacity, time and wire guidance status etc..
– Control panel with electrically adjustable tilt angle.
– Height-adjustable control panel.
– Non-switch two-handed operating principle for maximum safety and operating
comfort. Sensors record any contact made by the operator and feed this
information to the on-board computer.
– For EKS only:
Different control panel arrangements available (o).
Ergonomics and Comfort
– Generous entry room

– Large leg area, adjustable knee pads
– Excellent view of the load and travel lane with extremely low swivel/traverse guides
and clear view masts.
– Cushioned, adjustable and folding comfort seat.
– Individual truck programs.
– Limit position / transition damping for all hydraulic functions.
11.14 EN
24
Electrical System
– Electronic system with wear-free sensors.

– Service laptop connection interface:
To configure all the key truck data (limit position damping, lift cut-out, retardation
and acceleration patterns, cut-outs etc.) rapidly and reliably.
To read off the error log to analyse fault causes.
To simulate and analyse program operations.
Simple function extension by releasing code numbers.
– The controller is fitted with a CAN Bus and a constantly recording sensor system.
All operations can be set using parameters. The controller provide smooth start-up
and braking of the load in all limit positions through end position and intermediate
dampers. The MOSFET three phase controller provides smooth start-up of all
movements.
– Highly efficient three phase technology with energy recovery for the traction and lift
motors provides high travel and lift speeds and better use of energy.
– Simultaneous main lift and auxiliary lift raise / lower (EKS 513 - 515 / EKX 513 - 515
only).
– Simultaneous main lift and auxiliary lift lower.
– Speed recording on the wheels with traction control and drive wheel wear
recognition (o).
Z For traction battery options, (see "Battery types" on page 99).
Hydraulic system
– All hydraulic operations are controlled by a sturdy, maintenance-free AC motor with

no wear parts and with a flanged low emission gear pump.
– Oil is distributed via magnetic switch valves. The varying oil requirements are
controlled by the speed of the motor.
– During a lowering operation the hydraulic pump drives the motor which then acts
as a generator. The energy recovered in this way is fed into the battery
(regenerative lowering).
– Extremely torsion-resistant mast for high residual capacities and minimal mast
sway.
11.14 EN
25
Optional equipment
– Mechanical rail guidance for precision guidance in narrow aisles.

– Wire guidance for precise aisle guidance with no physical load on components.
– Faster cycles through synchronised swivel
– A range of modular telescopic forks.
– Truck prepared to receive work stations.
– “Workstation” comfort package with mirror, work lights and fan.
– Radio with CD player and MP3 interface.
– Mechanical and electrical interfaces for material flow management systems.
– Jungheinrich ISM: Information system for truck management.
– Cut-outs on the overhead guard (e.g. protective device, etc.).
– Modular system of lift and travel cut-outs plus speed reductions.
– Jungheinrich Warehouse Navigation:
– Connection of the truck to a warehouse management system via data radio
terminal or scanner.
– Direct receipt of target position in narrow aisle by the truck computer.
– Automatic vertical positioning.
– Automatic horizontal positioning.
– Automatic stacking.
– Effective twin cycles.
– Avoidance of wrong journeys through area detection
– Maximum flexibility in warehouse through adaptation to existing warehouse
management systems and warehouse extension.
– Transponder-based truck controller system:
– permanent route measurement for precise detection of all warehouse areas.
– High degree of flexibility for various functions (end of aisle safety device, lift/
travel cut-outs, speed reduction)
– Travel speed setting optimisation through ground topology.
– Integrated Jungheinrich personal protection system (PPS).
– On-board charger.
– Camera system.
– Rack Height Select, see description below. 11.14 EN
26
Rack Height Select (o)
Rack Height Select can be used both to lift and lower the load as well as for stacking
and retrieving.
With rack height select, the drive can select the required lift height via a keypad.
Lifting automatically ends when the required lift height is reached.
Rack Height Select is designed for a range of warehouse areas with different rack
heights.
11.14 EN
27
3.2 Assembly Overview
5 6 7 8 9 10 11
12 13 14 15
16 17 18 19
20
21
22
23
24
25
26
27,28
29
30
31
32 33 34 35 32 36 37 38 39 40 41
11.14 EN
28
Item Component
5 t Battery cover
6 o Mast bracing (depending on mast height)
Automatic chain lubrication on the free lift cylinders
7 o
(EKS 513 - 515 / EKX 513 - 515 with DZ mast only)
Automatic chain lubrication on the the top mast cross member
8 o
(EKS 513 - 515 / EKX 513 - 515 with ZT / DZ mast only)
9 t Mast
10 t Overhead guard
11 t Auxiliary mast (EKX only)
12 t Hydraulic control lever
13 t Emergency Disconnect switch
14 t Control panel and driver's display
15 t Travel control knob
16 t Left handle for two-hand operation
17 t Steering wheel
t Key switch (under the control panel)
18
o ISM Access Module (under the control panel)
19 t Right handle for two-hand operation
20 t Gates
21 t Height-adjustable driver's cab
22 o Height-adjustable knee pad
23 t Driver's seat
t Swivel traverse frame (EKX only)
24
o Telescopic table (EKX only)
25 t Fork tine
26 t Deadman switch
27 o Front sensor for wire guidance system (not shown)
28 o Front scanner for personal protection system (not shown)
29 o Rail guidance wheel attachment in front of the load wheel (on either side)
30 t Load wheel
31 t Chassis
32 t Tilt safety device
33 o Rear personal protection system scanner
34 o Rear sensor for wire guidance system
35 t Drive wheel
36 o Drive wheel rail guidance wheel attachment (on either side)
37 t Beacon
38 t Drive compartment cover
39 t Battery connector
40 t Side panel
41 o Rail guidance wheel attachment behind the load wheel (on either side)
o
11.14 EN
Indicates optional equipment
29
4 Technical Specifications
Z Technical data specified in accordance with VDI 2198.
Technical modifications and additions reserved.
4.1 Performance data
4.1.1 EKX 410 performance data
Component EKX 410

Q Capacity (where D = 600 mm) 1000 kg
D Load centre distance 600 mm
Operation type Three-way truck
Travel speed without load (free ranging) 9 km/h
Travel speed with load (free ranging) 9 km/h
Travel speed without load (RG) 91) km/h
Travel speed with load (RG) 91) km/h
Travel speed without load (WG) 7 km/h
Travel speed with load (WG) 7 km/h
Lift speed without load 0,40 2,*) m/s
Lift speed with load 0,36 2,*) m/s
Lower speed without load 0,40* m/s
Lower speed with load 0,40* m/s
Aux. lift speed without load 0,31 m/s
Aux. lift speed with load 0,30 m/s
Aux. lift lower speed without load 0,18 m/s
Aux. lift lower speed with load 0,29 m/s
Traverse speed without load 0,20 - 0,30 3) m/s
Traverse speed with load 0,20 - 0,30 3) m/s
Rotate without load 11 s/180°
Rotate with load 11 s/180°
Service brake Inversion / regenerative
Electric spring-loaded brake /
Parking brake
magnetic brake
Traction controller type AC drive controller
Steering Electric
11.14 EN
30
FF: free ranging
RG: Rail Guidance
WG: Wire guidance
* Depending on mast version
1) Available in conjunction with performance package up to 10,5 km/h
2) Available in conjunction with performance package up to 0,41 m/s
3) Available in conjunction with performance package up to max. 0,40 m/s
(Height-dependent 0,20 m/s to 0,40 m/s)
11.14 EN
31
4.1.2 EKS 513 and EKX 513 performance data
Component EKS 513 EKX 513

Q Capacity (where D = 600 mm) 1250 1250 kg
D Load centre distance 600 600 mm
Three-way
Operation type Order picker
truck
Travel speed without load (free ranging) 9 9 km/h
Travel speed with load (free ranging) 9 9 km/h
Travel speed without load (RG) 10,5 10,5 km/h
Travel speed with load (RG) 10,5 10,5 km/h
Travel speed without load (WG) 9 9 km/h
Lift speed without load 0,42* 0,42* m/s
Lift speed with load 0,42* 0,42* m/s
Lower speed without load 0,45* 0,45* m/s
Lower speed with load 0,45* 0,45* m/s
Aux. lift speed without load -- 0,35 m/s
Aux. lift speed with load -- 0,30 m/s
Aux. lift lower speed without load -- 0,25 m/s
Aux. lift lower speed with load -- 0,30 m/s
Combined raising of main and aux. lift -- 0,70* m/s
Traverse speed without load -- 0,2 - 0,3 3) m/s
Traverse speed with load -- 0,2 - 0,3 3) m/s
Rotate without load -- 13 s/180°
Rotate with load -- 13 s/180°
Parking brake
magnetic brake
Steering Electric
11.14 EN
32
FF: free ranging
RG: Rail Guidance
WG: Wire guidance
1) Available in conjunction with performance package up to 12 km/h
11.14 EN
33
4.1.3 EKS 515k and EKX 515k performance data
Component EKS 515k EKX 515k

Three-way
truck
Travel speed without load (RG) 10,5 1) 10,5 1) km/h
1)
Travel speed with load (RG) 10,5 10,5 1) km/h
Lift speed without load 0,47 2,*) 0,47 2,*) m/s
Lift speed with load 0,47 2,*) 0,47 2,*) m/s
Parking brake
magnetic brake
Steering Electric
11.14 EN
34
FF: free ranging
RG: Rail Guidance
WG: Wire guidance
11.14 EN
35
4.1.4 EKS 515 and EKX 515 performance data

Three-way
truck
Travel speed without load (RG) 10,5 1) 10,5 1) km/h
1)
Travel speed with load (RG) 10,5 10,5 1) km/h
Lift speed without load 0,47 2,*) 0,47 2,*) m/s
Lift speed with load 0,47 2,*) 0,47 2,*) m/s
Parking brake
magnetic brake
Steering Electric
11.14 EN
36
FF: free ranging
RG: Rail Guidance
WG: Wire guidance
11.14 EN
37
4.2 Dimensions (as per data plate)
4.2.1 EKX 410 dimensions with standard attachment
h4
h10
h15
h12
h3
h1
h6
1245mm / 49.02inch
h9
h7
s
m1 m2
x y z
l1
l2
l8
l10
r
b8
D Ast
b9 b6
l6 b2
b14 b1
l b7
e
b5
b3 x
b12
11.14 EN
38
Component EKX 410
D Load centre of gravity 600 mm
x Load distance 445 mm
y Wheelbase 1802 mm
Centre of drive wheel / counterweight
z 237 mm
(Truck geometry)
h1 Mast height retracted 3600 mm
h3 Lift 50002) mm
h4 Mast height extended 7550 mm
h6 Overhead guard height 2550 mm
h7 Seat height / standing height 430 mm
h9 Aux. lift 1780 mm
Overall lift EKX (h3+h9) 67802) mm
h10
Overall lift EKS (h3) -- mm
h12 Raised operator position height 54302) mm
Picking height
h15 70302) mm
(h12 + 1600)
Ast Aisle width for pallets 1200 x 1200 1640 mm
Wa Turning radius 2039 mm
s 40 mm
e Fork dimensions 120 mm
l 1200 mm
Lowest position top of fork tine
-- 75 mm
(s + 35 mm)
Z The data listed in the table (performance data, dimensions and weights) are based
on a truck with the following masts.
The data (performance data, dimensions and weights) for the particular truck
supplied can be found on the data plate.
1)EKX 410 with 500 telescopic mast (ZT mast)
11.14 EN
39
h4
h10
h15
h12
h3
h1
h6
1245mm / 49.02inch
h9
h7
s
m1 m2
x y z
l1
l2
l8
l10
r
b8
D Ast
b9 b6
l6 b2
b14 b1
l b7
e
b5
b3 x
b12
11.14 EN
40
Component EKX 410
b1/
Overall width 1210 / 1500 mm
b2
Fork carriage ISO 2328,
-- 2/B --
Class / type A, B
b3 Fork carriage width 880 mm
b5 Outside straddle 856 mm
b6 Width across guide wheels 1600 mm
b7 Traverse, sideways 1343 mm
b8 Traverse, to the side of truck centre 505 mm
b9 Outer operator position width 1440 mm
b12 Pallet width 1200 mm
b14 Swivel/traverse frame width 1440 mm
I1 Overall length w.o. load 3582 mm
I2 Head length 3286 mm
I6 Pallet length 1200 mm
I8 Fork pivot point distance 1103 mm
Fork pivot point - toothed rack
I8 - x 659 mm
distance
I10 Load handler width 172 mm
m1 Ground clearance below mast 80 mm
m2 Ground clearance centre wheelbase 80 mm
Forks swivel point - fork shank
r 144 mm
distance
Clear internal operator position height
-- (distance from operator position floor 2100 mm
to bottom of overhead guard)
-- Clear operator position entry width 420 mm
Net weight of the industrial truck without battery, (see "Data plate" on
--
page 66)
11.14 EN
41
4.2.2 EKS 513 / EKX 513 dimensions with standard attachment
h4
h15
h1
h12
h10
h3
h6
h9
h7
s m1 m2
x y z
l1
l2
l8
b14 I10 b9
r
b8 D b1 b2 b6 Ast
Wa
b7
l
l6
e
b5
b3 x
b12
11.14 EN
42
D Load centre of gravity 600 600 mm
x Load distance 440 440 mm
y Wheelbase 1826 1826 mm
z 280 280 mm
(Truck geometry)
h1 Mast height retracted 2955 2955 mm
h3 Lift 35001) 35002) mm
h4 Mast height extended 6050 6050 mm
h6 Overhead guard height 2550 2550 mm
h7 Seat height / standing height 430 430 mm
h9 Aux. lift -- 1780 mm
Overall lift EKX (h3+h9) -- 52802) mm
h10
Overall lift EKS (h3) 35001) -- mm
h12 Raised operator position height 39301) 39302) mm
Picking height
h15 55301) 55302) mm
(h12 + 1600)
Ast Aisle width for pallets 1200 x 800 1640 1640 mm
Wa Turning radius 2106 2106 mm
s 50 50 mm
e Fork dimensions 120 120 mm
l 1200 1200 mm
-- 75 75 mm
(s + 25 mm)
1)EKS 513 with 350 telescopic mast (ZT mast)
11.14 EN
43
h4
h15
h1
h12
h10
h3
h6
h9
h7
s m1 m2
x y z
l1
l2
l8
b14 I10 b9
r
b8 D b1 b2 b6 Ast
Wa
b7
l
l6
e
b5
b3 x
b12
11.14 EN
44
Component EKX 513 EKS 513
b1/
Overall width 1210 / 1400 1210 / 1400 mm
b2
-- 2/B 2/B --
Class / type A, B
b3 Fork carriage width 480 480 mm
b5 Outside straddle 465 465 mm
b6 Width across guide wheels 1500 1500 mm
b7 Traverse, sideways -- 1300 mm
b8 Traverse, to the side of truck centre -- 480 mm
b9 Outer operator position width 1440 1440 mm
b12 Pallet width 800 800 mm
b14 Swivel/traverse frame width -- 1440 mm
I1 Overall length w.o. load 3250 3250 mm
I2 Head length 3146 3146 mm
I6 Pallet length 1200 1200 mm
I8 Fork pivot point distance -- 904 mm
I8 - x -- 464 mm
distance
I10 Load handler width 172*) 172*) mm
m1 Ground clearance below mast 80 80 mm
m2 Ground clearance centre wheelbase 80 80 mm
r -- 154 mm
distance
-- (distance from operator position floor 2100 2100 mm
-- Clear operator position entry width 420 420 mm
--
page 66)
* Special Build: I10 = 190 mm
11.14 EN
45
4.2.3 EKS 515k / EKX 515k dimensions with standard attachment
h4
h15
h1
h12
h10
h3
h6
h9
h7
s m1 m2
x y z
l1
l2
l8
b14 I10 b9
r
b8 D b1 b2 b6 Ast
Wa
b7
l
l6
e
b5
b3 x
b12
11.14 EN
46
z 280 280 mm
(Truck geometry)
h3 Lift 35001) 35002) mm
h10
Picking height
h15 55301) 55302) mm
(h12 + 1600)
s 50 50 mm
l 1200 1200 mm
-- 75 75 mm
(s + 25 mm)
1)EKS 515k with 350 telescopic mast (ZT mast)
2)EKX 515k with 350 telescopic mast (ZT mast)
11.14 EN
47
h4
h15
h1
h12
h10
h3
h6
h9
h7
s m1 m2
x y z
l1
l2
l8
b14 I10 b9
r
b8 D b1 b2 b6 Ast
Wa
b7
l
l6
e
b5
b3 x
b12
11.14 EN
48
b1/
Overall width 1210 / 1500 1210 / 1500 mm
b2
-- 2/B 2/B --
Class / type A, B
I2 Headlength 3246 3246 mm
I8 - x -- 464 mm
distance
r -- 154 mm
distance
--
page 66)
1)EKS 515k with 350 telescopic mast (ZT mast)
2)EKX 515k with 350 telescopic mast (ZT mast)
11.14 EN
49
4.2.4 EKS 515 / EKX 515 dimensions with standard attachment
h4
h15
h1
h12
h10
h3
h6
h9
h7
s m1 m2
x y z
l1
l2
l8
b14 I10 b9
r
b8 D b1 b2 b6 Ast
Wa
b7
l
l6
e
b5
b3 x
b12
11.14 EN
50
z 280 280 mm
(Truck geometry)
h3 Lift 35001) 35002) mm
h10
Picking height
h15 55301) 55302) mm
(h12 + 1600)
s 50 50 mm
l 1200 1200 mm
-- 75 75 mm
(s + 25 mm)
11.14 EN
51
h4
h15
h1
h12
h10
h3
h6
h9
h7
s m1 m2
x y z
l1
l2
l8
b14 I10 b9
r
b8 D b1 b2 b6 Ast
Wa
b7
l
l6
e
b5
b3 x
b12
11.14 EN
52
b1/
Overall width 1210 / 1500 1210 / 1500 mm
b2
-- 2/B 2/B --
Class / type A, B
I2 Headlength 3560 3560 mm
I8 - x -- 464 mm
distance
r -- 154 mm
distance
--
page 66)
11.14 EN
53
4.3 Mast versions
4.3.1 Standard mast version with telescopic mast (ZT)
EKS 513
Component EKX 410
EKX 513
h1 Mast height retracted 2600 - 4925 2705 - 5055 mm
h3 Lift 3000 - 7500 3000 - 7500 mm
h4 Mast height extended 5550 - 10050 5550 - 10050 mm
h6 Height of overhead guard 2550 2550 mm
auxiliary lift EKX 1780 1780
h9 mm
auxiliary lift EKS -- --
Overall lift EKX (h3+h9) 4780 - 9280 4780 - 9280
h10 mm
Overall lift EKS (h3) -- 3000 - 7500
Raised operator position
h12 height 3430 - 7930 3430 - 7930 mm
(h3 + h7)
Picking height
h15 5030 - 9530 5030 - 9530 mm
(h12 + 1600 mm)
Z The standard dimension for the clear internal operator position height is 2100 mm.
EKS 515k EKS 515

Component
EKX 515k EKX 515
h3 Lift 3000 - 9500 3000 - 10000 mm
h9 mm
h10 mm
Overall lift EKS (h3) 3000 - 9500 3000 - 10000
h12 height 3430 - 9930 3430 - 10430 mm
(h3 + h7)
Picking height
h15 5030 - 11530 5030 - 12030 mm
(h12 + 1600 mm)
11.14 EN
54
4.3.2 Standard mast with two stage triplex mast (DZ)
EKS 513
Component EKX 410
EKX 513
h2 Free lift height 75 - 1125 0 - 3200 mm
h3 Lift 4500 - 7500 4000 - 7500 mm
h9 mm
h10 mm
Overall lift EKS (h3) -- 4000 - 7500
h12 height 4930 - 7930 4430 - 7930 mm
(h3 + h7)
Picking height
h15 6530 - 9530 6030 - 9530 mm
(h12 + 1600 mm)
EKS 515k EKS 515

Component
EKX 515k EKX 515
h2 Free lift height 0 - 3200 0 - 3200 mm
h3 Lift 4000 - 9500 4000 - 12500 mm
h9 mm
h10 mm
Overall lift EKS (h3) 4000 - 9500 4000 - 12500
h12 height 4430 - 9930 4430 - 12930 mm
(h3 + h7)
Picking height
h15 6030 - 11530 6030 - 14530 mm
(h12 + 1600 mm)
11.14 EN
55
4.4 Weights
4.4.1 Weight of basic truck / mast including driver's cab and attachment
42 43
Basic truck weight (excl. battery)
Z The weight of the basic truck (43) is shown in the following table.
Truck Weight of basic truck

EKX 410 1810 kg1)
EKS 513 / EKX 513 2600 kg2)
EKS 515k / EKX 515k 2600 kg2)
EKS 515 / EKX 515 2600 kg2)
1 This weight includes the additional weight from 180 kg, which is installed in the
industrial truck depending on the design
2 This weight includes the additional weight from 300 kg, which is installed in the
industrial truck depending on the design
11.14 EN
56
Weight of mast including driver's cab and attachment
Z The weight of the mast including driver's cab and attachment (42) can be calculated
by the following formula. The data required, for example the net weight (overall
weight) of the industrial truck without battery, may be taken from the data plate,
(see "Data plate" on page 66).
A Net weight of the industrial truck without battery

B Weight of mast including driver's cab and attachment
Formula for the EKX 410:
B = A - 1630 kg
Formula for the EKS 513 - 515 / EKX 513 - 515:
B = A - 2300 kg
Example:
Required information:
(see truck data plate)
– Type of industrial truck = EKX 513
– Net weight of the industrial truck without battery = 5112 kg
Formula:
B = A - 2300 kg = 5112 kg - 2300 kg = 2812 kg
Z The weight of the mast including driver's cab and attachment is 2812 kg.
11.14 EN
57
4.4.2 Tare weight / axle loads
Z All dimensions in kg.
EKS 513 EKS 515k EKS 515

Component EKX 410
EKX 513 EKX 515k EKX 515
Net weight of the industrial truck
(see "Data plate" on page 66)
without battery
Axle load with load at front 52001) 57202) 61902) 65902)
Axle load with load at rear 14901) 18802) 20602) 28102)
1) 2) 2)
Axle load without load at front 3590 3850 3980 44802)
Axle load without load at rear 21001) 25002) 27702) 34202)
2)EKS 513 - 515 / EKX 513 - 515 with 350 telescopic mast (ZT mast)
11.14 EN
58
4.5 Wheels, chassis
WARNING!
Accident risk from incorrect wheel disassembly/assembly
The load / drive wheels can only be disassembled or assembled by the
manufacturer's customer service department which has been trained to do this.
Exceptionally, this task may be performed by a customer service organisation
authorised by the manufacturer.
EKX 410
Component EKX 410
Tyres Vulkollan
Wheels, front (load wheel) 295 mm x 144 mm
Wheels, rear (drive wheel) 343 mm x 110 mm
Wheels, number of front (load wheel) 2
Wheels, number of rear (*= driven) 1*
EKS 513 - 515 / EKX 513 - 515

Component EKS 513 - 515 / EKX 513 - 515
Tyres Vulkollan
Wheels, front (load wheel) 380 mm x 192 mm
Wheels, rear (drive wheel) 400 mm x 160 mm
Wheels, number of front (load wheel) 2
Wheels, number of rear (*= driven) 1*
11.14 EN
59
4.6 Engine Data
EKS 513
Component EKX 410
EKX 513
Drive motor, output at S2 = 60 min 6,9 kW 7,6 kW
Lift motor, output where S3= 25 % 9,5 kW 20,0 kW
Steer motor, output at S2 = 60 min 0,7 kW 1,0 kW
EKS 515k EKS 515

Component
EKX 515k EKX 515
Drive motor, output at S2 = 60 min 7,6 kW 7,6 kW
Lift motor, output where S3= 25 % 20,0 kW 20,0 kW
Steer motor, output at S2 = 60 min 1,0 kW 1,0 kW
11.14 EN
60
4.7 EN norms
Noise emission level
– EKX 410: 60 dB(A)
– EKS 513 - 515 / EKX 513 - 515: 68 dB(A)
in accordance with EN 12053 as harmonised with ISO 4871.
Z The noise emission level is calculated in accordance with standard procedures and
takes into account the noise level when travelling, lifting and when idle. The noise
level is measured at the level of the driver's ear.
Vibration
– EKX 410: 0,64 m/s²
– EKS 513 - 515 / EKX 513 - 515: 1,14 m/s²
in accordance with EN 13059.
Vibration at driver's seat

– EKX 410: 0,66 m/s²
– EKS 513 - 515 / EKX 513 - 515: 0,70 m/s²
in accordance with EN 13059.
Z The internal accuracy of the measuring chain for at 21°C at ± 0,02 m/s². Further
deviations may occur in particular through the positioning of the sensor and
different driver weights.
Z The vibration acceleration acting on the body in the operating position is, in
accordance with standard procedures, the linearly integrated, weighted
acceleration in the vertical direction. It is calculated when travelling over bumps at
constant speed. These recordings were taken on a single occasion and must not
be confused with the human vibrations of the "2002/44/EC/Vibrations" operator
directive. The manufacturer offers a special service to measure these human
vibrations, (see "Human vibration measurement" on page 553).
11.14 EN
61
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!
Medical equipment can be damaged by non-ionised radiation
Electrical equipment on the truck emitting non-ionised radiation (e.g. wireless data
transmission) can affect operators' medical equipment (pacemakers, hearing aids
etc.) and result in malfunctions. Consult with a doctor or the medical equipment
manufacturer to clarify whether it can be used near the industrial truck.
11.14 EN
62
4.8 Conditions of use
Ambient temperature
– operating at +5°C to +40°C

Z Special equipment and authorisation are required if the truck is to be constantly
used in conditions of extreme temperature or air humidity fluctuations.
The truck is not authorised for use in cold stores.
The truck must only be used in an closed indoor environment. The following
conditions must apply:
– Ambient temperature in 24-hour mode: max. +25°C

– max. air humidity (inside) 70%, non-condensing.
4.9 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.
11.14 EN
63
5 Identification points and data plates
Z Warnings and notices such as capacity charts, strap points and data plates must
be legible at all times. Replace if necessary.
44 45 46 47 46 48 49 50 51
h3 (mm) Q (kg)
D (mm)
52
53
54
53
46
55
56
48
57 mV
1,5 V
58
59 60 61 55 62 63 62 46
11.14 EN
64
Item Component
44 Capacity decal
45 Truck data plate
46 Strap points for crane lifting
47 “Read operating instructions” warning decal
48 "Abseil device" notice
49 “No passengers” warning decal
50 Test plaque (o)
51 "Hazards in narrow aisle" warning decal
Attachments or special attachments (o) capacity plate, (see "Attachment
52
capacity plate" on page 68)
53 "Do not step onto or beneath the load, risk of trapping" warning decal
54 Safety belt with safety rope warning (EKS without front guard or gate only)
“Emergency lower key” decal:
– On the EKX 410 the plate and the emergency lower key are contained in
55 the frame underneath the battery panel
– On the EKS 513 - 515 / EKX 513 - 515 the plate and the emergency lower
key are contained in the frame underneath the flashing light
56 "Manual control panel unlock" notice (bottom left of control panel)
57 “Caution: Low voltage electronics system” decal
58 Company and model information
59 “Emergency lower” decal
60 "Add bio hydraulic oil" decal (o)
61 "Add hydraulic oil" decal (t)
62 Jack contact points
63 Serial number (engraved in chassis underneath the side panel)
11.14 EN
65
5.1 Data plate
64 65 66 67 68 69 70
71
72
73
74
75
Item Description Item Description

64 Type 70 Year of manufacture
65 Serial number 71 Load centre (mm)
66 Rated capacity (kg) 72 Output
67 Battery voltage (V) 73 Min./max. battery weight (kg)
68 Net weight w.o. battery (kg) 74 Manufacturer
69 Option 75 Manufacturer’s logo
Z For queries regarding the truck or ordering spare parts always quote the truck serial
number (65).
5.1.1 Serial number position
NOTE
The truck serial number (65) is indicated on the data plate (45) and is stamped on the
chassis (63) ((see "Identification points and data plates" on page 64)).
11.14 EN
66
5.2 Truck capacity plate
CAUTION!
Accident risk from fork replacement
If you replace the forks with ones that differ from the originals, the capacity will
change.
XWhen replacing the forks you must attach an additional capacity plate to the truck.
XTrucks supplied without forks are given a capacity plate for standard forks (length:
1150 mm).
44
h3 (mm) Q (kg)
D (mm)
The capacity plate (44) gives the capacity Q (kg) of the truck for an upright mast. The
maximum capacity is shown as a table with a given load centre of gravity D (mm) and
the required lift height h3 (mm).
The capacity plate (44) of the truck indicates the truck's capacity with the forks as
originally supplied.
Example of how to calculate the maximum capacity:
h3 (mm) Q (kg)
4250 850 850 600

3600 1105 1105 850
2900 1250 1250 850
D (mm) 500 600 700
For a load cente of gravity D of 600 mm and a maximum lift height h3 of 3600 mm the
maximum capacity is Q 1105 kg.
11.14 EN
67
5.3 Attachment capacity plate
The attachment capacity plate indicates the industrial truck's capacity Q [in kg] in
conjunction with the respective attachment. The serial number specified in the load
chart must match the data plate of the attachment, as the specific capacity for each
truck is indicated by the manufacturer. It is shown in the same way as the truck’s
capacity and can be determined accordingly.
Z For loads with a centre of gravity above 500 mm upward, the capacities are
reduced by the difference of the altered centre of gravity.
5.4 Jack contact points
The "Jack contact point" decal (62) indicates where the truck
62
may be lifted and jacked up ((see "Industrial Truck
Maintenance" on page 481))
11.14 EN
68
5.5 "Residual capacity" tilt safety device notice (o)
WARNING!
Exceeding the maximum capacity can cause a tipover
If you use the optional "residual capacity" tilt safety device, the maximum capacity
must still not be exceeded.
XNever exceed the maximum loads specified on the capacity chart, (see "Truck
capacity plate" on page 67) and (see "Attachment capacity plate" on page 68).
FN xxxxxxxx
With industrial trucks the residual capacity can be
increased by using the optional "residual
capacity" tilt safety devices. X .... mm
X Y .... mm
Unlike standard tilt safety devices, these devices
are fitted on the side of the truck chassis.
Y
Z For details of standard tilt safety devices (see
"Tilt safety device" on page 96). 76
If you use the optional "residual capacity" tilt safety device, the plate (76) is fitted in
the driver's cab below the data plate or capacity plate, (see "Identification points and
data plates" on page 64).
11.14 EN
69
6 Stability
WARNING!
Loss of stability can cause accidents
The stability as indicated in the capacity plate can only be guaranteed with the
components (battery, mast) as shown on the data plate. Only manufacturer-approved
batteries may be used.
The truck's stability has been tested according to latest technological standards.
These take into account the dynamic and static tipover forces that can occur if used
correctly.
Stability can also be affected by the following factors:

– Battery size and weight
– Wheels
– Mast
– Attachment
– Transported load (size, weight and centre of gravity)
– Floor clearance, e.g. modification of the support columns
WARNING!
Changing the components can alter the stability.
11.14 EN
70
C Transport and Commissioning
1 Transport
The truck can be transported in two different ways, depending on the height of the
mast and the local conditions.
– Vertically with the mast and load handler assembled
(for low heights).
– Vertically with the mast and load handler disassembled
(for large truck heights).
All hydraulic lines between the basic truck and mast are disconnected for
transportation.
– Vertically, with the mast tilted (EKX 410 only)
All hydraulic lines between the basic truck and mast are disconnected for
transportation.
11.14 EN
71
Safety Instructions for Assembly and Commissioning
WARNING!
Incorrect assembly can result in accidents
The assembly of the truck at the application site, commissioning and driver training
must only be performed by the manufacturer's customer service representatives who
have been specially trained for these tasks.
XThe hydraulic and electrical lines may only be connected to the basic truck / mast
interface when the mast has been properly assembled.
XThe truck can then be started.
XIf several trucks have been delivered, make sure that always the serial numbers of
the load handlers, masts and basic trucks match each other.
11.14 EN
72
2 Lifting by crane
WARNING!
All persons involved in loading by crane must be trained
Incorrect crane loading procedures due to untrained personnel can result in the truck
(basic truck, mast, ...) falling. There is a risk of injury to personnel and a risk of
material damage to the truck.
XLoading must be carried out by specially trained staff in accordance with
recommendations contained in Guidelines VDI 2700 and VDI 2703.
WARNING!
Improper lifting by crane can result in accidents
The use of unsuitable lifting gear can cause the truck to crash when being lifted by
crane.
Prevent the truck and mast from striking other objects when they are being raised,
and avoid any uncontrolled movement. If necessary, secure the truck and mast with
guide ropes.
XThe truck and mast should only be laden by people who are trained in handling
lifting slings and tools.
XWear personal protective equipment (e.g. safety boots, helmet, hi-vis jacket,
protective gloves etc.) when loading by crane.
XDo not stand under a swaying load.
XDo not walk into or stand in a hazardous area.
XAlways use lifting gear with sufficient capacity (for truck weight see truck data
plate).
XAlways attach the crane slings to the prescribed strap points and prevent them from
slipping.
XUse the lifting gear only in the prescribed load direction.
XCrane slings should be fastened in such a way that they do not come into contact
with any attachments when lifting.
11.14 EN
73
2.1 Lifting by crane with mast assembled
77 13
78
6
78 18
79
Safe lifting of the basic truck by crane with mast assembled

Requirements
– Park the truck on a level surface.
– Lower the load handler to the ground, (see "Lifting / lowering – outside and inside
narrow aisles" on page 226).
– Turn the industrial truck off with the key switch (18) and remove the key.
– Press the Emergency Disconnect switch (13) down.
– Remove the battery from the truck's battery compartment, (see "Battery removal
and installation" on page 108).
– Remove the mast bracing (6) if present. The mast bracing can only be
disassembled by the manufacturer's specialist customer service personnel who
have been trained to do this. Alternatively, this task may be performed by a
customer service organisation authorised by the manufacturer.
Tools and Material Required
– Crane slings, for capacity details refer to the truck data plate.
– A ladder if necessary.
Procedure
Z For details of the weight of the "basic truck with mast assembled" to be taken into
account when lifting by crane, refer to the truck data plate, (see "Data plate" on
page 66).
11.14 EN
74
WARNING!
Crane lifting gear can tear, resulting in accidents
Crane lifting gear can tear when routed over "sharp" edges, causing the load to crash.
XProtect the crane lifting gear with a suitable support (78).
XDo not route the crane lifting gear over "sharp" edges.
XCrane lifting gear should be fastened in such a way that they do not come into
contact with any parts of the truck when it is being raised.
• Attach the crane lifting gear to the attachment points (77,79) so that the truck
cannot slip.
• On either side attach the crane lifting gear to the "top mast cross member"
attachment point (77) on the mast.
• On either side attach the crane lifting gear to the "bottom mast bracing eyes"
attachment point (79) on the drive compartment.
The truck can now be lifted.
11.14 EN
75
2.2 Loading the basic truck by crane with mast tilted
(EKX 410 only)
77
80
78 81 80
Safe lifting of the basic truck by crane with a tilted mast

Requirements
– Turn the truck off with the key switch and remove the key.
– Press the EMERGENCY DISCONNECT switch down.
– Tilt the mast and fit the transport retainers (80). The mast can only be tilted and the
transport retainers (80) can only be fitted by the manufacturer's specialist customer
service personnel who have been trained to do this. Alternatively, this task may be
performed by a customer service organisation authorised by the manufacturer.
– Crane slings, for capacity details refer to the truck data plate.
Procedure
Z For details of the weight of the "basic truck with mast tilted" to be taken into account
when lifting by crane, refer to the truck data plate, (see "Data plate" on page 66).
11.14 EN
76
WARNING!
cannot slip.
attachment points (77) on the mast.
• On either side attach the crane lifting gear to the eyes (81) of the bottom mast
attachment.
The truck can now be lifted.
11.14 EN
77
2.3 Lifting the basic truck by crane
82
78
78 79
83
84
Safe lifting of the basic truck by crane

Requirements
– Remove the mast bracing (if present). The mast bracing can only be disassembled
by the manufacturer's specialist customer service personnel who have been
trained to do this. Alternatively, this task may be performed by a customer service
organisation authorised by the manufacturer.
– Dismantle the mast. The mast can only be disassembled by the manufacturer's
specialist customer service personnel who have been trained to do this.
Alternatively, this task may be performed by a customer service organisation

– Torque wrench with a minimum torque of 205 Nm.
– Torque wrench fixture: Allen key with key width EKX 410 = 14; EKS 5xx = 17; EKX
5xx = 17.
– Crane lifting gear, capacity (see "Weight of basic truck / mast including driver's cab
and attachment" on page 56).
Procedure
Z Weight of the basic truck to be taken into account, (see "Weight of basic truck / mast
including driver's cab and attachment" on page 56).
• Assemble the half shells (83) on either side of the truck:
11.14 EN
78
• On either side attach a half shell (83) above the "mast receptacle / top half shell"
attachment point (84).
• Attach the half shell (83) to the chassis with two Allen screws (84).
NOTE
Torque the Allen screws (key width EKX 410 = 14; EKS 5xx = 17; EKX 5xx = 17) to
205 Nm.
WARNING!
• Attach the crane lifting gear (82) to the attachment points (79,84) so that the truck
cannot slip.
• On either side attach crane lifting gear (82) to the "mast receptacle / top half
shell" attachment point (84).
• On either side attach crane lifting gear (82) to the "bottom mast bracing eyes"
attachment point (79) on the drive compartment.
The basic truck can now be lifted.
11.14 EN
79
2.4 Lifting the mast by crane with the cab and load handler
77
78
80
78 81
Safe lifting of the mast by crane with the cab and load handler
Requirements
– Remove the mast bracing (if present). The mast bracing can only be disassembled
by the manufacturer's specialist customer service personnel who have been
trained to do this. Alternatively, this task may be performed by a customer service
organisation authorised by the manufacturer.
– Crane lifting gear, capacity (see "Weight of basic truck / mast including driver's cab
and attachment" on page 56).
Procedure
Z Weight of the mast including cab and load handler to be taken into account, (see
"Weight of basic truck / mast including driver's cab and attachment" on page 56).
• Fit the transport retainer (80).
WARNING!
11.14 EN
80
cannot slip.
attachment points (77) on the mast.
• On either side attach the crane lifting gear to the eyes (81) of the bottom mast
attachment.
The mast can now be lifted.
11.14 EN
81
2.5 Lifting the battery by crane
WARNING!
All persons involved in loading by crane must be trained
Incorrect crane loading procedures due to untrained personnel can result in the
battery falling. There is a risk of injury to personnel and a risk of material damage to
the battery.
recommendations contained in Guidelines VDI 2700 and VDI 2703.
WARNING!
Improper lifting of the battery by crane can cause accidents

The use of unsuitable lifting gear can cause the battery to crash when being lifted by
crane.
Prevent the battery from striking other objects when they are being raised, and avoid
any uncontrolled movement. If necessary secure the battery with guide ropes.
XThe battery should only be laden by people who are trained in handling lifting slings
and tools.
protective gloves etc.) when loading by crane.
XDo not stand under a swaying load.
XDo not walk into or stand in a hazardous area.
XOnly use lifting gear with sufficient capacity (for battery weight see truck data plate).
XAttach the crane slings only to the prescribed strap points and prevent them from
slipping.
XUse the lifting gear only in the prescribed load direction.
XCrane slings should be fastened in such a way that they do not come into contact
with any attachments when lifting.
WARNING!
Batteries can be hazardous
Batteries contain an acid solution which is poisonous and corrosive. Above all avoid
any contact with battery acid.
XDispose of used battery acid in accordance with regulations.
XAlways wear protective clothing and goggles when working with batteries.
XDo not let battery acid come into contact with skin, clothing or eyes. If necessary,
rinse with plenty of clean water.
XIn the event of physical damage (e.g. skin or eye contact with battery acid) call for
a doctor immediately.
XSpilled battery acid should be neutralised immediately with plenty of water.
XOnly batteries with a sealed battery container may be used.
XFollow national guidelines and legislation.
11.14 EN
82
Safe lifting of the battery by crane
Requirements
– Remove the battery from the truck's battery
compartment, (see "Battery removal and
installation" on page 108).
– Crane lifting gear, for capacity details refer to the
battery data plate.
– Pallet
– Tie-down strap / tensioning belt
Procedure
Z The weight of the battery to be taken into account
when loading by crane can be taken from the
battery data plate.
• Lifting the battery with crane lifting gear:
• Attach the lifting gear to the four eyes of the battery tray (for weight refer to the
battery data plate).
The battery can now be raised and loaded with a crane.
• Loading the battery onto a pallet:
• Place the battery on a pallet.
• Attach the battery to the pallet with two tie-down straps / tensioning belts.
The battery can now be raised and loaded with a forklift truck.
11.14 EN
83
3 Securing the truck during transport
WARNING!
Accidental movement during transport
Improper fastening of the truck and mast during transport can result in serious
accidents.
recommendations contained in Guidelines VDI 2700 and VDI 2703 In each case
correct measurements must be made and appropriate safety measures adopted.
XThe truck must be securely fastened when transported on a lorry or a trailer.
XThe lorry / trailer must have fastening rings.
XUse wedges to prevent the truck from moving.
XUse only tension belts or tie-down straps or with sufficient strength.
3.1 Basic truck transport retainer
78 85 83 78 79 86
84
87
78
30
88
89 90 91 92 93 35 94
Securing the basic truck for transportation

Requirements
– Disconnect the battery if this is also contained in the truck.
– Disassemble the tilt safety mechanism.
– Load the basic truck correctly onto the lorry / trailer.

– Tie-down straps / tensioning belts with a rated strength of > 5 to..
– Two hard wooden blocks with identical dimensions and composition.
– Two identical wedges.
– Torque wrench with a minimum torque of 205 Nm.
11.14 EN
84
– Torque wrench fixture: Allen key with key width EKX 410 = 14; EKS 5xx = 17; EKX
5xx = 17.
Procedure
• Relieve the drive wheel (35). To do this place the hard wooden blocks (93) under
the chassis on either side in front of the drive wheel (35).
• Place wedges (88) in front of the load wheels (30) to prevent the truck from moving
accidentally.
• Disassemble the side panel if present and package it separately.
CAUTION!
The tie-down straps / tensioning belts must be attached on either side to at least three
different clamp rings (89,92,94).
WARNING!
Torn tie-down straps / tensioning belts can cause accidents
Tie-down straps / tensioning belts can tear when routed over "sharp" edges.
XProtect the tie-down straps / tensioning belts with a suitable support (78).
XDo not route the tie-down straps / tensioning belts over "sharp" edges. If this is not
possible, protect the tie-down straps/tensioning belts with a suitable material, e.g.
foam.
XProtect the tie-down straps/tensioning belts routed over the lift chains with a
suitable material, e.g. foam.
CAUTION!
Note the wire routing and protect it from damage.
• Guide the tie-down strap / tensioning belt (91) at the front of the chassis over both
wheel arms (90) and attach it to the clamp rings (92) on either side.
• Guide the tie-down strap / tensioning belt (86) through the "bottom mast bracing
eyes" strap points (79) on the battery compartment and attach it to the clamp
rings (94).
• Assemble the half shells (83) on either side of the truck:
• On either side attach a half shell (83) above the "mast receptacle / top half shell"
attachment point (84).
• Attach the half shell (83) to the chassis with two Allen screws (84).
• Guide the tie-down strap / tensioning belt (87) above the "mast receptacle/top half
shell" attachment point (84) through the two mast attachments (85) and secure it to
the clamp rings (89).
The basic truck can now be transported.
11.14 EN
85
3.2 Mast transport retainer
95 78 9 78 21 78 96 81
80
97
89
98
99
100
94 78 101 92 97 102 78 103
Securing the mast for transportation

Requirements
– Prevent the operator position (21) from slipping by using the transport retainer (80).
– Prevent the fork carriage (96) from slipping.
– Load the mast correctly onto the lorry / trailer.
– Transport pallet (100).
– Pallet (95) to stow any supplied parts (fork tines, guide wheels, ...).
Procedure
• Place the mast (9) on the pallet (100).
• From the bottom end of the mast (9) to the transport pallet (100) form a positive fit
with wooden beams (103).
WARNING!
foam.
11.14 EN
86
CAUTION!
different clamp rings (89,92,94).
• Secure the mast (9) to the transport pallet (100) with the tie-down straps (101).
• Guide the tie-down strap (102) through the driver's cab (21) and around the
mast (9) and secure it.
• Stow any supplied parts (fork tines, guide wheels, etc.)
on a pallet (95) so that they cannot slip.
• Place a pallet (95) on the top section of the mast (9).
• Guide the tie-down strap (99) through the pallet (95)
and around the mast (9) and secure it.
95
• On either side attach two tie-down straps / tensioning
belts (97) to the eyes (81) of the bottom cross-member of
the mast (9) and to the clamp rings (89,92).
• Route the tie-down straps / tensioning belts (98) over the top section of the
mast (9), if necessary over the pallet (95) and secure them to the clamp rings (94).
The mast can now be transported.
11.14 EN
87
3.3 Transport retainer for basic truck with the mast assembled
103 104 9 77 105
89 106 88 30 93 35 94
Securing the basic truck with the mast assembled for transport
Requirements
– Load the truck correctly onto the lorry / trailer.
– Two identical wedges.
– Wooden plank, pallet or rubber mat.
Procedure
• Ensure a positive fit with the front of the van:
• On the EKS:
Using a wooden plank, pallet or a rubber mat (103) from the load handler (106)
to the front of the van; ensure a positive fit.
• On the EKX:
From the fork carriage (106) to the front of the van form a positive fit using
wooden beams, a pallet or a rubber mat (103).
the chassis on either side in front of the drive wheel (35).
• Place wedges (88) in front of the load wheels (30) to prevent the truck from moving
accidentally.
11.14 EN
88
CAUTION!
The tie-down straps / tensioning belts must be attached on either side to at least two
different clamp rings (89,94).
WARNING!
foam.
• Attach at least four tie-down straps / tensioning belts, two to the left and two to the
right (104,105) to the "top cross-member" attachment points (77) on the mast (9)
and secure them to the clamp rings (89,94).
The truck can now be transported.
11.14 EN
89
3.4 Transport retainer for basic truck with the mast tilted
(EKX 410 only)
80
78
80 77
104
97
81
98
103 89 30 90 78 91 92 93 35 94 107
Securing the basic truck with the mast tilted for transport
Requirements
– Tilt the mast and fit the transport retainers (80). The mast can only be tilted and the
transport retainers (80) can only be fitted by the manufacturer's specialist customer
service personnel who have been trained to do this. Alternatively, this task may be
performed by a customer service organisation authorised by the manufacturer.
– Load the truck correctly onto the lorry / trailer.
– Wooden plank, pallet or rubber mat.
Procedure
• Using a wooden plank, pallet or a rubber mat (103), ensure a positive fit between
the load wheels (30) and the front of the van.
the chassis on either side at the height of the drive wheel (35).
11.14 EN
• Disassemble the side panel if present and package it separately.
90
CAUTION!
different clamp rings (89,92,94,107).
WARNING!
foam.
CAUTION!
Note the wire routing and protect it from damage.
• Guide the tie-down strap / tensioning belt (91) at the front of the chassis over both
wheel arms (90) and attach it to the clamp rings (92) on either side.
• Route the tie-down straps / tensioning belts (98) over the top of the mast (9) and
attach to the clamp rings (107) on either side.
• On either side attach a tie-down strap / tensioning belt (97) to the eyes (81) of the
bottom cross-member of the mast (9) and to the clamp rings (94).
• On either side attach a tie-down strap / tensioning belt (104) to the "top mast cross
member" attachment points (77) on the mast (9) and the clamp rings (89).
The truck can now be transported.
11.14 EN
91
4 Using the Truck for the First Time
Safety Instructions for Assembly and Commissioning
WARNING!
Incorrect assembly can result in accidents
The assembly of the truck at the application site, commissioning and driver training
must only be performed by the manufacturer's customer service representatives who
have been specially trained for these tasks.
XThe hydraulic and electrical lines may only be connected to the basic truck / mast
interface when the mast has been properly assembled.
XThe truck can then be started.
XIf several trucks have been delivered, make sure that always the serial numbers of
the load handlers, masts and basic trucks match each other.
CAUTION!
Only operate the truck with battery current. Rectified AC current will damage the
electronic components. Cable connections to the battery (tow leads) must be less
than 6 m long and have a minimum cross-section of 50 mm².
4.1 Moving the industrial truck without a battery

This operation must only be performed by suitably trained maintenance personnel.
WARNING!
It must not be performed on slopes or inclines (no brakes).
Z Moving the industrial truck without a battery (see "Recovering the truck from a
narrow aisle / Moving the truck without a battery" on page 278).
11.14 EN
92
4.2 Installing and removing the mast
WARNING!
The mast can only be disassembled / assembled by the manufacturer's specialist
customer service personnel who have been trained to do this. Exceptionally, this task
may be performed by a customer service organisation authorised by the
manufacturer.
WARNING!
Trapping hazard in the swivel and traverse area of the attachment
There is a trapping hazard in the attachment area while the attachment is traversing
and swivelling.
XKeep all personnel out of the hazardous area during hydraulic operations.
XInstruct other people to move out of the hazardous area of the industrial truck.
XStop working with the truck if people do not leave the hazardous area.
11.14 EN
93
4.3 Commissioning
108 30 109 110 111 112 23
Preparing the truck for operation after delivery or transport

Requirements
– Unload the truck from the van, lorry or trailer.
– Assemble the mast. The mast can only be assembled by the manufacturer's
– Fit the mast bracing (if present). The mast bracing can only be assembled by the
manufacturer's specialist customer service personnel who have been trained to do
this. Alternatively, this task may be performed by a customer service organisation
– Cable ties.
– Adhesive tape.
– For EKS 513 - 515 / EKX 513 - 515 only:
Allen key (key width 4) to undo the load wheel panels.
– For EKS 513 - 515 / EKX 513 - 515 only:
Allen key (key width 6) to undo the setscrews (110).
Procedure
• Check the equipment is complete.
• Loosen the transport chains (108).
• Fit the battery if necessary ((see "Battery removal and installation" on page 108)).
• Charge battery ((see "Battery removal and installation" on page 108)).
• Check hydraulic oil level and top up if necessary ((see "Checking the hydraulic oil
level" on page 542)).
• Remove the load wheel brake retainers (109) (EKS 513 - 515 / EKX 513 - 515 only).
Z The transport retainers release the load wheel brakes (109) when they are de-
energised.
• Disassemble the load wheel guards (30) by removing the three Allen screws
from the load wheels (30).
• Remove the transport retainers from the load wheel brakes (109) by removing
three setscrews (110) from the load wheel brakes (109).
The load wheel brakes (109) are now applied without power.
11.14 EN
• Store the setscrews (110) in the plastic bag supplied.

• Seal the plastic bag with adhesive tape / cable ties.
94
• Fit the guards of the load wheels (30) on both sides:
• Place the guards on the load wheels (30).
• Attach the guards to the load wheel (30) with three Allen screws.
• Store the plastic bag and setscrews (110) behind the driver's seat (23).
• Enter the operator position, (see "Entry and exit" on page 160)
• Remove the twist grip screws (111) from the left and right sides behind the
driver's seat (23).
• Tilt the operator seat (23) carefully in the load direction.
• Secure the plastic bag with cable ties behind the panel (112) of the driver's
seat (23).
Z Make sure the plastic bag does not come into contact with moving parts when
the truck is moving. Also ensure that the plastic bag cannot fall into the hole
below the panel (112) when the truck is moving.
• Carefully tilt the driver's seat (23) back.
CAUTION!
Hand trapping hazard
Trapping hazard for hands when tilting back the driver's seat.
XMake sure there is nothing between the driver's seat and the operator position
when you tilt the driver's seat back.
• Attach the driver's seat (23) to the operator position using the two twist grip
screws (111).
• Close the lowering valve for driver's cab / mast emergency lowering, (see "Driver's
cab emergency lowering" on page 265).
• Check that all safety mechanisms are present and test them (e.g. tilt safety devices
etc.).
• Start up the industrial truck as indicated ((see "Preparing the Truck for Operation"
on page 155) and (see "Preparing the truck for operation" on page 195)).
The truck is ready for operation after delivery or transport.
11.14 EN
95
4.4 Tilt safety device
Z Depending on the tilt test the EKS / EKX may be supplied with tilt safety
devices (32). The tilt safety devices are fitted to the left and right of the rear truck
chassis. When a tilt safety device (32) is used, under the right side panel (40) an
"X" is engraved in the chassis (31) after the serial number ((see "Identification
points and data plates" on page 64)).
CAUTION!
Before commissioning, check industrial
trucks to ensure the tilt safety devices (32)
are present.
NOTE
For a new drive wheel, the distance from
the tilt safety device (32) to the ground
should be 10 mm to 12 mm. 40 31
32
11.14 EN
96
D Battery - Servicing, Recharging,
Replacement
1 Safety Regulations Governing the Handling of Lead-Acid
Batteries
Maintenance personnel
Batteries may only be charged, serviced or replaced by trained personnel. This

operator manual and the manufacturer’s instructions concerning batteries and
charging stations must be observed when carrying out the work.
Fire protection
Do not smoke and avoid naked flames when handling batteries. Wherever an
industrial truck is parked for charging there shall be no inflammable material or
lubricants capable of creating sparks within 2 m around the truck. The room must be
ventilated. Fire protection equipment must be on hand.
Battery maintenance
The battery cell covers must be kept dry and clean. The terminals and cable shoes
must be clean, secure and have a light coating of dielectric grease.
CAUTION!
Before closing the battery panel make sure that the battery cable cannot be
damaged. There is a risk of short circuits with damaged cables.
Battery disposal
Batteries may only be disposed of in accordance with national environmental

protection regulations or disposal laws. The manufacturer’s disposal instructions
must be followed.
11.14 EN
97
1.1 General notes on handling batteries
WARNING!
WARNING!
Unsuitable batteries that have not been approved by Jungheinrich 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 by Jungheinrich for the truck can
lead to a deterioration of the braking system during energy recovery operations and
also cause considerable damage to the electrical control system. The use of batteries
that have not been approved by Jungheinrich can therefore affect the health and
safety of personnel.
XOnly manufacturer-approved batteries may be used on the truck.
XReplacement of the battery equipment requires the manufacturer's agreement.
XWhen replacing/installing the battery make sure the battery is securely located in
the battery compartment of the truck.
XDo not use batteries that have not been approved by the manufacturer.
Park the truck securely before carrying out any work on the batteries ((see "Parking
the truck securely" on page 239)).
11.14 EN
98
2 Battery types
WARNING!
Risk of short circuit or electric shock
Always use batteries whose covers or live components are insulated.
The EKS / EKX can be fitted with a variety of battery types. All battery types comply
with DIN 43531-A. The following table shows which combinations are included as
standard:
Truck model Battery type Voltage Capacity Weight

4Pzs 460 48 V 460 Ah 673 - 745 kg1)
5Pzs 575 48 V 575 Ah 813 - 899 kg1)
EKX 410
6Pzs 750 48 V 750 Ah 960 - 1062 kg1)
6Pzs 930 48 V 930 Ah 1319 - 1457 kg1)
EKS 513 80 V 1,238 kg1)
3 PzS 465 465 Ah
EKX 513 2 x 40 V 2 x 625 kg 2)
EKS 515k 80 V 1,558 kg1)
4 PzS 620 620 Ah
EKX 515k 2 x 40 V 2 x 800 kg 2)
EKS 515 80 V 2,178 kg1)
6 PzS 930 930 Ah
EKX 515 2 x 40 V 2 x 1,075 kg 2)
1 Single part battery version
2 Two part battery version
Z The battery weights can be taken from the battery data plate.
11.14 EN
99
WARNING!
The weight and dimensions of the battery have a considerable effect on the
operational safety of the industrial truck. When replacing the battery equipment, make
certain that the battery dimensions, types and weights of the replacement battery are
identical with those of the previously used battery. Failure to comply with the
prescribed battery weight range can render the truck unstable.
XUse only batteries whose weight is within the minimum and maximum range stated
on the truck's data plate.
XWhen replacing or installing a battery, ensure that it is correctly secured in the
truck's battery compartment.
XChanging the battery features requires the manufacturer’s approval, as
compensating weights are required if smaller batteries are fitted.
11.14 EN
100
2.1 Dimensions of the battery compartment
Truck model Length (L) Width (W) Height (H)

1,070 mm 635 mm 815 mm
EKX 410
Maximum battery height = 785 mm
EKS 513 1,060 mm 616.5 mm 925 mm
EKX 513 Maximum battery height = 880 mm
EKS 515k 1,060 mm 716.5 mm 925 mm
EKX 515k Maximum battery height = 880 mm
EKS 515 1,060 mm 1,012.5 mm 925 mm
EKX 515 Maximum battery height = 880 mm
11.14 EN
101
3 Exposing the battery
WARNING!
An unsecured truck can cause accidents
Parking the truck on an incline or with a raised load handler is dangerous and is
strictly prohibited.
XAlways park the truck on a level surface. In special cases the truck may need to be
secured with wedges.
XAlways fully lower the mast and forks.
XSelect a place to park where no other people are at risk of injury from lowering
forks.
EKX 410 EKS 513 -515 / EKX 513 - 515
13
13
18
18
5
5
39
39
11.14 EN
102
Opening the battery panel
Requirements
– Park the truck securely, (see "Parking the truck securely" on page 239).
Procedure
• Lower the load handler to the ground, (see "Lifting / lowering – outside and inside
• Switch off the truck, to do this:
• Turn the key in the key switch (18) left as far as the stop and remove the key.
• Press the red button on the ISM access module (o).
• Press the Emergency Disconnect switch (13) down.
• Lift up the battery cover (5) (see arrow direction).
The battery cover (5) is now open.
CAUTION!
Open covers can cause injury and accidents

XThe covers (battery cover, side panels, drive compartment cover etc.) must be
closed during operation.
CAUTION!
Trapping hazard
There is a risk of trapping when you close the battery cover.
XMake sure there is nothing between the battery cover and the truck when you close
the battery cover.
Closing the battery cover

Requirements
– Battery cover (5) open.
Procedure
• Close the battery panel (5) carefully.
The battery cover (5) is closed and prevented from opening automatically.
11.14 EN
103
4 Charging the battery
WARNING!
The gases produced during charging can cause explosions
The battery produces a mixture of nitrogen and hydrogen (electrolytic gas) during
charging. Gassing is a chemical process. This gas mixture is highly explosive and
must not be ignited.
XSwitch the charging station and truck off first before connecting/disconnecting the
charging cable of the battery charging station to/from the battery connector.
XThe charger must be adapted to the battery in terms of voltage and charge
capacity.
XBefore charging, check all cables and plug connections for visible signs of damage.
XVentilate the room in which the truck is being charged.
XThe battery cover must be open and the battery cell surfaces must be exposed
during charging to ensure adequate ventilation.
XDo not smoke and avoid naked flames when handling batteries.
XWherever an industrial truck is parked for charging there shall be no inflammable
material or lubricants capable of creating sparks within 2 m around the truck.
XFire protection equipment must be on hand.
XDo not lay any metallic objects on battery.
XIt is essential to follow the safety regulations of the battery and charger station
manufacturers.
NOTE
The use of unevenly charged batteries can result in material damage
If using the two battery version, the following safety regulations must be observed to
prevent material damage to the batteries.
Operating with unevenly charged batteries will result in material damage to the
batteries, so that both batteries will have to be replaced.
XAlways remove and install batteries in pairs.
XAlways charge batteries in pairs.
11.14 EN
104
Safety procedures for charging 5
batteries
Requirements
– Park the truck securely, (see "Parking
the truck securely" on page 239).
– Expose the battery, (see "Exposing the
battery" on page 102).
– Switch off the charger.
– Correct charging program set on
charger.
Procedure
• Disconnect the battery (39).
113
• Connect the charge cable of the battery 39
charging station to the battery
connector (39).
CAUTION!
When charging, the tops of the battery cells must be exposed to provide sufficient
ventilation. Do not place any metal objects on the battery. Before charging, check all
cables and plug connections for visible signs of damage.
NOTE
Risk of fire and material damage
The charger must be adapted to the battery in terms of voltage and charge capacity.
It is essential to follow the safety regulations of the battery and charger station
manufacturers.
• Switch on the charger.

• Charge the battery (113) in accordance with the battery and charging station
manufacturer's instructions.
The battery is charged.
11.14 EN
105
WARNING!
CAUTION!
Trapping hazard
There is a risk of trapping when you close the battery cover.
the battery cover.
11.14 EN
106
Preparing the battery for operation after 5
charging
Requirements
– The battery (113) is fully charged.
Procedure
• Switch off the charger.
• Disconnect the battery charging station
cable from the battery connector (39).
• Check all cables and plug connections
for visible signs of damage.
CAUTION!
There is a risk of short circuits with 113
damaged cables. 39
XReport any defects immediately to your
supervisor.
XTag out and decommission a faulty lift
truck.
XDo not return the industrial truck to
service until you have identified and
rectified the fault.
• Attach the battery connector (39) to the industrial truck.
CAUTION!
• Close the battery cover (5).

After the battery charge the truck is ready for operation.
Z After a fully discharged battery has been completely re-charged and the truck
switched on, it may take a few seconds before the truck is operational. During this
time the battery symbol in the driver's display flashes.
11.14 EN
107
5 Battery removal and installation
WARNING!
Accident risk during battery removal and installation
Due to the battery weight and acid there is a risk of trapping or burning when the
battery is removed and installed.
XNote the "Safety regulations for handling acid batteries" section in this chapter.
protective gloves etc.) when removing and installing the battery.
XUse only batteries with insulated cells and terminal connectors.
XWhen replacing a battery always install the same battery type in the battery
compartment. Extra weights must not be removed and must remain in the same
position.
XPark the truck on a level surface to prevent the battery from sliding out.
XMake sure the crane lifting gear has sufficient capacity to replace the battery.
XUse only approved battery replacement devices (battery roller stand, replacement
trolley etc.).
XMake sure the battery is securely located in the truck's battery compartment.
CAUTION!
Battery installation and removal can cause short circuits
The battery cable or connector can get trapped between the truck chassis and battery
when the battery is installed and removed.
Damaged cables can cause short circuits, setting the truck and battery on fire.
XPlace the battery cable and connector on the battery.
XDo not pinch or trap the battery cable and connector.
5.1 Removing and installing the battery with a battery roller stand
(single part batteries)
B 114
C
5
115
39
A
E
113
11.14 EN
40 116
108
Removing the battery
Requirements
– Expose the battery, (see "Exposing the battery" on page 102).

– Battery roller stand
Procedure
• Remove the battery connector (39).
• Disassemble the side panels (40):
• On the EKX 410:
Remove the top section of the side panels (40) from the battery compartment
and lift out the side panels (see arrow direction "A").
• On the EKS 5xx / EKX 5xx:
Pull up and lift out the side panels (40) (see arrow direction "A").
• Unlatch and remove the battery retainer (115):
• Turn the handle (114) approx. 180° anti-clockwise (see arrow direction "B").
• Lift up the battery retainer (115) (see arrow direction "C").
• Lift up the battery retainer (116) (see arrow direction "D").
• Position the battery roller stand in front of the battery compartment in such a way
that the battery (113) can be safely pushed onto the roller stand.
• Push the battery (113) sideways onto the prepared battery roller stand (see arrow
direction "E").
• Secure the battery (113) on the roller stand against accidental movement.
The battery is now removed.
WARNING!
Accident risk when battery is not installed
operational safety and capacity of the industrial truck. Working with the industrial
truck is prohibited when the battery is not installed in the battery compartment. In
exceptional cases, short shunting travel is permitted, for example to change the
battery.
The following conditions must apply:
XThe tow leads must be less than 6 m and have a minimum cross-section of 50 mm².
XMast completely lowered, (see "Lifting / lowering – outside and inside narrow
aisles" on page 226).
XNo load unit lifted.
XOnly carry out short shunting operations at inching speed.
XThis requires added concentration on the part of the operator.
11.14 EN
109
B 114
C
5
115
39
A
E
113
40 116
CAUTION!
Hand / arm trapping hazard
There is a risk of trapping when you close the battery cover and fit the side panels,
battery retainers, battery locks and battery.
XMake sure there is nothing between the parts mentioned above and the truck when
you fit the battery, retainers and side panels.
the battery cover.
Battery installation
Requirements

– Battery roller stand
Procedure
• Position the battery roller stand with the battery (113) in front of the battery
compartment in such a way that the battery (113) can be safely pushed into the
truck's battery compartment.
Z The battery retainers (115,116) can swap positions. This means that they can both
be fitted in either the left or right side of the truck’s chassis.
• Insert the battery retainer (116) opposite the entry side in the chassis (see arrow
direction "D").
• Undo the battery lock on the battery roller stand.
• Push the battery (113) off the roller stand as far as the stop in the truck's battery
compartment (see arrow direction "E").
• Insert and lock the battery retainer (115):
11.14 EN
• Insert the battery retainer (115) in the chassis (see arrow direction "C").
• Turn the handle (114) approx. 180° clockwise (see arrow direction "B").
110
CAUTION!
• Assemble the side panels (40):

• Insert the bottom section of the side panels (40) at an angle into the chassis (see
arrow direction "A").
• Pull up the side panels (40) and insert them in the chassis (see arrow
direction "A").
• Check all cables and plug connections for visible signs of damage.
CAUTION!
There is a risk of short circuits with damaged cables.
XReport any defects immediately to your supervisor.
XTag out and decommission a faulty lift truck.
XDo not return the industrial truck to service until you have identified and rectified the
fault.

When the battery has been installed the truck is ready for operation.
11.14 EN
111
5.2 Battery assembly / removal using a fork lift truck (two part batteries)
C 116
39
A 113
D
117
B
116
40 117
Removing the battery
Requirements

– Fork lift truck with a minimum fork length of 1200 mm and a capacity in excess of 2
to..
Attention!!
Note the maximum capacity with respect to the load centre distance.
Procedure
• Remove the battery connector (39) on either side.
• Disassemble the side panels (40) on either side:
• Pull up and lift out the side panels (40) (see arrow direction "A").
• Lift up the battery retainers (116) on either side (see arrow directions "B" and "C").
• Carefully pull out the battery (113) on the left or right hand sides using a forklift
truck.
NOTE
Risk of material damage
When replacing and installing the batteries avoid damaging the truck chassis,
batteries and battery compartment.
XUse a jack with sufficient capacity and the correct fork length.
XInsert the forks of the truck used for assembly / removal carefully into the fork shoe
of the battery roller stand.
XRaise the batteries just high enough so that they can be moved into the battery
compartment without striking it.
XAvoid tilting the batteries during removal / assembly.
11.14 EN
• Set the mast of the truck upright, thereby bringing the load handler into a
horizontal position.
112
• Insert the forks of the truck into the fork shoes (117) of the battery roller stand.
• Drive the fork lift slowly forward until the forks are touching the stop in the battery
compartment.
• Raise the battery (113) carefully until they are clear of the ground.
• Reverse the truck carefully and pull the battery (113) out of the battery
compartment (see arrow direction "D").
• Lower the battery (113) outside of the battery comparment.
• Slowly push the forks into the fork shoe (117) of the battery roller stand until the fork
shank is resting against the battery (113).
The battery is removed and can be transported.
WARNING!
Accident risk when battery is not installed
operational safety and capacity of the industrial truck. Working with the industrial
truck is prohibited when the battery is not installed in the battery compartment. In
exceptional cases, short shunting travel is permitted, for example to change the
battery.
The following conditions must apply:
XThe tow leads must be less than 6 m and have a minimum cross-section of 50 mm².
XMast completely lowered, (see "Lifting / lowering – outside and inside narrow
XNo load unit lifted.
XOnly carry out short shunting operations at inching speed.
XThis requires added concentration on the part of the operator.
11.14 EN
113
CAUTION!
the battery cover.
C 116
39
A 113
D
117
B
116
40 117
Battery installation
Requirements

– Fork lift truck with a minimum fork length of 1200 mm and a capacity in excess of 2
to..
Attention!!
Note the maximum capacity with respect to the load centre distance.
Procedure
• Bring the battery (113) in front of the battery compartment.
• Lower the battery (113).
• Reverse the fork lift truck so that the forks are flush with the battery roller stand and
are not sticking out of the fork shoes (117).
• Insert the battery in the battery compartment:
11.14 EN
114
NOTE
When replacing and installing the batteries avoid damaging the truck chassis,
batteries and battery compartment.
XUse a jack with sufficient capacity and the correct fork length.
XInsert the forks of the truck used for assembly / removal carefully into the fork shoe
XRaise the batteries just high enough so that they can be moved into the battery
compartment without striking it.
XAvoid tilting the batteries during removal / assembly.
• Raise the battery (113) so that it can be moved into the battery compartment
without striking it.
• Slowly insert the battery (113) into the battery compartment as far as the stop
(see arrow direction "D").
• Lower the battery (113).
• Slowly reverse the truck and pull the forks carefully out of the fork shoes (117)
Z The battery retainers (116) can swap positions. This means that they can both be
fitted in either the left or right side of the truck’s chassis.
• Insert the battery retainers (116) on either side into the truck chassis (see arrow
directions "B" and "C").
CAUTION!
• Assemble the side panels (40) on either side:

• Insert the bottom section of the side panels (40) at an angle into the chassis (see
arrow direction "A").
• Pull up the side panels (40) and engage them in the chassis (see arrow
direction "A").
CAUTION!
fault.

When the battery has been installed the truck is ready for operation.
11.14 EN
115
6 "Battery lock" sensors (o)
118
15
26 16 119 19
CAUTION!
An unsecured battery can result in accidents
If the battery retrainers are not applied in the chassis, the battery may slide out of the
battery compartment when the truck moves.
XApply the battery lock in the chassis.
XOnly short shunting operations can be performed without the battery locks. During
these operations the operator must apply greater concentration.
During operation the "battery lock" sensors monitor if the battery retainers in the
chassis have been applied.
If the battery retainers have not been inserted and latched correctly in the chassis,
the truck will not move. The driver's display shows the "Battery lock not applied"
symbol (118).
Operating the truck outside a narrow aisle without battery retainers in place
Requirements
– Prepare the truck for operation, (see "Preparing the truck for operation" on
(o)" on page 196).
Procedure
• Press the Deadman switch (26).
• Press and hold down on the (119) key below the "battery lock override"
symbol (118).
• The travel control button (15) controls travel speed and direction:
• Turn clockwise = Travel in load direction.
• Turn anti-clockwise = Travel in drive direction.
The truck can now travel at slow speed (max. 0,8 km/h).
11.14 EN
116
Operating the truck within a narrow aisle without battery retainers in place
Requirements
(o)" on page 196).
Procedure
• Press the Deadman switch (26).
• Grab hold of grip (16) with your left hand and grip (19) with your right hand (two-
hand operation).
• Press (119) under the "battery retainer override" symbol (118).
• The travel control button (15) controls travel speed and direction:
• Turn clockwise = Travel in load direction.
• Turn anti-clockwise = Travel in drive direction.
The truck can now travel at slow speed (max. 0,8 km/h).
Z The speed restriction is removed once the battery retainer(s) is/are inserted in the
chassis. The "battery lock not applied" symbol (118) fades out. The truck can now
travel again at the approved speed.
Z Hydraulic operations are not affected if the battery retainers are not in place.
11.14 EN
117
118
11.14 EN
E Operation
1 Safety Regulations for the Operation of the
Forklift Truck
Driver authorisation
The truck may only be used by suitably trained personnel, who have demonstrated to
the proprietor or his representative that they can drive and handle loads and have
been authorised to operate the truck by the proprietor or his representative.
Driver's rights, responsibilities and rules of behaviour
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. The driver
shall be afforded all due rights.
Unauthorised use of truck
The driver is responsible for the truck during the time it is in use. The driver must
prevent unauthorised persons from driving or operating the truck. Do not carry
passengers or lift other people.
Damage and faults
The supervisor must be immediately informed 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 driver must not carry out any repairs or alterations to the truck without the
necessary training and authorisation to do so. The driver must never disable or adjust
safety mechanisms or switches.
11.14 EN
119
Hazardous area
WARNING!
Risk of accidents / injury in the hazardous area of the truck
The hazardous area is defined as the area in which a person is at risk due to truck
movement, lifting operations, the load handler (e.g. forks or attachments) or the load
itself. This also includes areas which can be reached by falling loads or lowering
operating equipment.
XInstruct unauthorised people to leave the hazardous area.
XGive a warning signal with plenty of time for people to leave.
XIf unauthorised personnel are still within the hazardous area stop the truck
immediately.
DANGER!
Accident risk
XThe driver must remain within the protected area of the overhead guard while the
truck is being operated.
Safety devices and warning labels
Safety devices, warning signs ((see "Identification points and data plates" on
page 64)) and warning instructions in the present operating instructions must be
strictly observed.
Z Warnings and notices such as capacity charts, strap points and data plates must
be legible at all times. Replace if necessary.
WARNING!
Accident risk due to removing or disabling of safety devices

Removal or disabling of safety devices such as the Emergency Disconnect switch,
deadman switch, horn, warning lights, gates, protective window, covers, etc. may
result in accidents and injuries.
XOnly return the truck to service when you have identified and rectified the fault.
11.14 EN
120
2 Displays and Controls
2.1 Controls and displays on the control panel
12 120 121 122 123 124 125 126 127 15
128
19
16 13 17 129 119 130 131
14
20
23
26
18 132
11.14 EN
121
12 120 121 122 123 124 125 126 127 15
128
19
16 13 17 129 119 130 131
14
20
23
26
18 132
11.14 EN
122
Item Control / display Function
Controls the hydraulic functions, e.g. Main Lift raise
and lower, fork carriage rotate in conjunction with
Hydraulic control
12 t the "Fork carriage rotate" key (125), attachment
lever
traverse in conjunction with the "Attachment rotate"
key (126).
Emergency Disconnects the main power supply, all truck
13 t
Disconnect switch operations are disabled.
Truck functions can be controlled with the control
14 Control Panel t
panel.
15 Travel control knob t Controls the travel direction and speed of the truck.
Handle with hand Two-hand operation in narrow aisle (via contacts in
16 rest and contact t the handle).
point Enables lifting and travel in the narrow aisle.
17 Steering wheel t Steers the truck in the required direction.
Switches control current on and off.
Key switch and key t Removing the key prevents the truck from being
switched on by unauthorised personnel.
In addition to the key switch.
18 Releases the truck response with card or
transponder.
ISM access module o
– Time out monitoring
– Records the truck's operators (shifts)
– Operational data acquisition
Handle with hand Two-hand operation in narrow aisle (via contacts in
19 rest and contact t the handle).
point Enables lifting and travel in the narrow aisle.
11.14 EN
123
12 120 121 122 123 124 125 126 127 15
128
19
16 13 17 129 119 130 131
14
20
23
26
18 132
11.14 EN
124
Prevent the operator from falling out.
The EKS 513, EKS 515k and EKS 515 with load
20 Gates t guard also have gates in the load direction. These
also act as a block to prevent the driver from falling
out.
Adjusts the driver's seat, (see "Adjusting the
23 Driver's seat t
driver’s seat" on page 164).
The deadman switch ensures that the operator
remains in the driver's cab as travel and lift
operations are being performed.
With this version the deadman switch must be

applied at least once after the truck becomes ready
for operation and the gates have been closed, in
order to operate the truck (lift/./lower/travel/operate
attachment).
– Not applied ("Deadman switch not applied"
display is lit in the driver's display, (see "Driver's
display" on page 132)):
Deadman switch • Steering, driver's display and horn are
26 t enabled.
(foot switch)
• Travel functions are inhibited.
• Hydraulic functions are inhibited.
– Applied briefly at least once ("Deadman switch
not applied" display goes out, (see "Driver's
display" on page 132)):
• Travel operations are released. When the
travel control button has been released the
truck brakes regeneratively to a halt (parking
brake applied). The industrial truck coasts to
a stop according to the “coasting brake”
parameter setting.
• Hydraulic operations are released.
11.14 EN
125
12 120 121 122 123 124 125 126 127 15
128
19
16 13 17 129 119 130 131
14
20
23
26
18 132
11.14 EN
126
The deadman switch ensures that the operator
remains in the driver's cab as travel and lift
operations are being performed.
With this version the deadman switch must be

applied permanently while the truck is in operation
(lift/lower/travel/attachment operation).
– Apply and hold down on the deadman switch

("Deadman switch not applied" display goes out,
(see "Driver's display" on page 132)):
• Travel operations are released.
Deadman switch • Hydraulic operations are released.
26 o
(foot switch) – When the deadman switch has been released
("Deadman switch not applied" display is lit in
the driver's display, (see "Driver's display" on
page 132)):
• the truck brakes regeneratively until it comes
to a halt (parking brake applied). The
industrial truck coasts to a stop according to
the “coasting brake” parameter setting.
• travel functions are inhibited.
• hydraulic functions are inhibited.
• steering, the driver's display and the horn
remain enabled.
The functions shown in the driver's display (shown
as symbols) are activated or confirmed with the key
119 "Functions" key t
underneath the symbol. The symbol appears dark
or inverse when the corresponding key is pressed.
11.14 EN
127
12 120 121 122 123 124 125 126 127 15
128
19
16 13 17 129 119 130 131
14
20
23
26
18 132
11.14 EN
128
120 "Horn" key t Activates the horn, activates an audible warning.
Activates wire guidance in the narrow aisle.
Rail guidance:
“Switch automatic – Sets the drive wheel to the straight ahead
121 t position.
guidance on/off” key
Wire guidance:
– Activates wire acquisition (and frequency
selection for multi-frequencies).
Allows the control panel to be tilted between 130 °
“Control panel
122 t and 180 °, (see "Adjusting the control panel angle"
adjustment” key
on page 169).
Operating information and warning message
123 Driver's display t
display.
Note:
124 Indicators t
For manufacturer's service department only.
“Fork carriage Changes the hydraulic control lever to rotating the
125 t
rotate” key fork carriage.
“Attachment Changes the hydraulic control lever to traversing
126 t
traverse” key the attachment.
Activates the hydraulic control lever to lift and lower
127 "Auxiliary lift" key t
the fork carriage without the driver’s cab.
EKX 410:
– Changes the hydraulic control lever to
simultaneous lowering of the main and auxiliary
“Main and Aux. Lift lift.
128 t
raise/lower” key EKS 513 - 515 / EKX 513 - 515:
– Changes the hydraulic control lever to
simultaneous lifting and lowering of the main and
auxiliary lift.
11.14 EN
129
12 120 121 122 123 124 125 126 127 15
128
19
16 13 17 129 119 130 131
14
20
23
26
18 132
11.14 EN
130
Changes menu: When you press the "Quit sub-
“Quit sub-menu”
129 t menu" key the menu currently shown in the driver's
key
display changes to the higher-level menu.
Controls and settings for standard functions (e.g.
time setting) and additional functions (e.g. Rack
130 Numerical keypad t
Height Select, manual warehouse navigation data
entry).
Cursor keys for Controls and settings for standard functions (e.g.
131 special hydraulic t setting the time) and additional functions (e.g. rack
functions height select).
Control panel height The control panel height can be adjusted by 85
132 t
adjuster mm.
t Denotes standard equipment
o Denotes optional equipment
11.14 EN
131
2.2 Driver's display
133 134 135 136 137 138 139 140 141 142
0h 07:48 ETX 5xx IF FNxxxx
P 143
xx m xx kg
144
145
146
147
148
119 149 150
11.14 EN
132
Item Symbol Display Function
Truck is ready for operation.
"Parking brake Indicates the truck is stationary.

t
applied" indicator
Parking brake (drive wheel brake) is
133 applied.
For EKS 513 - 515 / EKX 513 - 515 only:
"Drive wheel brake
R referencing" indicator
t Indicates the truck has come to a halt and
the drive wheel brake is being referenced.
Displays the number of service hours
134 "Service hours" t since the truck was started for the first
time.
135 "Time" t Shows the time.

11.14 EN
133
133 134 135 136 137 138 139 140 141 142
P 143
xx m xx kg
144
145
146
147
148
119 149 150

Indicates the current steer angle with
136 Steer angle display t
reference to the centre position.
Rail guidance: Steer angle display is replaced by the following symbols:
Symbol lights up as soon as the truck is
"Truck guided (with
automatically guided and has received an
aisle detection)"
aisle signal.
automatically guided and has not
received an aisle signal.
136
o – Continue driving industrial truck along
"Truck guided
(without aisle the narrow aisle.
detection)" – As soon as the industrial truck receives
an aisle signal, the "Truck guided
(without aisle detection)" symbol is
replaced by the "Truck guided (with
aisle detection)" symbol.
11.14 EN
134
Wire guidance: Steer angle display is replaced by the following symbols:
“Acquisition in Symbol lights up as soon as the truck has
progress” acquired the guide wire.
"Truck guided (with
automatically guided on the wire and has
aisle detection)"
received an aisle signal.
"Truck guided Symbol lights up as soon as the truck is
(without aisle automatically guided on the wire and has
detection)" not received an aisle signal.
– Continue driving industrial truck along

the narrow aisle.
– As soon as the industrial truck receives
an aisle signal, the "Truck guided
(without aisle detection)" symbol is
replaced by the "Truck guided (with
136 aisle detection)" symbol.
o
Symbol is lit as soon as the industrial
truck has been turned off and on again
with the key switch on the guide wire.
– Continue driving industrial truck along

the narrow aisle.
"Truck not guided“ – "Truck not guided" symbol is replaced
by the "Acquisition in progress"
symbol.
– As soon as the industrial truck has
acquired the guide wire and received a
valid aisle signal, the "Truck guided
(with aisle detection)" symbol is lit.
Symbol lights up as soon as the truck
“Deviation from
moves away from the guide wire and
guide wire”
therefore from automatic guidance.
11.14 EN
135
133 134 135 136 137 138 139 140 141 142
P 143
xx m xx kg
144
145
146
147
148
119 149 150

Display:
– Truck model
137 "Truck features" t – Truck features (wire guidance / rail
guidance)
– Serial number
Shows the lift height of the forks after
“Overall lift” t
referencing.
"Main Lift raise"
t Requests Main Lift to raise.
referencing
"Main Lift lower"
138 t Requests Main Lift to lower.
referencing
"Aux. Lift raise"
t Requests Aux. Lift to lift.
referencing
"Aux. Lift lower"
t Requests Aux. Lift to lower.
referencing
Shows the battery charge status (bar
t
Battery Discharge display).
139
Indicator Displays the battery charge status
- +
75% o
(residual capacity as a percentage).
The current level is given a dark
140 "Level" t
background.
Indicates that the permissible water
content level in the hydraulic oil has been
exceeded. The hydraulic oil must be
"Change hydraulic
141 o replaced. Contact the manufacturer's
oil"
service department. The manufacturer
has a service department specially
trained for these tasks.
11.14 EN
136
Indicates that there are people / obstacles
in the warning field of the personal
protection system in the narrow aisle,
“Warning field (see "Obstacles and / or persons in the
infringement” o warning field" on page 328).
indicator
The truck brakes. During this time the
travel speed is restricted to slow travel
(2,5 km/h).
– Indicates that there are people /
obstacles in the protection field of the
personal protection system in the
narrow aisle, (see "Obstacles and / or
"Protection field persons in the protection field" on
142
infringement" o page 329).
indicator – Indicates zero activation frequency for
the stationary personal protection
system.
The truck brakes to a halt.
Indicates that the cycle test of the
personal protection system must be
performed (every 24 hours), (see "Cycle
“Perform cycle test”
o test" on page 327).
display
(2,5 km/h).
143 kg "Weigher function" o Shows the weight of the raised load in kg.
Displays the attachment's home position,

"Attachment home (see "Traversing and rotating the
t
position" attachment in the home position (t)" on
page 241).
Displays the telescopic table's centre
144
"Telescopic table position, (see "Traversing the telescopic
o
centre position" table to the centre position (o)" on
page 242).
“Horizontal positioning” Horizontal positioning, (see "Horizontal
o
function stacking display positioning (o)" on page 413).
11.14 EN
137
133 134 135 136 137 138 139 140 141 142
P 143
xx m xx kg
144
145
146
147
148
119 149 150

“Guide wire Wire guidance sensors that have
145 o
detection” detected the guide wire illuminate.
"Deadman switch not Truck is ready for operation.

t
pressed" Deadman switch not pressed.
"Gates not closed" Truck is ready for operation.
t
display Gates not closed.
"Emergency Truck is ready for operation.
Disconnect switch t
applied" Emergency Disconnect switch applied.
Travel and hydraulic functions are
146 inhibited.
– Do not touch the handles (16,19).

– Do not press the deadman switch.
"Remove hands from
t – "Remove hands from control panel
control panel" symbol goes out.
– Press the deadman switch.
– Touch the handles (16,19) again.
Travel and hydraulic functions are
released again.
Rabbit:
t
Displays possible – Max. travel speed.
147
travel speeds: Turtle:
t
– Inching speed.
11.14 EN
138
Shows event and / or information
"Service mode messages on the driver's display.
t
active" indicator The truck brakes. The travel speed is
restricted to slow travel (2,5 km/h).
A wire guidance antenna on the truck has
148
left the prescribed range of the guide wire.
"Wire guidance fault"
o The industrial truck immediately
indicator undergoes an emergency stop ((see "WG
emergency operation (event messages
3670 / 3752)" on page 277)).
"Function symbols"(t).
149 Description of function symbols, (see "Driver's display function symbols" on
page 144).
"Rack height select" / "Horizontal positioning" symbols (o), (see "Rack Height
150
Select (o)" on page 396) or (see "Horizontal positioning (o)" on page 413).
t Denotes standard equipment
o Denotes optional equipment
WG Wire guidance
RG Rail guidance
2.3 Hourmeter
Z Prepare the truck for operation, (see "Preparing the truck for operation" on
(o)" on page 196).
Service hours are counted while the truck is operational and the deadman button is
pressed.
11.14 EN
139
2.4 "Bar display" battery discharge indicator
Z The standard setting for the battery discharge indicator / discharge

monitor is based on standard batteries. When using maintenance-
free or special batteries the display and cutout points of the battery
discharge monitor must be set by authorised specialist personnel.
If this adjustment is not made the battery may become damaged
through excessive depletion.
NOTE
Full discharge can damage the battery
Self-discharge can cause the battery to fully discharge. Full discharge shortens the
useful life of the battery.
XCharge the battery at least every 2 months.
Z Charge the battery, (see "Charging the battery" on page 104).
13 123
Requirements
– Connect the battery to the truck.
– Close the battery cover.
– Enter the driver's cab.
Procedure
• Turn the EMERGENCY DISCONNECT
switch (13) to unlock it.
• Switch on the truck, to do this:
• Insert the key in the key switch (18) and
turn it as far right as it will go.
• Hold the card or transponder in front of the
ISM access module and depending on the 18
setting press the green button on the ISM
access module (o).
The battery discharge indicator in the driver's display (123) shows the available
battery capacity.
Z The lower section of the battery symbol is empty. It indicates the residual capacity
of the battery which is protected and cannot be used to avoid damaging the battery.
11.14 EN
140
2.4.1 Battery discharge monitor with bar display
Z When a battery is discharged to the permissible level (residual capacity) the battery
symbol in the driver's display is empty and flashing. An indicator appears in the
driver's display. Main Lift and Auxiliary Lift raising is inhibited.
Battery symbol Meaning

Battery is charged.
Permanently lit – The more bars the battery discharge indicator shows,
the greater the battery's residual capacity.
Battery charge recommended.
– Depending on the battery type, the battery discharge
indicator symbol flashes when there are one or two
remaining bars.
Flashing Battery charge required (charge is below residual
capacity level).
– The battery discharge indicator symbols does not
show any bars.
– Main Lift and Auxiliary Lift raising is inhibited.
"Raising" is only released when the connected battery:
– is at least 40 % charged (two bars) for a wet-cell battery.
– is at least 50 % charged (three bars) for a gel battery.
11.14 EN
141
2.5 "Percentage display" battery discharge indicator (o)
Z The standard setting for the battery discharge indicator /

- +
discharge monitor is based on standard batteries. When using
maintenance-free or special batteries the display and cutout 75%
points of the battery discharge monitor must be set by authorised
specialist personnel. If this adjustment is not made the battery
may become damaged through excessive depletion.
NOTE
13 123
Requirements
– Close the battery cover.
– Enter the driver's cab.
Procedure
• Turn the EMERGENCY DISCONNECT
switch (13) to unlock it.
• Switch on the truck, to do this:
• Insert the key in the key switch (18) and
turn it as far right as it will go.
• Hold the card or transponder in front of the
ISM access module and depending on the 18
setting press the green button on the ISM
access module (o).
The battery discharge indicator in the driver's display (123) shows the available
battery capacity.
11.14 EN
142
2.5.1 Percentage display battery discharge monitor (o)
Z If a battery is discharged to less than 31 % for wet-cell batteries or 41 % for gel
batteries (residual capacity), the battery symbols flashes in the driver's display.
Main Lift and Auxiliary Lift raising is disabled below 21 % for wet-cell batteries and
31 % for gel batteries.
Battery discharge monitor for wet-cell batteries:

Percentage Percentage Meaning
Battery is charged.
Permanently lit 100 % - 31 % – The higher the percentage, the greater the
battery residual capacity.
30 % - 21 % Battery charge recommended.
Battery charge required (charge is below
Flashing
20 % - 0 % residual capacity level).
Z Raising is only enabled when the battery connected is at least 40 % charged.
Battery discharge monitor for gel batteries:

Percentage Percentage Meaning
Battery is charged.
Permanently lit 100 % - 41 % – The higher the percentage, the greater the
battery residual capacity.
40 % - 31 % Battery charge recommended
Battery charge required (charge is below
Flashing
30 % - 0 % residual capacity level).
Z Raising is only enabled when the battery connected is at least 50 % charged.
11.14 EN
143
2.6 Driver's display function symbols
Procedure
Z The "Functions" key (119) underneath the 149
symbols (149) in the driver's display
activate or confirm the respective function.
The symbol (149) has a dark background.
The following section describes the
symbols for the displayed functions.
119
Symbol and meaning Function

Telescopic table, fork operation
“Single telescopic fork” Indicates that operation with single
o
display telescopic forks is possible.
Activates the single telescopic fork. This
hydraulic function is controlled with the
“Single telescopic fork”
o "hydraulic functions" control lever, (see
button
"Single telescopic forks (o)" on
page 384).
“Telescopic table fork Indicates that the forks of the telescopic
o
positioning” display table can be adjusted.
Activates movement of the telescopic
forks.
“Telescopic table fork
o This hydraulic function is controlled with
positioning” button the "hydraulic functions" control lever,
(see "Telescopic forks adjustment (o)"
on page 365).
Indicates that the telescopic forks can be
“Telescopic forks” display o
operated.
Activates the telescopic forks.
“Telescopic forks" button
the "hydraulic functions" control lever.
“Telescopic forks - Indicates that the “Telescopic forks -
synchronised movement” o synchronised movement” function can be
display operated.
Activates synchronised movement of the
telescopic forks.
“Telescopic fork - This hydraulic function is controlled with
synchronised movement” o the "hydraulic functions" control lever,
button (see "Individual movement of the
telescopic table fork tines (o)" on
page 367).
11.14 EN
144
“Top telescopic forks - Indicates that the “Top telescopic forks -
asynchronous o asynchronous movement” function can
movement” display be operated.
Activates asynchronous movement of
the top telescopic forks.
“Top telescopic forks - This hydraulic function is controlled with
asynchronous o the "hydraulic functions" control lever,
movement” button (see "Individual movement of the
page 367).
“Bottom telescopic forks - Indicates that the “Bottom telescopic
asynchronous o forks - asynchronous movement”
movement” display function can be operated.
Activates asynchronous movement of
the bottom telescopic forks.
“Bottom telescopic forks - This hydraulic function is controlled with
asynchronous o the "hydraulic functions" control lever,
movement” button (see "Individual movement of the
page 367).
“2nd stacking depth” Indicates that the "2nd stacking depth"
o
display function is possible.
Activates the 2nd stacking depth of the
telescopic forks.
“2nd stacking depth”
button the "hydraulic functions" control lever,
(see "Double telescopic forks (o)" on
page 385).
11.14 EN
145
Standard attachment, fork operation
“Synchronised rotate Changes the menu to “synchronised
t
menu change” display rotate” functions.
Changes menu: When you press the
"Synchronised rotate menu change"
button the menu currently shown in the
“Synchronised rotate driver's display changes to
t
menu change” button "Synchronised rotate", (see
"Simultaneous traversing - rotation
outside and inside narrow aisles" on
page 234).
“Fork manual Indicates that it is possible to manually
synchronised left rotate” t rotate the fork carriage to the left and
display traverse the load handler to the right.
Activates manual fork carriage
synchronised left rotate and load handler
“Fork manual right traverse.
synchronised left rotate” t The attachment traverse movement is
button controlled with the "hydraulic functions"
control lever, (see "Manual traverse/
rotate operation (t)" on page 235).
synchronised right rotate” t rotate the fork carriage to the right and
display traverse the load handler to the left.
synchronised right rotate and load
“Fork manual handler left traverse.
synchronised right rotate” t The attachment traverse movement is
button controlled with the "hydraulic functions"
control lever, (see "Manual traverse/
rotate operation (t)" on page 235).
Indicates that it is possible to
“Automatic fork
automatically rotate the fork carriage to
synchronised left rotate” t
the left and traverse the load handler to
display
the right.
Activates automatic fork carriage
“Automatic fork
synchronised left rotate and load handler
synchronised left rotate” t
right traverse.(see "Automatic traverse/
button
rotate operation (o)" on page 237).
11.14 EN
146
“Automatic fork
automatically rotate the fork carriage to
synchronised right rotate” t
the right and traverse the load handler to
display
the left.
“Automatic fork synchronised right rotate and load
synchronised right rotate” t handler left traverse.(see "Automatic
button traverse/rotate operation (o)" on
page 237).
synchronised rotate to o rotate the fork carriage 90° and traverse
centre position” display the load handler to the centre.
synchronised 90° rotate and load handler
centre traverse.
“Fork manual
synchronised rotate to o The attachment traverse movement is
centre position” button controlled with the "hydraulic functions"
control lever, (see "Manual synchronised
rotation until forks are in centre position
(o)" on page 236).
“Automatic fork
automatically rotate the fork carriage 90°
synchronised rotate to o
and traverse the load handler to the
centre position” display
centre.
“Fork automatic synchronised 90° rotate and load handler
synchronised rotate to o centre traverse, (see "Automatic
centre position” button synchronised rotation until forks are in
centre position (o)" on page 238).
11.14 EN
147
Attachment / fork positioner / sideshift
“Fork positioner /
Changes the menu to “Fork positioner /
sideshift menu change” o
sideshift” functions.
display
“Fork positioner / Activates fork positioner / sideshift menu
sideshift menu change” o change.
button
“Symmetrical fork Indicates that symmetrical fork
o
positioner” display positioning is possible.
Activates symmetrical fork positioning.
“Symmetrical fork
positioner” button
“Asymmetrical fork
Changes the menu to “Asymmetrical fork
positioning menu o
positioning menu change" functions.
change” display
“Asymmetrical fork Activates asymmetrical fork positioning
positioning menu o menu change.
change” button
“Left fork positioning” Indicates that the left fork can be
o
display adjusted.
Activates left fork positioning.
“Left fork positioning”
button
“Right fork positioning” Indicates that the right fork can be
o
display adjusted.
Activates right fork positioning.
“Right fork positioning”
button
Indicates that the forks can be moved to
“Fork sideshift” display o
the left or the right.
Activates fork sideshift.
“Fork sideshift” button o This hydraulic function is controlled with

the "hydraulic functions" control lever,
(see "Fork sideshift (o)" on page 373).

Attachment, fork tilt, special attachment
“Fork tilt” display o Indicates that fork tilt is possible.
Activates fork tilt.
“Fork tilt” button o This hydraulic function is controlled with
11.14 EN
148
“Special attachment” Indicates that a special attachment can
o
display be operated.
Activates special attachment operation.
“Special attachment”
button

Guidance systems
Indicates that wire guidance is available
"Select frequency 1"
o with frequency 1 (similar to other
display
frequencies, maximum 5 frequencies).
Activates wire guidance via frequency 1
"Select frequency 1"
o (sub-menu is quit automatically when
button
pressed for 1 sec.).
11.14 EN
149
Personal protection system (PSS)
– Indicates that there are people /
obstacles in the protection field of the
personal protection system in the
narrow aisle, (see "Obstacles and / or
“Protection field persons in the protection field" on
o page 329).
infringement” display
– Indicates zero activation frequency for
the stationary personal protection
system.
Overrides the protective function and
enables inching speed (2,5 km/h) if there
is sufficient distance from the obstacle,
“Protection field
o (see "Obstacles and / or persons in the
infringement" key protection field" on page 329).
Travel is controlled with the travel control
knob.
Indicates that there are people /
obstacles in the warning field of the
personal protection system in the narrow
“Warning field aisle, (see "Obstacles and / or persons in
o the warning field" on page 328).
infringement” display
(2,5 km/h).
Indicates that the cycle test of the
personal protection system must be
performed (every 24 hours), (see "Cycle
“Acknowledge cycle test”
o test" on page 327).
display
(2,5 km/h).
“Acknowledge cycle test”
o Automatically starts the cycle test.
key
11.14 EN
150
Warnings
“Slack chain protection” Appears as soon as the slack chain
t
display protection is activated.
Overrides the slack chain protection to
raise the driver's cab clear, (see "Slack
“Slack chain protection chain safety device override" on
t page 269).
override” key
This hydraulic function is controlled with
the hydraulic control lever.
Appears as soon as lift cutout is
“Fwd./Rev. travel only activated due to low battery capacity.
due to low battery t
capacity” display The truck can now only move forward or
in reverse.
Confirms lift cutout for low battery
“Acknowledge lift cutout capacity and releases travel.
due to battery discharge” t
key Travel is controlled with the travel control
knob.
“Height dependent lift Appears as soon as automatic lift cutout
o
cutout” display is activated.
Overrides lift cutout, (see "Lift cutout
override (o)" on page 271).
Attention:
“Lift cutout override” key o The maximum overhead clearance must
be taken into account.

Appears as soon as the automatic lower
“Lower limit” display o
limit is activated.
Overrides the lower limit, (see "Lower
cutout override (o)" on page 273).
“Lower limit override” key o
Appears as soon as automatic, height-
dependent travel cutout is activated, (see
“Travel cutout” display o
"Travel cutout override (o)" on
page 270).
Overrides the automatic, height
“Travel cutout override” dependent travel cutout.
o
key Travel is controlled with the travel control
knob.
11.14 EN
151
Indicates that the end of aisle safety
"End of aisle safety
o device has been activated.
device" display
Indicates that several warnings (e.g.
Select “Warning sub- slack chain protection, lift cutout, set date
t
menu” display / time, operator specific settings,…) have
been activated.
Select “Warning sub- Individual warnings are shown in the
t
menu” key driver's display.
Quit “warnings” sub-
t Indicates that the sub-menu can be quit.
menu
“Quit warnings sub- "Quit warnings sub-menu" key the menu
t
menu” key currently shown in the driver's display
changes to the higher-level menu.
Indicates that the sub-menu (e.g. set
Quit sub-menu t
date / time) can be quit.
"Quit sub-menu" key the menu currently
“Quit sub-menu” key t
shown in the driver's display changes to
the "Truck functions" menu.
Appears when the truck has been
"Battery latch not
t switched on but the battery latch has not
applied" display
been applied.
Overrides the "Battery latch not applied"
display, (see ""Battery lock" sensors (o)"
"Travel without battery on page 116).
t
latch" key
The truck can only travel at slow speed
(0,8 km/h).
11.14 EN
152
Optional equipment
“Work lights / fan menu Changes the menu to “work lights / fan”
o
change” display functions.
“Work lights / fan menu Activates the work lights / fan menu
o
change” key change.
“Overhead guard work Indicates that the overhead guard work
o
lights” display lights can be switched on / off.
“Overhead guard work Switches the overhead guard work lights
o
lights” key on and off.
"Operator position Indicates that the operator position
o
lighting" display lighting can be switched on / off.
"Operator position Switches the operator position lighting on
o
lighting" key and off.
“Load handler work Indicates that the load handler work
o
lights” display lights can be switched on / off.
“Load handler work Switches the load handler work lights on
o
lights” key and off.
“Overhead guard strobe” Indicates that the strobe on the overhead
o
display guard can be switched on / off.
“Overhead guard strobe” Switches the overhead guard strobe on
o
key and off.
"Spotlight positioning" Indicates that the spotlight can be
o
display switched on / off.
"Spotlight positioning" Switches the spotlight on and off.
o
key
"Reverse lights" display Indicates that the reverse lights can be
o
switched on / off.
"Reverse lights" key Switches the reverse lights on and off.
o
“Fan” display Indicates that the fan can be switched on
o
/ off.
"Fan" key Switches the fan on and off.
o
"Left camera" display Indicates that the pictures from the left
o
camera can be shown on the monitor.
"Left camera" key Switches the monitor to the left camera.
o
"Right camera" display Indicates that the pictures from the right
o
camera can be shown on the monitor.
"Right camera" key Switches the monitor to the right camera.
o
11.14 EN
153
"Warehouse or • Warehouse mode = Symbol has a
stockpicking mode" dark background
display • Stockpicking mode = Symbol has a
o light background
(see "Warehouse and stockpicking mode
(o)" on page 415)“.
"Warehouse or Toggles between warehouse and
stockpicking mode o stockpicking mode.
toggle" key
"Weighing system display Indicates that the weight measurement
zero setting" display o display can be set (tared) to zero, (see
0 "Weighing system display
o
"Weighing system (o)" on page 394).
Sets the weight measurement to zero.
zero setting" key
WG Wire guidance t Indicates standard equipment

RG Rail Guidance o Indicates optional equipment
11.14 EN
154
3 Preparing the Truck for Operation
WARNING!
Risk of accidents in the hazardous area of the truck
Before the truck can be started, operated or a load unit lifted, transported or lowered,
the driver must ensure that there is nobody within the hazardous area.
XInstruct other people to move out of the hazardous area of the industrial truck. Stop
working with the truck if people do not leave the hazardous area.
XThe truck must be prevented from being used by unauthorised people if people do
not leave the hazardous area despite the warning.
3.1 Checks and operations to be performed before starting daily

operation
WARNING!
Damage and other truck or attachment (special equipment) defects can result
in accidents.
If damage or other defects are discovered on the truck or attachment (special
equipment), the truck must be taken out of service until it has been repaired.
11.14 EN
155
3.1.1 Visual external inspection of the whole truck for damage
Procedure
• Check truck for damage.
• Check mast bracing for damage (o).
• Check side / safety gates for damage.
• Check driver's seat for damage.
• Check driver's seat setting and adjust if necessary ((see "Adjusting the driver’s
seat" on page 164)).
• Check operator position padding for damage (o).
• Check control panel for damage.
• Check control panel setting and adjust if necessary ((see "Control panel height
adjustment" on page 168) and (see "Adjusting the control panel angle" on
page 169)).
• Make sure panels are secure and check for damage.
• Check the overhead guard for damage.
• Check the driver's cab for damage.
• Check the protective window in the driver's cab for damage.
• Check the operator mat and step boards are non-slip and damage-free.
• Make sure tilt safety devices are present and check the setting (o), (see "Tilt safety
device" on page 96).
• Check the load handler (forks etc.) for visible signs of damage such as cracks, bent
or severely worn forks.
• Check static charge eliminator is present.
• If using an attachment: Check bearing points, guides and stops for wear and
damage.
• Check labels are legible and complete, (see "Identification points and data plates"
on page 64).
• Check "travel" control labels are legible and complete.
• Check "hydraulic" control labels are legible and complete.
• Test the gas pressure dampers on the battery panel and check for damage.
• Check that optional equipment such as mirrors, storage compartments, grips etc.
are working correctly and check for damage (o).
• Check overhead guard cover for damage and make sure it is secure (o).
11.14 EN
156
3.1.2 Hydraulic system visual inspection
Procedure
• Check entire truck externally for signs of leakage:
• check the hydraulic cylinders.
• check the hydraulic ports.
• check the lines.
• check the hoses.
WARNING!
Damaged / leaky hydraulic cylinders, ports, lines and hoses must be replaced before
the truck is started.
XSpilled fluids must be removed immediately with an appropriate bonding agent. The
bonding agent / consumable mixture must be disposed of in accordance with
regulations.
• Check that the lift chains are evenly tensioned and damage-free.
11.14 EN
157
3.1.3 Battery visual inspection
Procedure
• Check the battery and battery container for damage.
• Check the battery connector cable connections for damage.
• Check battery cables and cell connectors for damage.
• Check battery connectors for damage.
• Check the battery connectors are secure.
• Check battery lock / battery attachment is present and working.
• Make sure battery is securely fixed in the battery compartment.
• Check battery cover and side panels are secure and look for damage.
3.1.4 Wheel visual inspection

Procedure
• Check drive wheel and load wheels for wear and damage.
• For rail guidance systems check guide wheels run smoothly and check for wear
and damage (o).
11.14 EN
158
3.1.5 Rescue equipment / seat belt
WARNING!
Operating the truck without a front guard or gate can result in accidents
The owner must ensure that the driver is wearing a seat belt during operation.
Otherwise the operator could risk falling out of the cab.
XThe seat belt and safety rope must comply with national regulations.
XBefore operating the truck without a front guard or gate, the seat belt must be worn
and attached to the truck, (see "Fasten the safety belt with safety rope onto the
driver's cab" on page 186). You must not operate the truck without wearing a seat
belt.
XThe driver must undergo annual training in how to handle the safety belt with safety
rope.
XFor the operation and service intervals of the safety belt and safety rope, refer to
the accompanying operating instructions.
XFollow the maintenance intervals stated in operating instructions for the safety belt
with safety rope.
Z Industrial trucks are factory-equipped with the RKA 18 seat belt and theRFD 12
safety rope, (see "Seat belt with safety rope (EKS without front guard or gate only)"
on page 170).
Procedure
• Check to ensure the rescue equipment is present, (see "Rescue equipment storage
compartment in the driver's cab" on page 298).
• EKS without a front guard or gate only:
• Check the safety belt with safety rope for damage and to ensure both are
present, (see "Visual inspection of safety belt with safety rope" on page 180).
• Check the mounting rail for the safety belt at the front of the overhead guard is
secure and check for damage.
11.14 EN
159
3.2 Entry and exit
151
20
151
CAUTION!
Safety gate trapping hazard

There is a risk of trapping when the gates are opened and closed.
XMake sure there is nothing between the cab chassis / foot compartment and the
gates when the gates are opened and closed.
WARNING!
Risk of falling
The driver could fall out if the gate is open and the driver's cab raised.
XDo not open the gate when the driver's cab is raised.
Requirements
– Mast / driver's cab completely lowered.
11.14 EN
160
Procedure
• Lift up the gates (20).
• To enter and exit the cab, hold onto the cab chassis (151).
• Close the gates (20).
CAUTION!
No more than one person may operate the truck in the driver's cab at a time.
11.14 EN
161
3.3 Driver's seat removal and assembly
CAUTION!
An unsecured driver's seat can result in accidents and injury
An unsecured driver's seat can slide during operation and result in accidents.
XThe twist grip screws must be tightened before operating the truck.
XThe driver's seat must be lock in place before operating the truck.
XDo not adjust the driver's seat during operation.
Removing the driver’s seat
Requirements 23
– Park the truck securely, (see "Parking the truck
securely" on page 239).
Procedure
• Remove the twist grip screws (111) from the left and
right sides behind the driver's seat (23).
• Carefully tilt the driver's seat (23) slightly in the load
direction.
• If the driver’s seat (23) has seat heating, the seat 112
heating plug connection must be removed.
Z The driver's seat (23) including the panel (112) has a 111
net weight of 45 kg.
• Lift out the driver's seat (23) including the panel (112).
• Obtaining help from a second person, lift the driver's seat (23) out of the cab.
Driver's seat (23) removed.
11.14 EN
162
Install the driver's seat
Requirements
Procedure
Z The driver's seat (23) including the panel (112) has a net weight of 45 kg.
• Obtaining help from a second person, lift the driver's seat (23) and panel (112) into
the cab.
• Insert the driver's seat (23) and panel (112) into the guide slots in the cab.
• If the driver’s seat (23) has seat heating, the seat heating plug must be connected.
CAUTION!
screws (111).
Driver's seat (23) installed.
11.14 EN
163
3.4 Setting up the operator position
CAUTION!
An unsecured driver's seat and control panel can result in falls and injury
An unsecured driver's seat or control panel can slide during operation and result in
accidents.
XThe driver's seat and control panel must be locked in place when the truck is in
operation.
XDo not adjust the driver's seat and control panel during operation.
Procedure
• Before operating, adjust the driver’s seat and control panel so that all the controls
are within reach and can be applied without having to strain.
• Adjust the visibility aid equipment (mirrors, camera systems etc.) so that the
working environment can be clearly seen.
3.4.1 Adjusting the driver’s seat

Z The procedure for adjusting the driver’s seat applies to standard models. For other
models, follow the manufacturer’s setting instructions. When adjusting, ensure that
all controls are within easy reach.
WARNING!
Risk of accidents and damage to health
An incorrectly adjusted driver’s seat can result in accidents and damage to health.
XDo not adjust the driver’s seat while travelling.
XThe driver’s seat should lock in position after adjustment.
Z The driver’s seat (23) has a high backrest (153) and a sculpted seating area (160)
providing fatigue-free operation when seated. The padded underside of the seat is
used to lean against when the operator is standing.
11.14 EN
164
152
Adjusting the seated position
Procedure 153
• Pull the lever (159) up.
Sit down or stand up from the seat (160)
to seat the desired seat height. 154
• Release the lever (159) again.

Z The height of the seated position can be 155
adjusted by 120 mm.
156
157
111 158 159 160 161
Adjusting the armrest (o)

Procedure
• To adjust the height of the armrest (155):
• Loosen the screw (158).
• Move the armrest (155) up or down to the desired position.
• Tighten the screw (158).
• Adjust the tilt of the armrests (155) by turning the adjusting wheel (156).
The armrest (155) is adjusted.
11.14 EN
165
152
Adjusting the seat (o)
Procedure
153
• To adjust the angle of the seat (160):
• Push the lever (157) down.
The angle of the seat (160) is adjusted 154
up or down.
Z The seat (160) can be tilted by 40 mm. 155
• To adjust the seat (160) horizontally:
• Push the lever (161) down.
156
• Move the seat (160) in the drive or
load directions.
The seat (160) is now adjusted
horizontally. 157
Z The seat (160) can be moved by 50 mm.

• The seat (160) can now be folded up or
down. 111 158 159 160 161
Z When the driver's seat has been folded
up, it can be used as a backrest for standing operation.
The seat (160) is now adjusted.
11.14 EN
166
Adjusting the backrest (o)
Procedure
• Turn the adjusting wheel (154) clockwise:
The backrest tilts forward.
• Turn the adjusting wheel (154) anti-clockwise:
The backrest tilts back.
The backrest is now adjusted.
Switch the seat heating on / off (o)

Requirements
(o)" on page 196).
Procedure
• To switch the seat heating on and off with the "seat heating" switch (152):
• Seat the "seat heating" switch (152) to position '1'.
The seat heating is switched on.
• Seat the "seat heating" switch (152) to position '0'.
The seat heating is switched off.
11.14 EN
167
3.4.2 Control panel height adjustment
Z The height of the control panel (14) can be vertically adjusted by 85 mm.
CAUTION!
An unsecured control panel can cause accidents and injury
An unsecured control panel can slide during operation and result in accidents.
XThe control panel must be locked in place when the truck is in operation.
XDo not adjust the control panel during operation.
Procedure
• Hold onto the control panel (14).
• Turn the height adjustment twist-grip
screw (132) anti-clockwise.
• Set the control panel (14) to the required
position. A
• Pull the control panel up, see arrow
direction "A". 14
• Push the control panel down, see
arrow direction "B". B
• Turn the height adjustment twist grip
screw (132) clockwise and secure the 132
control panel (14).
The height of the control panel (14) is now adjusted.
11.14 EN
168
3.4.3 Adjusting the control panel angle
Z The angle of the control panel (14) can be infinitely adjusted by 50 °. (Control panel
angle range: 130 ° to 180 °).
CAUTION!
Requirements 122
– Prepare the truck for operation, (see
13
"Preparing the truck for operation" on
page 195) or (see "Preparing the truck for 14
operation with an additional access code
(o)" on page 196).
18
Procedure
• Apply and hold down on the "control panel
adjustment" key (122).
• Set the angle of the control panel (14) to the
desired position.
• Release the "control panel adjustment"
key (122) again.
• Make sure the control panel (14) is locked in
position. If necessary, angle the control panel
162
up or down slightly without applying the
"control panel adjustment" key (122).
The angle of the control panel (14) is now set.
NOTE
If the truck's electronic system is faulty or if there is no power supply, the control
panel (14) can be manually adjusted:
XPress and hold down on the unlocking pin (162).
XManually push the control panel (14) up.
XRelease the unlocking pin (162) again.
11.14 EN
169
3.5 Seat belt with safety rope (EKS without front guard or gate only)
WARNING!
Operating the truck without a front guard or gate can result in accidents
The owner must ensure that the driver is wearing a seat belt during operation.
Otherwise the operator could risk falling out of the cab.
XThe seat belt and safety rope must comply with national regulations.
XBefore operating the truck without a front guard or gate, the seat belt must be worn
and attached to the truck, (see "Fasten the safety belt with safety rope onto the
driver's cab" on page 186). You must not operate the truck without wearing a seat
belt.
rope.
XFor the operation and service intervals of the safety belt and safety rope, refer to
with safety rope.
NOTE
The RKA 18 seat belt and the RFD 12 safety rope are not included with the truck as
standard. The trucks can be optionally supplied with the RKA 18 seat belt and theRFD
12 safety rope.
XThe following sections describe and provide instructions for using the RKA 18“ seat
belt and the RFD 12 safety rope.
11.14 EN
170
There is a danger of falling for drivers operating industrial trucks with a height-
adjustable driver's cab without a front guard. For this reason the driver must wear the
seat belt RKA 18 and protect himself from falling with the safety rope RFD 12 on the
truck.
WARNING!
Untrained personnel and a non-serviced safety belt with safety rope can result
in accidents and injury
The safety belt with safety rope should only be used by people who are physically
capable, trained to use the equipment safely and who have the required expertise.
The user must have a rescue plan listing all necessary action to be taken in
emergencies.
rope.
XFor the operation and service intervals of the safety belt with safety rope, refer to
with safety rope.
Z The Jungheinrich AG customer service department is specially trained for these

operations.
11.14 EN
171
3.5.1 Test / maintenance of the safety belt with safety rope
WARNING!
An unchecked safety belt and safety rope can cause accidents
XThe safety belt must be checked by the manufacturer or a specialist approved by
the manufacturer after any "catching a person" accident (not including practice)!
The safety belt with safety rope must be checked at least annually by the
manufacturer or a specialist approved by the manufacturer.
More regular inspections may be required if the safety belt with safety rope are used
frequently or are subject to heavy duty usage (e.g. environmental or industrial factors
affecting the material).
operations.
WARNING!
No modifications or additions may be made to the safety belt with safety rope.
11.14 EN
172
3.5.2 Service life of the safety belt with safety rope
WARNING!
Service life of the safety belt
Safety belts have a service life of 8 years under normal operating conditions or if the
they are not used.
Service life of the safety rope
Safety ropes have a service life of 6 years under normal operating conditions or if they
are not used.
Z The exact service life of the karabiner hook and aluminium body of the friction
shock absorbing lanyard depend on the application and ambient conditions.
11.14 EN
173
3.5.3 Cleaning the safety belt with safety rope
The safety belt and safety rope must only be cleaned with a fine washing detergent
at max. 40° C.
NOTE
To protect the washing drum, stow the safety rope in a water-permeable bag before
starting the washing process. During the washing process, spin function must be
deactivated.
CAUTION!
Damp harness straps on the safety belt and/or a damp safety rope should always dry
off naturally, e.g. in a well-ventilated, shady location. Do not dry wet items of
equipment in tumble dryers, near fires or other heat sources.
11.14 EN
174
3.5.4 Storage and transport of the safety belt with safety rope
WARNING!
Accident risk if safety belt with safety rope are improperly stored
The storage of the safety belt with safety rope has a significant influence on service
life.
XProtect the safety belt with safety rope from moisture, heat and UV radiation during
storage.
XAvoid contact with acid, corrosive fluids and oils.
XProtect the safety belt with safety rope from contact with sharp objects.
CAUTION!
Damp harness straps on the safety belt and/or a damp safety rope should always dry
off naturally, e.g. in a well-ventilated, shady location. Do not dry wet items of
equipment in tumble dryers, near fires or other heat sources.
To transport the safety belt with safety rope always use a secure equipment bag or
case to prevent damage caused by external influences.
11.14 EN
175
3.5.5 Description of the safety belt with safety rope
The safety belt RKA 18 consists of two adjustable leg and shoulder straps, a chest
strap, two catch loops in the chest area and a back strap with D ring.
WARNING!
The two catch loops in the chest area must only be fastened onto the safety rope
together.
Adjust the chest and leg straps to achieve optimum adjustment of the safety belt. The
length of the chest strap / leg straps can be adjusted with clip-on buckles.
Z The temperature-dependent application range of the safety belt RKA 18 is from

ambient temperatures of -25 °C to +80 °C.
The safety belt RFD 12 is equipped with an integrated friction shock absorbing
lanyard.
The friction shock absorbing lanyard consists of an aluminium body through which the
safety rope is guided in accordance with EN 354 or EN 353-2.
At one end of the safety rope is a rope end connection (secured knot) that prevents
the safety rope from slipping through in the event of a fall. At the other end of the
safety rope is a safety karabiner hook.
The friction shock absorbing lanyard reduces the impact force that occurs in case of
a fall to max. 6 kN by reducing impact force through the friction of the core cladded
rope as it is guided through the aluminium body.
Z The temperature-dependent application range of the safety rope RFD 12is from
ambient temperatures of -30 °C to +80 °C.
WARNING!
11.14 EN
176
163
164
165
166
167
168
169
170
Item Description
163 Adjustable shoulder straps
164 Adjustable chest strap
165 D ring on back strap
166 Plastic lock on the chest strap
167 D ring on chest strap
168 Data plate, (see "Safety belt data plate" on page 178)
169 Clip-on buckles
170 Adjustable leg straps
171 Item Description

172
Karabiner hook
171
"Fastening on the safety belt"
172 Friction shock absorbing lanyard
173
173 Safety rope
174 End knot
174
Karabiner hook
175 175
"Fastening on the overhead guard“
11.14 EN
177
3.5.6 Technical specifications of the safety belt
Type: RKA 18
Net weight: 1 kg
Capacity: One person
Size: UNISIZE
Norm: EN 365
3.5.7 Safety belt data plate
176
RKA-18
Auffanggurt
177
EN 361
178
0158 179
Baujahr: xxxx
Fabr.-Nr.: xxxx 180
Nächste Revision
181
182
Hersteller
Item Description
176 Model description
177 Prototype tested to EN
178 CE mark
179 Year of manufacture
180 Serial number
181 Next inspection
182 Manufacturer
11.14 EN
178
3.5.8 Safety rope data plate
183 184 185
PSA 0158 186

Verbindungsmittel mit RFD KM 12 187
EN 355 : 2002 EN 354 : 2002
Seil O: 12mm Länge: xxm 188
Fabr.-Nr.: xxxx Baujahr: xxxx
189 190 191
Item Description
183 Manufacturer
184 Note: Read operating instructions
185 CE mark
186 Model name "Fastener with RFD KM 12“
188 Length
189 Diameter of the safety rope
190 Serial number
11.14 EN
179
3.5.9 Visual inspection of safety belt with safety rope
The user must carry out a visual inspection of the safety belt with safety rope before
each application. This will ensure that the safety belt with safety rope are operational
and fit for purpose.
WARNING!
Withdraw the safety belt with safety rope from use if you find any damage or if you
are in doubt as to the functionality of the safety belt with safety rope. Return the safety
belt with safety rope to the manufacturer or a specialist approved by the manufacturer
for inspection.

operations.
11.14 EN
180
3.5.10 Visual inspection of the safety belt with safety rope
The user must carry out a visual inspection of the safety belt with safety rope before
each application. This will ensure that the safety belt with safety rope are operational
When carrying out a visual inspection make sure that:

– the load-bearing harness material does not show any signs of damage such as
chafing, cracks or loose thread ends on the seams.
– the clip-on buckles are not corroded, physically damaged, deformed and/or
cracked.
– the D rings on the back strap are not corroded, damaged, deformed and/or
cracked.
– the two catch loops do not show any signs of damage such as chafing, cracks or
loose thread ends on the seams.
– the data plate is present and legible.
WARNING!
Withdraw the safety belt from use if you find any damage or if you are in doubt as to
the functionality of the safety belt. Return the safety belt to the manufacturer or a
specialist appointed by the manufacturer for inspection.

operations.
11.14 EN
181
3.5.11 Visual inspection of safety rope with karabiner hook
The user must carry out a visual inspection of the safety rope and karabiner hook
before each application. This will ensure that the safety rope is operational and fit for
purpose.
WARNING!
Withdraw the safety rope or karabiner hook from use if you find any damage or if you
are in doubt as to their functionality. Return the safety rope and karabiner hook to the
manufacturer or a specialist approved by the manufacturer for inspection.

operations.
Visual inspection of aluminium body
When carrying out the visual inspection make sure the aluminium body is not
corroded, physically damaged, deformed and/or cracked.
Visual inspection of the karabiner hook
When carrying out the visual inspection make sure the karabiner hook is not
Also check the functionality of the lock (catch) and the rivet on the karabiner hook.
– The union nut should open and close easily.

– The lock (catch) on the karabiner hook must be restored to its original position after
manual opening.
11.14 EN
182
Visual inspection of safety rope
The red marks on the safety rope must be at the same height, just under the rope
intake or outlet. If the two marks are one above the other on the rope outlet side, the
friction shock absorbing lanyard has already responded to a fall. Remove the safety
rope including the friction shock absorbing lanyard from service and return them to
the manufacturer or a specialist approved by the manufacturer for inspection.
The stitchings on the rope ends with the karabiner hook must be in good condition.
Check there is an end knot at the end of the rope. There must be a knot at the end of
the safety rope so that the it does not run out of the aluminium body during a fall.
When carrying out the visual inspection make sure that the safety rope does not show
any of the following signs of physical damage, defects or heat/chemical damage etc.:
– Ports,
– Fibre damage,
– Swelling,
– Twisting,
– Heavy wear, excessive wear such as fluff,
– Sheath displacement,
– Open, loose end connections,
– Loops,
– Knots,
– Burnt parts,
– Decayed parts.
Z Check the safety rope for the above features before using it. Do this by letting the
safety rope glide through your hands.
11.14 EN
183
3.5.12 Putting on the safety belt
163
164
165
166
167
168
169
170
Procedure
• Preparation:
• Remove all objects from your trouser pockets.
• Remove the safety rope from the equipment bag or case.
• Perform a visual inspection of the safety belt with safety rope, (see "Visual
inspection of safety belt with safety rope" on page 180).
• Hold the safety belt in front of your body with one hand on the D ring (165).
• Open the clip-on buckles (169) (2 buckles).
• Put on the safety belt:
• Pull the safety belt apart at the shoulder straps (163).
Z The D ring (165) on the back strap must be facing away from the body.
• Put on the safety belt like a jacket.
Z Avoid twisting the shoulder straps (163).
• Pull the leg straps (170) forward between your legs and then up.
• Adjust the safety belt to match the size of the operator's body:
• Close the clip-on buckles (169) on the leg straps (170) (2 buckles).
• Adjust the leg straps (170) to fit your individual size and tighten the straps.
Z Make sure the leg straps are adjusted so that you can push your hand flat
between the leg strap and thigh.
• Close the chest strap (164) with the plastic quick release (166).
• Adjust the chest strap (164) to fit your individual size and tighten the straps.
• Adjust the shoulder straps (163) to fit your individual size and tighten the straps.
• After you have adjusted the leg straps (170), chest strap (164) and shoulder
straps (163) to your individual size:
• the safety belt must be comfortable. The belt material must not be drawn too
tight, but it must also not restrict your freedom of movement.
• The D ring on the back strap must be exactly between your shoulder blades.
11.14 EN
• The leg straps must be resting below you and to the rear.
• The safety belt must not be pushing into any parts of your body.
184
• The shoulder straps must not slide down when you move.
• The two catch loops in the chest area must be resting centred against your
ribcage.
11.14 EN
185
3.5.13 Fasten the safety belt with safety rope onto the driver's cab
WARNING!
Danger of falling due to faulty or incorrectly worn safety belt
The industrial truck must not be operated unless the driver has put on the safety belt
and the safety rope is fastened onto the truck. In addition, a faulty safety belt or safety
rope must not be used. These causes can result in the driver falling.
XThe driver must put on the safety belt with safety rope before operating the
industrial truck.
XIf a safety belt or safety rope is faulty, identify it and withdraw it from use.
WARNING!
Danger of falling due to faulty fastening rail on the overhead guard
Do not operate the industrial truck if the fastening rail is damaged. This cause can
result in the driver falling.
WARNING!
An unchecked safety belt and safety rope can cause accidents
XThe safety belt must be checked by the manufacturer or a specialist approved by
the manufacturer after any "catching a person" accident (not including practice)!
165
171
192
193
175
173
Procedure
11.14 EN
• Perform a visual inspection of the safety belt with safety rope, (see "Visual
186
• Check the mounting rail (193) at the front of the overhead guard is secure and
check for damage.
• Put the seat belt (192) on, (see "Putting on the safety belt" on page 184)
• Attach the karabiner hook (171) of the friction shock absorbing lanyard to the D
ring (165) on the back belt of the safety belt (192).
WARNING!
Fastening the safety rope including the friction shock absorbing lanyard onto the
retaining hooks or D hooks of a restraint harness is prohibited.
• If present, attach the karabiner hook (171) of the friction shock absorbing lanyard
to the union nut.
• Fasten the karabiner hook (175) of the safety rope (173) onto the mounting
rail (193) of the overhead guard.
• If present, attach the karabiner hook (175) of the safety rope (173) to the union nut.
The driver is protected by the safety belt with safety rope and can operate the
industrial truck.
11.14 EN
187
4 Industrial Truck Operation
4.1 Safety regulations for truck operation
Travel routes and work areas
Only use lanes and routes specifically designated for truck traffic. Unauthorised third
parties must stay away from work areas. Loads must only be stored in places
specially designated for this purpose.
The truck must only be operated in work areas with sufficient lighting to avoid danger
to personnel and materials. Additional equipment is necessary to operate the truck in
areas of insufficient lighting.
DANGER!
Do not exceed the permissible surface and spot load limits on the travel routes.
At blind spots get a second person to assist.
NOTE
Loads must not be deposited on travel or escape routes, in front of safety
mechanisms or operating equipment that must be accessible at all times.
11.14 EN
188
Travel surface
The travel surface on which the truck is to be used on must be suitably maintained in
order to provide the required traction for travel, steering and braking under the
prevailing ambient conditions.
The details on the truck data plate assume a level and dry travel surface. Other
ground surfaces may have a negative affect on the stability of the truck. They will
result in a modification of the rated performance (e.g. speed reduction etc.) of the
truck.
Ground and ground conditions
The ground on which the trucks are used must be level and smooth. There must not
be any gaps, drainage systems etc. in this area.
The ground must be well maintained to keep it free of contamination, obstacles and
liquids that could affect the safe operation of the truck.
CAUTION!
There must be no ramps or inclines in areas where forklift trucks are used.
NOTE
Static charge can cause material damage to truck components
When the truck is operated on a surface with a shunt resistance in excess of 106ȍ,
static charge can result in damage to electric components (controller, control panel,
...).
XOperate the truck only on surfaces with a shunt resistance of less than 106ȍ.
XThe anti-static conductor must be in contact with the ground during operation.
11.14 EN
189
Travel conduct
The driver must adapt the travel speed to local conditions. The truck must be driven
at slow speed when negotiating bends or narrow passageways, when passing
through swing doors, at blind spots and when entering and leaving the narrow aisle.
The driver 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. Do not lean out or reach beyond the working and operating
area.
Do not use a mobile phone or walkie-talkie without a handsfree device while
operating the truck.
WARNING!
What to do it the industrial truck tips over
If the industrial truck is in danger of tipping over, the driver must not jump out of the
vehicle or hold any body parts outside of the driver's cab.
The driver must:
XCrouch down,
XHold onto the operator position with both hands,
XLean against the direction of fall.
11.14 EN
190
Visibility when travelling outside the narrow aisle
The driver must look in the direction of travel and must always have a clear view of
the route ahead.
Loads that affect visibility must be positioned at the rear of the truck. If this is not
possible, a second person must walk in front of the truck as a lookout. In this case
proceed only at walking pace and pay particular attention. Stop the truck immediately
if visual contact is lost between the lookout and the operator.
Use the mirror only to observe the traffic behind you. Should you need visibility aids
(mirrors, monitors etc.) to ensure adequate visibility, practice working with them
beforehand.
Procedure and visibility when operating with a raised driver's cab and load
handler
DANGER!
Accident risk when operating the truck with driver's cab and load handler
raised
Working with the driver's cab and load handler raised can affect the driver's visual
conditions. Other people can be injured in the truck's hazardous area. The hazardous
area is defined as the area in which people are at risk from the truck movement, the
load handler, attachments etc. This also includes areas which can be reached by
falling loads or lowering operating equipment. Apart from the driver (in the normal
operating position) there should be no other people in the truck's hazardous area.
XWhen carrying out hydraulic or travel operations, make sure that nobody is present
in the hazardous area.
XInstruct other people to move out of the hazardous area of the truck.
11.14 EN
191
Crash protection
The driver must not leave the operator position in a raised position. Do not climb onto
parts of the building or other trucks and do not climb over safety devices such as
railings or gates. If Euro pallets are stored lengthways it may not be possible to reach
items from the operator platform without the use of aids. The proprietor must provide
the operators with suitable tools to pick the items without putting them at risk.
Load aids may only be walked on if suitable safety devices such as pallet guard and
pallet tipover safety mechanisms are in place.
WARNING!
Danger of falling due to improper use of controls and components
Climbing on the gates, control panel, driver's cab guard, driver's seat, etc. can result
in the driver falling out of the driver's cab.
XThe operator must not climb on the gates, control panel, driver's cab guard, driver's
seat etc.
Z When the driver's cab is raised an optional warning may sound if a gate is opened.
The lift height at which the warning sounds, can be set by the manufacturer's
customer service department.
11.14 EN
192
Negotiating slopes and inclines
WARNING!
Do not negotiate slopes or inclines.
Travelling on docks / dock plates / loading platforms
WARNING!
Do not travel on docks, dock plates or loading platforms.
Negotiating lifts
Lifts may only be entered if they have sufficient capacity, are suitable for driving on
and authorised for truck traffic by the owner. The driver must satisfy himself of the
above before entering these areas. The truck must enter lifts with the load in front and
must take up a position which does not allow it to come into contact with the walls of
the lift shaft.
People travelling in the lift with the forklift truck must only enter the lift after the truck
has come to a halt and must exit the lift before the truck.
Towing trailers and other vehicles
CAUTION!
The truck must not be used to tow a trailer or other vehicles.
11.14 EN
193
Work platforms
WARNING!
The use of working platforms is governed by national law. In some states the use of
working platforms is prohibited on industrial trucks. Observe the applicable law.
Working platforms can only be used in the country of application if the law permits it.
XContact the national authorities before using a working platform.
Type of loads to be carried
The operator must make sure that the load is in a satisfactory condition. Loads must
always be positioned safely and carefully. Use suitable precautions to prevent parts
of the load from tipping or falling down. Prevent liquid loads from sloshing out.
WARNING!
Accident risk when transporting liquid loads
The following risks may be present when transporting liquid loads:
Liquids sloshing out.
A change in the load centre due to sudden lifting and drive movements the load falling
down as a result.
Adverse effect on the stability of the industrial truck due to slipping or unstable loads.
XFollow the instructions in the section "Transport the load unit.", (see "Transport the
load unit." on page 255).
WARNING!
Do not transport swinging loads.
11.14 EN
194
4.2 Preparing the truck for operation
Switching on the truck

Requirements
– Visual inspections and operations to be
performed before starting daily operation, (see
"Checks and operations to be performed before
starting daily operation" on page 155).
– Insert and lock the battery latch.
– Insert and lock the side panels correctly.
– Close the battery cover, (see "Exposing the
13 18
– Enter the driver's cab, (see "Entry and exit" on page 160).
– Seat belt checked and put on (EKS without front guard or gate only).
Visual inspection of the safety belt and safety rope performed, (see "Visual
Safety rope secured to safety belt and overhead guard, (see "Fasten the safety belt
with safety rope onto the driver's cab" on page 186).
Procedure
• Close the gates.
• Turn the EMERGENCY DISCONNECT switch (13) to unlock it.
Z Press the Emergency Disconnect (13) immediately if the truck starts to move or lift
as soon as it is switched on. Brief steering movements caused by steering
referencing are permissible.
• Switch on the truck. To do this:
• Insert the key in the key switch (18) and turn it as far right as it will go.
• Hold the card or transponder in front of the ISM access module and depending
on the setting press the green button on the ISM access module (o).
Z The truck is now operational.

The steering is in the straight-ahead position.
11.14 EN
195
4.3 Preparing the truck for operation with an additional access code (o)
Z Optionally, the truck can be prepared for operation with an additional 5 digit access
code (from 00001 to 99999). Up to 99 different access codes can be set. The
access codes can be set by the manufacturer's customer service department. The
initial access code for new trucks is 12345.
In addition to the access code the key switch / ISM access module (o) is still used
to switch on the truck.
Z In conjunction with the "user-specific setting" option, pre-defined travel programs
and hydraulic programs as well as various rights can be assigned to the different
access codes ((see "Operator-specific settings (o)" on page 387)).
Possible authorisation levels:

– "User" access code without change rights to user-specific settings.
– "User" access code with change rights to user-specific settings.
– "Master" access code with change rights to user-specific settings for the selected
"user" access codes.
11.14 EN
196
Switching on the truck
Requirements
– Visual inspections and operations to be
performed before starting daily operation, (see
"Checks and operations to be performed
before starting daily operation" on page 155).
– Insert and lock the battery latch.
– Insert and lock the side panels correctly.
– Close the battery cover, (see "Exposing the
13 18
– Enter the driver's cab, (see "Entry and exit" on
page 160).
– Seat belt checked and put on (EKS without front guard or gate only).
Visual inspection of the safety belt and safety rope performed, (see "Visual
Safety rope secured to safety belt and overhead guard, (see "Fasten the safety belt
with safety rope onto the driver's cab" on page 186).
Procedure
• Close the gates.
Z Press the Emergency Disconnect (13) immediately if the truck starts to move or lift
as soon as it is switched on. Brief steering movements caused by steering
referencing are permissible.
11.14 EN
197
123 194 195 18
*****
196 130 197 198
Procedure
• In the driver's display (123) you will be prompted to enter your 5 digit access code.
Enter the access code, to do this:
Z Unless the correct access code is entered, none of the truck's functions will work.
• Press the "Select" button (198) in the cursor field.
• Enter your 5 digit access code with the numerical keypad (130). The cursor
keys (194,195) can be used to enter each digit of the 5-digit access code:
- Cursor key (195): one digit forward.
- Cursor key (194): one digit back.
• Press the "CE" key (197) to cancel entering the 5 digit access code.
• Press "OK" (196) and confirm the access code entry.
Z If no travel, steer or hydraulic operations are performed within a factory-set
interval, the driver's display (123) will prompt you again to enter the 5 digit
access code with the numerical keypad (130). In addition all truck functions are
inhibited. When you have entered the access code the truck will be operational.
The interval can be changed by the manufacturer's customer service
department.
The truck is now operational. The steering is in the straight-ahead position.
11.14 EN
198
4.3.1 Log off user
Log off user if the truck is abandoned 199

Requirements
– Truck operational, (see "Preparing the
truck for operation with an additional
access code (o)" on page 196).
Procedure
• Press the "Quit sub-menu" key (129). 129 119 130
The "Log off user" symbol (199) appears
in the driver's display.
123
Z Truck operations are inhibited in this
menu.
• Press the (119) key under the "Log off
user" symbol (199). *****
The user is logged off. All truck functions
are inhibited. In the driver's display (123)
you will be prompted to enter your 5 digit access code with the numerical
keypad (130).
11.14 EN
199
4.4 Date and time setting
Date and time format
Z The date and time format can only be changed by the manufacturer's customer
service department.
Format Date Time

Standard setting dd.mm.yyyy hh:mm:ss
US setting mm.dd.yyyy hh:mm:ss am/pm
Selecting the “Set Date/Time” menu 01 . 0 5 . 2 0 11

Requirements 12 : 0 0 : 0 0
page 195) or (see "Preparing the truck
for operation with an additional access
code (o)" on page 196).
Procedure
129
• Press the "Quit sub-menu" button (129).
The driver's display shows the current date and time.
Z Truck operations are inhibited in this menu.
11.14 EN
200
Date and time setting 01 . 0 5 . 2 0 11
Procedure 12 : 0 0 : 0 0
• Press the "Select" button (198) in the
cursor field.
Z The first digit of the date is displayed
"dark".
• The operator can use the cursor
keys (200,201) to choose the required
setting in the selected field: 129 130
• Cursor key (200): increase number.
• Cursor key (201): decrease number. 200
198
Z The required number can also be 195
entered directly with the number field on 194
the numerical keypad (130).
• Use the cursor keys (194,195) to select 201
the next or previous field:
• Cursor key (194): previous field.
• Cursor key (195): one field forward.
Z The selected field appears with a "dark" background.
• Press "OK" on the numerical keypad (130) to save the date and time settings.
Leaving the menu 202
Procedure
• Press (119) under the "truck functions"
symbol (202). The driver's display
changes to the "truck functions" menu.
119
11.14 EN
201
4.5 Checks and operations to be carried out when the truck is
operational
DANGER!
Truck defects can result in accidents
Do not use the truck if the brake system, steering and/or hydraulic system is defective
or faulty.
If damage or other defects are discovered on the truck or attachment (special
equipment), the truck must be taken out of service until it has been repaired.
11.14 EN
202
Procedure
• Test warning indicators and safety devices:
• Test the Emergency Disconnect by pressing the Emergency Disconnect switch.
The main circuit is disconnected and no truck operations can be performed. Now
turn the Emergency Disconnect to unlock it.
• Test the horn by pressing the "horn" key.
• Test the deadman switch.
• Test the side / safety gates.
• Test the service and parking brakes, (see "Brakes" on page 212).
• Test the steering, (see "Steering" on page 212).
• Test the hydraulic system, (see "Lifting / lowering – outside and inside narrow
aisles" on page 226) and (see "Traversing / rotating outside and inside narrow
• Test the lift cutouts (o), (see "Lift cutout override (o)" on page 271).
• Test the travel functions, (see "Travel" on page 210) and (see "Negotiating
• Test the end of aisle safety device and aisle detection functions (o), (see "End
of aisle safety device (o)" on page 275).
• Test the travel cutouts (o), (see "Travel cutout override (o)" on page 270).
• Test the lighting (o).
• Test the Personal Protection System (o), (see "Personal safety system (o)" on
page 321).
• Check the front screens of the Personal Protection System laser scanner for dirt
(o) and clean as required, (see "Cleaning the laser scanner front screen" on
page 324).
• Test the controls and displays and check for damage, (see "Displays and Controls"
on page 121).
• Check the controls are automatically restored to zero after being applied (e.g. the
hydraulic control lever, deadman switch, ...).
• Check the handles (16,19) for damage and to ensure they are securely fastened,
(see "Displays and Controls" on page 121).
• Carry out a test run on the mast to adjust the height display, (see "Referencing the
main and auxiliary lift" on page 204).
• Test two-hand operation in narrow aisles, (see "Negotiating narrow aisle with rail-
guided trucks (o)" on page 214) and (see "Negotiating narrow aisles with wire-
guided trucks (o)" on page 219).
• Carry out the Personal protection system cycle test, (see "Cycle test" on page 327)
(o).
11.14 EN
203
4.6 Referencing the main and auxiliary lift
203 204
26 12 13 127
Z The symbols (203,204) indicate that a reference run is required, as indicated by the
driver's display. After the reference run the controller releases all the truck
operations at full speed. The reference run also adjusts the height display.
Referencing the Main Lift and Aux. Lift

Requirements
(o)" on page 196).
Procedure
• Press the deadman switch (26).
• Carry out a "Raise main lift" reference run:
• Raise the Main Lift. To do this turn the hydraulic control lever (12)
anti-clockwise.
• Carry out a "Lower main lift" reference run:
• Fully lower the Main Lift. To do this turn the hydraulic control
lever (12) clockwise.
• Carry out a "Raise aux. lift" reference run:
• Apply the "Auxiliary lift" button (127) and hold it down.
• Raise the Aux. Lift. To do this turn the hydraulic control lever (12)
anti-clockwise.
• Carry out a "Lower Aux.lift" reference run:
• Fully lower the Aux. Lift. To do this turn the hydraulic control
lever (12) clockwise.
After referencing the current lift height is shown in the driver's display.
11.14 EN
204
205
119
Lift cutout with referencing
CAUTION!
An extended mast can cause accidents
The lift cutout is an auxiliary function designed to support the operator which however
does not release him from his responsibility to stop hydraulic operations e.g. when
confronted with an obstacle.
Procedure
• Pressing the “lift cutout override” key (119) underneath to the "lift cutout"
symbol (205) disables the lift cutout.
• The hydraulic functions are controlled with the hydraulic control lever, (see "Main
Lift raise/lower" on page 227).
11.14 EN
205
Load handler post-referencing (sideshift / fork carriage)
Z The load handler needs to be post-referenced in case the position of the load
handler (attachment position, fork carriage rotation) has changed while the truck
was switched off.
When the truck is switched on again the "traverse reference run" (206) and "rotate
reference run" (207) symbols are shown in the driver's display. Attachment traverse
and fork carriage rotate must be referenced.
26 206
12 119 126
"Traverse" referencing
Procedure
• Press and hold down on the "Attachment traverse" key (126).
• Traverse the attachment through the centre of the swivel traverse frame:
• Turn the hydraulic control lever (12) clockwise =
Attachment right traverse.
• Turn the hydraulic control lever (12) anti-clockwise =
Attachment left traverse.
• Traverse attachment back to home position, (see "Traversing and rotating the
attachment in the home position (t)" on page 241).
"Traverse" referencing is successful if the "Traverse reference run" symbol (206)
goes out after referencing.
If the "Traverse reference run" symbol (206) does not go out after referencing,
contact the manufacturer’s service department and take the truck out of service.
11.14 EN
206
26
207
12 119 125
"Rotate" referencing
Procedure
• Press and hold down on the "Fork carriage rotate" key (125).
• Carry out a fork carriage 180° rotation:
• Turn the hydraulic control lever (12) clockwise =
Fork carriage right rotation.
• Turn the hydraulic control lever (12) anti-clockwise =
Fork carriage left rotation.
• Rotate fork carriage back to home position, (see "Traversing and rotating the
attachment in the home position (t)" on page 241).
"Rotate" referencing is successful if the "Rotate reference run" symbol (207) goes out
after referencing.
If the "Rotate reference run" symbol (207) does not go out after referencing, contact
the manufacturer’s service department and take the truck out of service.
11.14 EN
207
4.7 Emergency Disconnect
13
11.14 EN
208
CAUTION!
Accident risk
Applying the Emergency Disconnect switch during travel will cause the truck to brake
to a halt at maximum force. This may cause the load to slide off the forks. There is a
higher risk of accidents and injury!
The operation of the Emergency Disconnect button must not be affected by any
objects placed in its way.
Applying the Emergency Disconnect
Procedure
Z Do not use the Emergency Disconnect (13) as a service brake.
• Press the Emergency Disconnect (13).
All electrical functions are deactivated. The truck brakes to a halt.
Releasing the Emergency Disconnect
Procedure
• Trucks with ISM access module (o):
on the setting press the green button on the ISM access module.
All electrical functions are enabled and the truck is operational again (assuming the
truck was not operational before the Emergency Disconnect was pressed).
11.14 EN
209
4.8 Travel
208
12 13 17 127 15
26
209
WARNING!
Incorrect travel can cause accidents and injury
Incorrect travel can cause accidents and therefore injury to the operator and / or third
parties.
XAlways transport a load outside the narrow aisle as low as possible, allowing for
ground clearance.
XDo not lean out of the driver's cab while travelling.
XMake sure that the travel area is clear.
XAdapt the travel speed to the conditions of the route, the work area and the load.
XMake sure you have enough visibility when reversing.
XEnsure that there is nobody in the hazardous area when carrying out travel and
hydraulic operations.
CAUTION!
Do not drive the truck unless the panels and covers are closed and properly locked.
The truck can be operated in 3 modes:
– Free ranging in the apron field (FR)

– Rail guided (RG), (see "Negotiating narrow aisle with rail-guided trucks (o)" on
page 214).
– Wire guided (WG), (see "Negotiating narrow aisles with wire-guided trucks (o)" on
page 219).
11.14 EN
210
The operating mode used depends on the guide system of the racking systems in
question.
Industrial Truck Operation
Requirements
(o)" on page 196).
Procedure
• Fully lower the Main Lift:
• Turn the hydraulic control lever (12) clockwise.
• Fully lower the Aux. Lift:
• Carry out a test run on the mast (Main Lift) to adjust the height display, (see
"Referencing the main and auxiliary lift" on page 204).
• Raise the Main Lift with the hydraulic control lever (12) until the fork tines are clear
of the floor.
• Turn the hydraulic control lever (12) anti-clockwise.
• Set the travel direction and speed with the travel control knob (15):
• Turn the travel control knob (15) slowly clockwise:
Travel in load direction (208).
• Turn the travel control knob (15) slowly back:
Travel in drive direction (209).
• You can control the travel speed by turning the travel control knob (15) further
forward or back.
• Use the steering wheel (17) to steer the truck in the required direction.
The truck travels in the required direction at the requested speed.
11.14 EN
211
4.9 Steering
Requirements 136
Procedure
• Steering outside narrow aisles: 17 123
• Turn the steering wheel (17) to the left
or right, depending on the travel direction.
Z The drive wheel position (136) is indicated on the driver's display (123).
• Steering inside narrow aisles:
• The truck is automatically guided and steering wheel (17) operation is
deactivated.
4.10 Brakes
WARNING!
Accident risk while braking
The truck’s brake pattern depends largely on the ground conditions.
XThe driver must be aware of floor conditions and take them into account when
braking.
XBrake with care to prevent the load from slipping.
The truck can brake in three different ways:
– with the coasting brake (t).

– with the reversing brake (t).
– with the deadman button (o).
26 13 15
11.14 EN
212
Braking with the coasting brake (t)
Procedure
• During travel, release the travel control knob (15).
The travel control knob (15) reverts to the neutral position.
The truck brakes via the traction controller.
Braking with the reversing brake (t)

Procedure
• During travel, set the travel control knob (15) to the opposite direction.
The truck brakes regeneratively via the traction controller until it starts to move in the
opposite direction. This method reduces energy consumption. Energy is recovered,
which is controlled by the traction current controller.
Braking with the deadman button (o)

Procedure
• During travel, take your foot off the deadman button (26).
Z This method of braking only acts as a parking brake and not as a service brake.
11.14 EN
213
4.11 Negotiating narrow aisles
4.11.1 Negotiating narrow aisle with rail-guided trucks (o)
WARNING!
Unauthorised entry of narrow aisles by other trucks or people can cause
accidents
Unauthorised personnel must not enter narrow aisles (truck lanes in racking systems
with safety distances < 500 mm), nor must any personnel cross through them. These
work areas must be marked and identified accordingly.
XCarry out a daily inspection of the safety mechanisms on the truck or the racking
system to avoid hazards and to protect personnel.
XThese must not be rendered ineffective, misused, adjusted or removed.
XReport any defects to your supervisor immediately.
XTag out faulty racking systems and block them for entry.
XNote DIN 15185 Part 2.
XNarrow aisles must only be entered by trucks which are designated for this
purpose.
XBefore entering a narrow aisle, the driver must look for people or other trucks in the
aisle. Never enter an aisle where there are people or other trucks. If there are
people or trucks in the aisle, stop the truck immediately.
11.14 EN
214
NOTE
Note the safety clearances between the truck and rack
XMaintain a minimum 100 mm safety distance between a rail guided truck and the
rack.
XMaintain a minimum 125 mm safety distance between a wire guided truck and the
rack.
WARNING!
Objects protruding out of the racks can be hazardous
The driver of the truck in a narrow aisle can be injured by objects protruding from the
racks (e.g. pallets, load units etc.). A collision between the truck and the protruding
objects could also cause material damage to the truck and the rack construction.
XCheck the length and height of the narrow aisle for protruding objects before
entering it.
XOnce in the narrow aisle, enter the rack compartments carefully with the truck.
Raise and remove load units securely and stack them correctly.
Travelling in narrow aisles with rail-guided trucks
Requirements
– Narrow aisles must be equipped with guide rails (210).
(o)" on page 196).
11.14 EN
215
Procedure 210 210
Z Rail-guided trucks are fitted with sensors
or RFID readers. These sensors activate
aisle detection when the truck enters an
aisle.
211
WARNING!
Faulty or loose guide rails can be
dangerous 136
Do not operate the truck in narrow aisles
with faulty or loose guide rails. The lack of
guidance could cause a collision between
the truck and the racks.
XCheck the guide rails in the narrow aisle
for damage before travelling along the
full length.
XTravel only in narrow aisles with 121 123 15
undamaged, secure guide rails.
• Press the deadman button. 212

• Approach the aisle at reduced speed so
that the truck (211) is aligned with the
narrow aisle and is within the
demarcations.
• Note the markings attached along the
route (e.g. aisle centre line).
• Drive the truck slowly into the narrow 121 123 15
aisle (211). Ensure that the guide wheels
of the truck (211) enter the narrow aisle guide rails (210).
• Press the “Switch automatic guidance on/off” button (121).
Z The drive wheel is automatically set forward. The steer angle indicator (136)
changes to “Truck guided” (212). Manual steering is disabled.
11.14 EN
216
Procedure 212
• Grab hold of grip (16) with your left hand
and grip (19) with your right hand (two-
hand operation).
Z Travel and hydraulic operations can only
be activated in the narrow aisle with two-
handed operation.
• Set the travel direction and speed with
the travel control knob (15): 16 15 19
• Turn the travel control knob (15)
slowly clockwise:
Travel in load direction.
Travel in drive direction.
forward or back.
• For details of the brake functions, (see "Brakes" on page 212).
• For details of hydraulic operation, (see "Lifting / lowering – outside and inside
narrow aisles" on page 226) and (see "Traversing / rotating outside and inside
The truck has now entered the narrow aisle and is automatically guided.
11.14 EN
217
Leaving the narrow aisle 136
Procedure
• Drive the truck completely out of the
narrow aisle.
• Bring the truck to rest.
CAUTION!
You can only change from automatic to 121 17 123 15
manual steering once the truck has fully
exited the narrow aisle.

Z The "Truck guided” display (212) changes to the steer angle indicator (136). The
truck is now free to move again. The steer angle indicator (136) shows the current
position of the drive wheel.
Z Always travel outside of narrow aisles with the load lowered.
The truck has left the narrow aisle. Use the steering wheel (17) to adjust the angle of
the drive wheel again.
11.14 EN
218
4.11.2 Negotiating narrow aisles with wire-guided trucks (o)
WARNING!
Unauthorised entry of narrow aisles by other trucks or people can cause
accidents
Unauthorised personnel must not enter narrow aisles (truck lanes in racking systems
with safety distances < 500 mm), nor must any personnel cross through them. These
work areas must be marked and identified accordingly.
XCarry out a daily inspection of the safety mechanisms on the truck or the racking
system to avoid hazards and to protect personnel.
XThese must not be rendered ineffective, misused, adjusted or removed.
XReport any defects to your supervisor immediately.
XTag out faulty racking systems and block them for entry.
XNote DIN 15185 Part 2.
XNarrow aisles must only be entered by trucks which are designated for this
purpose.
XBefore entering a narrow aisle, the driver must look for people or other trucks in the
aisle. Never enter an aisle where there are people or other trucks. If there are
people or trucks in the aisle, stop the truck immediately.
11.14 EN
219
NOTE
Note the safety clearances between the truck and rack
XMaintain a minimum 100 mm safety distance between a rail guided truck and the
rack.
XMaintain a minimum 125 mm safety distance between a wire guided truck and the
rack.
WARNING!
Objects protruding out of the racks can be hazardous
The driver of the truck in a narrow aisle can be injured by objects protruding from the
racks (e.g. pallets, load units etc.). A collision between the truck and the protruding
objects could also cause material damage to the truck and the rack construction.
XCheck the length and height of the narrow aisle for protruding objects before
entering it.
XOnce in the narrow aisle, enter the rack compartments carefully with the truck.
Raise and remove load units securely and stack them correctly.
11.14 EN
220
CAUTION!
A non-guided truck can cause accidents
When a wire guided truck has been switched off and on again, the wire guidance will
no longer be active. The same applies if the guide system is faulty or switched off and
on again. If you continue to travel a warning sounds and the speed is reduced.
XWhen starting or continuing the truck after the wire guidance has been deactivated,
note the position of the drive wheel as manual steering is now activated again.
XRe-activate the wire guidance and re-align the truck. During alignment, the rear
section of the truck may veer out when it reaches the guide wire.
XIf the wire guidance system is faulty or switched off, exit the narrow aisle at inching
speed and with particular care.
Negotiating narrow aisles with wire-guided trucks
Requirements
– Narrow aisles must be equipped with a guide wire.
(o)" on page 196).
11.14 EN
221
213
Procedure
Z The truck should preferably acquire the
wire in the load direction, as this involves
less time and distance. 211
• Press the deadman button.
• Approach the guide wire (213) with the
industrial truck (211) at an angle and at
reduced speed.
• Before aligning, set the truck (211) to an
angle of between 10° and 50° to the guide 136
wire (213). During alignment, the
truck (211) should not be parallel to the
guide wire (213).
• Aligning the truck with the guide wire:
• When you are close to the guide
wire (213) switch wire guidance on with
the "Switch automatic guidance on/off" 121 123 15
button (121). The wire acquisition signal
sounds.
214
• Move the truck (211) slowly in the
direction of the guide wire (213).
Z The truck is automatically guided when it
reaches the guide wire. Alignment
ensues automatically at reduced speed.
Manual steering is deactivated.
• The steer angle indicator (136) changes
to “Acquisition in progress” (214). 121 123 15
• The acquisition signal sounds.
• The truck is now automatically steered 212
by wire guidance and is pivoted onto the
guide wire.
• Alignment is complete once the truck
has been aligned precisely with the
guide wire. “Alignment on” (214)
changes to “Truck guided” (212). The
acquisition signal no longer sounds.
121 123 15
Procedure 212
• Grab hold of grip (16) with your left hand
and grip (19) with your right hand (two-
hand operation).
Z Travel and hydraulic operations can only
be activated in the narrow aisle with two-
handed operation.
the travel control knob (15): 16 15 19
11.14 EN
222
forward or back.
• For details of the brake functions, (see "Brakes" on page 212).
• For details of hydraulic operation, (see "Lifting / lowering – outside and inside
narrow aisles" on page 226) and (see "Traversing / rotating outside and inside
The truck has now entered the narrow aisle and is automatically guided.
11.14 EN
223
Leaving the narrow aisle 136
Procedure
• Drive the truck completely out of the
narrow aisle.
• Bring the truck to rest.
CAUTION!
You can only change from automatic to 121 17 123 15
manual steering once the truck has fully
exited the narrow aisle.

Z The "Truck guided” display (212) changes to the steer angle indicator (136). The
truck is now free to move again. The steer angle indicator (136) shows the current
position of the drive wheel.
Z Always travel outside of narrow aisles with the load lowered.
The truck has left the narrow aisle. Use the steering wheel (17) to adjust the angle of
the drive wheel again.
11.14 EN
224
4.12 Diagonal travel
12 15
Requirements
– Drive the truck into the narrow aisle and
establish automatic guidance, (see 16 19
"Negotiating narrow aisles" on
page 214).
Procedure
• Press the deadman switch.
Z Travel and hydraulic operations can only be activated in the narrow aisle with two-
handed operation.
• Grab hold of grip (16) with your left hand and grip (19) with your right hand (two-
hand operation).
• Diagonal travel (simultaneous travel and lifting/lowering) can be achieved by
pressing the hydraulic control lever (12) while simultaneously depressing the travel
control knob (15).
• Main Lift - lower:
Turn the hydraulic control lever (12) clockwise.
• Main lift - raise:
Turn the hydraulic control lever (12) anti-clockwise.
• Travel in load direction:
Turn the travel control knob (15) slowly clockwise.
• Travel in drive direction:
Turn the travel control knob (15) slowly anti-clockwise.
forward or back.
11.14 EN
225
4.13 Lifting / lowering – outside and inside narrow aisles
WARNING!
Risk of accidents during lifting and lowering
Other people can be injured in the truck's hazardous area.
The hazardous area is defined as the area in which people are at risk from the truck
movement, the load handler, attachments etc. This also includes areas which can be
reached by falling loads or lowering operating equipment.
Apart from the operator (in the normal operating position) there should be no other
people in the truck's hazardous area.
XInstruct 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.
XOnly carry loads that have been secured and positioned in accordance with
regulations. Use suitable precautions to prevent parts of the load from tipping or
falling down.
XNever exceed the maximum loads specified in the capacity chart.
XNever stand underneath a raised load handler / driver's cab.
XDo not stand on the load handler.
XDo not lift other people on the load handler.
XNever reach or climb into moving truck parts.
XThe driver must not leave the operator position when it is raised –do not climb onto
building constructions or other trucks.
WARNING!
Risk of falling
The driver could fall out if the gate is open and the driver's cab raised.
XDo not open the gate when the driver's cab is raised.
11.14 EN
226
4.13.1 Main Lift raise/lower
Requirements 12
– In narrow aisles grab hold of grip (16)
with your left hand and grip (19) with your 16 19
right hand (two-hand operation). Travel
and hydraulic operations can only be activated in the narrow aisle with two-handed
operation.
Procedure
Z The lift and lower speeds are in proportion to how far the hydraulic control lever (12)
is moved. The maximum lift speed is achieved when the attachment is in the home
position or the telescopic table is in the centre position ((see "Traversing and
rotating the attachment in the home position (t)" on page 241) or (see "Traversing
the telescopic table to the centre position (o)" on page 242)).
The Main Lift is raised / lowered.
WARNING!
Unauthorised lowering speeds can cause accidents

If the safety valve applies for an unauthorised lowering speed (> 0,6 m/s), determine
the cause.
XIf there no leakage in the hydraulic system, raise the Main Lift slightly and then
lower it again slowly.
XSpilled fluids must be removed immediately with an appropriate bonding agent. The
bonding agent / consumable mixture must be disposed of in accordance with
regulations.
11.14 EN
227
4.13.2 Auxiliary Lift raise/lower
12 127
Requirements
operation.
Procedure
• To raise the auxiliary lift:
• Apply the "Auxiliary lift" key (127) and hold it down.
• To lower the auxiliary lift:
The Aux. Lift is raised / lowered.
11.14 EN
228
4.13.3 Simultaneous lifting / lowering of Main and Aux. Lift
Z Simultaneous Main / Auxiliary Lift raising

12 128
and lowering is not available on the EKS.
Requirements
for operation with an additional access 16 19
– In narrow aisles grab hold of grip (16) with your left hand and grip (19) with your
right hand (two-hand operation). Travel and hydraulic operations can only be
activated in the narrow aisle with two-handed operation.
Procedure
• Simultaneous main lift and auxiliary lift raising (EKX 513, EKX 515k and EKX 515
only):
• Apply and hold down on the “Main and Aux. Lift lower / raise” key (128).
• Simultaneous main lift and auxiliary lift lowering (EKX 410, EKX 513, EKX 515k and
EKX 515) only:
• Apply and hold down on the “Main and Aux. Lift lower / raise” key (128).
Z You can stop the raising / lowering of the Auxiliary Lift by releasing the "Main and
Aux. Lift raise / lower" key (128). Pressing the "Main and Aux. Lift raise / lower"
key (128) has no affect on Main Lift or diagonal travel.
The Main / Aux. Lift are raised / lowered simultaneously.
11.14 EN
229
4.14 Traversing / rotating outside and inside narrow aisles
WARNING!
Risk of trapping when swivelling or moving the forks
The hazardous area is defined as the area in which people are at risk from movement
of the load handler, attachments etc. This also includes areas which can be reached
by falling loads or lowering operating equipment.
XInstruct other people to move out of the hazardous area of the industrial truck. Make
sure there is nobody present in the danger zone when carrying out swivel, traverse,
synchronised rotate or lift / lower movements with the load handler. Stop working
regulations. Use suitable protection measure to prevent parts of the load from
tipping or falling down.
XNever exceed the maximum loads specified on the capacity chart.
XNever stand underneath a raised load handler.
XThe driver must not leave the operator position when the attachment is raised.
XDo not climb onto parts of the building or other trucks.
11.14 EN
230
WARNING!
A faulty attachment can be hazardous
Check the attachment daily for external signs of damage or defects. Faulty
attachments can cause the load to fall.
11.14 EN
231
4.14.1 Attachment traverse
12 126
Requirements
operation.
Procedure
• Traverse attachment to the right:
• Traverse attachment to the left:
Z The traverse speed is in proportion to how far the "Hydraulics function" control
lever (12) is rotated.
The attachment moves to the right or left.
Z If the attachment is not in the centre position, you can only travel, lift or lower at
reduced speed, (see "Traversing and rotating the attachment in the home position
(t)" on page 241).
11.14 EN
232
4.14.2 Fork carriage rotation
12 125
Requirements
operation.
Procedure
• Rotate fork carriage right:
• Rotate fork carriage left:
Z The rotary speed is in proportion to how far the "Hydraulics function" control
lever (12) is rotated.
The fork carriage is rotated to the right or left.
(t)" on page 241).
11.14 EN
233
4.15 Simultaneous traversing - rotation outside and inside narrow aisles
WARNING!
Risk of trapping when swivelling or moving the forks
sure there is nobody present in the danger zone when carrying out swivel, traverse,
synchronised rotate or lift / lower movements with the load handler. Stop working
WARNING!

11.14 EN
234
4.15.1 Manual traverse/rotate operation (t)
215
Z In manual traverse/rotate operation the
fork carriage rotates as the attachment is
moving.
Requirements
page 195) or (see "Preparing the truck for
operation with an additional access code 119
(o)" on page 196).
Procedure 216 217
• Press (119) under the "synchronised rotate
menu change" symbol (215).
The display changes from the menu item
“Synchronised rotate menu change” (215)
to "Synchronised fork right rotate" (217) or
"Synchronised fork left rotate" (216).
16 12 119 19
Z The rotary speed is pre-set. The traverse
speed is in proportion to how far the "Hydraulics function" control lever (12) is
moved. Manual traverse/rotate operation can be cancelled by releasing the (119)
key or the hydraulic control lever (12). The attachment must then be moved
manually to the home position.
• Synchonised fork carriage right rotation and load handler left traverse.
• Press and hold down on the (119) key under to the "synchronised fork right
rotation" symbol (217).
• At the same time turn the hydraulic control lever (12) anti-clockwise until you
reach the home position.
• Synchronised fork carriage left swivel and load handler right traverse.
• Press and hold down on the (119) key under to the "synchronised fork left
rotation" symbol (216).
• At the same time turn the hydraulic control lever (12) clockwise until you reach
the home position.
The attachment is located at the right or left mechanical limit position of the swivel
traverse frame and the forks are rotated 180°.
(t)" on page 241).
11.14 EN
235
4.15.2 Manual synchronised rotation until forks are in centre position (o)
Z With "Manual synchronised rotation until

215
forks are in centre position" the fork
carriage is rotated 90° from the home
position and the attachment is positioned
in the centre of the swivel traverse frame.
Requirements
page 195) or (see "Preparing the truck 119
code (o)" on page 196). 218
Procedure
• Press (119) under the "synchronised
rotate menu change" symbol (215).
“Synchronised rotation menu
change” (215) to “Synchronised rotation
until forks in centre position” (218).
16 12 119 19
Z The rotary speed is pre-set. The traverse
speed is in proportion to how far the "Hydraulics function" control lever (12) is
moved. "Synchronised rotation until forks in centre position" can be cancelled by
releasing the (119) key or the hydraulic control lever (12). The attachment must
then be moved manually to the home position.
• Synchonised fork carriage 90° right rotation and load handler centre traverse:
• Press and hold down on the (119) key under the "Synchronised rotation until
forks in centre position" symbol (218) until the attachment comes to rest and
rotary movement stops.
• At the same time turn the hydraulic control lever (12) anti-clockwise until you
reach the centre position.
• Synchonised fork carriage 90° left rotation and load handler centre traverse:
• At the same time turn the hydraulic control lever (12) clockwise until you reach
the centre position.
The attachment is in the centre position and the forks are at right angles (90°) to the
truck. Loads can now be lifted from the front.
(t)" on page 241).
11.14 EN
236
4.15.3 Automatic traverse/rotate operation (o)
215
Z In automatic traverse/rotate operation the
fork carriage rotates as the attachment is
moving.
Requirements
page 195) or (see "Preparing the truck for
operation with an additional access code 119
(o)" on page 196).
Procedure 216 217
• Press (119) under the "synchronised rotate
menu change" symbol (215).
“Synchronised rotate menu change” (215)
to "Synchronised fork right rotate" (217) or
"Synchronised fork left rotate" (216).
16 12 119 19
Z The rotary and traverse speeds are pre-
set. Automatic traverse/rotate operation can be cancelled by releasing the (119)
key. The attachment must then be moved manually to the home position.
• Synchonised fork carriage right rotation and load handler left traverse.
• Press and hold down on the (119) key under the "Synchronised fork right
rotation" symbol (217) until you reach the home position.
• Synchronised fork carriage left swivel and load handler right traverse.
• Press and hold down on the (119) key under the "Synchronised fork left rotation"
symbol (216) until you reach the home position.
The attachment is located at the right or left mechanical limit position of the swivel
traverse frame and the forks are rotated 180°.
(t)" on page 241).
11.14 EN
237
4.15.4 Automatic synchronised rotation until forks are in centre position (o)
Z With "automatic synchronised rotation

215
until forks are in centre position" the fork
carriage is rotated 90° from the home
position and the attachment is positioned
in the centre of the swivel traverse frame.
Requirements
page 195) or (see "Preparing the truck 119
Procedure
• Press (119) under the "synchronised
rotate menu change" symbol (215).
“Synchronised rotation menu
change” (215) to “Synchronised rotation
until forks in centre position” (218).
16 12 119 19
Z The rotary and traverse speeds are pre-
set. "Synchronised rotation until forks in centre position" can be cancelled by
releasing the (119) key. The attachment must then be moved manually to the home
position.
• Synchonised fork carriage 90° rotation and load handler centre traverse:
The attachment is in the centre position and the forks are at right angles (90°) to the
truck. Loads can now be lifted from the front.
(t)" on page 241).
11.14 EN
238
4.16 Parking the truck securely
WARNING!
Parking the truck on an incline, without the brakes applied or with a raised load / load
handler is dangerous and is strictly prohibited.
forks.
12
13
127
18
25
26
24
11.14 EN
239
Parking the truck securely
Procedure
• Park the truck on a level surface.
• Fully lower the mast:
• Fully lower the load handler (25):
• Traversing and rotating the attachment in the home position (t), (see "Traversing
and rotating the attachment in the home position (t)" on page 241).
• Traverse the telescopic table to the centre position (o), (see "Traversing the
telescopic table to the centre position (o)" on page 242).
The truck is now securely switched off.
11.14 EN
240
4.16.1 Traversing and rotating the attachment in the home position (t)
12
13
127
18
25
26
24
Requirements
(o)" on page 196).
Procedure
• Traverse the attachment to the right or left limit position of the sideshift frame (24),
(see "Attachment traverse" on page 232).
• Rotate the forks (25) parallel to the sideshift frame (24), (see "Fork carriage
rotation" on page 233).
The driver's display shows the "Attachment in home position" symbol.
11.14 EN
241
4.16.2 Traversing the telescopic table to the centre position (o)
Requirements
(o)" on page 196).
Procedure
• Traverse the telescopic table to the centre position, (see "Traversing the telescopic
forks of the telescopic table (o)" on page 364).
The driver's display shows the "Telescopic table in home position" symbol.
11.14 EN
242
5 Order picking and stacking
5.1 Adjusting the forks
WARNING!
Unsecured and incorrectly positioned loads can cause accidents
Before lifting a load unit the driver must ensure that it has been correctly palletised
and the truck’s capacity is not exceeded.
XOnly carry loads that have been correctly secured and positioned. Use suitable
protection measure to prevent parts of the load from tipping or falling down.
XDamaged loads must not be transported.
XCheck the fork spread before lifting the load and adjust if necessary.
XInsert the forks as far as possible underneath the load.
11.14 EN
243
5.1.1 Adjusting the Forks (t)
WARNING!
Incorrect fork adjustments can cause accidents
To lift the load securely, the fork tines should be as far apart as possible and centrally
positioned with respect to the fork carriage. The load centre of gravity must be
centrally aligned between the forks.
WARNING!
Unsecured forks can cause accidents
The forks must be prevented from falling with the extension safety
mechanisms (221). The truck must not be operated without an extension safety
mechanism (221).
XCheck the extension safety mechanisms (221) are present.
XEnsure the extension safety mechanisms (221) are secure.
Adjusting the forks
Requirements
– Park the truck securely, (see "Parking 219
the truck securely" on page 239).
Procedure
25
• Lift up the locking lever (219).
• Push the forks (25) into the correct 220
position on the fork carriage (220).
221
• Swing the locking lever (219) down and
move the fork tines until the locking pin
(25) engages in a slot.
The forks are now adjusted.
11.14 EN
244
5.1.2 Adjusting the forks (o)
WARNING!
Incorrect fork adjustments can cause accidents
To lift the load securely, the fork tines should be as far apart as possible and centrally
positioned with respect to the fork carriage. The load centre of gravity must be
centrally aligned between the forks.
WARNING!
The forks must be prevented from falling with the lock screws (222). The truck must
not be operated without retraining screws (222).
XCheck the lock screws (222) are present.
XEnsure the lock screws (222) are secure. Lock screw torque: 80 Nm.
222 25
Adjusting the forks
220
Requirements
25
– Truck parked securely, (see "Parking the 222
truck securely" on page 239).
Procedure
• Push the forks (25) into the correct
position on the fork carriage (220).
The forks are now adjusted.
11.14 EN
245
5.2 Replacing the forks
WARNING!
Faulty fork tines can cause accidents
Faulty fork tines can cause the load to fall.
XDo not operate the truck with faulty forks.
XIf one fork tine is damaged, both fork tines must be replaced.
XTag out faulty forks and withdraw them from use.
CAUTION!
Trapping risk when moving the forks
You can trap your arms and legs when moving the forks on the fork carriage.
XWear personal protective equipment (e.g. safety boots etc.) when replacing the
forks.
XAlways push the forks away from your body, never towards it.
XSecure heavy forks with lifting slings and a crane before pushing them down from
the fork carriage.
XKeep all parts of your body away from the forks and fork carriage.
WARNING!
Using two different forks can cause accidents
Installing fork tines that are not identical in design will affect the stability of the
industrial truck.
XUse only the same type of fork that has been approved by the manufacturer.
XAlways replace forks in pairs.
XThe fork tine dimensions must match.
11.14 EN
246
5.2.1 Replacing the fork tines (t)
CAUTION!
Injury risk when replacing forks
The forks can slide off the fork carriage when being replaced. As a result you could
injure your legs.
forks.
the fork carriage.
XAfter replacing the forks fit the extension safety mechanism and make sure it is
seated correctly in the fork carriage.
Disassembling the forks
Requirements
– Load handler lowered and forks not
touching the ground. 25
Procedure 220
• Disassemble the extension safety
221
mechanism (221).
• Lift up the locking lever (219).
• Carefully push the fork tines (25) off the fork carriage (220).
The fork tines (25) are now dismantled from the fork carriage (220) and can be
replaced.
11.14 EN
247
Assembling the forks
Requirements
– Truck parked securely, (see "Parking the truck securely" on page 239).
– Mast lowered.
– Fork carriage raised so that the fork tine can be pushed onto the fork carriage.
– Extension safety mechanism (221) disassembled.
Procedure
• Carefully push the fork tines (25) onto the fork carriage (220).
• Adjust the forks (25), (see "Adjusting the forks" on page 243).
• Bring the locking lever (219) down and move the fork tines (25) until the locking pin
engages in a slot.
WARNING!
The forks must be prevented from falling with the extension safety
mechanisms (221). The truck must not be operated without an extension safety
mechanism (221).
XCheck the extension safety mechanisms (221) are present.
XEnsure the extension safety mechanisms (221) are secure.
• Assemble the extension safety mechanism (221) and check that it is firmly seated.
The fork tines (25) are mounted on the fork carriage (220).
11.14 EN
248
5.2.2 Replacing the fork tines (o)
CAUTION!
Injury risk when replacing forks
The forks can slide off the fork carriage when being replaced. As a result you could
injure your legs.
forks.
the fork carriage.
XAssemble the lock screws (222) in the fork carriage after replacing the forks.
Ensure the lock screws are seated correctly. Lock screw torque: 80 Nm.
222 25
Disassembling the forks
220
Requirements
25
– Driver's cab lowered and forks not
touching the ground.

– Torque wrench
– M12-Allen key to release or tighten the
lock screws (222)
Procedure
• Disassemble the lock screws (222).
• Carefully push the fork tines (25) off the fork carriage (220).
The fork tines (25) are now dismantled from the fork carriage (220) and can be
replaced.
11.14 EN
249
Assembling the forks
Requirements
– Mast lowered.
– Fork carriage raised so that the fork tine can be pushed onto the fork carriage.
– Lock screws (222) disassembled.
– Torque wrench
– M12-Allen key to release or tighten the lock screws (222)
Procedure
• Carefully push the fork tines (25) onto the fork carriage (220).
• Adjust the forks (25), (see "Adjusting the forks (o)" on page 245).
WARNING!
The forks must be prevented from falling with the lock screws (222). The truck must
not be operated without retraining screws (222).
XCheck the lock screws (222) are present.
XEnsure the lock screws (222) are secure. Lock screw torque: 80 Nm.
• Insert the lock screws (222) into the fork carriage (220). Torque the lock
screws (222) to 80 Nm.
The fork tines (25) are mounted on the fork carriage (220).
11.14 EN
250
5.3 Lifting, transporting and depositing loads
WARNING!
Before lifting a load unit the driver must make sure that it has been correctly palletised
and does not exceed the truck’s capacity.
precautions to prevent parts of the load from tipping or falling down.
XDo not transport loads other than on the authorised load handler.
XIf the stacked load obscures forward visibility, then you must reverse the truck.
XDo not reach through the mast.
Z The section "Order picker - EKS" details how to lift and lower the load with:
- a mechanical lock on the forks, (see "Lifting / depositing a load with a mechanical
lock on the fork tines (with / without load-sensing)" on page 353).
- a mechanical lock, (see "Lifting / depositing a load with a mechanical lock on the
load handler (with / without load-sensing)" on page 355).
- a locking clamp or claw, (see "Lifting / depositing a load with load-sensing and a
clamp / claw for locking" on page 357).
11.14 EN
251
5.3.1 Lifting load units
EKX - Raising a load unit from the side
Requirements
(o)" on page 196).
– Load unit correctly palletised.
– Fork spread for the pallet checked and adjusted if necessary, (see "Adjusting the
forks" on page 243).
– Load unit weight does not exceed the truck's capacity.
– Forks evenly loaded for heavy loads.
– Good ground conditions.
Procedure
• Drive carefully up to the storage location.
• Lower/raise the load handler so that the load can be lifted.
• Slowly insert the forks into the pallet until the fork shank
touches the load or the pallet.
Z The load unit must not extend by more than 50 mm
beyond the fork tips.
• Raise the load slightly until it rests freely on the forks.
• Slowly retract the forks to the home position, (see
"Traversing and rotating the attachment in the home
position (t)" on page 241) or (see "Traversing the
• Make sure you have a clear view and sufficient area to
move in.
• The load can now be transported with the truck, (see
"Transport the load unit." on page 255).
The load has been lifted correctly.
11.14 EN
252
EKX - Raising a load unit from the front (standard attachment only)
Requirements
(o)" on page 196).
– Fork spread for the pallet checked and adjusted if necessary, (see "Adjusting the
forks" on page 243).
Procedure
• Set the attachment to the "front lifting" position: 90˚
• Traverse the attachment to the centre position, (see
"Attachment traverse" on page 232).
• Rotate the fork carriage so that it is at right angles (90°)
to the truck, (see "Fork carriage rotation" on page 233).
Z The load unit must not extend by more than 50 mm
beyond the fork tips.
• Make sure you can see behind you and that you have
sufficient space to move. Now reverse the truck slowly
until the load is clear (e.g. out of the rack).
• Slowly traverse and rotate the forks in the home position,
(see "Traversing and rotating the attachment in the home
position (t)" on page 241).
• Make sure you have a clear view and sufficient area to
move in.
• The load can now be transported with the truck, (see
"Transport the load unit." on page 255).
11.14 EN
253
EKS - Lifting load units
Requirements
– Prepare the truck for operation, (see "Preparing the truck
for operation" on page 195) or (see "Preparing the truck
for operation with an additional access code (o)" on
page 196).
– Fork spread for the pallet checked and adjusted if
necessary, (see "Adjusting the forks (o)" on page 245).
Procedure
Z The load unit must not extend by more than 50 mm beyond the fork tips.
• Make sure you can see behind you and that you have sufficient space to move.
Now reverse the truck slowly until the load is clear (e.g. out of the rack).
• Make sure you have a clear view and sufficient area to move in.
• The load can now be transported with the truck, (see "Transport the load unit." on
page 255).
11.14 EN
254
5.3.2 Transport the load unit.
WARNING!
Ensure there are no other people standing underneath the raised load and
driver's cab.
XNever stand underneath a raised and unsecured load handler / driver's cab.
Requirements
page 196).
– Load unit correctly lifted, (see "Lifting load units" on
page 252).
Procedure
Z Always transport loads with both forks. When transporting
heavy loads always ensure that both forks carry the same
weight.
• Raise the load slightly.
Z Always transport a load outside the narrow aisle as low as possible, allowing for
ground clearance.
• Accelerate gradually.
• Travel at a constant speed.
• Adapt your travel speed to the conditions of the route and the load you are
transporting.
• Be prepared to brake at all times.
• Brake gently in normal circumstances.
• Only stop suddenly in dangerous situations.
• Reduce speed accordingly on narrow bends.
• Watch out for other traffic at crossings and passageways.
• Always travel with a lookout at blind spots.
11.14 EN
255
5.3.3 Lowering the load unit
Z The section "Order picker - EKS" details how to lift and lower the load with:
- a mechanical lock on the forks, (see "Lifting / depositing a load with a mechanical
lock on the fork tines (with / without load-sensing)" on page 353).
- a mechanical lock, (see "Lifting / depositing a load with a mechanical lock on the
load handler (with / without load-sensing)" on page 355).
- a locking clamp or claw, (see "Lifting / depositing a load with load-sensing and a
clamp / claw for locking" on page 357).
CAUTION!
Before a load can be deposited, the driver must ensure that the storage location is
suitable for storing the load (size and capacity).
NOTE
11.14 EN
256
EKX - Depositing a load unit from the side
Requirements
(o)" on page 196).
– Load unit correctly lifted, (see "Lifting load units" on page 252).
– Storage location suitable for the load (size and capacity).
Procedure
• Raise the load handler so that the load can enter the
storage location without striking any objects.
• Carefully set the load into its storage location.
• Carefully lower the load handler so that the forks are clear
of the load.
Z Avoid depositing the load suddenly to avoid damaging the
load, load handler and the rack.
• Carefully withdraw the load handler from the load.
position (t)" on page 241) or (see "Traversing the
• Fully lower the load handler.
The load has been deposited correctly.
11.14 EN
257
EKX - Depositing a load unit from the front
Requirements
(o)" on page 196).
– Load unit correctly lifted, (see "Lifting load units" on page 252).
Procedure
• Set the attachment to the "front lifting" position: 90˚
• Traverse the attachment to the centre position, (see

• Rotate the fork carriage so that it is at right angles (90°)
to the truck, (see "Fork carriage rotation" on page 233).
• Raise the load handler so that the load can be taken to
the storage location without striking any objects.
• Carefully bring the load to its storage location.
• Carefully lower the load handler so that the forks are clear
of the load.
Z Avoid depositing the load suddenly to avoid damaging the
load, load handler and the rack.
• Make sure you can see behind you and that you have
sufficient space to move.
• Carefully remove the load handler from the load.
position (t)" on page 241).
11.14 EN
258
EKS - Depositing load units
Requirements
page 196).
– Load unit correctly lifted, (see "Lifting load units" on
page 252).
Procedure
• Raise the load handler so that the load can be taken to
the storage location without striking any objects.
• Carefully lower the load handler so that the forks are clear of the load.
Z Avoid depositing the load suddenly to avoid damaging the load, load handler and
the rack.
11.14 EN
259
6 Troubleshooting
6.1 Troubleshooting
This chapter enables the user to identify and rectify basic faults and the effects of
incorrect operation. When trying to locate a fault, proceed in the order shown in the
table.
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.
Additional troubleshooting must only be performed by the manufacturer’s specialist
service engineers. The manufacturer's customer service department is specially
trained to carry out these operations.
In order for customer services to react quickly and specifically to the fault, the
following information is essential:
- Truck serial number
- Error number on the display unit (if applicable)
- Error description
- Current location of truck
11.14 EN
260
Fault Possible Cause Remedy
Truck does – Battery connector – Check battery connector and plug in if
not start not plugged in necessary.
– Gates open – Close the gates.
– Emergency – Unlock Emergency Disconnect switch
Disconnect pressed ((see "Emergency Disconnect" on
page 208)).
– Key switch turned off – Turn on key switch ((see "Preparing the
truck for operation" on page 195)).
– ISM access module – Hold the card or transponder in front of
switched off (o) the ISM access module and depending
on the setting press the green button on
the ISM access module.
– Battery charge too – Check battery charge, charge battery if
low necessary ((see "Charging the battery"
on page 104)).
– Deadman switch not – Press the deadman switch.
pressed
– Faulty fuse – Check fuses and replace if necessary
((see "Checking electrical fuses" on
page 522)).
– Travel cutout – Press the key next to the "travel cutout
activated override" symbol ((see "Travel cutout
override (o)" on page 270)).
– Travel cutout – Set the travel control knob to neutral and
activated via end of press it again.
aisle safety device
– Lift chains slack – Tension the lift chains again, (see "Slack
chain safety device override" on
page 269).
11.14 EN
261
Load cannot – Truck not operational – Carry out all remedial measures listed
be lifted under “Truck does not start”.
– Battery charge too – Check battery charge, charge battery if
low, lift cutout necessary ((see "Charging the battery"
on page 104)).
– Lift cutout activated – Press the key next to the "lift cutout
override" symbol ((see "Lift cutout
override (o)" on page 271)).
– Insufficient hydraulic – Check hydraulic oil, if necessary top up
oil ((see "Checking the hydraulic oil level"
on page 542)).
– Faulty fuse – Check fuses and replace if necessary
((see "Checking electrical fuses" on
page 522)).
– Lift chains slack – Tension the lift chains again, (see "Slack
chain safety device override" on
page 269).
Rapid travel – Forks are not in the – Traverse and rotate the forks in the
disabled home position home position, (see "Traversing and
rotating the attachment in the home
position (t)" on page 241) or (see
"Traversing the telescopic table to the
centre position (o)" on page 242).
– Main Lift / Aux. Lift – Lower Main Lift / Aux. Lift below 0,5 m.
raised above 0,5 m
– WG search mode – Align truck or turn off WG mode.
activated
– No reference run – Carry out a reference run, (see
performed "Referencing the main and auxiliary lift"
on page 204).
– Load in scanning – Raise the Main Lift / driver's cab until the
range of personal "protection field infringement" symbol is
protection system no longer displayed.
laser scanner
Truck cannot – Truck not operational – Carry out all remedial measures listed
be steered under “Truck does not start”.
– Automatic guidance – Press the “Switch automatic guidance
switched on on/off” key and switch off "Travelling in
narrow aisle".
1901 – Travel control knob – Do not apply travel control knob, switch
applied during truck off and on again.
power-up test
2902 – Hydraulic control – Do not apply the hydraulic control lever;
lever applied during switch truck off and on again.
power-up test
11.14 EN
262
3670 – Truck has – Restore wire guidance
abandoned the guide ((see "WG emergency operation (event
wire messages 3670 / 3752)" on page 277)).
3752 – Truck has – Restore wire guidance
abandoned the guide ((see "WG emergency operation (event
wire messages 3670 / 3752)" on page 277)).
4916 – During the power-up – Do not press the key, switch truck off
test a "Functions" and on again.
key under the
driver's display and /
or a key on the
numerical keypad
has been pressed
4917 – A key / function pre- – Do not press the key / function pre-
select key (switch select key (switch guidance on/off, Aux.
guidance on/off, Aux. Lift raise/lower), switch the truck off and
Lift raise/lower) on again.
pressed during
power-up test
4918 – Deadman switch – Do not press the deadman switch,
pressed during switch truck off and on again.
power-up test
9901 – The Personal – Carry out the Personal protection
protection system system cycle test, (see "Cycle test" on
cycle test must be page 327).
performed
9963 – Front screen of – Front screen of Personal protection
personal protection system (PPS laser scanner) is dirty;
system (PPS) laser clean, (see "Daily checks before starting
scanner dirty the Personal Protection System" on
page 327).
11.14 EN
263
6.2 Emergency stop device
When the automatic emergency stop device applies (e.g. if the wire is abandoned,
electrical steering fails) the truck brakes to a halt. Determine the cause of the fault and
eradicate it before starting up the truck again. When starting the truck again, follow
the manufacturer's instructions as indicated in the present operating instructions
((see "Industrial Truck Operation" on page 188)).
11.14 EN
264
6.3 Driver's cab emergency lowering
WARNING!
Risk of accidents / material damage through automatic lowering of load handler
If the load handler is in the rack, emergency lowering cannot be performed. Due to
leakage from the hydraulic system there is also the risk that the rack could be
damaged by the load handler lowering.
XPrevent the load handler from lowering further, e.g. with strong chains.
XArrange for trained personnel to recover the truck as soon as possible.
11.14 EN
265
WARNING!
Lowering the load handler / driver's cab can result in injuries
The hazardous area is defined as the area in which a person is at risk due to the mast,
driver's cab or load handler (e.g. forks or attachments) or the load itself. This also
includes areas which can be reached by falling loads or lowering operating
equipment.
XInstruct other people to move out of the hazardous area of the truck during
emergency lowering.
XIf a second person is used to lower the load handler / driver's cab via the emergency
lowering device, this person must consult with the driver. Both people must be in a
safe area to avoid danger.
XEmergency lowering of the load handler / driver’s cab is prohibited when the load
handler is in the rack.
Traverse the attachment to the home position (t), (see "Traversing and rotating
the attachment in the home position (t)" on page 241).
Traverse the telescopic table to the centre position (o), (see "Traversing the
XTag out and decommission the faulty industrial truck.
NOTE
Risk of material damage to the locking clamp / claw
When performing an emergency lowering of the driver's cab with the load lifted and
clamped, the locking clamp / claw can be damaged when it reaches the floor (EKS
with locking clamp or claw option only).
XStop lowering approx. 10 cm before the floor.
11.14 EN
266
18 13 18
13
223
224
223
225
225
224 37
Emergency lowering of the driver's cab / mast
Requirements
– Load handler is not in the rack.

– Allen key (supplied with the truck).
Procedure
Z If necessary, a second person can be deployed from the ground to lower the cab.
• Turn the key in the key switch as far to the left as it will go (18).
• Allen key (224) storage location on the EKX 410:
• Open the battery panel (5).
• Remove the Allen key (224) from the bracket next to the battery connector.
• Allen key (224) storage location on the EKS 513 - 515 / EKX 513 - 515:
• Remove the Allen key (224) from the bracket below the strobe light (37).
• Insert the Allen key (224) into the hole (225).
WARNING!
Trapping hazard during emergency lowering
There is a trapping hazard for the driver in the driver's cab during emergency
lowering.
XKeep the whole of your body inside the cab.
11.14 EN
267
NOTE
Risk of material damage to the locking clamp / claw
When performing an emergency lowering of the driver's cab with the load lifted and
clamped, the locking clamp / claw can be damaged when it reaches the floor (EKS
with locking clamp or claw option only).
XStop lowering approx. 10 cm before the floor.
• Turn the lowering valve (223) with Allen key (224):

• max. two revolutions anti-clockwise:
The driver's cab / mast are lowered.
Z The lowering speed increases the further the lowering valve (223) is opened.
• clockwise as far as it will go:
Lowering stops.
The driver's cab / mast are lowered.
• Storing the Allen key (224) on the EKX 410:
• Place the Allen key (224) in the bracket next to the battery connector.
• Storing the Allen key (224) on the EKS 513 - 515 / EKX 513 - 515:
• Place the Allen key (224) in the bracket below the strobe light (37).
WARNING!
Only return the truck to service when you have identified and rectified the fault.
11.14 EN
268
6.4 Slack chain safety device override
Z The slack chain safety device applies when a chain is not tensioned, or slack. For
example, a chain can become slack when the load handler or the cab are attached,
when the chain is loosened and/or breaks.
12 226
Raising the Main Lift when the slack
chain device device is activated
Procedure
Z “Main Lift lower” is disabled when the
slack chain protection is activated.
• Press and hold down on the (119) key
next to the "slack chain protection
override" symbol (226).
119
• Turn the hydraulic control lever (12) anti-
clockwise.
• Raise the Main Lift slightly (approx. 0,25 m) until the "slack chain protection
override" symbol (226) is no longer displayed.
• If necessary traverse and rotate the forks in the home position, (see "Traversing
and rotating the attachment in the home position (t)" on page 241) or (see
"Traversing the telescopic table to the centre position (o)" on page 242).
The chains are tensioned again and the truck is ready for operation.
WARNING!
If the "slack chain safety device override" symbol does not disappear after the Main
Lift has been raised approx. 0,25 m, the truck can only be started again when the fault
has been identified and rectified.
11.14 EN
269
6.5 Travel cutout override (o)
Z The “travel cutout override" symbol (227) is illuminated in the driver's display
whenever further travel is inhibited beyond a certain lift height or range. If however
the position of the truck needs to be adjusted with respect to the rack in order to
stack or retrieve a load, proceed as follows:
WARNING!
The truck can cause accidents
Travel cutout is an additional function designed to support the operator, but which
does not release him from any responsibility, e.g. to monitor braking at the aisle end
and if necessary to apply the brakes.
227 15
Driving the truck in the event of a travel
cutout
Procedure
• Press and hold down on the (119) key
under the "Travel cutout override"
symbol (227).
the travel control knob (15):
119
slowly clockwise:
The truck can now travel at slow speed.
NOTE
Pressing the (119) button under the corresponding override symbol releases
different travel and hydraulic speeds as well as travel and hydraulic directions. The
override functions can be adjusted by the manufacturer's customer service
department.
11.14 EN
270
6.6 Lift cutout override (o)
Z If local conditions require, an automatic lift cutout can be installed to be activated
from a given lift height. The automatic lift cutout, which is active from a fixed height,
prevents the Main and Auxiliary Lifts from raising. The driver's display shows the
"Lift cutout override" symbol (205).
CAUTION!
An extended mast can cause accidents
The lift cutout is an auxiliary function designed to support the operator which however
does not release him from his responsibility to stop hydraulic operations e.g. when
confronted with an obstacle.
Z Lift cutout only becomes effective after referencing has been carried out ((see
"Referencing the main and auxiliary lift" on page 204)). When referencing has been
completed, the height actual value is shown in the driver's display.
CAUTION!
Disabling the lift cutout can cause accidents
If the lift cutout is disabled, the driver must pay particular attention to obstacles when
the mast is extended.
11.14 EN
271
12 205 127
Lift cutout override
Procedure
• Raising the Main Lift despite a lift cutout:
• Activate and hold down on the (119)
key under the "Lift cutout override"
symbol (205).
• Turn the hydraulic control lever (12)
anti-clockwise.
119
The Main Lift is raised. Lift cutout is
deactivated.
• Raising the Aux. Lift despite a lift cutout:
• Activate and hold down on the (119) key under the "Lift cutout override"
symbol (205).
The Aux. Lift is raised. Lift cutout is deactivated.
Z The lift cutout is re-activated each time the mast falls below the lift limit height.
NOTE
department.
11.14 EN
272
6.7 Lower cutout override (o)
Z If local conditions require, an automatic lower cutout can be installed to be activated
from a given height. The automatic lower cutout, which is active from a fixed height,
prevents the Main and Auxiliary Lifts from raising. The driver's display shows the
"Lower cutout override" symbol (228).
CAUTION!
Accident risk due to setting down the driver's cab or load handler
The lower cutout is an auxiliary function designed to support the operator which
however does not release him from his responsibility to stop hydraulic operations e.g.
when confronted with an obstacle.
Z Lower cutout only becomes effective after referencing has been carried out ((see
"Referencing the main and auxiliary lift" on page 204)). When referencing has been
completed, the height actual value is shown in the driver's display.
CAUTION!
Disabling the lower cutout can cause accidents
If the lower cutout is disabled, the driver must pay particular attention to obstacles
when the driver's cab or load handler are lowered.
11.14 EN
273
12 228 127
Lower cutout override
Procedure
• Lowering the Main Lift despite a lower
cutout:
• Activate and hold down on the (119)
key under the "Lower cutout override"
symbol (228).
clockwise. 119
The Main Lift is lowered. The lower cutout is deactivated.
• Lowering the Aux. Lift despite a lower cutout:
• Activate and hold down on the (119) key under the "Lower cutout override"
symbol (228).
The Aux. Lift is lowered. The lower cutout is deactivated.
Z The lower cutout is re-activated each time the mast is raised above the lower cutout
height.
NOTE
department.
11.14 EN
274
6.8 End of aisle safety device (o)
Trucks with the end of aisle safety device brake before the aisle exit or in the transfer
aisle. There are two basic versions for this:
1) Braking to a halt
2) Braking to 2,5 km/h
Other variants (affecting the subsequent travel speed, lift height etc.) are available.
1. Braking to a halt
When the truck passes over the aisle end safety devices (route measurement,
magnets, ...) in the direction of the end of the aisle, it comes to a halt.
WARNING!
The stopping distance depends on the travel speed.
To continue travelling:
• Briefly release the travel control knob and then apply it again.
The truck can be driven out of the narrow aisle at max. 2,5 km/h.
WARNING!
Accident risk due to truck without braking system
End of aisle safety braking is an additional function designed to support the operator,
but which does not release him from his responsibilities such as to monitor braking at
the aisle end and if necessary to apply the brakes.
11.14 EN
275
2. Braking up to 2,5 km/h
When the truck passes over the aisle end safety devices (route measurement,
magnets, ...) in the direction of the end of the aisle, it brakes to 2,5 km/h and can be
driven out of the narrow aisle at this speed.
WARNING!
The stopping distance depends on the travel speed.
WARNING!
Accident risk due to truck without braking system
End of aisle safety braking is an additional function designed to support the operator,
but which does not release him from his responsibilities such as to monitor braking at
the aisle end and if necessary to apply the brakes.
11.14 EN
276
6.9 WG emergency operation (event messages 3670 / 3752)
In a wire guidance system if the truck's antenna extends beyond the pre-
determined range of the guide wire, an emergency stop is immediately
induced. The driver's display flashes the "Wire guidance fault" symbol
and displays the event messages "3670" and "3752".
Z If in addition to the "wire guidance fault" symbol the "screwdriver" symbol is also lit.
This indicates that other faults have occurred apart from the wire guidance fault.
The resulting event messages and / or information messages are shown on the
driver's display.
If the truck is travelling parallel to the guide wire, travel is not disabled. The “alignment
on” display and the audible alignment signal however remain permanently on and
hence warn the driver.
Automatic Emergency Stop
If during operation one of the monitors for steering control, steering system, wire
guidance, the safety cutout for the traction electronic system or the power electronic
system applies, the truck safety devices will cause the truck to stop.
To enable the truck to travel again after an Emergency Stop, carry out the
following:
Procedure
Z The driver's display flashes the "Wire guidance fault" symbol and displays the event
messages "3670" and "3752".
• Determine the possible cause of the Emergency Stop and rectify it.
• Turn the Emergency Disconnect to unlock it.
• The "Wire guidance fault" symbol and the event messages "3670" and "3752"
go out in the driver's display.
• Switch on automatic wire guidance again, (see "Negotiating narrow aisles with
wire-guided trucks (o)" on page 219).
• Press the “Automatic guidance on/off” button.
• Apply the travel control knob and carefully align the truck with the guide wire.
The truck is now operational and aligned with the guide wire.
11.14 EN
277
Z If you cannot start the truck again after an automatic or manual Emergency Stop,
despite having rectified the problem, turn the truck off and on again with the key
switch.
Then perform a reference run ((see "Referencing the main and auxiliary lift" on
page 204)) and carry out the above items again.
The truck is now operational again.
Z When the truck is operational again, test it with both manual steering (outside the
narrow aisle) and automatic guided steering.
Manual Emergency Stop
A manual Emergency Stop is induced when the Emergency Stop button is pressed.
The truck is operational again when the Emergency Stop has been released.
6.10 Recovering the truck from a narrow aisle / Moving the truck without
a battery
WARNING!
Disabling the brakes can be dangerous
Recovering the truck from a narrow aisle or moving the truck without a battery must
only be performed by specialist repair personnel.
XThe specialist must be trained in operating the truck with the brakes disabled.
XWhen the brakes are de-activated the truck must be parked on a level surface,
since the brakes are no longer effective.
XIf the brakes are not working, place wedges underneath the wheels of the truck to
prevent it from moving.
Obtain assistance from another person. The other person must be trained and
familiar with recovery operations.
Z To recover the truck from the narrow aisle, the drive wheel brake must first be
released. In addition, on the EKS 513 - 515 / EKX 513 - 515 the load wheel brakes
must be released.
11.14 EN
278
6.10.1 Release and activate the drive wheel brake
WARNING!
Uncontrolled truck movement
When the brakes are de-activated the truck must be parked on a level surface, since
the brakes are no longer effective.
XDo not release the brake on slopes or inclines.
XApply the brake again when you reach your destination.
XDo not park the truck with the brake released.
18 13 18 13 5
5
38
38
229
229
230
229
231
232
232 231 230
Releasing the drive wheel brake
Requirements
– Fully lower the mast, (see "Lifting / lowering – outside and inside narrow aisles" on
page 226) or (see "Driver's cab emergency lowering" on page 265).
– For EKX only:
– Disconnect the battery.
– Two setscrews (hex socket) with hex. nuts (supplied with the truck).
Procedure
• Open the battery panel (5).
• Use wedges to prevent the truck from moving.
11.14 EN
• Disassemble the drive compartment cover (38), (see "Drive compartment cover
disassembly/assembly" on page 518).
279
• Disassemble the setscrews (229) from their bracket (230) above the magnetic
brake (231).
• Insert the setscrews (229) into the magnetic brake (231) above the drive
motor (232) and tighten them with the two hex. nuts.
Z The two setscrews (229) are used to tension (unlock) the compression springs
which activate the parking brake, so that the truck does not brake when de-
energised.
• Release the load wheel brake (if applicable), (see "Releasing and applying the load
wheel brake" on page 283).
• Remove the wedges.
The drive wheel brake is now released and the truck can be moved. The truck can
now be pulled or pushed without a battery.
11.14 EN
280
WARNING!
forks.
WARNING!
If the brakes are not working, place wedges underneath the wheels of the truck to
18 13 18 13 5
5
38
38
229
229
230
229
231
232
232 231 230
11.14 EN
281
Activating the drive wheel brake
Requirements
– Drive wheel brake wheel.
– Truck parked securely.
Procedure
• Remove the setscrews (229) from the magnetic brake (231).
• Assemble the setscrews (229) on their bracket (230) above the magnetic
brake (231).
CAUTION!
• Assemble the drive compartment cover (38), (see "Drive compartment cover
• Apply the load wheel brake (if applicable), (see "Releasing and applying the load
• When using the truck again, check its deceleration rate.
The drive wheel brake can now be applied without current. The industrial truck can
now longer be moved without the battery.
WARNING!
11.14 EN
282
6.10.2 Releasing and applying the load wheel brake
Z The load wheel brakes are fitted only on the EKS 513 - 515 / EKX 513 - 515.
WARNING!
23
13 112
111
110
18
233
234
235 30 233
Releasing the load wheel brake

Requirements
– For EKX only:

– Six setscrews (Allen screws). The setscrews are supplied with the truck.
– Allen key (key width 6).
Procedure
11.14 EN
283
• Fit the panels (235) of the load wheels (30) on both sides:
• Unscrew three Allen screws from each load wheel (30).
• Remove the panels (235).
Z The load wheel (30) has five notches (234) which are arranged so that for each
position of the load wheel (30) at least three out of nine possible thread holes (233)
can be accessed by the load wheel brake.
• Remove the twist grip screws (111) from the left and right sides behind the driver's
seat (23).
• Remove the plastic bag including the setscrews (110) to release the load wheel
brake from the storage compartment (112) behind the driver's seat (23).
Z The setscrews are used to tension (unlock) the compression springs which activate
the load wheel brakes, so that the truck does not brake when de-energised.
CAUTION!
screws (111).
• For each load wheel (30), insert three setscrews with an angle offset of 120°
loosely into the thread holes (233) of the load wheel brake:
• Loosely insert the setscrews in the thread holes (233) of the load wheel brake.
• Tighten the setscrews by maximum half a turn.
• Release the drive wheel brake, (see "Release and activate the drive wheel brake"
on page 279).
• Remove the wedges.
The load wheel brakes are now released and the truck can be moved. The truck can
now be pulled or pushed without a battery.
11.14 EN
284
WARNING!
forks.
WARNING!
23
13 112
111
110
18
233
234
235 30 233
Activating the load wheel brake

Requirements
– Load wheel brakes released.
– Truck parked securely.
Procedure
• Remove the setscrews from the thread holes (233) of the load wheel brake.
• Store the setscrews in a plastic bag.
• Seal the plastic bag with adhesive tape.
• Store the plastic bag and setscrews (110) behind the driver's seat (23):
11.14 EN
285
• Remove the twist grip screws (111) from the left and right sides behind the
driver's seat (23).
• Secure the plastic bag with cable ties behind the panel (112) of the driver's
seat (23).
Z Make sure the plastic bag does not come into contact with moving parts when
the truck is moving. Also ensure that the plastic bag cannot fall into the hole
below the panel (112) when the truck is moving.
CAUTION!
screws (111).
• Fit the panels (235) of the load wheels (30) on both sides:
• Place the panels (235) onto the load wheels (30).
• Attach the panels (235) to the load wheel (30) with three Allen screws.
• Activate the drive wheel brake, (see "Release and activate the drive wheel brake"
on page 279).
• When using the truck again, check its deceleration rate.
The load wheel brakes can now be applied without current. The industrial truck can
now longer be moved without the battery.
WARNING!
11.14 EN
286
6.10.3 Steering the truck without its own drive system
CAUTION!
A non-steered truck can cause accidents
It may not be possible to steer the truck if the steering system is damaged. The truck
can only be steered without its own drive system when it is stationary.
XDo not adjust the truck's steering angle during a recovery operation.
XWhen setting an angle of more than 4 degrees it is advisable to relieve the wheel
by raising/jacking up the truck.
18 13
Adjusting the steer angle
Requirements
– Fully lower the mast, (see "Lifting /
38
lowering – outside and inside narrow
aisles" on page 226) or (see "Driver's cab
emergency lowering" on page 265).
– For EKX only:
Traverse the attachment to the home
position (t), (see "Traversing and
rotating the attachment in the home
position (t)" on page 241). 236
Traverse the telescopic table to the
centre position (o), (see "Traversing the
telescopic table to the centre position
(o)" on page 242).
35
– Allen key (key width 8).
Procedure
• Set the drive wheel (35) to the required direction using the Allen key via the
screw (236) at the top of the steer motor.
Z If you are setting an angle of more than 4 degrees it is advisable to discharge the
drive wheel (35) by raising/jacking up the truck securely.
The steer angle is now set.
WARNING!
11.14 EN
287
6.10.4 Recovering the truck from a narrow aisle
WARNING!
WARNING!
Risk of accidents and trapping during recovery operations
During recovery operations there is a risk of accidents and trapping from the truck
being recovered.
XRecover the truck carefully and slowly.
XDo not stand between the tow truck and the recovered truck during a recovery
operation.
XIf the steering angle has to be changed during a recovery operation, this can only
be performed when the truck is stationary ((see "Steering the truck without its own
drive system" on page 287)).
WARNING!
forks. 11.14 EN
288
13
18
38
237
31 238 11 239
Recovering the truck in the drive direction with and without load
Requirements
– For EKX only:
– Release the drive wheel brake, (see "Release and activate the drive wheel brake"
on page 279).
– For EKS 513 - 515 / EKX 513 - 515 only:
Release the load wheel brake, (see "Releasing and applying the load wheel brake"
on page 283).
– Tow rope, tow force > 5 to..
Procedure
11.14 EN
289
NOTE
Risk of damage from the tow rope
Do not route the tow rope (237) over the tailgate (238) as the tailgate (238) is not
designed for recovery operations and will get damaged.
Do not guide the tow rope (237) over or around hydraulic lines or electric cables.
WARNING!
A torn tow rope can be hazardous
The tow rope can tear if routed over "sharp" edges.
XProtect the tow rope with a suitable support (78).
• Route the tow rope (237) through the recess around the truck chassis (31) (see
illustration).
WARNING!
Risk of injury during recovery operations
Do not stand between the tow truck and the recovered truck during a recovery
operation.
• Recover the truck carefully and slowly.

• If the steering angle has to be changed during a recovery operation, brake until the
truck comes to a halt.
CAUTION!
A non-steered truck can cause injury
The truck can only be steered without its own drive system when it is stationary ((see
"Steering the truck without its own drive system" on page 287)).
• After recovery, secure the truck to prevent it from moving accidentally:

• Activate the drive wheel brake, (see "Release and activate the drive wheel
brake" on page 279).
WARNING!
WARNING!
11.14 EN
290
13
18
38
237
31 238 11 239
EKX with standard attachment - recovery in load direction with and without
load
Requirements
– For EKX only:
on page 279).
– For EKS 513 - 515 / EKX 513 - 515 only:
on page 283).
Procedure
11.14 EN
291
NOTE
During recovery route the tow ropes to the front in such a way as to avoid damaging
the hydraulic lines, the electric cables, the auxiliary mast, the fork carriage pivot joint,
the telescopic table and / or the attachment.
WARNING!
• Route the tow rope (239) around the auxiliary mast (11) (see illustration).
WARNING!
operation.

CAUTION!

WARNING!
WARNING!
11.14 EN
292
13
239 24
18
78
EKX with telescopic table - recovery in load direction with and without load
Requirements
– For EKX only:
on page 279).
– For EKS 513 - 515 / EKX 513 - 515 only:
on page 283).
Procedure
NOTE
the hydraulic lines, the electric cables, the auxiliary mast, the fork carriage pivot joint,
the telescopic table and / or the attachment.
11.14 EN
293
WARNING!
• Route the tow rope (239) around the telescopic table (24) (see illustration).
WARNING!
operation.

CAUTION!

WARNING!
WARNING!
Only return the truck to service when you have identified and rectified the fault. 11.14 EN
294
239
13
18
237 31 238 5 240 9 241
EKS - Recovery in load direction with and without load

Requirements
– For EKX only:
on page 279).
– For EKS 513 - 515 / EKX 513 - 515 only:
on page 283).

Procedure
CAUTION!
Risk of damage from tow ropes
the hydraulic lines, the mast cable, the mast and the driver's cab.
11.14 EN
295
WARNING!
• Sling the tow ropes (239,241) around both sides of the mast cross member (240)
(see illustration).
• Route the tow ropes (239,241) around the outside of the mast (9) and past the
driver's cab to the front (see illustration).
WARNING!
operation.

CAUTION!

WARNING!
WARNING!
11.14 EN
296
7 Exiting the driver's cab with the rescue equipment
Z Industrial trucks with a driver's cab which can be raised more than 3 m off the
ground have an emergency lowering mechanism and a rescue equipment (rescue
harness / abseil device / rescue rope) for the driver which can be used to reach the
ground should the operator position be blocked.
If the driver’s cab cannot be lowered due to a fault, not even with emergency lowering
((see "Driver's cab emergency lowering" on page 265)), the operator must exit the
driver's cab via the emergency abseil device.
WARNING!
Untrained personnel and non-serviced rescue equipment can result in
accidents and injury
The rescue equipment (rescue harness / abseil device with rescue rope) should only
be used by people who are physically capable, trained to use the equipment safely
and who have the required expertise.
emergencies.
XThe driver must undergo annual training in how to handle the rescue equipment.
XFor the operation and service intervals of the rescue harness and the emergency
abseil device, refer to the accompanying operating instructions.
XFollow the maintenance intervals stated in rescue harness and emergency abseil
device operating instructions.

operations.
11.14 EN
297
7.1 Rescue equipment storage compartment in the driver's cab
In the driver's cab the rescue equipment 21

can be fitted or stored in the following
places:
– The rescue equipment is located in the
storage compartment (112) below the
driver's seat (23). 242
– The rescue equipment is attached
behind the driver's seat (23) on the back
23
wall of the driver's cab (21).
Procedure
112
• Remove the twist grip screws (111) from
the left and right sides behind the driver's
seat (23). 111
• Tilt the operator seat (23) carefully in the
load direction.
• "Rescue equipment in storage compartment below the driver's seat" version:
• Take the rescue equipment out of the storage compartment (112) below the
driver's seat (23).
• "Rescue equipment on back wall of driver's seat" version:
• Remove the tensioning rubber (242).
• Take the rescue equipment from the back wall of driver's cab (21).
CAUTION!
screws (111).
11.14 EN
298
7.2 Rescue equipment testing / servicing
WARNING!
Unchecked rescue equipment can result in accidents
XThe rescue equipment (rescue harness / abseil device and rescue rope) must be
inspected by the manufacturer or an authorised person (specialist) after every
rescue operation (not practice).
The rescue equipment (rescue harness / abseil device) must be checked at least
annually by the manufacturer or an authorised person (specialist).
More regular inspections may be required if the rescue equipment is used frequently
or is subject to heavy duty usage (e.g. environmental or industrial factors affecting the
material).
operations.
WARNING!
No modifications or additions may be made to the rescue harness and abseil device.
11.14 EN
299
7.3 Rescue equipment service life
WARNING!
7.3.1 Rescue equipment useful life

Rescue harnesses have a service life of 8 years under normal operating conditions
or if the harness is not used.
7.3.2 Rescue device service life

Rescue ropes have a useful life of 6 years under normal operating conditions or if they
are not used.
Z The exact service life of the abseil device, karabiner hook and screw lock karabiner
depend on the application and ambient conditions.
11.14 EN
300
7.4 Rescue equipment storage and transportation
WARNING!
Incorrectly stored rescue equipment can cause accidents
The storage of the rescue equipment has a considerable effect on its service life.
XStore the rescue equipment in the truck's storage compartment. This is will ensure
that the equipment is protected from damp, heat and UV radiation and can be
reached in emergencies.
XAvoid contact with acid, corrosive fluids and oils.
XProtect the rescue equipment from contact with sharp objects.
CAUTION!
Damp harness straps and/or damp rescue rope should always dry off naturally, e.g.
in a well-ventilated, shady location. Do not dry wet items of equipment in tumble
dryers, near fires or other heat sources.
To transport the rescue equipment always use a secure equipment bag or case to
prevent damage caused by external influences.
11.14 EN
301
7.5 Description / use of rescue equipment (07.09 -)
The rescue equipment consists of a rescue harness ARG 30, an abseil device MARK
1, a connector (screw lock karabiner OVALINK 8) and a pre-assembled rescue rope
with karabiner hooks and a secured end knot.
The rescue equipment must not be used for collecting purposes and is authorised for
a pay load of 30 kg to 150 kg or 1 person.
WARNING!
Accident risk due to improper use of the rescue equipment
The rescue equipment must not be used as a fall protection restraint harness.
WARNING!
11.14 EN
302
7.5.1 Description of the safety belt ARG 30
If the driver's cab cannot be lowered due to a fault, the ARG 30 rescue harness in
conjunction with the abseil kit (abseil device and rescue rope) can be used to rescue
individual people from the faulty truck.
The ARG 30 rescue harness consists of two adjustable leg and should straps, a chest
strap with a D ring and a back strap with a D ring. The supporting rubber harnesses
consist of a 45 mm wide harness material.
Adjust the chest and leg straps to achieve optimum adjustment of the ARG 30 rescue
harness. The length of the chest strap / leg straps can be adjusted with clip-on
buckles.
Z The temperature-dependent application area of the ARG 30 rescue harness ranges
from ambient temperatures of -23 °C to +60 °C.
11.14 EN
303
243
244
245
246
247
248
Item Description
243 Adjustable shoulder straps
244 D ring on chest strap
245 D ring on back strap
246 Data plate, (see "Data plate of ARG 30 rescue harness" on page 305)
247 Clip-on buckles
248 Adjustable leg straps
7.5.2 ARG 30Rescue Harness Technical Specifications
Type: ARG 30
Net weight: 1,2 kg
Size: UNISIZE
Norm: EN 361
11.14 EN
304
7.5.3 Data plate of ARG 30 rescue harness
249 250
251
252 253
254
255
256
257
Item Description
249 Serial number
251 Type
254 Manufacturer
255 CE mark
256 Next inspection
257 Manufacturer's item no.
11.14 EN
305
7.5.4 Description of the MARK 1 abseil device with rescue rope and screw lock
karabiner OVALINK 8
If the driver's cab cannot be lowered due to a fault, the MARK 1 abseil device and
rescue rope can be used in conjunction with the ARG 30 rescue harness to rescue
individual people from the faulty truck. The MARK 1 abseil device and rescue rope
must not be used for collecting purposes.
The MARK 1 abseil device consists of a main body to which the controls and brake
unit are attached. The bottom area of the body contains a D-ring to which a fastener
(OVALINK 8 screw lock karabiner) in accordance with EN 362 can be attached. The
MARK 1 is authorised for a pay load of30 kg to 150 kg or 1 person.
One end of the rescue rope has a karabiner hook while the other has an end knot.
The end knot is secured by a cable tie and prevents the rescue rope from running out
of the abseil device. The rescue rope data plate is located below a transparent
protective hose on the rope end of the karabiner hook.
The OVALINK 8 screw lock karabiner (to EN 362) is used to connect theMARK 1
abseil device to theARG 30 rescue harness. The lock is secured with a threadlocker
to prevent it from releasing accidentally during operation.
Z The temperature-dependent application range for the abseil device MARK 1,

rescue rope and OVALINK 8 screw lock karabiner varies from -35 °C to +60 °C.
11.14 EN
306
Item Description
Rescue rope with karabiner hook (to attach 258
258 the MARK 1 abseil device to the truck) and 259
secured end knot
260
259 Brake cam
260 MARK 1 abseil device

261
261 Control handle
262
D ring for fastener (karabiner / screw lock
262
karabiner)
OVALINK 8 screw lock karabiner to attach 258
263
the MARK 1 abseil device to the ARG 30
263
264 End knot
264
265 Cable tie
265
7.5.5 Specifications of MARK 1 abseil device
Type: MARK 1
Net weight: 0,35 kg excl. rescue rope
Capacity: One person 30 kg - 150 kg
Max. abseil height: 200 m
in accordance with EN 341:
– 11 mm
Rope diameter:
in accordance with EN 12841:
– 10 mm - 12 mm
Static rope in accordance with EN 1891
Authorised rope type:
Type A
EN 341 Class A
Norm:
EN 12841 Type C
11.14 EN
307
7.5.6 Specifications of rescue rope and karabiner hook
Type: PARALOC Static 12,0

Net weight: approx. 1,5 kg
Material: Polyamine (PA)
Length: 17,5 m
Rope diameter: 12 mm
Rope type: Semi-static rope
Norm: EN 1891 Type A
7.5.7 Specifications of OVALINK 8 screw lock karabiner
Type: OVALINK 8
Net weight: approx. 0,04 kg
Dimensions: 74 mm x 39 mm
EN 362 / Q
Norm:
EN 12275
7.5.8 Specifications on housing of MARK 1 abseil device
266 Item Description

01
23
267 266 CE mark
DSD 30+25
267 Abseil device type

30-150kg
max. 200m
268
EN 341 CLASS A
ROPE 11mm 268 Rope diameter / max. abseil height
269
EN 12841 Type C
10 ≤ ∅ ≤ 12mm
269 Pictogram (insert rope)

270 270 Prototype tested to EN
11.14 EN
308
7.5.9 Rescue rope data plate
271
272
273 274
275
276
277 278
Item Description
271 Serial number
272 Type
275 CE mark
276 Manufacturer
277 Manufacturer's item no.
11.14 EN
309
7.5.10 Visual Inspection of the Rescue Equipment
The user must carry out a visual inspection of the rescue equipment (rescue harness
/ rescue rope / screw lock karabiner) before each operation. This will ensure that the
rescue equipment is operational and fit for purpose.
WARNING!
Withdraw the rescue equipment from use if you find any damage or if you are in doubt
as to its functionality. Return the equipment to the manufacturer or a specialist
appointed by the manufacturer for inspection.

operations.
11.14 EN
310
7.5.11 Visual inspection of the ARG 30 rescue harness
The user must carry out a visual inspection of the ARG 30 rescue harness before
each operation. This will ensure that the ARG 30 rescue harness is operational and
fit for purpose.

– the load-bearing harness material does not show any signs of damage such as
chafing, cracks or loose thread ends on the seams.
– the clip-on buckles are not corroded, physically damaged, deformed and/or
cracked.
– the D rings on the chest strap and the back strap are not corroded, damaged,
deformed and/or cracked.
– the data plate is present and legible.
WARNING!
Withdraw the ARG 30 rescue harness from use if you find any damage or if you are
in doubt as to the functionality of the ARG 30 harness. Return the ARG 30 rescue
harness to the manufacturer or a specialist appointed by the manufacturer for
inspection.

operations.
11.14 EN
311
7.5.12 Visual inspection of the MARK 1 abseil device
The user must carry out a visual inspection of the MARK 1 abseil device before each
operation. This will ensure that the MARK 1 abseil device is operational and fit for
purpose.
– the abseil device is not corroded, deformed and/or suffering from any other
mechanical damage.
– the abseil device does not have excessive traces of wear.
– the details on the abseil device are clearly legible.
– the control handle is not corroded, deformed and/or suffering from any other
mechanical damage.
Also carry out a test on the control handle by pulling the rescue rope, both when the
control handle is not applied and pushed through. The rescue rope should not slip
through the device.
WARNING!
Withdraw the MARK 1 abseil device from use if you find any damage or if you are in
doubt as to the functionality of the MARK 1 abseil device. Return the MARK 1 abseil
device to the manufacturer or a specialist appointed by the manufacturer for
inspection.

operations.
11.14 EN
312
7.5.13 Visual inspection of rescue rope with karabiner hook
The user must carry out a visual inspection of the rescue rope and karabiner hook
before each operation. This will ensure that the rescue rope is operational and fit for
purpose.
WARNING!
Withdraw the rescue rope or karabiner hook from use if you find any damage or if you
are in doubt as to their functionality. Return the rescue rope and karabiner hook to the
manufacturer or a specialist appointed by the manufacturer for inspection.

operations.
Visual inspection of the karabiner hook
When carrying out the visual inspection make sure the karabiner hook is not
Also check the functionality of the lock (catch) and the rivet on the karabiner hook.
– The union nut should open and close easily.
– The lock (catch) on the karabiner hook must be restored to its original position after
manual opening.
11.14 EN
313
Visual inspection of the rescue rope
Check that the end knot is present and secured to the end of the rope by the cable
tie. There must be a knot at the end of the rope so that the rescue rope does not run
out of the abseil device during abseiling.
The stitching on the rope end with the karabiner hook must be in good condition.
When carrying out the visual inspection make sure that the rescue rope does not
show any of the following signs of physical damage, defects or heat/chemical
damage etc.:
– Cut marks,
– Fibre damage,
– Swelling,
– Twisting,
– Heavy wear, excessive wear such as fluff,
– Sheath displacement,
– Open, loose end connections,
– Loops,
– Knots,
– Burnt parts,
– Decayed parts.
Z Check the rescue rope for the above features before dropping it. Do this by letting
the rescue rope drop through your hands.
11.14 EN
314
7.5.14 Visual inspection of the OVALINK 8 screw lock karabiner
The user must carry out a visual inspection of the OVALINK 8 screw lock karabiner
before each operation. This will ensure that the screw lock karabiner is operational

– the screw lock karabiner is not corroded, deformed and/or suffering from any other
mechanical damage.
– the threadlocker on the lock is not broken or damaged.
WARNING!
Withdraw the OVALINK 8 screw lock karabiner from use if you find any damage or if
you are in doubt as to the functionality of the OVALINK 8 screw lock karabiner. Return
the OVALINK 8 screw lock karabiner to the manufacturer or a specialist appointed by
the manufacturer for inspection.

operations.
11.14 EN
315
7.5.15 Putting on the rescue harness
Procedure
•
• Preparation:
• Remove all objects from your trouser
pockets.
• Remove the lead seal.
• Remove the rescue equipment from the
equipment bag or case.
• Visually inspect the rescue equipment, (see
"Visual Inspection of the Rescue
3x
Equipment" on page 310).
• Hold the rescue harness in front of your
body with one hand on the D ring.
• Open the clip-on buckles (3 off).
•
• Put on the rescue harness:

• Put on the rescue harness like a jacket.
• Pull the leg straps forward between your
legs and then up.
11.14 EN
316
•
• Adjust the rescue harness to match the size of

the operator's body:
• Close the clip-on buckles (2 off) on the leg
straps.
• Guide the clip-on buckle on the chest strap
through the front D ring.
• Close the clip-on buckle of the chest strap.
• Adjust the rescue harness to fit your
individual size and tighten the straps. 3x
Z Make sure the leg straps are adjusted so

that you can push your hand flat between
the leg strap and thigh. After adjusting the D
ring on the back strap you be exactly
between your shoulder blades.
• Undo the Velcro strip and hence the abseil
device from the rescue harness. 4x
11.14 EN
317
7.5.16 Exiting the driver's cab with the rescue equipment
Procedure
• Turn the key in the key switch left as far as the stop and remove the key.
• Press the Emergency Disconnect switch.
• Remove the abseil device and rescue harness from the storage compartment in
the driver's cab, (see "Rescue equipment storage compartment in the driver's cab"
on page 298).
Z The assembled rescue equipment is ready for use on breaking the seal, removal
from the equipment bag or case and after carrying out a visual inspection.
• Visually inspect the rescue harness, abseil device, rescue rope and screw lock
karabiner (see "Visual Inspection of the Rescue Equipment" on page 310).
• Put on the rescue harness, (see "Putting on the rescue harness" on page 316).
•
• Insert the karabiner hook of the rescue rope

into the D ring (in accordance with EN 795) on
the overhead guard and secure it with the
union nut.
11.14 EN
318
•
• Throw the rescue rope down to the

ground so that it is free of knots (except
for the end knot).
WARNING!
Insufficient rescue rope can result in
accidents
The rope must reach the ground,
otherwise you must not abseil down it.
WARNING!
Rescue rope can tear, resulting in
accidents
The rope must pass over fixed objects. It
must not pass over sharp edges.
XUse an edge trim for abseiling over
sharp edges, e.g. the rescue harness
bag.
XStore the rescue equipment in the
truck's storage compartment. This will
ensure that the rescue rope is protected
from damp, heat and UV radiation.
XAvoid contact with acid, corrosive fluids
and oils.
XProtect the rescue equipment from
contact with sharp objects.
Abseiling
Procedure
• Pull the rescue rope taut between the overhead guard and abseil device. The free
rescue rope must be free to run in and out over the rope inlet and outlet points on
the abseil device.
CAUTION!
Risk of accidents from abseiling
XAlways use the rescue harness to abseil.
XAvoid slack rope to keep the fall distance as short as possible.
XDo not fall into loose rescue rope or jump from the operator position into the rescue
rope.
XWatch out for obstacles when abseiling.
11.14 EN
319
Z Make sure that the person exiting the driver's cab
does so slowly to avoid swinging on the rescue
rope.
• Exit with both feet firmly on the edge and facing
towards the truck.
Z The default position of the control lever on the
abseil device is “Stop” which indicates that the
device is not ready to descend (see position "A").
• To abseil, push the control lever slightly towards
the abseil device (see position "B").
Z The lowering speed depends on the weight of the
user and position of the control lever. The
maximum descent speed lies between 0,4 m/s A B C
and 0,7 m/s.
• To stop abseiling, release the control lever (see position "A") or push fully in the
direction of the abseil device (see position "C").
CAUTION!
When abseiling take care to avoid obstacles.
WARNING!
Unchecked rescue equipment can result in accidents
XThe rescue equipment (rescue harness / abseil device and rescue rope) must be
inspected by the manufacturer or an authorised person (specialist) after every
rescue operation (not practice).
11.14 EN
320
8 Personal safety system (o)
8.1 Personal Protection System (PPS)
The truck's integrated personal protection system
(PSS) is designed to protect persons. The Personal
Protection System (PSS) is used with industrial trucks in
warehouse systems where pedestrians are not
permitted to be in narrow aisles at the same time as
industrial trucks.
Z The Personal Protection System meets the
requirements of BGV D 27, §28 paragraph 2 and DIN
15185, Part 2 section 3.13. The Personal Protection
System complies with ISO 13849 PXF Level D for
detection of persons and obstacles. The safety laser
scanner corresponds to laser protection class 1. No
other measures for screening the laser beam are
required (eye protection).
The laser scanner meets the requirements of standards CDRH 21,CFR 1030.10
and DIN EN 60825:2001.
WARNING!
Caution – exposure to hazardous radiation can result if the operating or adjusting
devices used or procedures carried out differ from those stated in the above
standards and directives.
National / international regulations apply to the assembly and use of the safety laser
scanner both for commissioning and recurrent technical inspections, in particular:
– Machinery Directive 2006 / 42 / EG
– Use of Work Equipment Directive 89 / 655 / EWG
– Accident prevention / health and safety regulations
– other relevant safety regulations
Z The manufacturer and operators of the machine on which the safety laser scanner
is being used are responsible for agreeing and complying with all valid safety
regulations issued by the relevant authorities.
11.14 EN
321
8.2 Functional description
– Mobile personal protection system with laser scanner based obstacle detection.
– Apron field protection.
– Optimum integration in the truck.
– Easy adjustment / settings to match warehouse environment.
– Automatic speed reduction / stopping in front of obstacles / personnel / other
industrial trucks.
8.2.1 Standard functions

– Crawl speed released when scanner covered (load handler lowered).
– Crawl speed released when approaching the last pallet location at a closed narrow
aisle end.
– Automatic reduction of maximum speed to 2,5 km/h before exiting the aisle.
– Additional stop at aisle end; optionally temporary, confirmed or absolute.
– Short range apron field protection (directly in front of and behind the truck –
depending on travel direction).
– Lower cutout for protection field infringement.
WARNING!
The Personal Protection System does not provide collision protection in accordance
with DIN 15185 Part 2 Section 3.7.
11.14 EN
322
8.2.2 Special functions depending on the ground conditions
– Aisle type identification within a warehouse.
– Speed reductions for escape routes within the lane.
– Stopping for escape routes within the lane.
– Zone change within a lane with short range recognition.
– Twin lane width recognition. Protection field change – wider monitoring field on one
side.
– Option of fitting additional sensors for operator position carriage control with lower
cutout on detection of persons.
8.3 Environmental awareness

The safety laser scanner is designed to keep environmental damage to a minimum.
It uses minimal energy and resources. Always act with regard to the environment at
your place of work. Please note the following disposal information.
Disposal:
– Always dispose of unusable or irreparable equipment in accordance with national

waste disposal regulations.
– Remove plastic parts and send the aluminium housing of the safety laser scanner
for recycling.
– Dispose of all electronic components as special waste.
– Electronic components are easy to disassemble.
11.14 EN
323
8.4 Cleaning the laser scanner front screen
Z The material required to clean the front screen of the laser scanner is outlined in
"Consumables", (see "Consumables" on page 515).
Requirements
– Laser scanner under load axle:
Preventing the driver's cab from accidentally lowering, (see "Preventing the driver's
cab from accidentally lowering" on page 527).
– Laser scanner in drive compartment:
Disassemble the drive cover, (see "Drive compartment cover disassembly/
assembly" on page 518).
Procedure
• Damp-clean the front screen.
Z Dry cleaning carries the risk of static charge. More dust will be attracted to the front
screen. There is also the risk of scratching the front screen.
• In addition, damp-clean the connecting
lug at the bottom of the front screen.
• Wipe the screen dry with a clean, soft
woollen cloth / micro fibre cloth or a new
soft paper towel.
CAUTION!
Cleaning can damage the front screen
Do not use dirty or large fibre cleaning
cloths as these can scratch the front
screen. A scratched front screen will result
in faults. The front screen must be
replaced
• After cleaning, hold a light / torch against

the front screen. Check for any
contamination / scratching on the front
screen and clean again if necessary.
The front screen is now clean.
11.14 EN
324
8.5 Displays on the seven segment display and indicator light (LED)
Z The seven segment display and the indicator light (LED) on the laser scanner act
as the display for the operator and the customer service engineer.
Display LED signal Description

– Protection field clear, no object in
protection field
Off
– The truck can move at the maximum
speed setting.
– Protection field infringement, object in
Lit protection field
– The truck stops.
– Warning field clear, no object in warning
field
Off
– The truck can move at the maximum
speed setting.
– Warning field infringement, object in
warning field
Lit
– The truck decelerates to 2,5 km/h and will
only travel at this speed.
– Front screen clean.
Off – The truck can move at the maximum
speed setting.
– Front screen contaminated.
– Operation inhibited.
Lit
– Clean the front screen ((see "Cleaning the
laser scanner front screen" on page 324)).
– Front screen contaminated.
flashes at 0.5 Hz
– Operation still enabled.
(one second off, one
second on) – Clean the front screen ((see "Cleaning the
laser scanner front screen" on page 324)).
11.14 EN
325
Z Other seven segment and indicator light (LED) error displays are relevant only to
the manufacturer’s service department. Troubleshooting must only be performed
by the manufacturer’s specialist service engineers. The manufacturer has a service
department specially trained for these tasks.
- Error number on the seven segment display (if applicable)
- Indicator light (LED) display.
- Error description
- Current truck location.
11.14 EN
326
8.6 Daily checks before starting the Personal Protection System
– Check the front screens of the Personal Protection System laser scanner for
contamination and clean as required ((see "Cleaning the laser scanner front
screen" on page 324)).
– Cycle test ((see "Cycle test" on page 327))
8.6.1 Cycle test
NOTE
To ensure the correct operation of the personal protection system a cycle test must
be carried out after a 24 hour timer has expired or each time the truck is switched off
and on again.
XThe information message "9901" and the "Perform cycle test" symbol (142) prompt
you to perform the cycle test. During this time the travel speed is restricted to slow
travel (2,5 km/h).
XThe speed restriction is only removed when the cycle test has been performed.
279 142
Cycle test
Procedure
• Switch off the truck.
• Switch on the truck.
Z When the truck is switched on the display
unit shows the “Acknowledge cycle test”
symbols (142,279).
• Press (119) under the "Acknowledge
cycle test" symbol (279).
The truck automatically performs the 119
cycle test.
• When the cycle test has been successfully performed:

• The "Perform cycle test" symbol (142,279) fades out.
• The speed restriction is removed.
• The 2424 hour timer is reset and starts afresh.
The cycle test has been performed successfully.
11.14 EN
327
8.7 Personal safety system
8.7.1 No obstacles and / or persons detected

Z Provided there are no persons and / or obstacles in the PPS warning or protection
fields, the truck can travel at the maximum speed setting.
8.7.2 Obstacles and / or persons in the warning field
280
Requirements
establish automatic guidance, (see
page 214).
119 15
Obstacles and / or persons in the PPS warning field:

– The driver's display shows the "Warning field infringement" symbol (280).
– The travel speed is restricted to 2,5 km/h.
The obstacle or person are no longer in the warning field:
– The truck can travel again at the maximum speed setting.
– The "warning field infringement" symbol (280) fades out.
11.14 EN
328
8.7.3 Obstacles and / or persons in the protection field
Z Protection field infringements are

281
displayed via the "protection field
infringement" symbol (281). For
protection field infringements the truck
also brakes to a halt.
The obstacle or person are no longer in

the protection field
Requirements
"Preparing the truck for operation" on 119 15
for operation with an additional access code (o)" on page 196).
– Drive the truck into the narrow aisle and establish automatic guidance, (see
"Negotiating narrow aisles" on page 214).
Procedure
• Press (119) under the "protection field infringement" symbol (281).
• The "protection field infringement" symbol (281) fades out.
The truck can travel again at the maximum speed setting.
11.14 EN
329
281
Travelling in the event of obstacles and
/ or persons located in the PSS
protection field
Requirements
– Drive the truck into the narrow aisle and 119 15
page 214).
Procedure
WARNING!
Risk of accidents and injury from the truck
Travel cutout override is an additional function to ensure the position of the truck can
be adjusted despite a protection field infringement. However, it does not release the
operator from his responsibility to bring the truck to a halt in good time before it
reaches any obstacles and / or persons.
• The personal protection system has detected a person and / or obstacle in the
protection field.
Z The truck stops. The driver's display shows the "Protection field infringement"
symbol (281).
• Press and hold down on the key (119) under the "Protection field infringement"
symbol (281).
• Set the travel direction and speed with the travel control knob (15):
Depending on the truck's settings the truck can be operated without restriction, over
a certain distance or for a certain time in the set direction. The maximum travel speed
is restricted to 2,5 km/h.
The setting for continued travel after encountering obstacles and / or persons located
in the PSS protection field is made by the manufacturer's customer service
department.
11.14 EN
330
9 Order picker - EKS
NOTE
The following functions described in chapter E do not apply to the EKS:
XAttachment traverse, (see "Attachment traverse" on page 232).
XFork carriage rotation, (see "Fork carriage rotation" on page 233).
XSimultaneous load handler traverse and fork carriage rotation, (see "Simultaneous
traversing - rotation outside and inside narrow aisles" on page 234)
9.1 Possible control panel arrangements

Z The illustrations shown are examples and do not represent the equipment supplied.
Control panel in load direction:

– For a description of the truck's control panel,
– For details of the driver's seat, (see "Driver's
seat removal and assembly" on page 162)
and (see "Adjusting the driver’s seat" on
page 164).
– For control panel height and angle
adjustment, (see "Control panel height
adjustment" on page 168) and (see "Adjusting
the control panel angle" on page 169).
Control panel in drive direction:
Control panel in drive direction with side-stance:

11.14 EN
331
Two control panels in the load direction:
– For details of the driver's seat, (see "Driver's
seat removal and assembly" on page 162)
and (see "Adjusting the driver’s seat" on
page 164).
– The truck is controlled via two control panels:
– The details of the two control panels do not
differ from those of the non-divided control
panel, (see "Displays and Controls" on
page 121).
– For details and arrangement of the controls
on the two panels, (see "Controls on the
two control panels" on page 333).
– For details of the angle and height
adjustment on the two panels, (see "Height
and angle adjustment of the two control
panels" on page 335).
11.14 EN
332
9.2 Controls on the two control panels
282 283
284 285
286 287
287
286
11.14 EN
333
Item Component
Left control panel
The left hand control panel contains the following controls:
– Emergency Disconnect switch – Hydraulic control button
282
– "Horn" key – Steering wheel
– Handle with hand rest and contact – “Switch automatic guidance on/off”
point (two-handed operation) key
Right control panel
The right hand control panel contains the following controls:
– Driver's display – Key switch
– Travel control knob – “Quit sub-menu” key
– "Functions" key – Indicators
283
– Numerical keypad – Cursor keys for special hydraulic
– "Auxiliary lift" key functions
– Handle with hand rest and contact – “Attachment traverse” key
point (two-handed operation) – “Main and Aux. Lift raise/lower”
key
Twist grip screw for infinitely variable angle adjustment of the left hand
284
control panel
Twist grip screw for infinitely variable angle adjustment of the right hand
285
control panel
Lever for left hand control panel height adjustment
286
Knob for left hand control panel height adjustment
Lever for right hand control panel height adjustment
287
Knob for right hand control panel height adjustment
11.14 EN
334
9.3 Height and angle adjustment of the two control panels
282 283
A A
B B
284 285
286 287
Procedure
• Before operating, adjust the driver’s seat and control panel so that all the controls
are within reach and can be applied without having to strain.
• Adjust the visibility aid equipment (mirrors, camera systems etc.) so that the
working environment can be clearly seen.
CAUTION!
Z The height of the control panels (282,283) can be vertically adjusted by 170 mm.
Adjusting the control panel height
Procedure
• Set the left hand control panel (282) to the required position:
• Push the knob (286) or pull the lever (286) up.
• Pull the control panel (282) up, see arrow direction "A".
• Push the control panel (282) down, see arrow direction "B".
• Do not apply the knob (286) or release the lever (286).
• Make sure the control panel (282) is locked in position after any height
adjustment.
• Set the right hand control panel (283) to the required position:
• Push the knob (287) or pull the lever (287) up.
11.14 EN
• Pull the control panel (283) up, see arrow direction "A".
335
• Push the control panel (283) down, see arrow direction "B".
• Do not apply the knob (287) or release the lever (287).
• Make sure the control panel (283) is locked in position after any height
adjustment.
The heights of the control panels (282,283) are now adjusted.
Adjusting the control panel angles

Procedure
• To adjust the angle of the left hand control panel (282):
• Undo the twist grip screw (284) slightly by turning it anti-clockwise.
Z Do not remove the screw (284) fully as it is also used to secure the control
panel (282) .
• Set the angle of the control panel (282) to the desired position.
• Tighten the twist grip screw (284) by turning it clockwise.
• Make sure the control panel (282) is locked in position after any angle
adjustment.
• To adjust the angle of the right hand control panel (283):
• Undo the twist grip screw (285) slightly by turning it anti-clockwise.
Z Do not remove the screw (285) fully as it is also used to secure the control
panel (283) .
• Set the angle of the control panel (283) to the desired position.
• Tighten the twist grip screw (285) by turning it clockwise.
• Make sure the control panel (283) is locked in position after any angle
adjustment.
The angle of the control panels (282,283) is now set.
11.14 EN
336
9.4 Truck with load guard and walk-on pallet
WARNING!
Risk of accidents / crashing when using walk-on pallets
When the gates are opened, the driver's cab can be raised to a fixed height up to a
maximum of 1200 mm. When the gates are closed, the load handler can be raised to
the maximum lift height.
XBefore operating the truck without a front guard or gate the seat belt must be put
on, (see "Seat belt with safety rope (EKS without front guard or gate only)" on
page 170). You must not operate the truck without wearing a seat belt.
XUse only undamaged pallets of a suitable size to fit a pallet guard.
XOnly walk on pallets with a pallet guard (o).
XBeyond lift heights > 1200 mm the gates must be closed to enable travel, lifting and
lowering (Main Lift).
XDo not use one-way pallets as a walk-on surface.
XThe ground surface must be in good condition to ensure this works correctly.
11.14 EN
337
9.5 Truck equipment - stockpicking platform without pallet lift option
Version A
– The stockpicking platform has a closed guard.

– The stockpicking platform can only be accessed from the truck.
Version B 288
Z The illustrations shown are examples and do not

represent the equipment supplied.
– The order picking platform has a guard with side
gates (288).
– The stockpicking platform can:
• be accessed from truck.
• be accessed via the side gates (288) when the
order picking platform is lowered.
11.14 EN
338
288
Version C 288
Z The illustrations shown are examples and do not
represent the equipment supplied.
– The order picking platform has a guard with side
gates (288) and front gates (289).
• be accessed via the side gates (288) when the
289
• be accessed via the front gates (289) when the
Version D
Z The illustrations shown are examples and do not represent

the equipment supplied.
– The order picking platform has a guard with front
gates (289).
• be accessed via the front gates (289) when the order
picking platform is lowered. 289
11.14 EN
339
9.6 Stockpicking platform with pallet lift option (not monitored, not
locked)
Z The illustrations shown are examples and do not represent the equipment supplied.
Version E
– The raised pallet can be accessed from the truck via the side gates (290) in the load
direction.
– The raised pallet has a side guard (291) but is open at the front.
290
291
292
Version F
– The raised pallet can be accessed from the truck. The truck does not have any
gates in the load direction.
– The raised pallet has a side guard (291) but is open at the front.
291
292
11.14 EN
340
Version G
direction.
– The raised pallet has a side guard (291) and a front guard (293).
290
291
293
292
Version H
– The pallet has side gates (288) but is open at the front.
288
292 288
11.14 EN
341
Version I
direction.
– The pallet has side gates (288) but is open at the front.
290
288
292 288
Version J
– The pallet has side gates (288).
– There is an option for a front guard through the gates (294).
288
294
292 288
11.14 EN
342
Version K
direction.
– The pallet has side gates (288).
– There is an option for a front guard through the gates (294).
288 290
294
292 288
Version L
– The raised pallet cannot be accessed from the truck.

– The raised pallet can be reached through the driver's cab extension (295).
295
11.14 EN
343
9.7 Stockpicking platform with pallet lift option including pallet
monitoring and fixing
Z When pallets, pick boxes or load containers specially designed for the task are
raised, they can be monitored and also fixed. The illustrations shown are examples
and do not represent the equipment supplied.
Raised pallet load sensing version

296
Raised pallet load sensing via switches or
non-contact sensors.
Example:
The "load sensing" switch (296) is located
on the load handler between the forks.
When the load sensing switch (296) is
pressed, the controller is notified that a
pallet has been lifted.
Raised pallet mechanical stop with load

sensing version
297
Raised pallet load sensing via non-contact
sensors.
Requirements: 298
– The pallet must have a bolt for a pallet
stop (298).
– The pallet fixing / pallet stop locating
eye (297) must be located on the truck's
load handler.
11.14 EN
344
Claw with load sensing version 296

The "load sensing" switches or non-contact
sensors (296) are located on the left and
right sides of the load handler. 299
The claw (299) is used to clamp pallets.
Clamp with load sensing version 296

The "load sensing" switch or non-contact

sensors (296) are located on the load 300
handler.
The clamp (300) is used to secure pallets.

11.14 EN
345
9.8 Display of stockpicking platform side and / or front gates and load
direction gates
Z The monitored side and / or front gates of the stockpicking platform as
well as the load direction gates are shown on the driver's display,
depending on the use of the load handler ((see "Displays and Controls"
on page 121)).
Stockpicking platform without The fitted gates are displayed as a single gate.
pallet lift option
Stockpicking platform with The fitted gates are shown like a side gate,
guard and pallet lift option irrespective of whether the pallet or picking box
has been lifted and locked.
Stockpicking platform with Without a picking box raised and locked, the load-
panel and pallet lift option facing pallet lift gates are displayed as a side
gate.
With a picking box raised and locked, the load-
facing pallet lift gates are not displayed.
The position of the load-facing gates is not
evaluated by the truck in this case.
11.14 EN
346
9.8.1 Example: Monitored and non-monitored gates in load direction (o)
Closed gates: Open gates:
290 301
301
290
11.14 EN
347
When the four gates (290,301) in the load direction have been opened, the raised
pallet can be accessed from the truck.
– The two gates (301) can be lowered and are not monitored by the truck.
– The two gates (290) are safety gates. The positions of the safety gates are
monitored by the truck. The gates (290) are shown in the driver's display depending
on whether the load handler is being used.
Example:
– With a picking box raised and locked, the load-facing pallet lifting gates (290)
are not displayed.
The position of the load-facing gates (290) is not evaluated by the truck in this
case. The load handler can be raised to the maximum lift height.
– Without a picking box raised and locked, the load-facing pallet lift
gates (290) are displayed as a side gate. The driver's display shows
the "Gates not closed" symbol..
11.14 EN
348
9.9 Additional symbols in driver's display
The following symbols are displayed depending on the truck's equipment:
Symbol Meaning
Clamp open
Clamp closed, no load clamped
Clamp closed, load clamped
Pallet / picking box raised and / or locked
Claw open
Claw closed
11.14 EN
349
NOTE
When the pallet or picking box is raised and locked by the clamp / claw, Main Lift -
Auxiliary Lift lowering can only be performed using the override button at heights
below 10 cm. This is to avoid damaging the clamp / claw.
11.14 EN
350
9.10 Lifting / depositing a load with a load lock (with / without load
sensing)
WARNING!
Risk of accidents / crashing when using picking boxes
Without a raised and locked picking box, the driver's cab can be raised with open side
gates up to a maximum of 1200 mm (fixed driver's cab height).
Without a raised and locked picking box, the driver's cab can be raised with closed
gates for pallet lifting to the maximum lift height.
When the picking box is lifted and closed, the operator position can be raised to the
maximum lifting height. The gates for pallet lifting are not monitored in this case.
WARNING!
Risk of accidents / crashing when using walk-on pallets
When the gates are opened, the driver's cab can be raised to a fixed height up to a
maximum of 1200 mm. When the gates are closed, the load handler can be raised to
the maximum lift height.
XBefore operating the truck without a front guard or gate the seat belt must be put
on, (see "Seat belt with safety rope (EKS without front guard or gate only)" on
page 170). You must not operate the truck without wearing a seat belt.
XUse only undamaged pallets of a suitable size to fit a pallet guard.
XOnly walk on pallets with a pallet guard (o).
XBeyond lift heights > 1200 mm the gates must be closed to enable travel, lifting and
lowering (Main Lift).
XDo not use one-way pallets as a walk-on surface.
XThe ground surface must be in good condition to ensure this works correctly.
11.14 EN
351
WARNING!
Before lifting a load unit the driver must make sure that it has been correctly palletised
and does not exceed the truck’s capacity.
precautions to prevent parts of the load from tipping or falling down.
XDo not transport loads other than on the authorised load handler.
XIf the stacked load obscures forward visibility, then you must reverse the truck.
XDo not reach through the mast.
WARNING!
Ensure there are no other people standing underneath the raised load and
driver's cab.
XNever stand underneath a raised and unsecured load handler / driver's cab.
11.14 EN
352
9.10.1 Lifting / depositing a load with a mechanical lock on the fork tines (with /
without load-sensing)
Lifting a load with a mechanical lock on

the fork tines (with / without load-
sensing) 296
Requirements
– Load unit weight matches the truck's
capacity.
– Forks evenly loaded.
292
Procedure
• Drive the truck carefully up to the load.
CAUTION!
Risk of injury and accidents
The pallet / picking box must rest fully on the fork tines behind the anti-slip
mechanisms (292).
• Insert the forks slowly into the pallet / picking box until:
• The fork shank is touching the load (pallet / picking box).
• The load activates the load-sensing switch (296) (o).
CAUTION!
NOTE
11.14 EN
353
Depositing a load with a mechanical lock on the fork tines (with / without load-
sensing)
Requirements
(o)" on page 196).
– Load unit correctly lifted.
Procedure
• Preparing to deposit the load in the rack:
• Raise or lower the load handler so that the load can be taken to the storage
location without striking any objects.
NOTE
Avoid depositing the load suddenly to avoid damaging the load, load handler and the
rack.
NOTE
When driving in reverse make certain the goods are not damaged or knocked down
by the front guard.

11.14 EN
354
9.10.2 Lifting / depositing a load with a mechanical lock on the load handler (with /
without load-sensing)
Lifting a load with a mechanical lock on

the load handler (with / without load-
sensing) 297
Requirements
"Preparing the truck for operation" on 298
capacity.
Procedure
Z The pallet / picking box to be lifted must have a bolt for a pallet stop (298). The
pallet fixing / pallet stop recess (297) must be located on the truck's load handler.
CAUTION!
The stop bolt (298) should enter the recess in the load handler (297).
• The stop bolt (298) is in the recess in the load handler (297).
• The stop bolt (298) is resting against the "Load sensing" sensor (o).
The load has been correctly lifted and is mechanically (297,298) protected against
slipping.
CAUTION!
NOTE

11.14 EN
355
Depositing a load with a mechanical lock on the load handler (with / without
load-sensing)
Requirements
(o)" on page 196).
Procedure
NOTE
rack.
• Carefully lower the load handler so that:

• the fork tines are clear of the load.
• the stop bolt (298) can be withdrawn from the recess in the load handler (297).
NOTE
by the front guard.

11.14 EN
356
9.10.3 Lifting / depositing a load with load-sensing and a clamp / claw for locking
12 302 303
Lifting a load with load-sensing and a
clamp / claw for locking
Requirements
capacity. 119
Procedure
• Open the clamp / claw:
• Press and hold down on the (119) key under the "clamp / claw" symbol (302/
303).
• The load activates the load-sensing switch (o).
• Slowly raise the load until it is clear of the ground.
CAUTION!
Lock the pallet / picking box with the clamp / claw to prevent it from slipping / crashing.
• Close the clamp / claw:

303).
NOTE
When the pallet / picking box is locked, the load cannot be lowered down to the
ground. This is to avoid damaging the clamp / claw.
11.14 EN
357
CAUTION!
NOTE

11.14 EN
358
12 302 303
Depositing a load with load-sensing and
a clamp / claw for locking
Requirements
– Storage location suitable for the load 119
(size and capacity).
Procedure
• Carefully lower the load handler to a height of approx. 10 cm above the ground /
rack surface.
• Open the clamp / claw:
303).
NOTE
rack.
NOTE
by the front guard.

11.14 EN
359
9.11 Auxiliary Lift raise/lower (o)
Z For details of how to operate the Aux. Lift refer to "Auxiliary Lift raise/lower", (see
"Auxiliary Lift raise/lower" on page 228).
– Without a raised picking box the load handler can be raised approx. 450 mm with
the auxiliary lift.
– With a raised and lock picking box, raising of the auxiliary lift is inhibited when it
reaches the seamless transition from the driver's cab to the pallet / picking box.
11.14 EN
360
10 Optional equipment
10.1 Telescopic table (o)
WARNING!
Risk of accidents during lifting and lowering
The hazardous area is defined as the area in which people are at risk from the truck
movement, the load handler, attachments etc. This also includes areas which can be
reached by falling loads or lowering operating equipment.
11.14 EN
361
WARNING!
Trapping hazard when moving the telescopic forks of the telescopic table
sure there is nobody present in the danger zone when carrying out traverse or lift /
lower movements with the load handler. Stop working with the truck if people do not
leave the hazardous area.
11.14 EN
362
WARNING!
Z Maintenance intervals are specified in the section Maintenance checklist, (see

"Maintenance checklist" on page 489).
WARNING!
An incorrectly raised load can be hazardous
Loads can fall off the telescopic table if they are incorrectly raised with the telescopic
forks.
XRaise and transport loads which are evenly distributed with both telescopic forks.
WARNING!
Accident risk from increased tipover hazard and reduced residual capacity
There is a greater tipover risk with extended telescopic attachments (e.g. reach
carriages, telescopic forks, telescopic crane booms).
XOnly use the telescopic function for stacking and retrieving.
XAlways retract the attachment fully during transport.
XAdapt the travel speed to changed load centre of gravity.
11.14 EN
363
10.1.1 Traversing the telescopic forks of the telescopic table (o)
NOTE
Risk of material damage to the telescopic forks
The telescopic forks must not be used to push or press loads.
12 126
Requirements
operation.
Procedure
• To traverse the telescopic forks of the telescopic table to the right:
• To traverse the telescopic forks of the telescopic table to the left:
lever (12) is moved. The extended position of the telescopic table forks is limited
both electrically and mechanically.
The telescopic forks move to the right or left.
Z The telescopic forks automatically stop in the centre position. If you release the
"Hydraulic functions" control lever (12) and press it again, the telescopic forks can
be moved further to the left or right.
Z If the telescopic forks are not in the centre position, you can only travel, lift or lower
at reduced speed(see "Traversing the telescopic table to the centre position (o)"
on page 242).
11.14 EN
364
10.1.2 Telescopic forks adjustment (o)
WARNING!
Trapping hazard and risk of material damage when adjusting the telescopic
forks
Other people can be damaged when the telescopic forks are adjusted.
XThe fork spread must only be adjusted without load.
NOTE
11.14 EN
365
12 304
Requirements
with your left hand and grip (19) with your
and hydraulic operations can only be
activated in the narrow aisle with two- 16 119 19
handed operation.
Procedure
• Press and hold down on the key (119) under the "telescopic fork adjustment"
symbol (304).
• To traverse the telescopic forks in the load direction:
• To traverse the telescopic forks in the drive direction:
Z The traverse speed of the telescopic forks is in proportion to the movement of the
hydraulic control lever (12).
The telescopic forks traverse in the load or drive directions.
on page 242).
11.14 EN
366
10.1.3 Individual movement of the telescopic table fork tines (o)
WARNING!
The load can fall down if the telescopic forks do not traverse correctly
If a single telescopic fork tine moves when the loads on the two telescopic forks are
overlapping, this can cause the load to fall. Always take into account the load on the
telescopic table when choosing the telescopic forks.
An individual telescopic fork tine must not be chosen when the load on the two
telescopic forks is overlapping, i.e. when laden with a wire box.
XAlways take into account the load on the telescopic table when choosing the
telescopic forks.
XDo not move an individual telescopic fork when the load on both telescopic forks is
overlapping.
NOTE
12 305 306 307 126

Requirements
handed operation.
Procedure
Z You can only choose telescopic forks if both telescopic forks are in the centre
position.
• To select the telescopic fork to be moved:
• Move the bottom telescopic fork:
Press (119) under the "Bottom telescopic fork selection" symbol (305).
• Move the top telescopic fork:
Press (119) under the "Top telescopic fork selection" symbol (306).
• Move both telescopic forks:
Apply the (119) key under the "Both telescopic forks selection" symbol (307).
• To traverse the selected telescopic fork of the telescopic table to the right:
• To traverse the selected telescopic fork of the telescopic table to the left:
11.14 EN
367
lever (12) is moved. The extended position of the telescopic table forks is limited
both electrically and mechanically.
The selected telescopic fork traverses to the right or left.
on page 242).
11.14 EN
368
10.1.4 Turning the rotary telescopic table (o)
NOTE
12 125
Requirements
operation.
Procedure
Z The telescopic table can only be rotated if both telescopic forks are in the centre
position.
• To turn the telescopic table right:
• To turn the telescopic table left:
Z The rotary speed is proportional to how far the "Hydraulics function" control
lever (12) is rotated. The rotation of the telescopic table is limited both electrically
and mechanically.
The telescopic table is rotated to the right or left.
• To traverse the telescopic forks of the rotary telescopic table to the right or left, (see
"Traversing the telescopic forks of the telescopic table (o)" on page 364).
(t)" on page 241).
11.14 EN
369
A
31.5 inch
Lifting pallets from the left - rotating and
800 mm
traversing the pallet in the pick position B
Requirements
*
– Prepare the truck for operation, (see "Preparing
the truck for operation" on page 195) or (see
"Preparing the truck for operation with an
additional access code (o)" on page 196).
– In narrow aisles grab hold of grip (16) with your
left hand and grip (19) with your right hand (two-
hand operation). Travel and hydraulic
operations can only be activated in the narrow
*
aisle with two-handed operation.
C
Procedure
• Lower/raise the telescopic table so that the
pallet can be lifted.
• To lift the pallet from the left with the rotary
telescopic table:
• Extend the telescopic forks to the left until the
pallet is centred above the telescopic forks
((see "Traversing the telescopic forks of the telescopic table (o)" on page 364)).
• Raise the telescopic table slightly until the pallet rests freely on the telescopic
forks.
• Slowly retract the telescopic forks to the home position, (see "Traversing the
The pallet has been raised correctly and is in the home position.
• Turn the pallet 90° clockwise, (see "Turning the rotary telescopic table (o)" on
page 369).
• Push the pallet carefully towards the driver's cab, (see "Traversing the telescopic
The pallet is in the pick position.
* Note the fork marking. The telescopic forks must be rotated in the corresponding
direction before lifting a pallet, (see "Turning the rotary telescopic table (o)" on
page 369).
11.14 EN
370
Lifting pallets from the right - rotating and *
31.5 inch
traversing the pallet in the pick position B
800 mm
A
Requirements
– Prepare the truck for operation, (see "Preparing
the truck for operation" on page 195) or (see
"Preparing the truck for operation with an
– In narrow aisles grab hold of grip (16) with your
left hand and grip (19) with your right hand (two-
hand operation). Travel and hydraulic
operations can only be activated in the narrow
aisle with two-handed operation.
*
Procedure
C
• Lower/raise the telescopic table so that the
pallet can be lifted.
• To lift the pallet from the right with the rotary
telescopic table:
• Extend the telescopic forks to the right until
the pallet is centred above the telescopic
forks ((see "Traversing the telescopic forks of
the telescopic table (o)" on page 364)).
• Raise the telescopic table slightly until the pallet rests freely on the telescopic
forks.
The pallet has been raised correctly and is in the home position.
• Turn the pallet 90° anti-clockwise, (see "Turning the rotary telescopic table (o)" on
page 369).
• Push the pallet carefully towards the driver's cab, (see "Traversing the telescopic
The pallet is in the pick position.
page 369).
11.14 EN
371
*
Relocating pallets - turning a pallet 180°
A
Requirements
– Prepare the truck for operation, (see "Preparing the
truck for operation" on page 195) or (see "Preparing
the truck for operation with an additional access code
(o)" on page 196).
– In narrow aisles grab hold of grip (16) with your left *
B
hand and grip (19) with your right hand (two-hand
operation). Travel and hydraulic operations can only
be activated in the narrow aisle with two-handed
operation.
Procedure
• Press the deadman switch. C
• Lower/raise the telescopic table so that the pallet can
be lifted. *
• To lift the pallet from the right with the rotary
telescopic table:
• Extend the telescopic forks to the right until the
pallet is centred above the telescopic forks ((see
"Traversing the telescopic forks of the telescopic
table (o)" on page 364)).
• Raise the telescopic table slightly until the pallet *
rests freely on the telescopic forks.
• Slowly retract the telescopic forks to the home
position, (see "Traversing the telescopic table to
the centre position (o)" on page 242).
The pallet has been raised correctly and is in the
home position.
• Turn the pallet 180° clockwise, (see "Turning the rotary telescopic table (o)" on
page 369).
• To deposit the pallet on the left with the rotary telescopic table:
• Extend the telescopic forks to the left, (see "Traversing the telescopic forks of
the telescopic table (o)" on page 364).
• Carefully lower the telescopic table until it no longer is in contact with the pallet.
The pallet has been deposited correctly and the telescopic forks are in the home
position.
page 369).
11.14 EN
372
10.2 Sideshifter / Fork positioner (o)
WARNING!

10.2.1 Fork sideshift (o)

Requirements
(o)" on page 196).
11.14 EN
373
12 308
Procedure
• Press and hold down on the key (119)
under the "fork sideshift" symbol (308).
• Attachment is in the "front lift" position,
i.e. the forks are at right angles to the
swivel traverse frame:
• To shift the forks to the right:
Turn the hydraulic control lever (12)
clockwise.
• To shift the forks to the left: 16 119 19
anti-clockwise.
• Attachment is in the right home position, i.e. the fork carriage is at the right end of
the swivel traverse frame and the forks are facing left:
• To shift the forks in the load direction:
• To shift the forks in the drive direction:
• Attachment is in the left home position, i.e. the fork carriage is at the left end of the
swivel traverse frame and the forks are facing right:
Z The traverse speed of the forks is in proportion to the movement of the hydraulic
control lever (12).
Both forks move evenly in the prescribed direction.
11.14 EN
374
10.2.2 Fork positioner (o)
WARNING!
Trapping hazard and risk of material damage when adjusting the forks
Other people can be damaged when the forks are adjusted.
Requirements
(o)" on page 196).
12 309
Procedure
Z The fork spread is changed when the two
forks traverse simultaneously. The forks
cannot be adjusted individually.
under the "Fork adjustment"
symbol (309).
• To reduce the fork spread:
clockwise. 16 119 19
• To increase the fork spread:
Z The traverse speed of the fork spread is in proportion to the movement of the
The fork spread is reduced or increased.
11.14 EN
375
10.2.3 Symmetric sideshift with integrated fork positioner (o)
WARNING!
WARNING!
Risk of injury and material damage when operating the sideshift with integrated
fork positioner
Due to the special design of the sideshift with integrated fork positioner, the operator
must ensure that the forks and sideshifter do not extend into the area of the operator
position.
The fork positioner is used to extend the forks beyond the geometry of the sideshift
frame.
XTo avoid injury to personnel and damage to the truck and load, trained operators
must handle the attachment with particular care.
11.14 EN
376
12 308
Requirements
handed operation.
Procedure
• Press (119) under the "Fork adjustment / sideshift menu change" symbol (199).
The display changes from the menu item “Fork adjustment / sideshift menu
change” (199) to "Fork sideshift" (308) or "Fork adjustment" (309).
12 309
Procedure
symbol (309).
12 308
Procedure
11.14 EN
clockwise.
16 119 19
377
• To shift the forks to the left:
control lever (12).
11.14 EN
378
10.2.4 Asymmetric sideshifter with integrated fork positioner (o)
WARNING!
WARNING!
Risk of injury and material damage when operating the sideshift with integrated
fork positioner
Due to the special design of the sideshift with integrated fork positioner, the operator
must ensure that the forks and sideshifter do not extend into the area of the operator
position.
The fork positioner is used to extend the forks beyond the geometry of the sideshift
frame.
XTo avoid injury to personnel and damage to the truck and load, trained operators
must handle the attachment with particular care.
11.14 EN
379
Asymmetric sideshifter with integrated fork positioner
Attachment is in the right home position, i.e. the fork carriage is at the right end of the
swivel traverse frame and the forks are facing left:
– In this home position the forks can be adjusted through the asymmetrical
arrangement of the attachment as far as the driver’s cab, e.g. for stockpicking.
– Be careful when adjusting the sideshifter and fork positioner! In this home position
the attachment / raised load can damage the driver's cab.
Attachment is in the left home position, i.e. the fork carriage is at the left end of the
– Pallets 3,3 m long can be transported in this home position.
– The sideshifter and forks cannot be adjusted as far as the cab for stockpicking.
11.14 EN
380
12 308
Requirements
handed operation.
Procedure
• Press (119) under the "Fork adjustment / sideshift menu change" symbol (199).
The display changes from the menu item “Fork adjustment / sideshift menu
change” (199) to "Fork sideshift" (308) or "Fork adjustment" (309).
12 309
Procedure
symbol (309).
12 308
Procedure
11.14 EN
clockwise.
16 119 19
381
• To shift the forks to the left:
control lever (12).
11.14 EN
382
10.3 Telescopic forks (o)
WARNING!
Loss of truck stability
When the telescopic forks are extended and the load exceeds the weight specified on
the capacity plate, the industrial truck could tip over.
XWhen the telescopic forks are extended, do not lift any loads that exceed the weight
specified on the capacity plate, (see "Identification points and data plates" on
page 64).
WARNING!
Accident risk from increased tipover hazard and reduced residual capacity
There is a greater tipover risk with extended telescopic attachments (e.g. reach
carriages, telescopic forks, telescopic crane booms).
XOnly use the telescopic function for stacking and retrieving.
XAlways retract the attachment fully during transport.
XAdapt the travel speed to changed load centre of gravity.
WARNING!
Z Maintenance intervals are specified in the section

Maintenance checklist, (see "Maintenance checklist" on
page 489).
Telescopic fork description
Telescopic forks are used to achieve a greater stacking depth

(single telescopic forks) or double-deep storage (double
telescopic forks).
11.14 EN
383
10.3.1 Single telescopic forks (o)
12 310 311 126

Extending and retracting single
telescopic forks
Requirements
with your left hand and grip (19) with your 16 119 19
operation.
Procedure
• Traverse the attachment to the right or left limit position of the swivel traverse
frame, (see "Attachment traverse" on page 232).
• Press and hold down on the key (119) under the "single telescopic forks"
symbol (310).
• Extend the telescopic forks:
• To extend to the left:
• To extend to the right:
Z When a load greater than the weight specified on the capacity plate for fully
extended telescopic forks is lifted, telescopic fork extension is disabled. The
"Telescopic fork reach cutout" symbol (311) lights up in the driver's display.
• Retract the telescopic forks:
• To retract to the right:
• To retract to the left:
Z The extending and retracting speed of the telescoping forks is in proportion to the
movement of the hydraulic control lever (12).
• Traverse attachment right or left to the home position, (see "Attachment traverse"
on page 232).
(t)" on page 241).
11.14 EN
384
10.3.2 Double telescopic forks (o)
12 312 126
Extending double telescopic forks
Requirements
right hand (two-hand operation). Travel 16 119 19
Procedure
• Traverse the attachment left or right until the automatic stop, (see "Attachment
traverse" on page 232).
The first stacking depth has been reached.
• Press the (119) key under the “2nd stacking depth” symbol (312) (symbol has dark
background = active mode).
• Traverse the telescopic forks right or left to the next automatic stop, (see
The second stacking depth has been reached.
Z When a load greater than the weight specified on the capacity plate for fully
extended telescopic forks is lifted, telescopic fork extension is disabled.
Version A “Retract telescopic forks, then move the attachment back to the
home position”:
Requirements
– Telescopic forks extended as far as the second stacking depth.
Procedure
• Retract the telescopic forks left or right to the automatic stop, (see "Attachment
• Press the (119) key under the “2nd stacking depth” symbol (312) (symbol changes
to normal view = non-active mode).
• Traverse attachment right or left to the home position, (see "Attachment traverse"
on page 232).
Right or left home position has been reached.
11.14 EN
385
Version B “Move the attachment back, then retract the telescopic forks to the
home position”
Requirements
– Telescopic forks extended as far as the second stacking depth.
Procedure
• Retract the attachment left or right until the automatic stop, (see "Attachment
• Traverse telescopic forks right or left to the home position, (see "Attachment
Right or left home position has been reached.
(t)" on page 241).
11.14 EN
386
10.4 Operator-specific settings (o)
10.4.1 Settings in "User-specific settings" menu as a function of access code rights
Access right Description

"User" access code without – User-specific settings can be displayed.
rights – User-specific settings cannot be changed.
– User-specific settings can be displayed.
"User" access code with rights
– User-specific settings can be changed.
– User-specific settings for the selected "user"
access code can be displayed.
– User-specific settings for the selected "user"
"Master" access code with access code can be changed. The master can
change rights to user-specific determine for new or inexperienced users
settings for the selected "user" ("user" access code without rights) the
access code. maximum settings for the travel and hydraulic
functions outlined in the following section, (see
"Variable functions in the “user-specific
settings” menu" on page 388).
11.14 EN
387
10.4.2 Variable functions in the “user-specific settings” menu
CAUTION!
Altering travel parameters can cause accidents
Increasing the settings for travel and hydraulic functions can result in accidents.
XCarry out a test run in a secure environment.
XThis requires greater attention on the part of the operator.
Functions Driver's display
Travel acceleration a
Apron speed v
Aisle Speed v
Main lift- raise speed V
Main lift – lower speed V
Sideshift speed V
Z The sideshift speed can only be altered on the EKX. On the EKS this function is not
displayed.
11.14 EN
388
10.4.3 Changing the user-specific settings
Select the "Operator-specific settings" 313

menu
Requirements
code (o)" on page 196). 129 119
Procedure v,a
• Press the "Quit sub-menu" button (129). 314
The "Warnings sub-menu" item (313)
appears in the driver's display.
menu.
• Press the button (119) under the
"Warnings sub-menu" symbol (313). The
"Operator-specific settings" menu
item (314) appears in the driver's display. 129 119
• Press the button (119) under the
"Operator-specific settings" symbol (314).
The “Operator-specific settings” menu now opens.
11.14 EN
389
“User-specific settings” menu settings 315 316
Procedure
menu.
• Select the function to be set in the "user-
specific settings” menu:
• Press (119) under the "Other 129 119 130
functions" symbol (316).
The driver's display shows other 198 200
functions for the user-specific settings,
195
(see "Variable functions in the “user-
194
specific settings” menu" on page 388).
• Press (119) under the "Previous
functions" symbol (315). 201
The driver's display shows the
previous functions for the user-specific settings, (see "Variable functions in the
“user-specific settings” menu" on page 388).
11.14 EN
390
8
Procedure
• Press (119) under the symbol for the 317
function to be set. 1
The current setting is displayed in a bar
chart (317).
• The operator can use the cursor

keys (194,195) to set the functions from
1 (weak) to 8 (strong). This allows
individual settings to be made within a 129 119 130
pre-defined area in the program.
• Cursor key (194): weaken the setting. 198 200
• Cursor key (195): strengthen the 195
setting. 194
• Press OK on the numerical keypad (130)
to save the settings.
201
• Press the "Quit sub-menu" key (129).
The driver's display shows the current
date and time.
11.14 EN
391
Leaving the menu 202
Procedure
• Press (119) under the "truck functions"
symbol (202). The driver's display
changes to the "truck functions" menu.
119
CAUTION!
Altering travel parameters can cause accidents
Increasing the settings for travel and hydraulic functions can result in accidents.
XCarry out a test run in a secure environment.
XThis requires greater attention on the part of the operator.
11.14 EN
392
10.4.4 Determining user-specific settings for the "user" access code with the
"master" access code
123 194 195 18
*****
196 130 197 198
Requirements
– Prepare the truck for operation, (see "Preparing the truck for operation with an
Procedure
• In the driver's display (123) you will be prompted to enter your 5 digit access code.
• Enter the "master" access code:
• Press the "Select" key (198) in the cursor field.
Under the "master" access code entered you will be prompted to enter the "user"
access code.
• Enter the "user" access code:

• Press the "Select" key (198) in the cursor field.
The user-specific settings for the "user" access code can be defined.
• To define / change user-specific settings for the "user" access code, (see
"Changing the user-specific settings" on page 389).
11.14 EN
393
10.5 ISM access module (o)
Z If the truck is equipped with an ISM access module or Can Code refer to the “ISM
Access Module” operator manual.
10.6 Weighing system (o)
Z The truck can be fitted optionally with a

143
xx kg
weighing system. When the load has
been raised slightly with the Main Lift, the
weight is shown on the driver's display in
kg (143), (see "Main Lift raise/lower" on
page 227).
NOTE
The weighing system is not a substitute for a calibrated weigher.
10.6.1 Tare function (o)

Z The weighing system can optionally be equipped with tare function. The tare
function sets the weigher display to zero.
11.14 EN
394
12 318 319 202 127
Display zero setting
Requirements
0
Procedure
129 119
• Raise the Main Lift without load by
approx. 10 cm:
143
anti-clockwise.
0 kg
• If applicable, raise the Auxiliary Lift

without load by approx. 10 cm:
• Apply the "Auxiliary lift" key (127) and
hold it down.
anti-clockwise.
• Press the "Quit sub-menu" key (129).
Z Truck movement is inhibited in this truck menu.
• The driver's display shows the "Weigher display zero setting" symbol (319).
• Press the (119) key under the "Weighing system display zero setting"
symbol (319).
The weight measurement in the driver's display is zero (143).
• Press (119) under the "truck functions" symbol (202).
Z The driver's display changes to the "Truck functions" menu.
• Fully lower the Main Lift:
• If applicable, fully lower the auxiliary lift.
11.14 EN
395
10.7 Rack Height Select (o)
To pick, lift or deposit loads in pre-selected storage locations, the truck must be
adapted to the warehouse setup.
Z The manufacturer's customer service department is specially trained to carry out

these operations.
In addition to the current lift height, the following symbols are shown in the
driver's display:
Symbol
Telescopic Function
Attachment
table
– Attachment in home position without load
– Attachment in centre position without load
– Attachment in home position with load

– Attachment in centre position with load
– Lowering and lifting an attachment without

load
– Lowering and lifting a telescopic table without
load
– Lowering and lifting an attachment with load
– Lowering and lifting a telescopic table with
load
– Traversing an attachment to the left / right
without load
– Traversing a telescopic table to the left / right
without load
– Traversing an attachment to the left / right with
load
– Traversing a telescopic table to the left / right
with load
– Zone selection
– Area selection
Z A load sensor between the forks detects whether there is a load on the forks.
11.14 EN
396
10.7.1 Entering area recognition (zones)
Z Area recognition can occur manually or automatically depending on the setting.
Automatic area (zone) detection
Z The area is automatically recognised by the truck. There is no requirement for the
operator to make an entry.
Manual area recognition (zone) entry 320

Requirements
200
establish automatic guidance, (see 198
"Negotiating narrow aisles" on 195
page 214). 194
Procedure
• Press the "Select" button (198) in the 201
cursor field.
• Using the numerical keypad (130) enter the area.
• If an incorrect entry is made it can be deleted by pressing the “CE” button on the
numerical keypad (130).
• Press "OK" on the numerical keypad (130) to save the area entry.
The entered zone is now shown in the driver's display above the “zone selection”
symbol (320).
11.14 EN
397
10.7.2 Rack number entry (lift height)
Requirements 321 1
– Drive the truck into the narrow aisle and 130
"Negotiating narrow aisles" on 200
page 214). 198
195
Procedure 194
• Using the numerical keypad (130) enter
the rack number.
Z The rack number can be entered as a
201
single digit (0 - 9), 2-digit (00-99) or 3-
digit number (000-999).
For a 2-digit entry, the first number entered is a multiple of ten and the second a
unit.
For a 3-digit entry, the first number entered is a multiple of one hundred, the second
a multiple of ten and the third a unit.
• If an incorrect entry is made it can be deleted by pressing the “CE” key on the
numerical keypad (130).
• Press "OK" on the numerical keypad (130) to save the area entry.
The entered rack number (321) is now shown above the fork in the driver's display.
An arrow (321) is also displayed to the left of the rack number that has been entered.
This arrow indicates whether the Main Lift needs to be raised or lowered to reach the
warehouse location.
11.14 EN
398
10.7.3 Approaching the warehouse location with Rack Height Select
12 321 320 127 15

Requirements
"Preparing the truck for operation" on 1
"Negotiating narrow aisles" on 16 130 19
page 214).
198 200
Procedure
• Using the numerical keypad (130) enter 195
the area (320), (see "Entering area 194
recognition (zones)" on page 397).
• Using the numerical keypad (130) enter 201
the rack number (321), (see "Rack
number entry (lift height)" on page 398).
Z Depending on the current lift height, an arrow is shown on the driver's display next
to the rack number that has been entered. This arrow indicates whether the Main
Lift needs to be raised or lowered to reach the warehouse location.
11.14 EN
399
12 321 320 127 15
Procedure
Z In order to lift or deposit loads in pre-
1
selected storage locations, the auxiliary
lift must be fully lowered ((see "Auxiliary
Lift raise/lower" on page 228)). The
auxiliary lift height is irrelevant for
stockpicking.
• Approaching the warehouse location
with Rack Height Select: 16 130 19
• Grab hold of the handle (16) with your 198 200
left hand and grab hold of the
195
handle (19) with your right hand (two-
hand operation). 194
Turn the hydraulic control lever (12) 201
anti-clockwise.
Z If another rack is selected during the positioning process, this is displayed for
approx. 1 second and stored in an intermediate log. On reaching the current
warehouse location the rack number is automatically transferred from the
intermediate log and can be approached as detailed above.
The rack number entered has now been reached.
Z Primarily the rack height entered is approached with the Main Lift. Trucks with
auxiliary lift only:
if the lift height (nominal height) cannot be approached with a fully extended Main
Lift, the remaining height can be approached with the Auxiliary Lift, (see "Auxiliary
Z The warehouse location approach can be cancelled by pressing the “CE” button on
the numerical keypad or by pressing the EMERGENCY DISCONNECT switch.
11.14 EN
400
To reach the required height there are various operating modes depending on
the parameter setting
Z In narrow aisles grab hold of grip (16) 12

activated in the narrow aisle with two-
handed operation.
To approach the required height 16 19
manually (t):
The "Hydraulic functions" control lever (12) must be pressed and held down until the
required height has been reached (automatic stop).
Z The lift and lower speeds are in proportion to the movement of the "Hydraulic
functions" control lever (12).
11.14 EN
401
To approach the "Pre-limit" required 12
height manually (o):
The "Hydraulic functions" control lever (12)

must be pressed shortly before the
required height is reached. The rest of the
hydraulic operation is performed
automatically. 16 19
Z The lift and lower speeds are in proportion to the movement of the "Hydraulic
functions" control lever (12).
11.14 EN
402
"Jog mode" - To approach the required 12
height automatically (o):
Turn the "Hydraulic functions" control

lever (12) briefly in the desired direction.
The desired height is then automatically
approached.
16 19
Z The lift and lowering speeds are fixed
and cannot be influenced.
11.14 EN
403
To approach the required height
automatically (o):
Set the travel direction and speed with the

travel control knob (15): 208
– Turn the travel control knob (15) slowly
clockwise:
Travel in load direction (208).
– Turn the travel control knob (15) slowly
back:
Travel in drive direction (209). 15
209
The nominal height is then approached
automatically in the optimum manner,
depending on how far away the warehouse
location is.
Z The lift and lowering speeds are fixed
and cannot be influenced. The travel 16 19
speed can be controlled with the travel
control knob.
11.14 EN
404
10.7.4 Stacking operation (o)
General procedure:
– Retrieval:
• Extend the load handler, (see "Attachment traverse" on page 232).
• Raise the load handler, (see "Main Lift raise/lower" on page 227).
• Retract the load handler, (see "Attachment traverse" on page 232)
– Stacking:
• Extend the load handler, (see "Attachment traverse" on page 232).
• Leave to settle.
• Lower the load handler, (see "Main Lift raise/lower" on page 227).
• Retract the load handler, (see "Attachment traverse" on page 232)
11.14 EN
405
The following stacking options are available for stacking operations:
12 125 126 127 15

Stacking procedure not active
– Grab hold of the handle (16) with your left
hand and grab hold of the handle (19)
with your right hand (two-hand
operation).
– When the selected height is reached, the
Rack Height Select order disappears 16 130 19
from the driver's display.
– The operator can start to stack and retrieve goods manually, (see "Traversing /
rotating outside and inside narrow aisles" on page 230).
11.14 EN
406
12 125 126 127 15
Stacking operation not active / feedback
to radio data transmission terminal
operation).
– When the selected height is reached, the 16 130 19
Rack Height Select order disappears
from the driver's display.
– The message "Order processed" to the data radio terminal is only issued when the
attachment has abandoned and then returned to the home position.
During the positioning procedure another compartment can be entered. This entry is
shown for approx. 1 sec. in the driver's display and stored in the cache. After stacking,
the shelf is automatically taken from the intermediate log.
Z The stacking operation can be cancelled by pressing the “CE” button on the
numerical keypad (130) or by pressing the EMERGENCY DISCONNECT switch.
No "Order processed" message is sent to the radio data transmission terminal.
11.14 EN
407
12 125 126 127 15
Manual stacking operation
operation).
Z Stacking / retrieval can be performed 16 130 19
when the selected nominal height has
been reached. Stacking and retrieval are prescribed to the driver in the driver's
display via the load sensor.
• On reaching the respective limit position (traverse / lift height reached), the next
stage can follow if the hydraulic control lever (12) is in neutral.
Z The hydraulic speeds are in proportion to the movement of the hydraulic control
lever (12).
11.14 EN
408
12 125 126 127 15
Automatic stacking operation with the
hydraulic control lever (version A)
operation).
Z Stacking / retrieval can be performed
16 130 19
when the selected nominal height has been reached.
– The prescribed stacking operation direction must be confirmed and adhered to
throughout the stacking operation via the hydraulic control lever (12):
• "Left" stacking operation = turn the hydraulic control lever (12) anti-clockwise
and hold it down until the operation is complete.
• "Right" stacking operation = turn the hydraulic control lever (12) clockwise and
hold it down until the operation is complete.
Z The hydraulic speeds are fixed and cannot be influenced.
The hydraulic functions stop when the hydraulic control lever (12) is released. The
stacking operation continues when the hydraulic control lever (12) is applied again.
11.14 EN
409
12 125 126 127 15
Automatic stacking operation with the
hydraulic control lever (version B)
operation).
Z Stacking / retrieval can be performed
16 130 19
when the selected nominal height has been reached.
– The prescribed stacking operation direction must be confirmed and adhered to
throughout the stacking operation via the hydraulic control lever (12):
• "Left" stacking operation = turn the hydraulic control lever (12) anti-clockwise
and hold it down until the operation is complete.
• "Right" stacking operation = turn the hydraulic control lever (12) clockwise and
hold it down until the operation is complete.
Z The hydraulic speeds are fixed and cannot be influenced.
The hydraulic functions stop when the hydraulic control lever (12) is released. The
stacking operation continues when the hydraulic control lever (12) is applied again.
Pressing one of the "Attachment traverse" (126) or "Fork carriage rotate" (125)
buttons cancels the automatic stacking operation. The driver is notified of this via
an audible signal. After the cancellation the operator must carry out the stacking
operation manually, see "Manual stacking operation".
11.14 EN
410
12 125 126 127 15
16 130 19
The following symbols appear in the driver's display for “left” stacking
operations:
Symbol
Stacking Retrieval
hand and grab hold of the handle (19) with
your right hand (two-hand operation).
– Traverse attachment to the left:
• Press and hold down on the "Attachment
traverse" key (126).
• Turn the hydraulic control lever (12) anti-
clockwise.
– Rest time active.
– When stacking, after the attachment has been
extended there is an interval to reduce mast
vibration.
– hydraulic control lever (12):
• Anti-clockwise turn:
Lift (retrieve)
• Clockwise turn:
Lower (stack)
11.14 EN
411
Symbol
Stacking Retrieval
– Traverse attachment right to the home
position:
• Press and hold down on the "Attachment
traverse" key (126).
clockwise.
11.14 EN
412
10.8 Horizontal positioning (o)
Your truck may optionally be equipped with the “Horizontal Positioning (HozPos)”
function. This function supports the owner in positioning (automatic, direct targeted
positioning of the pallet location) the truck in the rack and at the transfer station.
"Horizontal Positioning (HozPos)" offers programmable warehouse conditions. The
setting is made by the manufacturer's customer service department.
10.8.1 Horizontal positioning on the EKS

In conjunction with the integrated rack height select, this provides for consistent
stockpicking in the rack and at transfer stations with minor, monitored deviations.
Positioning accuracy:
– The positioning accuracy with warehouse navigation is ± 5 mm vertically and ± 30
mmhorizontally.
Options
– Manual entry of destination via cursor keys and numerical keypad
– Entry of destination via barcode scanner on the control panel or load handler
– Destination entry via radio connection
11.14 EN
413
10.8.2 Horizontal positioning on the EKX
In conjunction with the integrated rack height select, this provides for consistent
stopping and load collecting in the rack and at transfer stations with minor, monitored
deviations.
Positioning accuracy:
– The positioning accuracy with warehouse navigation is ± 5 mm vertically and ± 30
mmhorizontally.
To achieve constant insertion widths over the entire lift height, ten height-dependent
traverse adjustment values can be programmed as an option.
The aisle and fork positions are checked on entry to the aisle.

these operations.
Options
– Manual entry of destination via cursor keys and numerical keypad
– Entry of destination via barcode scanner on the control panel or load handler
– Destination entry via radio connection
– Type of stacking operation, (see "Stacking operation (o)" on page 405)
– Extension lock during travel without target or incorrect target
11.14 EN
414
10.8.3 Warehouse and stockpicking mode (o)
Warehouse mode:
– In storage mode pallets can be stacked and retrieved, (see "Traversing / rotating
outside and inside narrow aisles" on page 230).
– The vertical position of the warehouse location entered is the height of the forks.
This ensures that the required pallet is stacked or retrieved.
– The horizontal position of the warehouse location entered is the centre of the load
handler. This ensures that the required pallet is stacked or retrieved.
Stockpicking mode:
– In stockpicking mode articles can be gathered together.

– The vertical position of the warehouse location entered is the picking height (raised
operator position height: 1600 mm). This ensures that the required articles can be
picked.
– The horizontal position of the warehouse location entered is the centre of the
driver's cab. This ensures that the required articles can be picked.
11.14 EN
415
10.8.4 Changing between warehouse and stockpicking mode
Requirements 322
Procedure
119
• Press the "Select" key (198) in the cursor
field. 200
The driver's display shows the "Change 198
between warehouse and stockpicking 195
mode" symbol (322). 194
• Press (119) under the "Change between

201
warehouse and stockpicking mode"
symbol (322) to activate warehouse or
stockpicking mode.
• Warehouse mode is set if the "Change between warehouse and stockpicking
mode" symbol (322) has a dark background.
• Stockpicking mode is set if the "Change between warehouse and stockpicking
mode" symbol (322) has a light background.
11.14 EN
416
10.8.5 Displays shown for the EKX
Z The position of the symbols can be adapted to customer requirements. The setting
is made by the manufacturer's customer service department. In this case the
positions (rack row, location (marker), compartment (height) and zone) must be
entered so as to match the symbol display.
The following symbols are displayed along with the lift height:
323
324 325 326
! !
327
0h
P
07:48 ETX 5xx IF FNxxxx
! 328
329
xx m xx kg
!
330
331 332 333 334 335
336 337 338

! ?
0 8
339
A H
340
Item Symbol Function / Description
323 Truck detected in narrow aisle / transponder.
The "travel in drive direction" symbol indicates that a

324 horizontal adjustment in the drive direction is required to reach
the destination.
The "travel in load direction" symbol indicates that a horizontal
325 adjustment is required in load direction to reach the
destination.
326 “Truck horizontally positioned” symbol
"Forks" warning symbol, (see "Horizontal positioning error

327 ! ! description" on page 421).
328
! "Turn fork carriage right" warning symbol.
329
! "Turn fork carriage left" warning symbol.
The “lower” or “lift” symbols indicate that vertical adjustments

330
11.14 EN
are required to reach the storage location.
417
The "Order in memory" symbol indicates that in addition to the
331
current order there is another order in the truck's memory.
Zone selection / area selection:
332 Zone display = Different lift heights.
Single digit entry only.
Rack row display:
333
The entry can be one, two or three digit.
Location (marker) display = Horizontal position in narrow aisle:
334
Rack (height):
335 Rack display = Lift height vertical position in narrow aisle.
Warning symbol, (see "Horizontal positioning error
336 ! description" on page 421).
"Question mark" symbol, (see "Horizontal positioning error
337 ? description" on page 421).
Lightning symbol, (see "Horizontal positioning error
338
description" on page 421).
0 7
339 ... Warehouse block display from 0 to 8.
A H
340 ... Warehouse block display from A to H.
11.14 EN
418
10.8.6 Displays shown for the EKS
The following symbols are displayed along with the lift height:
323
324 325 326
330
0h 07:48 EKS 5xx IF FNxxxx
P
xx m xx kg
331 332 333 334 335
336 337 338

! ?
0 8
339
A H
340
323 Truck detected in narrow aisle / transponder.
The "travel in drive direction" symbol indicates that a

324 horizontal adjustment in the drive direction is required to reach
the destination.
The "travel in load direction" symbol indicates that a horizontal
325 adjustment is required in load direction to reach the
destination.
326 “Truck horizontally positioned” symbol
The “lower” or “lift” symbols indicate that vertical adjustments

330
are required to reach the storage location.
The "Order in memory" symbol indicates that in addition to the

331
current order there is another order in the truck's memory.
Zone selection / area selection:
332 Zone display = Different lift heights.
Single digit entry only.
Rack row display:
333
11.14 EN
419
Location (marker) display = Horizontal position in narrow aisle:
334
Rack (height):
335 Rack display = Lift height vertical position in narrow aisle.
Warning symbol, (see "Horizontal positioning error
336 ! description" on page 421).
"Question mark" symbol, (see "Horizontal positioning error
337 ? description" on page 421).
Lightning symbol, (see "Horizontal positioning error
338
description" on page 421).
0 7
339 ... Warehouse block display from 0 to 8.
A H
340 ... Warehouse block display from A to H.
11.14 EN
420
10.8.7 Horizontal positioning error description
Item Error Description

324 – Enter the correct aisle.
Truck has entered the wrong – The direction symbol flashes.
325
aisle.
336
327 – Position the forks / attachment in the
Forks / attachment are not in home position shown.
home position for the order – The "forks" symbol and the warning
336 entry symbol flash alternately every 5
seconds.
– Apply the correct direction for the
Stacking operation: stacking operation with the hydraulic
327 Wrong direction applied with control lever.
the hydraulic control lever – The "forks" symbol flashes for as long as
the wrong direction is specified.
327 – Position the forks / attachment in the
328 Forks / attachment are not in direction shown.
the correct position for the – The "forks" symbol and the "Rotate fork
stacking operation requested carriage right" or "Rotate fork carriage
329 (error in stacking operation) left" warning symbols flash until the
correct position is reached.
333 – Check entry.
Incorrect rack row entered with
– The question mark and rack row symbols
337 order
flash alternately.
Incorrect location (marker)
– The question mark and location (marker)
337 entered with order
symbols flash alternately.
Incorrect rack (height) entered
– The question mark and rack (height)
337 with order
symbols flash alternately.
Position reached: – Aisle start, end or centre transponder
334 Wrong position in narrow aisle must be passed over again.
(transponder not detected) – The location / marker and lightning
Position not detected, symbols flash alternately.
338
tolerance level exceeded
– The stacking operation is performed until
336 No load when unstacking the attachment is in the home position.
– The warning symbol lights up.
– The order cannot be performed.
Incorrect checksum on data – Re-enter the data or amend the order.
336
entry – The warning symbol flashes until the
order is cleared.
Orders cannot be entered as – The order entry is blocked.
--- there is already an order in the – Carry out the existing order.
11.14 EN
memory.
421
Item Error Description
– The order is not accepted.
--- Faulty data transmission
– The error number is displayed.
Data transmission not – The order is not accepted.
--- repeated despite error – The error number is displayed.
recognition (NAK)
– The order cannot be performed.
--- Wrong checksum
– Re-enter the data or amend the order.
11.14 EN
422
10.8.8 Storage mode symbols in the driver's display
144
During storage mode the following
symbols (144) are shown in the driver's 0h 07:48 EKX 5xx IF FNxxxx
display: P
Z
xx m xx kg
A load sensor between the forks detects

whether there is a load on the forks.
Symbols in storage mode with attachment
Symbol Function
– Attachment in home position without load / with load
– Without load, lower / lift to reach the warehouse location
– With load, lower / lift to reach the warehouse location
– Without load, traverse the attachment to the left / right
– With load, traverse the attachment to the left / right
– Rest time without / with load

11.14 EN
423
Symbols in storage mode with telescopic table
Symbol Function
– Telescopic forks in home position without load / with load
– Telescopic forks in home position without load / with load

– The telescopic forks can be extended to the left / right
– Without load, lower / lift to reach the warehouse location
– With load, lower / lift to reach the warehouse location
– Without load, traverse the telescopic forks to the left / right
– With load, traverse the telescopic forks to the left / right
– Without load, traverse the telescopic forks to the left / right into
the second stacking depth, (see "Double telescopic forks (o)"
on page 385).
– With load, traverse the telescopic forks to the left / right into the
second stacking depth, (see "Double telescopic forks (o)" on
page 385).
– Rest time without / with load
11.14 EN
424
10.8.9 Stockpicking mode symbols in the driver's display
144
During stockpicking mode the following
symbols (144) are shown in the driver's 0h 07:48 EKX 5xx IF FNxxxx
display: P
xx m xx kg
Symbol Function
– Stockpicking mode active
– Lower / lift to reach the warehouse location
– Remove articles from the left / right warehouse location
– Display for required adjustment (lower or lift) to reach the

warehouse location
– Display for required adjustment (lower or lift) to reach the right

warehouse location
11.14 EN
425
10.8.10Warehouse target destination entry
The destination for horizontal positioning can be entered in three different ways and
can be adapted to customer requirements:
– Manual destination input:

the required destination is entered and confirmed manually.
– Destination input with barcode scanner:
The destination position is scanned in with a barcode scanner.
– Destination input via radio:
The destination is transmitted to the truck via radio.
Warehouse destination manual entry (default setting)
Requirements
(o)" on page 196).
11.14 EN
426
Procedure 12 333 334 335 332 127 15
• Press the "Select" key (198) in the cursor
field.
The background of the “rack row”
field (333) goes dark.
• Use the numerical keypad (130) to enter
the rack row.
The entry in the “rack row” field (333) can
be one, two or three digit.
• Press the cursor key (195). 16 119 130 19
The operator can toggle between input
fields using the cursor keys (194,195): 200
198
• Cursor key (194): Go back an entry 195
field.
194
• Cursor key (195): Go forward an entry
field.
201
• The background of the “location
(marker)” field (334) becomes blue.
• Enter the required location (marker) with the numerical keypad (130).
The entry in the “location (marker)” field (334) can be one, two or three digits.
• Press the cursor key (195).
The background of the “Rack (height)” field (335) goes dark.
• Enter the required rack (height) with the numerical keypad (130).
The entry in the “Rack (height)” field (335) can be one, two or three digit.
• Press the cursor key (195).
The background of the “zone selection / area selection” field (332) goes dark.
• Enter the required zone / area with the numerical keypad (130).
Only single digit entries are allowed in the “zone selection / area selection”
field (332).
• Press "OK" on the numerical keypad (130) to save the entry.
Manual destination entry is now complete. The destination can now be approached.
11.14 EN
427
12 331 127 15
Z A maximum of two orders can be stored
in the truck’s memory. The destination
entered first is shown on the driver's
display as the current order. The second
destination entered is stored in the
truck’s memory. In this case the "order in
memory" symbol (331) is shown in the
driver's display.
• When the current order has been 16 119 130 19

processed it is deleted from the driver's
display and any order stored in the memory is displayed.
• An order shown on the driver's display can be deleted by pressing the “CE” button
twice on the numerical keypad (130).
11.14 EN
428
Destination input with barcode scanner
Requirements
(o)" on page 196).
Procedure
• Scan in the label with the barcode scanner.
• The destination stored on the label is transmitted directly to the driver's display.
Destination entry with the barcode scanner is now complete. The destination can now
be approached.
12 331 127 15
Z A maximum of two orders can be stored
in the truck’s memory. The destination
scanned in first is shown on the driver's
display as the current order. The second
destination scanned in is stored in the
truck’s memory. In this case the "order in
memory" symbol (331) is shown in the
driver's display.
• When the current order has been 16 119 130 19

processed it is deleted from the driver's
display and any order stored in the memory is displayed.
Z Destinations can be inputted manually if the barcode scanner fails.
11.14 EN
429
Destination input via data radio transmission
12 331 127 15
Requirements
"Negotiating narrow aisles" on 16 119 130 19
page 214).
Procedure
• The destination transmitted by radio is received by the industrial truck and appears
directly on the driver's display.
Destination input via the radio terminal is now complete. The destination can now be
approached.
• When the current order has been processed it is deleted from the driver's display.
• Feedback is sent from the industrial truck to the data terminal.
• Then an additional destination transferred by the data terminal is received and
appears in the driver's display.
Z Destinations can optionally be entered manually if the radio terminal fails.
11.14 EN
430
10.8.11Stockpicking or stacking / retrieval after entering the destination
Automatic horizontal and manual vertical destination approach (t)
Requirements
(o)" on page 196).
– For EKX only:
The attachment must be in the correct position. Note the symbols in the driver's
display. If necessary push / turn the attachment to the correct home position.
– The truck is located in the set aisle and is automatically guided. An
incorrect aisle is indicated in the driver's display with the "warning" symbol. !
– Enter the storage location destination, (see "Warehouse target destination
entry" on page 426).
12 324 325 326 127 15

Procedure
• Grab hold of the handle (16) with your left
operation).
• Travel in the drive direction when the
"Travel in drive direction" symbol (324) is
displayed: 16 119 130 19
slowly anti-clockwise.
forward or back.
• Travel in the load direction if the "travel in load direction" symbol (325) is displayed.
• Turn the travel control knob (15) slowly clockwise.
forward or back.
• When you have reached the warehouse location the "Truck horizontally positioned"
symbol (326) appears in the driver's display and the truck stops.
The horizontal position of the warehouse location has now been reached.
11.14 EN
431
12 341 342 127 15
Procedure
operation).
• Raise the Main Lift if the "Lift"
symbol (342) is displayed.
• Turn the hydraulic control lever (12) 16 119 130 19
anti-clockwise.
• Lower the Main Lift if the "Lower" symbol (341) is displayed:
Z Continue to apply the hydraulic control lever (12) until you reach the required
height.
• Trucks with auxiliary lift only:
• if the lift height (nominal height) cannot be approached with a fully extended
Main Lift, the remaining height can be approached with the Auxiliary Lift:
Apply the "Auxiliary lift" key (127) and hold it down.
• if the lift height (nominal height) cannot be approached with a fully lowered Main
Lift, the remaining height can be approached with the Auxiliary Lift:
Apply the "Auxiliary lift" key (127) and hold it down.
The vertical position of the warehouse location has now been reached.
The operator can start to pick goods (on the EKS and EKX).
The operator can start to stack and retrieve goods (on the EKX).
Z When you reach the warehouse location it can be optionally illuminated by the
respective position light. The operator can start to pick goods.
Z The entered warehouse location can also be approached through diagonal travel
(simultaneous travel and lifting/lowering of the Main Lift). For details of diagonal
travel (see "Diagonal travel" on page 225). 11.14 EN
432
Automatic horizontal and vertical destination approach (o)
Requirements
(o)" on page 196).
– For EKX only:
The attachment must be in the correct position. Note the symbols in the driver's
display. If necessary push / turn the attachment to the correct home position.
– The truck is located in the set aisle and is automatically guided. An
!
incorrect aisle is indicated in the driver's display with the "warning" symbol.
– Enter the storage location destination, (see "Warehouse target destination
entry" on page 426).
12 324 325 326 15

Procedure
operation).
the travel control knob (15):
• Turn the travel control knob (15) 16 119 130 19
slowly clockwise:
341 342
slowly anti-clockwise:
• You can control the travel speed by
turning the travel control knob (15)
further forward or back. 13 127
• The industrial truck begins automatic
horizontal and vertical destination approach.
Z Vehicle movements can be interrupted by releasing the travel control knob (15) or
handles (16,19), or by pressing the Emergency Disconnect switch (13).
• After the warehouse location is reached:
• The "Truck horizontally positioned“ (326) symbol appears in the driver's display.
• The truck stops.
• Lifting or lowering stops automatically.
• The "Lift“ or "Lower" symbol (342,341) goes out.
The horizontal and vertical position of the warehouse location have now been
reached.
The operator can start to pick goods (on the EKS and EKX).
The operator can start to stack and retrieve goods (on the EKX).
11.14 EN
433
Z When you reach the warehouse location it can be optionally illuminated by the
respective position light. The operator can start to pick goods.
10.8.12Order picking direction position light (o)

Z After the warehouse location is reached, the position lights on the driver's cab
illuminate it. The driver can begin order picking in the illuminated area.
11.14 EN
434
10.9 Passenger mode for a second person in the driver's cab (o)
In chapter E of the operating instructions: “Safety Regulations for the Operation of
Forklift Trucks” the item “Unauthorised use of truck” strictly prohibits the carrying of
passengers in the driver's cab and on the load handler.
CAUTION!
If the truck is equipped for passenger mode with an additional control panel (two-hand
operation), a second person may be allowed in the driver's cab in exceptional
circumstances.
XThe driver must instruct the passenger how to operate in passenger mode and
inform him of potential hazards.
Example:
Do not lean out of the driver's cab while travelling or lifting / lowering.
WARNING!
A second person can only be transported if there is an additional control panel for the
passenger in the driver's cab. This control panel monitors the "Two-handed
operation" of the passenger.
XThe additional control panel should only be added to activate passenger mode on
the truck.
XIf unused, the control panel must be kept safe by an appointed person.
10.9.1 Operation of passenger mode for a second person in the driver's cab
NOTE
The driver must check the passenger mode safety mechanisms before starting to
travel. If one of the safety mechanisms is not functional, passenger mode must not
be activated. Notify the manufacturer's customer service department.
WARNING!
The two-hand control switches on the additional control panel must be operational at
all times.
If in exceptional circumstances, a second person is allowed to ride in the

driver’s cab with the owner’s permission, proceed as follows.
Requirements
– The additional control panel is provided to enable passenger mode on the truck.
– The driver must instruct the passenger how to operate in passenger mode and
inform him of potential hazards.
Procedure
• Turn the key in the key switch as far to the left as it will go.
11.14 EN
435
• Attach the additional control panel to the side panel in the driver's cab.
• Establish an electrical connection between the truck and the additional control
panel.
• Insert the key in the key switch and turn it as far right as it will go.
• During operation (travel / lifting / lowering) the passenger must depress the
switches on the additional control panel with both hands (two-hand control).
Z If at any time while travelling or carrying out a hydraulic operation the two-hand
operation switches installed for passenger mode are not pressed, travel and/or
hydraulic operations are deactivated.
The additional control panel for passenger mode is installed and activated.
11.14 EN
436
10.10 Working platform (o)
The truck operator manual, in chapter E "Safety Regulations for the Operation of the
Forklift Truck" under the item "„Unauthorised use" specifically prohibits the carrying
(travel / lift / lower) of one or more persons on the load handler.
If the truck is equipped with a detachable, approved work platform, in exceptional
cases a person authorised by the owner may be carried in the work platform.
CAUTION!
The work platform is authorised for one person only.
XIf a second person is to be carried in the work platform, it must be fitted with an
additional two-hand control system.
The owner / driver must instruct the person(s) carried in the work platform in how to
operate the work platform and point out the hazards.
Example: do not lean out of the work platform while travelling or lifting / lowering.
Z Operate the work platform only at reduced travel / hydraulic speeds.
WARNING!
The use of working platforms is governed by national law. In some states the use of
working platforms is prohibited on industrial trucks. Observe the applicable law.
Working platforms can only be used in the country of application if the law permits it.
XContact the national authorities before using a working platform.
WARNING!
Unsuitable work platforms can be hazardous
Do not use work platforms that have not been approved for this truck. Unsuitable work
platforms can slide off the load handler and fall when used with the truck.
XUse only work platforms that have been approved by the owner.
XThe work platform must be connected both physically and electrically to the truck
at all times during operation.

11.14 EN
437
10.10.1Work platform components
343 344 345 346 344 345
347 348 346 349 350 351 347 352 348 350 351
Item Component
343 Key to open the door in emergencies
344 Handles (two-handed operation)
345 Connecting cable between work platform and truck
346 Door
347 Operator platform
348 Fork shoes
349 Work platform for the standard attachment
350 Work platform lock
351 Stop on the attachment of the truck
352 Work platform for the telescopic table
11.14 EN
438
10.10.2Lifting the work platform with the standard attachment
343 344 345

If, in an exceptional circumstance
approved by the owner, the work
platform is to be raised and an operator
carried in the work platform, proceed as
follows:
Requirements
– Use only work platforms that have been
approved for this truck by the owner.
347 348 346 349 350 351
Procedure
• Check the work platform for damage before using it.
• Check the lock (350) on the work platform is present and check for damage.
• Close the gate (346).
Z The work platform must be lifted in such a way that at all times during travel, lifting
or lowering, eye contact is maintained between the driver and the operator of the
work platform.
• Before raising the work platform make sure there is no one inside it.
• Position the truck in front of the work platform so that the forks can be inserted into
the fork shoes (348).
• Carefully push the forks into the fork shoes (348) of the work platform.
• Raise the work platform securely:
WARNING!
Unsecured work platforms can be hazardous
The work platform must be connected both physically and electrically to the truck at
all times during operation.
XThe physical lock of the work platform must engage with the stop on the load
handler.
XThe work platform must be connected electrically to the truck at all times during
operation.
• Raise the work platform slightly until it is clear of the ground.

The physical lock (350) of the work platform must engage with the stop
on the load handler (351). The work platform is prevented from falling.
The "Work platform raised securely" symbol appears in the driver's
display. The raised and locked work platform is monitored by non-
contact sensors.
• Slowly retract the forks and work platform back to the home position.
• Attach the connecting cable (345) of the work platform to the truck.
Z When the truck and work platform have been connected electrically, the truck
11.14 EN
can only travel and/or carry out hydraulic operations with the two-hand
439
compulsion system (handles (344) grabbed) and the gate closed (346). If the
truck is not connected electrically to the work platform, travel and hydraulic
operations are inhibited when the work platform has been raised.
The work platform has been raised correctly with the standard attachment.
Z The "Attachment traverse" and / or "Fork carriage rotate" functions are inhibited
when the work platform is raised and electrically connected.
11.14 EN
440
10.10.3Lifting the work platform with the standard attachment
346 344 345

If, in an exceptional circumstance
approved by the owner, the work
platform is to be raised and an operator
carried in the work platform, proceed as
follows:
Requirements
– Use only work platforms that have been
approved for this truck by the owner. 347 352 348 350 351
Procedure
• Check the work platform for damage before using it.
• Check the lock (350) on the work platform is present and check for damage.
Z The work platform must be lifted in such a way that at all times during travel, lifting
or lowering, eye contact is maintained between the driver and the operator of the
work platform.
• The work platform for the telescopic table can only be lifted from the left hand side
(viewed in the load direction). Before raising the work platform make sure there is
no one inside it.
• Position the truck in front of the work platform so that the forks can be inserted into
the fork shoes (348).
• Carefully push the forks into the fork shoes (348) of the work platform.
• Raise the work platform securely:
WARNING!
Unsecured work platforms can be hazardous
The work platform must be connected both physically and electrically to the truck at
all times during operation.
XThe physical lock of the work platform must engage with the stop on the load
handler.
XThe work platform must be connected electrically to the truck at all times during
operation.
• Raise the work platform slightly until it is clear of the ground.

• Slowly retract the forks and work platform back to the home position.
The physical lock (350) of the work platform must engage with the stop
on the load handler (351). The work platform is prevented from falling.
The "Work platform raised securely" symbol appears in the driver's
display. The raised and locked work platform is monitored by non-
contact sensors.
11.14 EN
441
• Prevent the lock (350) on the work platform from loosening by applying the bolt
on the stop of the load handler (351).
• Attach the connecting cable (345) of the work platform to the truck.
Z When the truck and work platform have been connected electrically, the truck
can only travel and/or carry out hydraulic operations with the two-hand
compulsion system (handles (344) grabbed) and the gate closed (346). If the
truck is not connected electrically to the work platform, travel and hydraulic
operations are inhibited when the work platform has been raised.
The work platform has been raised correctly with the telescopic table.
Z Adjusting the telescopic forks (e.g. traversing) is inhibited when the work platform
has been lifted and connected electrically.
11.14 EN
442
10.10.4Operation in the work platform
WARNING!
Faulty work platform safety mechanisms can cause accidents
Faulty work platform safety mechanisms (handles (two-hand compulsion), gate,
"Work platform raised" sensors...) can cause the work platform and / or the person in
the work platform to fall. Do not use the work platform if one of the safety mechanisms
is not working.
XTest the work platform safety mechanisms before using it.
XOnly return the work platform to service when you have identified and rectified the
fault.
WARNING!
Work platforms can be hazardous
When operating the work platform the person in the platform is at risk from falling.
XClose the work platform gate during operation.
XGrab the work platform handles (two-hand compulsion) with both hands while the
truck is travelling and/or performing hydraulic operations.
XDo not use other climbing tools (such as ladders, stools etc.) in the work platform.
XThe working platform must not be accessed or left while in a raised position.
11.14 EN
443
WARNING!
Objects protruding or falling out of the work platform can be hazardous
Objects protruding out of the perimeter of the work platform can collide with other
components during operation (e.g. racking systems). This can cause the work
platform to fall and injure people inside the work platform.
Objects falling out of the work platform can injure the operator of the truck or damage
the truck.
XBefore operating the work platform make sure there are no objects protruding out
of it.
XBefore operating the work platform make sure that any objects inside are secured
correctly.
NOTE
The maximum load for the work platform:
Xmust not be exceeded.
Xis shown on the data plate.
11.14 EN
444
343 344 345 346 344 345
347 348 346 349 350 351 347 352 348 350 351
Operating the work platform

Requirements
(o)" on page 196).
– Work platform raised securely, (see "Lifting the work platform with the standard
attachment" on page 439) or (see "Lifting the work platform with the standard
attachment" on page 441).
Procedure
• Step on the work platform:
• Press the "Gate opener" switch on the work platform.
• Open the work platform gate (346).
• Step on the work platform.
• Close the work platform gate (346).
Z While the truck is in operation, the work platform attachment and the closed
gate (346) are permanently monitored. Opening the gate (346) will cause travel
and / or hydraulic operations to stop.
Person has stepped onto the work platform.
• Raise, lower and / or transport a person in the work platform:

• Grab the work platform handles (344) (two-hand compulsion) with both hands
while the truck is travelling and/or performing hydraulic operations.
Z The travel and / or hydraulic operations are interrupted or cannot be performed as
soon as the handles (344) (two-hand compulsion) of the work platform are
released.
11.14 EN
445
WARNING!
The driver must never leave the truck while there are people in the raised work
platform.
XThe working platform must not be accessed or left while in a raised position.
XThe driver must never leave the truck while the work platform is in operation.
Destination reached. The person in the work platform can start to work.
• Leaving the work platform:

• Lower the work platform to the ground.
• Press the "Gate opener" switch on the work platform.
• Open the work platform gate (346).
• Leave the work platform.
• Close the work platform gate (346).
Person has left the work platform.
NOTE
In the event of a fault the gate (346) can be opened with the key (343) supplied.
11.14 EN
446
10.10.5Lowering the work platform with the standard attachment
343 344 345
Requirements
– Work platform raised securely, (see
"Lifting the work platform with the
standard attachment" on page 439) or
(see "Lifting the work platform with the
standard attachment" on page 441).
– There are no people in the work platform.
Procedure
• Raise or lower the work platform until it is
clear of the ground. 347 348 346 349 350 351
• Disconnect the work platform electrically
from the truck:
• Remove the connecting cable (345) and suspend it in the work platform.
• Fully extend the attachment and work platform.
• Lower the forks until they are no longer in contact with the work platform.
The physical lock (350) of the work platform is disconnected from the stop on the
load handler (351).
• Retract the forks to their home position.
The work platform is lowered.
11.14 EN
447
10.10.6Lowering the work platform with the telescopic table
346 344 345

Requirements
– Work platform raised securely, (see
"Lifting the work platform with the
standard attachment" on page 439) or
(see "Lifting the work platform with the
standard attachment" on page 441).
– There are no people in the work platform.
Procedure
• Raise or lower the work platform until it is 347 352 348 350 351
clear of the ground.
• Disconnect the work platform electrically from the truck:
• Remove the connecting cable (345) and suspend it in the work platform.
• Remove the physical lock (350) of the work platform from the stop on the load
handler (351).
• Fully extend the telescopic forks and work platform.
• Lower the telescopic forks until they are no longer in contact with the work platform.
• Retract the forks to their home position.
The work platform is lowered.
11.14 EN
448
10.11 Closed driver's cab (o)
The truck can be fitted optionally with a closed driver's cab. In an emergency you can
leave the driver's cab via the egress system.
10.11.1Opening and locking the door of the closed driver's cab
353
354
355
356 357
358
Procedure
Z On trucks fitted with a closed driver's cab, both doors (358) can be closed.
• To open the cab door (358);
• Insert the key in the door lock (356).
• Turn the key anti-clockwise as far as the stop.
• To lock the cab door (358):
• Insert the key in the door lock (356).
• Turn the key clockwise as far as the stop.
11.14 EN
449
10.11.2Opening and closing the door of the closed driver's cab from the outside and
inside
CAUTION!
Cabin doors can pose a trapping hazard
You can trap hands or feet when the cab doors are opened and closed.
XMake sure there is nothing between the cab chassis / leg well and the cab doors
when the doors are opened and closed.
Requirements
– Cabin door has been opened, (see "Opening and locking the door of the closed
driver's cab" on page 449).
Procedure
Z The monitored cab doors are shown in the driver's display as a gate
((see "Displays and Controls" on page 121)).
• To open the cab door (358) from the outside:
• press the door lock in (356).
• Open the cab door (358) from the inside.
• To open the cab door (358) from the inside:
• push the handle (355) as far as the stop in the arrow direction.
• Open the cab door (358) from the inside.
• To close the cab door (358) from the outside:
• close the cab door (358) to the outside with the door handle (357).
• Engage the bar of the cab door (358) in the driver's cab.
• To close the cab door (358) from the inside:
• close the cab door (358) to the outside with the handle (355).
• Engage the bar on the cab door (358) in the driver's cab.
11.14 EN
450
10.11.3Entering / exiting the driver's cab
151
358
151
151
358
358
WARNING!
The operator could fall
When the cab door is open and the driver's cab raised, there is a risk that the operator
could fall out of the cab.
XDo not open the cab door when the driver's cab is raised.
Requirements
– Mast / driver's cab completely lowered.
Procedure
• Open the cab door (358), (see "Opening and closing the door of the closed driver's
cab from the outside and inside" on page 450).
• To enter and exit the cab, hold onto the cab chassis (151).
• Close the cab door (358), (see "Opening and closing the door of the closed driver's
CAUTION!
No more than one person may operate the truck in the driver's cab at a time.
11.14 EN
451
10.11.4Opening / closing the roof hatch
WARNING!
Risk of injury when the roof hatch is full opened
When the roof hatch is fully opened the operator is not protected from falling objects.
XDo not open the roof hatch fully during operation.
XDo not perform any travel or hydraulic operations when the roof hatch is open.
Requirements 354
– Enter the driver's cab, (see "Entering / exiting 353
the driver's cab" on page 451).
Procedure
• To close the roof hatch (353):
• Lock the roof hatch (353) down.
• Turn the lever (354) clockwise as far as it will
go.
The roof hatch is now closed.
• Open the roof hatch (353) at an angle of 10°:

• Turn the lever (354) anti-clockwise.
• Open the roof hatch (353) up.
The roof hatch is opened at an angle of 10°.
This position allows the driver's cab to be
ventilated. The operator is still protected from
falling objects.
• To fully open the roof hatch (353):
• Turn the lever (354) anti-clockwise as far as
it will go.
• Open the roof hatch (353) up.
The roof hatch is opened at an angle of 85°.
This position allows the operator to exit the
raised driver's cab in the event of a hazard or fault, (see "Leaving a raised driver's
cab through the roof hatch" on page 455). When the roof hatch is opened the
operator is not protected from falling objects.
11.14 EN
452
10.11.5Leaving a raised driver's cab - general safety notices
Z Industrial trucks with a driver's cab which can be raised more than 3 m off the
ground have an emergency lowering mechanism and a rescue equipment (rescue
harness / abseil device / rescue rope) for the driver which can be used to reach the
ground should the operator position be blocked.
If the driver’s cab cannot be lowered due to a fault, not even with emergency lowering
((see "Driver's cab emergency lowering" on page 265)), the operator must exit the
driver's cab via the emergency abseil device.
WARNING!
Untrained personnel and non-serviced rescue equipment can result in
accidents and injury
The rescue equipment (rescue harness / abseil device with rescue rope) should only
be used by people who are physically capable, trained to use the equipment safely
and who have the required expertise.
emergencies.
XThe driver must undergo annual training in how to handle the rescue equipment.
XFor the operation and service intervals of the rescue harness and the emergency
abseil device, refer to the accompanying operating instructions.
XFollow the maintenance intervals stated in rescue harness and emergency abseil
device operating instructions.

operations.
11.14 EN
453
10.11.6Leaving a raised driver's cab through the cab doors
193
Requirements
– Sufficient space between the cab and rack
to leave the driver's cab through the cab
door.
Procedure
359
• Turn the key in the key switch (18) left 193
as far as the stop and remove the key.
• Press the red button on the ISM access
module (o).
13
• Remove the abseil device and rescue
harness from the storage compartment in
the driver's cab, (see "Rescue equipment
storage compartment in the driver's cab"
on page 298).
Z The assembled rescue equipment is
358
ready for use on breaking the seal, 18
removal from the equipment bag or case
and after carrying out a visual inspection.
• Open the cab door (358), (see "Opening and closing the door of the closed driver's
WARNING!
The operator could fall after opening the cab door
When the cab door is open and the driver's cab raised, there is a risk that the operator
could fall out of the cab.
XInsert the karabiner hook of the rescue rope in the D ring of the overhead guard
before leaving the driver's cab.
XWhen attaching the karabiner hook of the rescue rope make sure you are standing
securely in the driver's cab.
• Insert the karabiner hook (359) of the rescue rope into the D ring (193) on the
overhead guard (in accordance with EN 795) and secure it with the union nut.
• Abseil from the truck, (see "Exiting the driver's cab with the rescue equipment" on
page 318).
11.14 EN
454
10.11.7Leaving a raised driver's cab through the roof hatch
193
Requirements
– Sufficient space to open and exit the 354
driver's cab via the roof hatch.
353
Procedure
• Turn the key in the key switch (18) left 193
• Press the red button on the ISM 359
access module (o).
• Remove the abseil device and rescue 13
harness from the storage compartment
in the driver's cab, (see "Rescue
equipment storage compartment in the
Z The assembled rescue equipment is 18
ready for use on breaking the seal,
removal from the equipment bag or case
and after carrying out a visual inspection.
• Turn the lever (354) anti-clockwise as far as the stop to open the roof hatch (353).
WARNING!
The operator not secured to the overhead guard could fall
The operator may only exit via the roof hatch once he has secured himself to the
driver's cab with the karabiner hook. Otherwise the non-secured operator could slide
and fall after leaving the driver's cab through the roof hatch.
• Leaving the driver's cab via the roof hatch. The seat and backrest of the driver's
seat can be used to help climb out of the cab.
page 318).
11.14 EN
455
10.11.8Leaving a raised driver's cab through the front window
13
Z Only exit the driver's cab via the front
window if you cannot exit via the roof
hatch or cab door. 359 193
Requirements
– A raised driver's cab cannot be exited
through the cab door.
– A raised driver's cab cannot be exited
through the roof hatch. 18
Procedure
• Switch off the truck, to do this: 193
• Turn the key in the key switch (18) left
• Press the red button on the ISM
access module (o).
• Remove the abseil device and rescue 360
harness from the storage compartment
in the driver's cab, (see "Rescue 361
equipment storage compartment in the
Z The assembled rescue equipment is ready for use on breaking the seal, removal
from the equipment bag or case and after carrying out a visual inspection.
11.14 EN
456
359
Procedure 193
• Remove the emergency hammer (360)
from its bracket in the driver's cab.
CAUTION!
Risk of injury when striking the front
window
Glass splinters can injure your face when
you strike the front window.
XTurn your face away and close your
eyes before striking the front window.
• Strike the front window (361) with the

emergency hammer (360).
360
CAUTION!
361
Glass splinters from the front window
can cause injury
Glass splinters can cut the operator's body when exiting the driver's cab through the
front window.
XCarefully remove any glass splinters before exiting the driver's cab through the front
window.
XUse hand protection to remove the glass splinters. You can use for example the
rescue harness bag as hand protection.
• Push out the glass splinters of the front window (361) in a forward direction (load
direction).
WARNING!
The operator could fall out when the front window is missing
If there is no front window and the driver's cab raised, the operator risks falling out of
the cab.
page 318).
11.14 EN
457
10.12 On-board charger (o)
10.12.1EKS 5xx / EKX 5xx on-board charger assemblies
362
363
364
365
Item Component
On-Board Charger
362 o Possible on-board charger assembly locations:

– On the mast
– In the drive compartment
363 o On-board charger main switch
364 o Control panel, (see "On-board charger control panel" on page 461)
Charger lead for stationary charging of the battery with the on-board
365 o charger, (see "Battery charge with the on-board charger without the
collector" on page 468)
o Indicates optional equipment
11.14 EN
458
10.12.2Collectors
The collectors (367) can be secured on one or either side of the truck. Depending on
the truck's equipment, the collectors (367) are equipped with or without an electric
motor. In narrow aisles the collectors (367) engage with the bus bars (366), forming
the connection with the grid of the utility company.
Collector (367) for open bus bars (366) Collector (367) for closed bus bars (366)
366
366
367
367
11.14 EN
459
10.12.3On-board charger symbols in driver's display

368
P
xx m xx kg
369
370

– Truck is operational.
– Truck is in narrow aisle.
"Risk of colliding with
368 o – Load handler at bus bar height.
the bus bar" display – Load handler traversing is inhibited
to prevent it from being pushed into
the bus bar.
"Charger ON"
369 indicator (yellow o
symbol) – Battery is charged with the on-
board charger.
– Battery is not charged with the on-
board charger.
Example:
– faulty collector
"Charger fault"
– faulty on-board charger
indicator (red symbol,
370 o – faulty bus bar
symbol flashes each
second) – no power supply
– etc.
Note
If the "charger fault" indicator appears
during charging, notify the
manufacturer's customer service
department.
t Standard equipment o Optional equipment
11.14 EN
460
10.12.4On-board charger control panel
Z The on-board charger control panel is attached to the side (right or left) of the mast.
10.12.5Control panel charge status indicator
371
364
372
373
The charge status indicator attached to the centre of the control panel (371) shows
the battery's current charge status.
Charge status indicator

Function
(371)
Off – No charge, battery is not charged
Red – is charged
– is charged
Yellow
– The battery is charged between 80% and 99%
– is charged
Green
– charge status is 100%
11.14 EN
461
10.12.6Control panel controls
371
364
372
373
Item Component
372 "Charging ON" button
373 Plug to collector
11.14 EN
462
10.12.7Daily checks and operations to be performed before using the on-board
charger
WARNING!
Damage and other defects with the on-board charger or live attachments can
result in accidents.
If damage or other defects are discovered with the on-board charger or live
attachments (collectors, mains cables, connectors, ...) the truck must be taken out of
service until it has been repaired.
XNotify the customer service department.
WARNING!
Damage and other defects on the bus bars or the feed funnel can result in
accidents
If damage or other defects are discovered on the bus bars in the narrow aisle or the
feed funnel, the narrow aisle must not be operated in until it has been repaired.
XTag out the faulty aisle and prevent it from being entered.
XDe-energise the faulty narrow aisle and prevent it from being switched on again.
XOnly return the aisle to service when you have identified and rectified the fault.
Z In addition to the inspections and operations detailed in the "Starting up the Truck"
in the operating instructions, the following items must be checked each day before
starting operation.
11.14 EN
463
10.12.8Visual inspection of on-board charger and narrow aisle
Procedure
• Check the bus bar feed funnels for damage.
• Check the bus bars for damage.
• Check the narrow aisle for overhanging components and remove them if found.
Overhanging components can damage the collector or tear it out of the bus bar.
• Check the on-board charger for damage.
• Check the collector including its mechanically moving attachments for damage.
• Check the wires and connectors of the collector for damage.
• Check the wires and connectors of the on-board charger for damage.
• Check the mains plug for damage.
11.14 EN
464
10.12.9Truck operating modes with on-board charger
The on-board charger allows two different operating modes to be selected:
– Compensation charging mode, (see "Compensation charging mode" on page 465).
– Charging during travel (trickle charge), (see "Charging during travel (trickle
charge)" on page 465).
10.12.10Compensation charging mode

Z Compensation charging should be performed at least weekly to preserve the life of
the battery. It requires the truck to be switched off.
Compensation charging can be carried out in two ways:

– Battery charge with the on-board charger without the collector, (see "Battery
charge with the on-board charger without the collector" on page 468).
– Battery charge in the narrow aisle at a fixed charging position with the collector,
(see "Stationary battery charging in narrow aisles" on page 470).
10.12.11Charging during travel (trickle charge)

This form of charging is used in narrow aisles to capture peak currents which occur
during stacking and to keep the battery at a constant operating voltage, (see "Battery
charging in narrow aisles during operation" on page 472). With this type of charge the
battery is charged up to 80%.
11.14 EN
465
10.12.12Battery charging variants
Batteries may only be charged, serviced or replaced by trained personnel. This

operator manual and the manufacturer’s instructions concerning batteries and
charging stations must be observed when carrying out the work.
Fire protection
Do not smoke and avoid naked flames when handling batteries. Wherever an
industrial truck is parked for charging there shall be no inflammable material or
lubricants capable of creating sparks within 2 m around the truck. The room must be
ventilated. Fire protection equipment must be on hand.
Battery maintenance
The battery cell covers must be kept dry and clean. The terminals and cable shoes
must be clean, secure and have a light coating of dielectric grease.
CAUTION!
Before closing the battery panel make sure that the battery cable cannot be
damaged. There is a risk of short circuits with damaged cables.
Battery disposal
Batteries may only be disposed of in accordance with national environmental

protection regulations or disposal laws. The manufacturer’s disposal instructions
must be followed.
11.14 EN
466
WARNING!
WARNING!
XThe charger must be adapted to the battery in terms of voltage and charge
capacity.
XThe battery cover must be open and the battery cell surfaces must be exposed
during charging to ensure adequate ventilation.
XWherever an industrial truck is parked for charging there shall be no inflammable
material or lubricants capable of creating sparks within 2 m around the truck.
XFire protection equipment must be on hand.
XDo not lay any metallic objects on battery.
XIt is essential to follow the safety regulations of the battery and charger station
manufacturers.
NOTE
The use of unevenly charged batteries can result in material damage
If using the two battery version, the following safety regulations must be observed to
prevent material damage to the batteries.
Operating with unevenly charged batteries will result in material damage to the
batteries, so that both batteries will have to be replaced.
XAlways remove and install batteries in pairs.
XAlways charge batteries in pairs.
11.14 EN
467
10.12.13Battery charge with the on-board charger without the collector
374
371
362
372
373
364
363
365 375
Battery charge with the on-board charger and charger lead without the
collector
Procedure
• Drive the truck out of the narrow aisle to the stationary charger.
• Lower the load handler to the ground.
• Turn the truck off with the key switch and remove the key.
• Press the EMERGENCY DISCONNECT switch down.
• Open the battery panel.
CAUTION!
• Switch on the on-board charger (362) with the main switch/isolator (363).
• Remove the connector (373) from the collector on the control panel (364).
• Attach connector (375) to the control panel (364).
• Attach connector (374) to the grid connection.
• Press the button (372).
The battery is charged. The charge status indicator (371) switches on after a few
seconds. When the battery is fully charged the charger switches to compensation
charging.
Z All truck travel operations are inhibited while the battery is being charged.
11.14 EN
468
Preparing the battery for operation after charging
Requirements
– The battery is fully charged.
Procedure
• Press (372).
The on-board charger is switched off.
• Remove connector (374) from the grid connection.
• Remove connector (375) from the control panel (364).
• Attach connector (373) to the collector on the control panel (364).
CAUTION!
fault.
CAUTION!
• Close the battery cover.

11.14 EN
469
10.12.14Stationary battery charging in narrow aisles
371
372
362
373
364
363
Stationary battery charge with the on-board charger via the collector
Requirements
– Connector (373) attached to the collector on the control panel (364).
– On-board charger (362) switched on with the main switch/isolator (363).
– Bus bar connected to the grid of the utility company.
Procedure
• Enter the narrow aisle slowly and carefully. Make sure the collectors are in the bus
bar.
• Park the truck securely at a fixed charging position in the narrow aisle.
• Tag out the narrow aisle and prevent it from being entered.
• Lower the load handler to the ground.
• Turn the truck off with the key switch and remove the key.
• Press the EMERGENCY DISCONNECT switch down.
• Open the battery panel.
CAUTION!

The battery is charged. The charge status indicator (371) switches on after a few
seconds. When the battery is fully charged the charger switches to compensation
charging.
Z All truck travel operations are inhibited while the battery is being charged.
11.14 EN
470
Preparing the battery for operation after charging
Requirements
– The battery is fully charged.
Procedure
The on-board charger is switched off.
CAUTION!
fault.
CAUTION!
• Close the battery cover.

11.14 EN
471
10.12.15Battery charging in narrow aisles during operation
371
372
362
373
364
363
Battery charging in narrow aisles during operation
Requirements
– Connector (373) attached to the collector on the control panel (364).
– On-board charger (362) switched on with the main switch/isolator (363).
– Bus bar connected to the grid of the utility company.
Procedure
• Enter the narrow aisle slowly and carefully. Make sure the collectors are in the bus
bar.
Once the collectors are fully engaged in the bus bars and the ground sensor system
has been evaluated, the maximum speed is enabled.
Z If adjustable collectors are being used, the truck's electronic system checks the
position of the collector. When the correct position of the collector has been
reached, the maximum speed is enabled.
• The on-board charger is switched on by the truck's controller.
The battery is charged up to 80%.
• The "Charger ON" symbol is shown in the driver's display.

11.14 EN
472
NOTE
When the "Charger fault" symbol flashes red once a second in the driver's
display, this indicates a risk of material damage to the truck, on-board
charger and/or battery.
XStop the truck immediately.
XDe-energise the bus bar in this narrow aisle and prevent it from being switched on
again.
XSwitch off the on-board charger (362) with the main switch/isolator (363).
XDrive out of the narrow aisle.
XPark the truck securely.
XSwitch off the truck.
• The charge status indicator (371) switches on after a few seconds.

Z The on-board charger is switched off by the truck controller as soon as energy is
recovered from regenerative lowering, braking and/or reversing.
• Before leaving the narrow aisle the on-board charger is switched off by the truck
controller.
Z If adjustable collectors are being used, the truck's electronic system checks the
position of the truck in the narrow aisle. When the pre-defined position has been
reached in the narrow aisle, the adjustable collectors are retracted.
11.14 EN
473
10.12.16On-board chargers - Troubleshooting / Driver Displays
This chapter enables the user to identify and rectify basic faults and the effects of
incorrect operation. When trying to locate a fault, proceed in the order shown in the
table.
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.
Additional troubleshooting must only be performed by the manufacturer’s specialist
service engineers. The manufacturer's customer service department is specially
trained to carry out these operations.
- Error number on the display unit (if applicable)
- Error description
- Current location of truck
Fault / Display Possible Cause Remedy

– No power supply to – Arrange for a competent
the bus bar electrically trained person to check
the bus bar power supply
– Arrange for a competent electrically
"Charging fault" trained person to check the mains
symbol lights up fuse
every second in – Bus bar disconnection – De-energise the bus bar of the
the driver's narrow aisle and prevent it from
display being switched on again
– Check the entire length of bus bar
for damage and disconnection
– Notify the customer service
department
– Collector faulty – Notify the customer service
department
– The on-board charger – Notify the customer service
has been switched off department
by the truck's
controller
E5138 – LH adjustable collector – Notify the customer service
does not extend department
– Collector does not
reach defined end
position
E5138 – RH adjustable – Notify the customer service
collector does not department
extend
– Collector does not
reach defined end
11.14 EN
position
474
Fault / Display Possible Cause Remedy
E5139 – Adjustable collector – Drive out of the aisle in the
does not reach defined opposite direction.
end position within a – Enter the narrow aisle again slowly
specific time and carefully.
– Notify the customer service
department if the fault is displayed
again
11.14 EN
475
10.12.17On-board charger maintenance notes
WARNING!
Electric currents can cause accidents
Maintenance and repair work to on board chargers and the live attachments
(collectors, mains plug, connectors etc.) can only be performed by trained specialists
or electrical engineers.
XCarry out work on on-board chargers only when they are de-energised.
XCarry out work on live attachments (collectors, mains plug, connectors etc.) only
when they are de-energised.
XDisconnect the battery from the on-board charger.
XWhen carrying out repairs outside the narrow aisle, disconnect the mains plug of
the charger lead from the grid.
XWhen carrying out repairs in the narrow aisle, disconnect the bus bar power supply.
Z Battery maintenance and servicing is subject to the regulations specified in Chapter

D of the operating instructions.
11.14 EN
476
10.13 Fire extinguisher (o)
WARNING!
The use of unsuitable extinguishing agents can cause fire to spread
The extinguishing agents in a fire extinguisher are suitable only for certain types of
fires, due to their extinguishing properties. The use of inappropriate extinguishing
agents can cause fire to spread, and hence injure the operator.
XThe proprietor is responsible for choosing suitable extinguishing agents and fire
extinguishers.
XThe fire extinguisher must comply with national regulations.
Z The fire extinguisher (378) can be

fastened to the operator position or the
376
overhead guard.
Procedure
• Open the latch (377).
• Pull the fire extinguisher (378) out of its
bracket (376) (see arrow direction). 377
Z To operate, refer to the illustrations on
the fire extinguisher (378).
378
11.14 EN
477
10.14 Rear view mirror (o)
379 379
NOTE
Use the mirror only to observe the traffic behind you. Should you need visibility aids
(mirrors, monitors etc.) to ensure adequate visibility, practice working with them
beforehand.
The rear view mirror (379) is fitted with a swivel link. This allows the driver to adjust
the rear view mirror (379) to his or her individual needs.
CAUTION!
Incorrect adjustment of the rear view mirror can cause accidents

An incorrectly adjusted rear view mirror can collide with the rack or goods when
operating in narrow aisles.
XAdjust the rear view mirror to comply with the safety distances between the
industrial truck and the rack in accordance with EN 1726-2 section 7.3.2.
XMaintain a minimum 100 mm safety distance between a rail guided truck and rack.
XMaintain a minimum 125 mm safety clearance between a wire guided truck and
rack.
11.14 EN
478
10.15 Camera system
CAUTION!
Accident risk from hidden work areas
XThe camera system acts as an aid to assist safe operation.
XPractice travelling and working with the camera system.
XAlign the camera so that the hidden work area can be seen.
Z When using the camera to reverse, the monitor automatically switches on when
you set the travel direction switch to "travel in drive direction".
NOTE
Risk of material damage when working with visual aids

Should you need visual aids (monitors etc.) to ensure adequate visibility, practice
working with them beforehand.
380 381 382 383 384

Using the camera system
– Press the button (384) on the monitor to switch the camera system on or off.
– Press the button (383) to lighten or darken the screen (day / night settings).
– Press the button (380) to open the menu.
Z Pressing the button several times changes the menu item (contrast, brightness,
colour saturation, language, video, light reflection) or quits the menu.
Adjusting the menu items

– Press the button (382) to go one step forward.
– Press the button (381) to go one step back.
Z Clean a dirty screen or vent slots with a soft cloth or brush.
11.14 EN
479
480
11.14 EN
F Industrial Truck Maintenance
1 Operational Safety and Environmental Protection
The checks and servicing operations contained in this chapter must be performed in
accordance with the intervals as indicated in the servicing checklists.
WARNING!
Risk of accidents and damage to components
All modifications to the forklift truck assemblies, in particular the safety mechanisms,
are prohibited. The operating speeds of the truck must not be increased under any
circumstances.
Exception: Owners should only make changes or have changes made to powered
industrial trucks if the truck manufacturer is no longer operating in the field and there
is no successor to the business; owners 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 graphic records of the plans, tests and completion of the changes
– carry out and have authorised the respective changes to the capacity data plates,
decals and stickers as well as the operator and service manuals.
– attach permanent and clearly visible marking to the truck indicating the types of
changes made, the date of the changes and the name and address of the
organisation responsible for the work.
11.14 EN
481
NOTE
Only original spare parts have been certified by our quality assurance department. To
ensure safe and reliable operation of the truck, use only the manufacturer's spare
parts.
For safety reasons, only components which have been specially agreed by the
manufacturer for this truck may be installed near the computer, controllers and wire
guidance sensors (antennae). These components (computers, controllers, wire
guidance sensors (antennae)) must therefore not be replaced either by similar
components from other trucks of the same series.
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
"Restoring the truck to service after maintenance and repairs" on page 546)).
11.14 EN
482
2 Maintenance Safety Regulations
The truck should only be serviced and repaired by the manufacturer's specialist
customer service personnel who have been trained to do this. We therefore
recommend that you enter into a maintenance contract with the manufacturer’s local
sales office.
Lifting and jacking up
WARNING!
Lifting and jacking up the truck safely
In order to raise the truck, the lifting gear must only be secured to the points specially
provided for this purpose.
You may only work under a raised load handler / raised cab if they have been secured
with a sufficiently strong chain or the fastening bolt.
In order to raise and jack up the truck safely, proceed as follows:
XJack up the truck only on a level surface and prevent it from moving accidentally.
XOnly use a jack with sufficient capacity. When jacking up the truck, take appropriate
measures to prevent it from slipping or tipping over (e.g. wedges, wooden blocks).
XIn order to raise the truck, the lifting gear must only be secured to the points
specially provided for this purpose. (see "Identification points and data plates" on
page 64).
XWhen jacking up the truck, take appropriate measures to prevent it from slipping or
tipping over (e.g. wedges, wooden blocks).
Z Prevent the driver's cab from being lowered accidentally ((see "Preventing the
driver's cab from accidentally lowering" on page 527)) and and jacking points ((see
"Identification points and data plates" on page 64)).
11.14 EN
483
Cleaning
CAUTION!
Fire hazard
Do not use flammable liquids to clean the industrial truck.
XAlways disconnect the battery before starting cleaning work.
XCarry out all necessary safety measures to prevent sparking before cleaning (e.g.
by short-circuiting).
CAUTION!
Risk of electrical system damage
The electrical system can be damaged if it is cleaning with water. It is prohibited to
clean the electrical system with water.
XDo not clean the electrical system with water.
XClean the electrical system with weak suction or compressed air (use a compressor
with a water trap) and not a conductive, anti-static brush.
CAUTION!
Risk of component damage when cleaning the truck
If the truck is to be cleaned with a water jet or a high-pressure cleaner, all electrical
and electronic components must be carefully covered beforehand as moisture can
cause malfunctions. Do not clean with pressurised water.
Z After cleaning, carry out the operations detailed in “Recommissioning the truck after
cleaning or maintenance work” ((see "Restoring the truck to service after
maintenance and repairs" on page 546)).
11.14 EN
484
Electrical system
WARNING!
Accident risk
XOnly suitably trained electricians may operate on the truck's electrical system.
XBefore working on the electrical system, take all precautionary measures to avoid
electric shocks.
XAlways disconnect the battery before starting cleaning operations.
WARNING!
Make sure the electrical system is voltage-free before starting work on it. The
capacitors built into the controller must be completely discharged. The capacitors are
completely discharged after about 10 minutes. Before starting maintenance on the
electrical system:
XPark the truck securely ((see "Parking the truck securely" on page 239)).
XPress the Emergency Disconnect.
X Disconnect the battery.
XRemove any rings or metal bracelets etc. before working on electrical components.
11.14 EN
485
Consumables and used parts
CAUTION!
Consumables and used parts are an environmental hazard
Used parts, oils and fuels must be disposed of in accordance with the relevant
environmental protection regulations. To change the oil contact the manufacturer's
customer service department, who have been specially trained for this task.
XNote the safety regulations when handling these materials.
Welding
Remove electrical and electronic components from the truck before performing
welding operations, to avoid damage.
WARNING!
Load bearing parts of the industrial may only be welded after consultation with the
manufacturer!
Settings
When repairing or replacing hydraulic, electric or electronic components or

assemblies, always note the truck-specific settings.
11.14 EN
486
Wheels
WARNING!
The use of wheels that do not match the manufacturer's specifications can
result in accidents.
The quality of wheels affects the stability and performance of the truck.
Uneven wear affects the truck's stability and increases the stopping distance.
XWhen replacing wheels make sure the truck is not skewed.
XAlways 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.
Attachment Repairs and Inspection
WARNING!
11.14 EN
487
3 Servicing and Inspection
Thorough and expert servicing is one of the most important requirements for the safe
operation of the industrial truck. Failure to perform regular servicing can lead to truck
failure and poses a potential hazard to personnel and equipment.
WARNING!
The application conditions of an industrial truck have a considerable impact on the
wear of the service components.
We recommend that a Jungheinrich customer service adviser carries out an
application analysis on site to work out specific service intervals to prevent damage
due to wear.
The service intervals stated are based on single shift operation under normal
operating conditions. They must be reduced accordingly if the truck is to be used in
conditions of extreme dust, temperature fluctuations or multiple shifts.
The following servicing checklist indicates the operations to be performed and the
respective intervals to be observed. Maintenance intervals are defined as:
W = Every 50 service hours, at least weekly

A = Every 500 service hours
B = Every 1000 service hours, or at least annually
C = Every 2000 service hours, or at least annually
t = Standard maintenance interval
Cold store maintenance interval (in addition to standard maintenance
k =
interval)
Z W maintenance intervals must be performed by the owner.
11.14 EN
488
4 Maintenance checklist
4.1 Owner
4.1.1 Standard equipment
Brakes W A B C
1 Test brakes. t
Electrical System W A B C
Test warning and safety devices in accordance with operating
1 t
instructions.
2 Test displays and controls. t
3 Test Emergency Disconnect switch. t
4 Check static charge eliminator is present. t
Power Supply W A B C
Check battery cable connections are secure, grease terminals if
1 t
necessary.
2 Check battery and battery components. t
3 Check acid level and add demineralised water if necessary. t
Check battery connector for damage, test it and make sure it is
4 t
secure.
Travel W A B C
1 Check wheels for wear and damage. t
11.14 EN
489
Chassis and superstructure W A B C
1 Check truck for damage and leaks. t
2 Check doors and/or covers. t
3 Check labels are legible and complete. t
Test driver's seat, backrest and padding in the operator position and
4 t
check for damage.
Test operation and dimensions of the gates, railings and doors and
5 t
check for damage.
Test the gas pressure dampers on the battery panel and check for
6 t
damage.
Check overhead guard and / or cab are secure and check for
7 t
damage.
8 Check mast bracing for damage. t
9 Check mast guard / protective mesh for damage. t
10 Check support mushrooms / tilt safety devices are in place. t
Hydraulic operations W A B C
Test "hydraulic" controls and make sure the labels are present,
1 t
legible and complete.
2 Check load chain lubrication and lubricate if necessary. t
Check lubrication of contact surfaces in the mast sections, clean and
3 t
lubricate if necessary. ATTENTION: RISK OF FALLING!
4 Test hydraulic system. t
Check cylinders, hydraulic ports, lines and hoses for leaks and
5 t
damage.
6 Check hydraulic oil level and top up if necessary. t
7 Check forks or load handler for wear and damage. t
8 Check gear rack lubrication; clean and lubricate if necessary. t
11.14 EN
490
4.1.2 Optional equipment
Work lights
1 Test lighting. t
On-Board Charger
Charger W A B C
1 Check collector contacts for wear. t
Check collector is securely mounted. Check for damage and wear,
2 t
and test operation.
3 Check mains plug and mains cable. t
4 Check the bus bars and feed funnels for damage. t
Aisle recognition
1 Check optical sensors for cleanliness and clean if necessary. t
Heating

1 Test the heating. t
Load sensing
11.14 EN
491
Mast bracing

Personal Protection System (on truck)
System Components W A B C
1 Clean front screens of the PPS laser scanner. t
Rail guidance
Travel W A B C
1 Check rail guide rollers for wear and damage. t
Swivel traverse frame
1 Check attachment lubrication; clean and lubricate if necessary. t
Safety belt

Check the mounting rail for the safety belt at the front of the
1 t
overhead guard is secure and check for damage.
11.14 EN
492
Support columns

1 Check support mushrooms / tilt safety devices are in place. t
Telescopic forks
Telescopic table
Fork positioner
Optional equipment

Check that optional equipment such as mirrors, storage
1 compartments, grips, windscreen wipers and washing systems etc. t
are working correctly and check for damage.
11.14 EN
493
4.2 Customer Service
4.2.1 Standard equipment
Brakes W A B C
1 Test brakes. t
Test the emergency recovery:
2 Vent drive wheel brake and load wheel brakes if applicable with t
setscrews.
3 Check magnetic brake air gap, adjust if necessary. t
Make sure sensors are secured, not damaged, clean and
4 t
operational.
5 Check connections and wiring. t
6 Check brake lining. t
Record stopping distance and adjust if necessary. Draw up brake
7 t
record.
11.14 EN
494
1 Test cable and motor attachments. t
Test warning and safety devices in accordance with operating
2 t
instructions.
3 Test displays and controls. t
Test micro switch and sensor settings, operation, attachment,
4 t
cleanliness and check for damage.
5 Test Emergency Disconnect switch. t
6 Check contactors and/or relays. t
7 Check static charge eliminator is present. t
8 Test safety cutouts on the traction, hydraulic and steering controllers. t
9 Check fuse ratings. t
10 Check control current fuse ratings. t
Check combi controller service seal. If the seal is damaged, check
11 the internal main current fuses for damage and check their ratings. t
Attach a new seal to the controller after the test.
12 Carry out a frame leakage test. t
Check electric wiring for damage (insulation damage, connections).
13 t
Make sure wire connections are secure.
11.14 EN
495
Check battery cable connections are secure, grease terminals if
1 t
necessary.
2 Check battery and battery components. t
Check battery, battery cable and cell connectors for damage,
3 t
contamination and ensure they are secure.
4 Check acid density and battery voltage. t
Check battery connector for damage, test it and make sure it is
5 t
secure.
Travel W A B C
Check transmission oil level or grease filling of the transmission and
1 t
top up if necessary.
Test "travel" controls and make sure the labels are present and
2 t
complete.
3 Test Deadman switch . t
Check vent slots on combi controller for contamination and clean if
4 t
necessary.
5 Checking bedding and attachment of the drive system. t
6 Check drive support plate attachment. t
7 Check transmission for noise and leakage. t
8 Replace transmission oil. t
9 Check wheels for wear and damage. t
10 Check wheel suspension and attachment. t
11.14 EN
496
1 Check truck for damage and leaks. t
2 Check chassis and screw connections for damage. t
3 Check doors and/or covers. t
4 Check battery roller and/or support rubber are present and test them. t
5 Check labels are legible and complete. t
6 Check attachment and setting function of the driver's seat. t
Test driver's seat, backrest and padding in the operator position and
7 t
check for damage.
Test operation and dimensions of the gates, railings and doors and
8 t
check for damage.
Test the gas pressure dampers on the battery panel and check for
9 t
damage.
Check vent slots on drive compartment covers for contamination and
10 t
clean if necessary.
11 Check mast attachment / mounting. t
Check overhead guard and / or cab are secure and check for
12 t
damage.
13 Check operator mat and steps are non-slip and damage-free. t
15 Check mast guard / protective mesh for damage. t
Check support mushrooms / tilt safety devices are in place. Check
16 t
the height and capacity related settings.
11.14 EN
497
Test "hydraulic" controls and make sure the labels are present,
1 t
legible and complete.
2 Test operation and settings of the slack chain switches. t
3 t
operational.
4 Test lifting mechanism, check for wear, damage and test the settings. t
Check cylinders and piston rods for damage and leaks, and make
5 t
sure they are secure.
6 Test safety valve. t
Check settings and wear levels of slide pieces and stops and adjust
7 t
the slide pieces if necessary.
8 Check load chain setting and tension if necessary. t
9 Check load chain lubrication and lubricate if necessary. t
Check lateral clearance of the mast connections and the fork
10 t
carriage.
Visually inspect the mast rollers and check contact surface wear
11 t
level.
Clean contact surfaces in the mast sections and apply grease.
12 t
ATTENTION: RISK OF FALLING!
13 Check cab locking device is present and test it. t
14 Test hydraulic system. t
15 Replace hydraulic oil filter, ventilation/discharge filter. t
Check cylinders, hydraulic ports, lines and hoses for leaks and
16 t
damage.
Check that hydraulic ports, hose and pipe lines are secure, check for
17 t
leaks and damage.
18 Test emergency lowering system. t
19 Check hydraulic oil level and top up if necessary. t
20 Test relief valve and adjust if necessary. t
21 Replace hydraulic oil. t
22 Check forks or load handler for wear and damage. t
23 Check mast tilt. t
Check the rotate and/or traverse hydraulic motor for damage and
24 t
leaks.
Lubricate the chain, rollers, guide rollers and traverse bearings on
25 t
the traverse rotate forks.
26 Clean and lubricate the toothed racks. t
27 Check lift and lower speeds and traverse/rotate speeds if applicable. t
11.14 EN
498
Agreed performance levels W A B C
Carry out a test run with rated load, if necessary with a customer-
1 t
specific load.
2 Lubricate truck according to the lubrication schedule. t
Check motor housing of traction and lift motors for contamination and
3 t
clean if necessary.
4 Demonstration after servicing. t
Steering W A B C
1 Test electric steering and its components. t
2 Test operation and settings of the wheel position indicator. t
Check steering head bearings, steering play and steering toothing or
3 t
steering chain. Lubricate steering toothing or steering chain.
1 Test lift, traction and other customer-specific cutouts. t
11.14 EN
499
4.2.2 Optional equipment
2. Stacking depth
1 Test operation and settings. t
Discharge roller
1 Check anti-static discharge roller is present and not damaged. t
Active stabilisers

Test the operation and setting of the active stabilisers and check for
1 t
damage.
Aquamatik
Test Aquamatik plug, hose connections and float and check for
1 t
leaks.
2 Test flow indicator and check for leaks. t
Work lights
1 Test lighting. t
11.14 EN
500
Battery refill system
1 Test battery refill system and check for leaks. t
Walk-on platform
Check attachment is properly secured to the truck and the
1 t
supporting elements.
Test locking clamp, claw or mechanical lock on the load handler and
2 t
check for damage.
Data recorder
1 Check data recorder is secure and check for damage. t
Data radio
Test scanner and terminal, check for damage and make sure they
1 t
are secure and clean.
2 Check fuse ratings. t
3 Check wiring is secure and check for damage. t
11.14 EN
501
On-Board Charger
Charger W A B C
1 Check collector contacts for wear. t
Check collector is securely mounted. Check for damage and wear,
2 t
and test operation.
3 Check mains plug and mains cable. t
4 Test the immobiliser on trucks with an on-board charger. t
Check the wires and electrical connections are secure and not
5 t
damaged.
Carry out potential measurement on chassis while charging is in
6 t
progress.
Electrical optional equipment
1 Test the electrical optional equipment and check for damage. t
Electrolyte recirculation
1 Replace air filter wadding. t
2 Check hose connections and test the pump. t
11.14 EN
502
Fire extinguisher
Agreed performance levels W A B C

1 Check fire extinguisher is present, secure and Check test interval. t
End of aisle safety device - transponder
1 Test end of aisle safety device and aisle detection functions. t
End of aisle safety device - magnet
Aisle recognition
Test aisle recognition magnetic switch and/or light button, check for
1 t
contamination and damage.
11.14 EN
503
Heating

1 Test the heating. t
2 Replace heating breather. t
Rack height select with automatic stacking operation
Test "empty space check" function on Rack Height Select / automatic
1 t
stacking function and load sensing.
2 Test operation and setting of Rack Height Select. t
Wire guidance
1 Test two-hand operation in narrow aisles. t
Measure wire guidance current and frequency in the guide wire,
1 t
adjust if necessary.
2 Check truck's acquisition of the guide wire when it enters the aisle. t
Check handling on the guide wire, check maximum deviation and
3 t
4 Test wire guidance and distance limits, adjust if necessary. t
5 Test the wire guidance EMERGENCY STOP operation. t
11.14 EN
504
Warehouse Navigation
Test "empty space check" function on Rack Height Select / automatic
1 t
stacking function and load sensing.
Load sensing
1 t
operational.
Mast bracing

Personal Protection System
Test the function of the external personal protection system, e.g.
1 t
cutouts through activation frequency.
11.14 EN
505
Personal Protection System (on truck)
1 Test personal protection system. t
2 Check laser scanner attachment. t
3 Clean front screens of the PPS laser scanner. t
Test warning and protective field areas of the personal protection
4 t
system.
Rail guidance
1 Test two-hand operation in narrow aisles. t
Travel W A B C
Check distance between the guide rollers and the guide rails over
1 t
the entire length of the rails.
2 Check rail guide roller bedding and attachment. t
3 Check rail guide rollers for wear and damage. t
Impact sensor
1 Check impact sensor is secure and check for damage. t
11.14 EN
506
Swivel traverse frame
1 t
leaks and damage.
2 t
Check the eccentric bolt setting on the swivel traverse frame and
3 t
Test operation and setting of the attachment. Check attachment for
4 t
damage.
Check attachment bearing points, guides and stops for wear and
5 t
damage, grease and clean these components.
7 Check hydraulic ports and tighten if necessary. t
8 Check cylinder seals. t
Check piston and piston rod for damage, check setting and adjust if
9 t
necessary.
Lower cutout
Travel W A B C
Check that sensors / switches are secured, not damaged, clean and
1 t
operational.
11.14 EN
507
Safety belt

Check the mounting rail for the safety belt at the front of the
1 t
overhead guard is secure and check for damage.
Support columns

Check support mushrooms / tilt safety devices are in place. Check
1 t
the height and capacity related settings.
Telescopic forks
1 t
2 t
damage.
3 t
7 t
leaks and damage.
Check piston and piston rod for damage, check setting and adjust if
8 t
necessary.
11.14 EN
508
Telescopic table
1 Test drive shaft and its suspension and check for damage. t
2 Check axial play of the front and rear rollers and adjust if necessary. t
3 t
4 t
damage.
5 Check sliding blocks are complete. t
6 t
Test the drive chains, check the settings and check for damage.
9 t
Adjust if necessary.
Check the rotate and/or traverse hydraulic motor for damage and
10 t
leaks.
Video system
1 Check wiring is secure and check for damage. t
2 Test the camera, make sure it is secured and clean. t
3 Test the monitor, make sure it is secured and clean. t
11.14 EN
509
Weigher sensors / switches
1 Test weigher system and check for damage. t
Fork positioner
1 Test the hose reel and check for leaks and damage. t
2 Check axial play of the front and rear rollers and adjust if necessary. t
3 t
4 t
damage.
5 Check sliding blocks are complete. t
6 t
9 Test the fork positioner and check for damage. t
11 Check cylinder piston rods and bushings. t
11.14 EN
510
Access module
1 Test access module, check for damage and make sure it is secure. t
Optional equipment

Check that optional equipment such as mirrors, storage
1 compartments, grips, windscreen wipers and washing systems etc. t
are working correctly and check for damage.
Optional controls
1 Check optional controls are present and plausible. t
Issued on: 09.03.2012 08:52:09

11.14 EN
511
5 Lubricants and Lubrication Schedule
5.1 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.
XKeep consumables away from hot components and naked flames.
XAlways keep consumables in prescribed containers.
XAlways fill consumables in clean containers.
XDo not mix up different grades of consumable. The only exception to this is when
mixing is expressly stipulated in the operating instructions.
CAUTION!
Spilled liquids can cause slipping and endanger the environment
Risk of slipping from spilled liquids. The risk is greater when combined with water.
XDo not spill fluids.
XSpilled fluids must be removed immediately with an appropriate bonding agent.
XThe bonding agent / consumable mixture must be disposed of in accordance with
regulations.
11.14 EN
512
WARNING!
Oils (chain spray / hydraulic oil) are flammable and poisonous.
XDispose of used oils in accordance with regulations. Store used oil safely until it can
be disposed of in accordance with regulations.
XDo not spill oil.
regulations.
XObserve national regulations when handling oils.
XWear safety gloves when handling oils.
XPrevent oil from coming into contact with hot motor parts.
XDo not smoke when handling oil.
XAvoid contact and digestion. If you swallow oil do not induce vomiting but call for a
doctor immediately.
XSeek fresh air after breathing in oil fumes or vapours.
XIf oil has come into contact with your skin, rinse your skin with water.
XIf oil has come into contact with your eyes, rinse them with water and call for a
doctor immediately.
XReplace oil-soaked clothing and shoes immediately.
Consumables and used parts
CAUTION!
11.14 EN
513
5.2 Lubrication Schedule
EKX 410 /
EKS 513 - 515
EKX 513 - 515
D C
C
E
E
C C D
g Contact surfaces c Hydraulic oil drain plug

s Grease nipple b Transmission oil filler neck
Hydraulic oil filler neck a Transmission oil drain plug

11.14 EN
514
5.3 Consumables
Package
Code Order no. Component Application
quantity
51 037 497 5l HLP D22 including – Hydraulic System
2% share of additive 68 EKX 410:
51 037 494 1l ID – Volume approx. 33 l
A
– Hydraulic System
Plantohyd 22 S EKS 5xx / EKX 5xx:
51 085 361* 5l
(BIO hydraulic oil)
– Volume approx. 105 l
– Transmission EKX 410:
51 076 550 20 l Renolin CLP 100
– Volume approx. 2.9 l
B – Transmission EKS 5xx /
British Petroleum (BP)
51 179 177 1l EKX 5xx:
Enersyn EP-XF150
– Volume approx. 6.6 l
400 g – General
14 038 650 (cartridge Lithium KP2K-30 – Toothed racks
C ) grease (DIN 51825) – Mast
29 201 430 1 kg
Chain spray Tunfluid LT – Lift chains
29 201 280 400 ml
220
D Lubricant cartridge incl. – Lift chains
battery set – Automatic chain
51 079 513 120 ml
lubrication system
lubricant cartridge
E 50 002 004 400 ml Contact spray / grease – Running surfaces
51 085 365 500 ml All purpose cleaner – Laser scanner of
F personal protection
51 085 537 1 unit Cleaning cloth system (PPS)
* Add a 2 % content of Additiv 68 ID to the hydraulic oil (order number: 50 307 735)
WARNING!
Industrial trucks are factory-equipped with hydraulic oil "HLP D22" or BIO hydraulic
oil "Plantohyd 22 S + 2% Additiv 68 ID".
You cannot change from BIO hydraulic oil "Plantohyd 22 S" to hydraulic oil "HLP
D22". The same applies to changing from hydraulic oil "HLP D22" to bio hydraulic oil
"Plantohyd 22 S".
Mixed operation with hydraulic oil "HLP D22" and BIO hydraulic oil "Plantohyd 22 S"
is not permitted.
11.14 EN
515
6 Maintenance and repairs
6.1 Preparing the truck for maintenance and repairs
EKX 410 EKS 513 -515 / EKX 513 - 515
13
13
18
18
5
5
39
39
All necessary safety measures must be taken to avoid accidents when carrying out
maintenance and repairs. The following preparations must be made:
11.14 EN
516
Procedure
• Fully lower the main and auxiliary lift.
• Park the truck securely, (see "Parking the truck securely" on page 239).
• Disconnect the battery connector (39) to prevent the truck from being switched on
accidentally.
• When working under a raised lift truck, secure it to prevent it from lowering, tipping
or sliding away.
WARNING!
Risk of accidents when working under the load handler, driver's cab and lift
truck
XWhen working under a raised load handler, driver's cab or a raised truck, secure
them to prevent the truck from from lowering, tipping or sliding away.
XWhen raising the truck, follow the instructions, (see "Transport and
Commissioning" on page 71). When working on the parking brake, prevent the
truck from accidentally rolling away (e.g. with wedges).
11.14 EN
517
6.2 Drive compartment cover disassembly/assembly
6.2.1 EKX 410 - Drive compartment cover disassembly/assembly
Drive compartment cover disassembly

Requirements
– Prepare the truck for maintenance and
repairs ((see "Preparing the truck for
maintenance and repairs" on page 516)). 385
– Slotted screwdriver.
Procedure
• Open the battery cover (5). 38
• Remove the two slotted screws (385)
using the slotted screwdriver.
• Tilt the cover (38) back and lift it up.
5
11.14 EN
518
Drive compartment cover assembly
Procedure 385
CAUTION!
Trapping hazard
There is a risk of trapping when you fit the
drive compartment cover.
XMake sure there is nothing between the 38
battery cover and the truck when you fit
the battery cover.
• Insert the cover (38) vertically into the 5

chassis and tilt it forward.
CAUTION!
• Attach the cover (38) to the truck with the slotted screws (385). Tighten the slotted
screws (385) using the slotted screwdriver.
• To restore the industrial truck to service after cleaning or maintenance work, (see
"Restoring the truck to service after maintenance and repairs" on page 546).
11.14 EN
519
6.2.2 EKS 513 - 515 / EKX 513 - 515 - Drive compartment cover disassembly/
assembly
Drive compartment cover disassembly

Requirements
– Prepare the truck for maintenance and 385
repairs ((see "Preparing the truck for
38
Procedure
• Remove the Allen key (224) from the
bracket below the strobe light (37).
• Remove the two Allen screws (385) using
the Allen key (224).
• Tilt the cover (38) back and lift it up.
224 37
11.14 EN
520
Drive compartment cover assembly
– Allen key (supplied with the truck). 385
Procedure
CAUTION!
Trapping hazard
There is a risk of trapping when you fit the 38
drive compartment cover.
XMake sure there is nothing between the
battery cover and the truck when you fit
the battery cover.
• Insert the cover (38) vertically into the

chassis and tilt it forward.
CAUTION!
Open covers can cause injury and
accidents 224 37
• Attach the cover (38) to the truck with the Allen screws (385). Tighten the Allen
screws (385) using the Allen key (224).
• Place the Allen key (224) in the bracket below the strobe light (37).
11.14 EN
521
6.3 Checking electrical fuses
386
387
388 A
1 2 3 4 5 6 7 8 9
389
390
391
392
393
394
WARNING!
Only suitably trained electricians may operate on the truck's electrical system.
WARNING!

electrical system:
CAUTION!
The use of incorrect fuses can cause fire and damage components
The use of incorrect fuses can damage the electrical system and result in fire. The
safety and functionality of the truck cannot be ensured.
XUse only fuses with the prescribed rated current, (see "Fuse ratings" on page 524).
Checking and where necessary replacing electric fuses
Requirements
– Prepare the truck for maintenance and repairs ((see "Preparing the truck for
11.14 EN
522
– Disassemble the drive compartment cover, (see "Drive compartment cover
Procedure
• Check all fuses (386-392) in accordance with the "fuse rating" table below and
replace as required.
• Using the slotted screwdriver turn each fuse (386-392) anticlockwise out of the
controller (393).
• Pull the fuses (386-392) and their brackets out of the controller (393).
• Check the fuses (386-392) in accordance with the following table and replace as
required.
• Insert the fuses (386-392) and their brackets into the controller (393).
• Using the slotted screwdriver turn each fuse (386-392) clockwise into the
controller (393).
• Assemble the drive compartment cover, (see "Drive compartment cover
11.14 EN
523
6.3.1 Fuse ratings
386
387
388 1 2 3 4 5 6 7 8 9
A
B
389
390
391
392
393
394
11.14 EN
524
Item Description Electric circuit Rating
386 6F6 ISM data recorder control fuse (o) 10 A
Options fuse (personal safety system
387 7F7 scanner, barcode scanner, radio terminal 10 A
etc.)
388 F1.2 Control panel and horn control fuse 10 A
Overhead guard control fuse (e.g. work
389 5F1 10 A
lights, operator position lighting, fan etc.)
390 F2.1 Internal DC/DC converter control fuse 10 A
391 7F3 DC/DC converter control fuse 10 A
Threephase controller control fuse (AC-3
392 1F3 10 A
Power Control U8)
393 Threephase control (AC-3 Power Control U8)
394 Controller display
11.14 EN
525
6.3.2 Controller display
Display status when truck is switched off
When the truck is switched off the displays indicated grey (A3, A4, A5, B4) are lit
green. If one of these displays is not lit, replace the corresponding fuse.
1 2 3 4 5 6 7 8 9
A
B
1 2 3 4 5 6 7 8 9
Key
Controlle
A 1F3 switch F1.2 7F7 6F6 VBatt VBatt VBatt
r active
on
Load
B Not used 5F1 F2.1 7F3 Controller active
circuit
Display status when truck is switched on
When the truck is switched on the displays indicated grey are lit green. If one of the
displays (A1, A3, A4, A5, B2, B3, B4) is not lit, replace the corresponding fuse. The
other displays reflect truck-specific operating conditions. The "controller on" displays
(A9, B6-B9) flash when the truck is ready for operation.
1 2 3 4 5 6 7 8 9
A
B
1 2 3 4 5 6 7 8 9
Key
Controlle
A 1F3 switch F1.2 7F7 6F6 VBatt VBatt VBatt
r active
on
Load
B Not used 5F1 F2.1 7F3 Controller active
circuit
11.14 EN
526
6.4 Preventing the driver's cab from accidentally lowering
DANGER!
Risk of accidents when working under an unsecured driver's cab
When carrying out maintenance and repair work under the driver's cab or load
handler, the raised cab must be protected against accidental lowering. The cab must
not be secured with a load on the load handler, to prevent people below the cab from
being injured by falling loads. Do not perform any work underneath the driver's cab
without a cab locking device in place.
XDo not secure the cab with a load on the load handler.
XSecure the driver's cab for maintenance and repairs below the cab or load handler.
11.14 EN
527
240
12
B D
240 A E 13
396 C 395
395 18
397
396
20
398 398
23 23
21
397 399 26
Preventing the driver's cab from accidentally lowering
Requirements
– Park the industrial truck on a level surface, (see "Parking the truck securely" on
page 239).
– Fully lower the main and auxiliary lift, (see "Lifting / lowering – outside and inside

– Safety ladder (at least 3,0 m long)
Procedure
• Position the safety ladder against the truck so that the raised driver's cab (approx.
2,0 m high) can be exited safely above the safety ladder.
• Enter the operator position, (see "Entry and exit" on page 160).
• Raise the driver's cab (21) above the first or second mast cross-member (240).
Z The first mast cross-member (240) is located approx. 0,45 m and the second (240)
approx. 1,8 m above the ground. Any number of attachment heights are possible
between the DZ and ZT masts.
• Remove the twist grip screws (111) from the left and right
sides behind the driver's seat (23).
• Undo the lever (398) by turning it anti-clockwise.
• Raise the pin retainer (396) and flip it over to the left out of
the first groove (399) (see arrow directions A and B).
23
• Push the fastening pin (395) through as far as the second
groove (397) in the drive direction (see arrow direction C). 111
• Engage the pin retainer (396) in the second groove (397)
(see arrow directions D and E).
• Prevent the pin retainer (396) from moving:
11.14 EN
• Turn the lever (398) anti-clockwise to tighten it.
528
CAUTION!
screws (111).
• Slowly lower the driver's cab (21) until the fastening pin (395) is resting on the mast
cross-member (240).
• Turn the hydraulic control lever (12) slowly clockwise.
• Open the gate (20).
CAUTION!
Risk of falling when vacating the driver's cab
Move carefully and slowly from the driver's cab to the safety ladder. The stability of
the safety ladder must be ensured at all times.
XUse only sufficiently long step ladders (at least 3,0 m).
• Carefully leave the driver's cab (21) with the safety ladder.
• Open the battery cover, (see "Exposing the battery" on page 102).
• Disconnect the battery to prevent the truck from being switched on accidentally.
The driver's cab (21) is now protected against accidental lowering. Maintenance and
repair work can now be started below the driver's cab or load handler.
11.14 EN
529
240
12
B D
240 A E 13
396 C 395
395 18
397
396
20
398 398
23 23
21
397 399 26
Removing the cab locking device

– Safety ladder (at least 3,0 m long)
Procedure
• Position the safety ladder next to the truck so that the driver's cab at a height of
approx. 2,0 m can be safely reached.
• Re-connect the battery.
CAUTION!
the battery cover.
• Close the battery cover, (see "Exposing the battery" on page 102).
CAUTION!
Risk of falling when entering the driver's cab
Move carefully and slowly from the safety ladder to the driver's cab. The stability of
the safety ladder must be ensured at all times.
XUse only sufficiently long step ladders (at least 3,0 m).
• Step into the driver's cab (21) safely via the safety ladder.
11.14 EN
530
• Raise the driver's cab (21) so that the fastening pin (395) is no longer resting on the
mast cross member (240).
• Remove the twist grip screws (111) from the left and right
sides behind the driver's seat (23).
• Undo the lever (398) by turning it anti-clockwise.
• Raise the pin retainer (396) and flip it over to the left out of
the second groove (397) (see arrow directions E and D).
23
• Pull the fastening pin (395) back to the first groove (399)
(see arrow direction C). 111
• Engage the pin retainer (396) in the first groove (399) (see
arrow directions B and A).
• Prevent the pin retainer (396) from moving:
• Turn the lever (398) anti-clockwise to tighten it.
CAUTION!
screws (111).
• Fully lower the driver's cab (21):
The truck is now operational again.
11.14 EN
531
6.5 Lift chain servicing
WARNING!
Non-lubricated and incorrectly cleaned lift chains can cause accidents
Lift chains are safety-critical parts. They must not contain any serious contamination.
Lift chains and pivot pins must always be clean and well lubricated.
XLift chains should only be cleaned with paraffin derivatives e.g. petroleum or diesel
fuels.
XNever clean lifting chains with steam jet high pressure cleaners or chemical
cleaning agents.
XImmediately after cleaning, dry the lift chain with compressed air and apply a chain
spray.
XAlways lubricate a chain when it is discharged.
XLubricate a lift chain with particular care around the pulleys.
WARNING!
Solvents (e.g. paraffin derivatives) can be hazardous
XSolvents can cause irritation if they come into contact with the skin. Rinse any
affected areas thoroughly.
XIf they come into contact with the eyes rinse them immediately with flowing water
and call for a doctor.
XWear personal protective equipment (e.g. safety boots, hi-vis jacket, goggles, work
gloves etc.) when working with solvents.
Z The intervals stated in the service checklist apply to normal duty use. More
demanding conditions (dust, temperature) require more regular lubrication of the lift
chains. The prescribed chain spray must be used in accordance with the
instructions. Applying grease externally will not provide sufficient lubrication of the
lift chains.
6.6 Lubricate the lift chains, clean and grease the contact surfaces in
the mast sections
WARNING!
Accident risk during maintenance work on elevated maintenance points

There is danger of falling and trapping when performing maintenance work on
elevated maintenance points (for example lubricating the mast).
XWear personal protective equipment.
XUse a working platform, lifting stage or safety ladder.
XDo not use leaning ladders.
XDo not stand under the driver's cab and / or load handler.
Requirements
– Industrial truck parked on a level surface.
– Arrange for a second person to operate the industrial truck.
11.14 EN
– Wear personal protective equipment.
532
– Working platform, lifting stage or safety ladder
Procedure
WARNING!
Accident risk
Be aware of the ceiling height when raising the load handler and / or driver's cab
• Arrange for the second person to raise the load handler and / or driver's cab.
• Switch off the truck.
• Disconnect the battery.
WARNING!
Risk of accidents when working underneath an unsecured load handler /
driver's cab
Do not place the working platform, lifting platform or safety ladder underneath an
unsecured load handler and / or driver's cab.
• Position the working platform, lifting stage or safety ladder directly next to the
industrial truck.
• From your position on the working platform, lifting stage or safety ladder:
• Lubricate lift chains. Lubricant (see "Consumables" on page 515).
• Clean and grease contact surfaces in the mast sections, (see "Consumables" on
page 515).
Z Lubricant (see "Consumables" on page 515).
• Remove the working platform, lifting stage or safety ladder.
• Connect the battery to the truck.
• Switch on the truck.
• Arrange for the load handler and / or driver's cab to be lowered completely by the
second person.
11.14 EN
533
6.7 Automatic Chain Lubrication (o)
6.7.1 Automatic chain lubrication
The truck can be optionally equipped with an 400

automatic chain lubrication system to lubricate the lift
chains.
401
The lubrication unit (400) used in automatic chain
lubrication consists of a drive unit (401) and a
402
lubrication cartridge (402).
The lubrication unit (400) lubricates the lift chains over
a set period of either one, three, six or twelve months. This period can be adjusted
via the drive unit (401), (see "Setting the lubrication period" on page 538).
After the set lubrication period the lubrication cartridge (402) must be replaced, (see
"lubrication cartidge replacement" on page 536).
11.14 EN
534
6.7.2 Automatic chain lubrication system arrangement
Z The number of lubrication units (400) used depends on the mast.
400
Number and arrangement of lubrication units (400) on the telescopic mast (ZT mast):
– Two lubrication units are fitted on the right and left sides of the top mast cross
member.
Number and arrangement of lubrication units (400) on the two stage-triplex mast (DZ
mast):
– Two lubrication units are fitted on the right and left sides of the top mast cross
member. A lubrication unit is fitted on the left and right free lift cylinders
respectively.
11.14 EN
535
6.7.3 lubrication cartidge replacement
WARNING!
Risk of falling during maintenance work on elevated maintenance points
There is risk that service personnel could fall when replacing the lubrication cartidge
on elevated maintenance points (for example the top mast cross member). The same
applies to adjusting the lubrication period on the drive unit.
XWear personal protective equipment.
XUse a working platform, lifting stage or safety ladder.
XDo not use leaning ladders.
401
400 402
403
Requirements

– Working platform, lifting stage or safety ladder
Procedure
• Wear personal protective equipment.
• Position the work platform, lifting platform or safety ladder directly next to the truck
so that the lubrication unit (400) can be reached safely.
• Turn the rotary switch of the lubrication unit (400) from OFF to ON.
• From your position on the working platform, lifting stage or safety ladder, unscrew
the lubrication unit (400) from its bracket.
• Unscrew the drive unit (401) from the lubrication cartridge (402).
• Insert the new battery pack in the drive unit (401).
Z When replacing the lubrication cartridge (402) a new battery pack must be inserted
in the drive unit (401) to ensure sufficient power supply during operation.
11.14 EN
• Screw the drive unit (401) and the new lubrication cartridge (402) together.
536
• Set the lubrication period, (see "Setting the lubrication period" on page 538).
• Remove the drain plug (403) from the lubrication cartridge (402).
• Screw the lubrication unit (400) into its corresponding bracket.
• Turn the rotary switch of the lubrication unit (400) from OFF to ON.
Z A steady red light for 25 seconds indicates that the automatic chain lubrication is
working correctly, (see "Luminous display on the drive unit" on page 539).
• Remove the working platform, lifting stage or safety ladder.
• Connect the battery to the truck.
The lubrication cartridge has now been replaced. The lift chains have been lubricated
by the automatic chain lubrication.
11.14 EN
537
6.7.4 Setting the lubrication period
The lubrication intervals can be set via the two

switches on the drive unit (401). 400
401
402
Switch setting Lubrication Interval
1 month
3 months
6 months
12 months
After setting the lubrication period the decals supplied must be attached to the
lubrication unit (400) as detailed below:
– Attach the set lubrication period to the drive unit (401).
– Attach the installation date to the lubrication cartridge (402).
11.14 EN
538
6.7.5 Luminous display on the drive unit
Display Function Duration

– Initial run after replacing the
Red permanent signal lubrication cartridge or the 25 secs
battery pack
– The lubrication unit is
Green flashing signal operational 15 secs
– No fault
Red flashing signal – Error / fault 8 secs
– Lubrication cartidge is empty
– To replace the lubrication
Green / red flashing signal cartridge, ((see "lubrication 3 secs
cartidge replacement" on
page 536))
Red signal – Lift chain lubrication process 1 - 5 sec.
11.14 EN
539
6.8 Lift chain inspection
Unauthorised wear and external damage:
NOTE
In accordance with official regulations, a chain is considered to be worn if it has
extended in length by 3 % in the section which passes over the deflection pulley. For
safety reasons, Jungheinrich advises replacing chains when they elongate by 2%.
Replace a chain immediately if it shows external signs of damage. This type of
damage will result in permanent breakage.
WARNING!
Accident risk from damaged lift chains
Replace a chain immediately if it shows external signs of damage. Damage will result
in permanent breakage and hence tearing of the lift chain.
XLift chains must only be replaced by the manufacturer's customer service
department which has been specially trained.
WARNING!
If the truck is fitted with two lift chains, both chains must always be replaced. This is
the only way to ensure even load distribution over the two chains.
XWhen replacing chains the connecting bolts between the chain anchor and the
chain must be replaced.
XAlways use new original parts.
XLift chains must only be replaced by the manufacturer's customer service
department which has been specially trained.

operations.
6.9 Hydraulic hoses

operations.
11.14 EN
540
WARNING!
Leaky hydraulic systems can result in accidents
Hydraulic oil can escape from leaky and faulty hydraulic systems.
XMark defective truck and take out of service.
fault.
XRemove any spilled hydraulic immediately with an appropriate bonding agent.
regulations.
WARNING!
Faulty hydraulic hoses can result in injury and infection
Pressurised hydraulic oil can escape from fine holes or hairline cracks in the hydraulic
hoses. Brittle hydraulic hoses can burst during operation. People standing near the
truck can be injured by the hydraulic oil.
XCall for a doctor immediately in the event of an injury.
XDo not touch pressurised hydraulic hoses.
XMark defective truck and take it out of service.
fault.
NOTE
Testing and replacing hydraulic hoses
Hydraulic hoses can become brittle through age and must be checked at regular
intervals. The application conditions of the industrial truck have a considerable impact
on the ageing of the hydraulic hoses.
XCheck the hydraulic hoses at least annually and replace if necessary.
XIf the operating conditions become more arduous the inspection intervals must be
reduced accordingly.
XIn normal operating conditions a precautionary replacement of the hydraulic hoses
is recommended after 6. The owner must carry out a risk assessment to ensure
safe, prolonged use. The resulting protection measures must be observed and the
inspection interval reduced accordingly.
11.14 EN
541
6.10 Checking the hydraulic oil level
CAUTION!
The hydraulic oil is pressurised during operation and is a hazard to health and to the
environment.
XDo not touch pressurised hydraulic lines.
XDispose of used oil in accordance with regulations. Store used oil safely until it can
be disposed of in accordance with regulations.
XDo not spill hydraulic oil.
regulations.
XObserve national regulations when handling hydraulic oil.
XWear safety gloves when handling hydraulic oil.
XPrevent hydraulic oil from coming into contact with hot motor parts.
XDo not smoke when handling hydraulic oil.
XAvoid contact and digestion. If you swallow oil do not induce vomiting but call for a
doctor immediately.
XSeek fresh air after breathing in oil fumes or vapours.
XIf oil has come into contact with your skin, rinse your skin with water.
XIf oil has come into contact with your eyes, rinse them with water and call for a
doctor immediately.
XReplace oil-soaked clothing and shoes immediately.
11.14 EN
542
WARNING!
Leaky hydraulic systems can result in accidents
Hydraulic oil can escape from leaky and faulty hydraulic systems.
XMark defective truck and take out of service.
fault.
regulations.
CAUTION!
11.14 EN
543
404
405
406
Checking the hydraulic oil level and replenishing if necessary

Requirements
– Fully lower the main and auxiliary lift.
– Disassemble the drive compartment cover, (see "Drive compartment cover
Procedure
• Unscrew the breather (404) and dipstick (405) clockwise out of the hydraulic
reservoir (406).
• The hydraulic oil level should be between the "MIN" and "MAX" marks on the
dipstick (405).
WARNING!
Overfilling the hydraulic reservoir can result in accidents and damage the
environment
The hydraulic oil should not be above the "MAX" marking on the dipstick, as any
escaping oil can damage the environment and cause truck malfunctions. The
escaping hydraulic oil could run under the drive wheel for example and extend the
truck's stopping distance, as well as affect its handling.
XAdd hydraulic oil only as far as the "Max" marking on the dipstick.
XThe bonding agent / hydraulic oil mixture must be disposed of in accordance with
regulations.
11.14 EN
544
• If the hydraulic oil level is below the "MIN" mark on the dipstick (405), add new
hydraulic oil in accordance with the consumables table to reach the upper "MAX"
mark on the dipstick (405).
Z The hydraulic oil volume between the "MIN" and "MAX" marks on the dipstick (405)
is approx. EKX 410 = 2,85 l / EKS 5xx = 3,75 l / EKX 5xx = 3,75 l.
• Trucks with bio hydraulic oil have a warning notice on the hydraulic
reservoir: “Add bio hydraulic oil only”. In this case you may only use
"Plantohyd 22 S" bio hydraulic oil to replenish the hydraulic
reservoir.
• Trucks with normal hydraulic oil have a warning notice on the
hydraulic reservoir: “Add hydraulic oil”. In this case you may only use
hydraulic oil "HLP D22 including 2% share of Additiv 68 ID" to fill the
hydraulic reservoir.
WARNING!
You cannot change from BIO hydraulic oil "Plantohyd 22 S" to hydraulic oil "HLP
D22". The same applies to changing from hydraulic oil "HLP D22" to bio hydraulic oil
"Plantohyd 22 S".
Mixed operation with hydraulic oil "HLP D22" and BIO hydraulic oil "Plantohyd 22 S"
is not permitted.
• Check the hydraulic oil level again and top up if necessary.

When you have reached the upper "MAX" marking on the dipstick (405) the
hydraulic reservoir (406) is completely full.
• Screw the breather (404) and dipstick (405) anticlockwise into the hydraulic
reservoir (406).
• Assemble the drive compartment cover, (see "Drive compartment cover
11.14 EN
545
6.11 Restoring the truck to service after maintenance and repairs
The truck can only be restored to service after cleaning or maintenance after the
following procedures have been carried out:
EKX 410 EKS 513 -515 / EKX 513 - 515
13
13
18
18
5
5
39
39
Procedure
• Thoroughly clean the truck.
• Re-connect the battery (39).
WARNING!
After cleaning or maintenance work test all the safety mechanisms to ensure they are
working correctly.
• Test the safety mechanisms:

• Press the Emergency Disconnect switch (13) to test Emergency
Disconnect (13). The main circuit is disconnected and no truck operations can
be performed. Now turn the Emergency Disconnect switch (13) to unlock it.
• Test the controls and displays.
• Test the horn by pressing the "horn" button.
• Test the deadman switch.
• Test the steering.
• Test the gates.
11.14 EN
546
• Check the front screens of the personal protection system laser scanner for dirt
(o) and clean as required, (see "Cleaning the laser scanner front screen" on
page 324).
WARNING!
Faulty brakes can cause accidents
As soon as the truck has been started, test the brakes several times.
• Test the service and parking brakes.

• Lubricate the industrial truck in accordance with the lubrication schedule, (see
"Lubrication Schedule" on page 514).
Z If there are switching problems in the electrical system, apply contact spray to the
exposed contacts and remove any oxide layers on the contacts of the controls by
applying them repeatedly.
WARNING!
Accident risk due to electrical current when working with contact spray
electrical system:
11.14 EN
547
7 Decommissioning the industrial truck
Z If the truck is to be out of service for more than a month, e.g. for commercial
reasons, it must be stored in a frost-free and dry room. All necessary measures
must be taken before, during and after decommissioning as described hereafter.
WARNING!
Lifting and jacking up the truck safely
In order to raise the truck, the lifting gear must only be secured to the points specially
provided for this purpose.
You may only work under a raised load handler / raised cab if they have been secured
with a sufficiently strong chain or the fastening bolt.
In order to raise and jack up the truck safely, proceed as follows:
XJack up the truck only on a level surface and prevent it from moving accidentally.
XOnly use a jack with sufficient capacity. When jacking up the truck, take appropriate
measures to prevent it from slipping or tipping over (e.g. wedges, wooden blocks).
XIn order to raise the truck, the lifting gear must only be secured to the points
specially provided for this purpose. (see "Identification points and data plates" on
page 64).
XWhen jacking up the truck, take appropriate measures to prevent it from slipping or
tipping over (e.g. wedges, wooden blocks).
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.
If the truck is to be out of service for more than 6 months, agree further measures with
the manufacturer's customer service department.
11.14 EN
548
7.1 Prior to decommissioning
Procedure
WARNING!
• Test the brakes.

• Check the hydraulic oil level and replenish if necessary, (see "Checking the
hydraulic oil level" on page 542).
• Apply a thin layer of oil or grease to any non-painted mechanical components.
• Lubricate the truck according to the lubrication schedule, (see "Lubrication
Schedule" on page 514).
• Charge the battery, (see "Charging the battery" on page 104).
• Disconnect the battery, clean it and grease the terminals.
Z In addition, follow the battery manufacturer’s instructions.
• Spay all exposed electrical contacts with a suitable contact spray.
11.14 EN
549
7.2 During decommissioning
NOTE
11.14 EN
550
7.3 Restoring the truck to service after decommissioning
Procedure
• Lubricate the truck according to the lubrication schedule, (see "Lubrication
Schedule" on page 514).
• Clean the battery, grease the terminals and connect the battery.
• Charge the battery, (see "Charging the battery" on page 104).
• Check the transmission oil for condensation water and replace if necessary.
• Check the hydraulic oil for condensation water and replace if necessary.
these operations.
WARNING!
• Start up the truck, (see "Preparing the Truck for Operation" on page 155).
Z If there are switching problems in the electrical system, apply contact spray to the
exposed contacts and remove any oxide layers on the contacts of the controls by
applying them repeatedly.
WARNING!
Accident risk due to electrical current when working with contact spray
electrical system:
11.14 EN
551
8 Safety tests to be performed at intervals and after unusual
incidents
Z Perform a safety check in accordance with national regulations. Jungheinrich
recommends the truck be checked to FEM guideline 4.004. The Jungheinrich
safety department has trained personnel who are able to carry out inspections.
The truck must be inspected at least annually or after any unusual event by a qualified
inspector (be sure to comply with national regulations). The inspector shall assess the
condition of the truck from purely a safety viewpoint, without regard to operational or
economic circumstances. The inspector shall be sufficiently instructed and
experienced to be able to assess the condition of the truck and the effectiveness of
the safety mechanisms based on the technical regulations and principles governing
the inspection of forklift trucks.
A thorough test of the truck must be undertaken with regard to its technical condition
from a safety aspect. The truck must also be examined for damage caused by
possible improper use. A test report shall be provided. The test results must be kept
for at least the next 2 inspections.
The owner is responsible for ensuring that faults are rectified immediately.
Z A test plate is attached to the truck as proof that it has passed the safety inspection.
This plate indicates the due date for the next inspection.
11.14 EN
552
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, fuels 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. Note the manufacturer’s safety
instructions as specified in the service documentation.
10 Human vibration measurement

Z Vibrations that affect the driver during operation over the course of the day are
known as human vibrations. Excessive human vibrations will cause the driver long
term health problems. The European "2002/44/EC/Vibration" operator directive has
therefore been established to protect drivers.
To help operators to assess the application situation, the manufacturer offers a
service of measuring these human vibrations.
11.14 EN
553
A Traction Battery Appendix
Contents
A Traction Battery Appendix....................................................... 1

1 Correct Use and Application.................................................................... 2
2 Data plate ................................................................................................ 2
3 Safety Instructions, Warning Indications and other Notes ....................... 3
4 Lead acid batteries with armour plated cells and liquid electrolyte.......... 4
4.1 Description............................................................................................... 4
4.2 Operation................................................................................................. 5
4.3 Servicing lead-acid batteries with armour plated cells............................. 8
5 PzV and PzV-BS lead-acid batteries with sealed armour plated cells..... 9
5.1 Description............................................................................................... 9
5.2 Operation................................................................................................. 10
5.3 Servicing PzV and PzV-BS lead-acid batteries with sealed armour plated
cells ......................................................................................................... 13
6 Aquamatik water replenishment system.................................................. 14
6.1 Water replenishment system design ....................................................... 14
6.3 Adding water............................................................................................ 15
6.4 Water pressure ........................................................................................ 15
6.5 Filling time ............................................................................................... 16
6.6 Water quality............................................................................................ 16
6.7 Battery tubing .......................................................................................... 16
6.8 Operating temperature ............................................................................ 16
6.9 Cleaning measures.................................................................................. 17
6.10 Service mobile vehicle............................................................................. 17
7 Electrolyte circulation............................................................................... 18
8 Cleaning batteries.................................................................................... 20
9 Storing the battery ................................................................................... 22
10 Troubleshooting....................................................................................... 22
11 Disposal................................................................................................... 22
03.13 EN
1
1 Correct Use and Application
Failure to observe the operating instructions, carrying out repairs with non-original
spare parts, tampering with the battery or using electrolyte additives will invalidate the
warranty.
Observe the instructions for maintaining the safety rating during operation for
batteries in accordance with Ex I and Ex II (see relevant certification).
2 Data plate
1,2 3
4 5
6 7
8 9
10 15
11
13
12
14
1 Battery name
2 Battery type
3 Production week/year manf.
4 Serial number
5 Supplier number
6 Rated voltage
7 Rated capacity
9 Battery weight in kg
8 Number of cells
15 Electrolyte volume in litres
10 Battery number
11 Manufacturer
13 Manufacturer's logo
12 CE mark only for batteries beyond 75 volts
14 Safety instructions and warning information
03.13 EN
2
3 Safety Instructions, Warning Indications and other Notes
Used batteries must be treated as hazardous waste.

These batteries are marked with the recycling symbol and the sign
showing a crossed-out rubbish bin, and should not be disposed of
with ordinary household waste.
waste.
Buy-back terms and type of recycling are to be agreed with the

manufacturer as described in § 8 of the battery legislation.
Do not smoke!
No naked flames, glowing embers or sparks near the battery - fire
and explosion hazard!
Avoid fire and explosion hazards and short circuits due to

overheating!
Keep away from naked flames and strong heat sources.
Always wear protective clothing (e.g. safety goggles and safety

gloves) when working on cells and batteries.
batteries.
Always wash your hands after completing the work. Use insulated
tools only. Do not physically
alter the battery, strike, crush, compress, notch, dent or modify it in
any way.
Hazardous electric voltage! The metal parts of the battery cells are
permanently live. Therefore do not place any foreign objects or tools
on the battery.
Observe national health and safety regulations.
If the materials leak, do not inhale the fumes. Wear safety gloves.
Follow the user instructions and keep them in a visible position in the
charging area.
Work on the batteries should be performed only as instructed by
specialist personnel.
03.13 EN
3
4 Lead acid batteries with armour plated cells and liquid
electrolyte
4.1 Description
Jungheinrich traction batteries are lead acid batteries with armour plated cells and
liquid electrolyte. The names of the traction batteries are PzS, PzB, PzS Lib and PzM.
Electrolyte
The rated density of the electrolyte assumes a temperature of 30°C and the rated
electrolyte level is fully charged. Higher temperatures will reduce, lower temperatures
will increase the electrolyte density. The adjustment factor is ± 0.0007 kg/l per K, e.g.
electrolyte density 1.28 kg/l at 45°C corresponds to a density of 1.29 kg/l at 30°C.
The electrolyte must conform to DIN 43530 Part 2 purity regulations.
4.1.1 Battery nominal data
1. Product Traction battery

2. Nominal voltage 2.0 V x no. of cells
3. Rated capacity C5 See data plate
4. Discharge current C5/5h
5. Nominal electrolyte density1 1.29 kg/l
2
6. Nominal temperature 30 °C
7. System rated electrolyte level up to "Max" electrolyte level marking
Limit temperature3 55°C
1. Reached within the first 10 cycles.
2. Higher temperatures shorten the useful life, lower temperatures reduce
the available capacity.
3. Not permissible as operating temperature.
03.13 EN
4
4.2 Operation
4.2.1 Commissioning unfilled batteries

Z The operations required must be carried out by the manufacturer's customer
service department or a customer service organisation authorised by the
manufacturer.
4.2.2 Commissioning filled and charged batteries

Checks and operations to be performed before starting daily work
Procedure
• Make sure the battery is in physically good condition.
• Make sure the terminals are correct (positive to positive and negative to negative)
and check that contacts on the battery terminal conducting system are secure.
• Check the terminal screw torques (M10 = 23 ±1 Nm) of the terminal conductors and
connectors.
• Charge up the battery.
• Check the electrolyte level.
Z The electrolyte level must be above the cell baffle or the top of the separator.
• Add electrolyte with distilled water up to the nominal level.
Checks completed.
4.2.3 Discharging the battery

Z To achieve an optimum useful life avoid operational discharge of more than 80% of
nominal capacity (full discharge). This corresponds to a minimum electrolyte
density of 1.13 kg/l at the end of the discharge. Recharge a discharged battery
immediately.
03.13 EN
5
4.2.4 Charging the battery
WARNING!
The battery gives off a mixture of oxygen and hydrogen (electrolytic gas) during
XAlways disconnect the charger and truck before connecting or disconnecting the
charger and battery.
XThe charger must be adapted to the battery in terms of voltage, charge capacity
and battery technology.
XBattery cell surfaces must remain exposed during charging in order to ensure
sufficient ventilation, see truck operating instructions, chapter D, Charging the
Battery.
XWherever an industrial truck is parked for charging there must be no inflammable
material or consumables capable of creating sparks within a minimum distance of
2 m from the truck.
XFire protection equipment must be available.
XDo not place any metallic objects on the battery.
XAlways follow the safety regulations of the battery and charger station
manufacturers.
NOTE
The battery must only be charged with DC current. All charging processes in
accordance with DIN 41773 and DIN 41774 are permissible.
03.13 EN
6
Z The electrolyte temperature rises by approx. 10 K during charging. Charging should
therefore only begin when the electrolyte temperature is below 45°C. The
electrolyte temperature of batteries must be at least +10°C before charging.
Otherwise the battery will not charge correctly. Below 10°C the battery is
insufficiently charged with standard charging systems.
Charging the battery

Requirements
– Electrolyte temperature min. 10°C to max. 45°C
Procedure
• Open or take off the tray lid or covers from the battery compartment.
Z Deviations are outlined in the truck's operating instructions. The plugs remain on
the cells or remain closed.
• Connect the battery to the switched off charger, ensuring the terminals are connect
(positive to positive and negative to negative).
Battery charged
Z Charging is considered to be complete when the electrolyte density and battery
voltage remain constant for more than 2 hours.
Compensation charging
Compensation charging is used to ensure the useful life and maintain capacity after
full discharge and repeated insufficient charging. The maximum compensation
charge current is 5 A/100 Ah rated capacity.
Z Compensation charging should be carried out weekly.
Trickle charging
Battery trickle charging is partial charging that extends the daily application time.
Higher average temperatures occur during trickle charging which reduce the useful
life of the batteries.
Z Trickle charges should only be performed when the charge level is below 60 %. Use
replacement batteries instead of regular trickle charging.
03.13 EN
7
4.3 Servicing lead-acid batteries with armour plated cells
Water quality
Z The quality of the water used to fill up electrolyte must correspond to purified or
distilled water. Purified water can be produced through distillation or ion
exchangers and is then suitable for the production of electrolyte.
4.3.1 Daily
– Charge the battery after each discharge.
– After charging, check the electrolyte level.
– If necessary, add purified water up to the rated level after charging.
Z The height of the electrolyte level should not be below the cell baffle or above the
top of the separator, or the "Min" and "Max" electrolyte markings respectively.
4.3.2 Weekly
– After re-charging, carry out a visual inspection for dirt and physical damage.
– If the battery is charged regularly according to the IU characteristic, carry out a
compensation charge.
4.3.3 Monthly
– Towards the end of the charging process measure and record the voltages of all
the cells with the charger switched on.
– After charging measure and record the electrolyte density and the electrolyte
temperature in all the cells.
– Compare the results with the previous ones.
Z If you find significant differences compared with the previous measurements or
differences between the cells, contact the manufacturer's customer service
department.
4.3.4 Annually
– Measure the truck insulation resistance in accordance with EN 1175-1.
– Measure the battery insulation resistance in accordance with EN 1987-1.
Z In accordance with DIN EN 50272-3 the battery insulation resistance should not be
less than 50 ȍ per volt of rated voltage.
03.13 EN
8
5 PzV and PzV-BS lead-acid batteries with sealed armour
plated cells
5.1 Description
PzV batteries are sealed batteries with fixed electrolytes, to which no water can be
added over the entire lifespan of the battery. Relief valves are used as plugs which
are destroyed when opened. During operation the same safety requirements apply to
the sealed batteries as for batteries with liquid electrolyte. This is to avoid electric
shock, explosion of the electrolyte charging gases or hazardous electrolyte burns if
the cell vessels are destroyed.
Z PzV batteries are low gassing, but not gassing-free.
Electrolyte
The electrolyte is sulphuric acid which is fixed in gel. The density of the electrolyte
cannot be measured.
5.1.1 Battery nominal data
1. Product Traction battery

2. Nominal voltage 2.0 V x no. of cells
3. Rated capacity C5 See data plate
4. Discharge current C5/5h
5. Rated temperature 30 °C
Limit temperature1 45°C, not permissible as operating
temperature.
6. Rated density of the electrolyte Cannot be measured
7. System rated electrolyte level Cannot be measured
1. Higher temperatures shorten the useful life, lower temperatures reduce
the available capacity.
03.13 EN
9
5.2 Operation
5.2.1 Commissioning
Checks and operations to be performed before starting daily work
Procedure
• Make sure the battery is in physically good condition.
• Make sure the terminals are correct (positive to positive and negative to negative)
and check that contacts on the battery terminal conducting system are secure.
• Check the terminal screw torques (M10 = 23 ±1 Nm) of the terminal conductors and
connectors.
• Re-charge the battery.
• Charge the battery.
Check completed.
5.2.2 Discharging the battery

Z To achieve an optimum useful life avoid operational discharges of more than 60%
of nominal capacity.
Z If the battery is discharged during operation by more than 80% of rated capacity the
useful life of the battery will reduce significantly. Fully or partially discharged
batteries must be re-charged immediately and not left unattended.
5.2.3 Charging the battery
WARNING!
The battery gives off a mixture of oxygen and hydrogen (electrolytic gas) during
XAlways disconnect the charger and truck before connecting or disconnecting the
charger and battery.
XThe charger must be adapted to the battery in terms of voltage, charge capacity
and battery technology.
XBattery cell surfaces must remain exposed during charging in order to ensure
sufficient ventilation, see truck operating instructions, chapter D, Charging the
Battery.
XWherever an industrial truck is parked for charging there must be no inflammable
material or consumables capable of creating sparks within a minimum distance of
2 m from the truck.
XFire protection equipment must be available.
XDo not place any metallic objects on the battery.
XAlways follow the safety regulations of the battery and charger station
03.13 EN
manufacturers.
10
NOTE
Charging the battery incorrectly can result in material damage.
Incorrect battery charging can result in overloading of the electric wires and contacts,
hazardous gas formation and electrolyte leakage from the cells.
XAlways charge the battery with DC current.
XAll DIN 41773 charging procedures are permitted in the format approved by the
manufacturer.
XAlways connect the battery to a charger that is appropriate to the size and type of
the battery.
XIf necessary have the charger checked by the manufacturer's customer service
department for suitability.
XDo not exceed limit currents in the gassing area in accordance with DIN EN 50272-
3.
03.13 EN
11
Charging the battery
Requirements
– Electrolyte temperature between +15°C and 35°C
Procedure
• Open or take off the tray lid or covers from the battery compartment.
• Connect the battery to the switched off charger, ensuring the terminals are connect
(positive to positive and negative to negative).
Z The electrolyte temperature rises by approx. 10 K during charging. If the
temperatures are permanently higher than 40°C or lower than 15°C, a temperature-
dependent constant voltage control of the charger is required. The adjustment
factor must be applied with -0.004 V/C per K.
Battery charged
Z Charging is considered to be complete when the electrolyte density and battery
voltage remain constant for more than 2 hours.
Compensation charging
Compensation charging is used to ensure the useful life and maintain capacity after
full discharge and repeated insufficient charging.
Z Compensation charging should be carried out weekly.
Trickle charging
Battery trickle charging is partial charging that extends the daily application time.
Higher average temperatures occur during trickle charging which can reduce the
useful life of the batteries.
Z Trickle charges should only be performed when the charge level is below 50%. Use
replacement batteries instead of regular trickle charging.
Z Avoid trickle charging with PzV batteries.
03.13 EN
12
5.3 Servicing PzV and PzV-BS lead-acid batteries with sealed armour
plated cells
Z Do not add water!
5.3.1 Daily
– Charge the battery after each discharge.
5.3.2 Weekly
– Visually inspect for dirt and physical damage.
5.3.3 Every three months

– Measure and record the overall voltage.
– Measure and record the individual voltages.
– Compare the results with the previous ones.
Z Carry out the measurements after full charging and subsequent resting for at least
5 hours.
Z If you find significant differences compared with the previous measurements or
differences between the cells, contact the manufacturer's customer service
department.
5.3.4 Annually
– Measure the truck insulation resistance in accordance with EN 1175-1.
– Measure the battery insulation resistance in accordance with EN 1987-1.
Z In accordance with DIN EN 50272-3 the battery insulation resistance should not be
less than 50 ȍ per volt of rated voltage.
03.13 EN
13
6 Aquamatik water replenishment system
6.1 Water replenishment system design
15
16
17
>3m 18
19
20
+ -
15 Water container
16 Tap connection with ball cock
17 Flow indicator
18 Shut-off cock
19 Locking coupling
20 Battery lock connector 03.13 EN
14
The Aquamatik water replenishment system is used to adjust the rated electrolyte
level automatically on traction batteries for industrial trucks.
The battery cells are interconnected through hoses and are attached to the water
supply (e.g. water container) through a plug connection. When the shut-off cock is
opened all the cells are filled with water. The Aquamatik plug controls the amount of
water required and, at the relevant water pressures, ensures the water supply is shut
off and the valve is closed securely.
The plug systems have an optical level indicator, a diagnostic port to measure the
temperature and electrolyte density and a degassing port.
6.3 Adding water

Water should be added to the batteries just before the battery is fully charged. This
ensures that the amount of water added is mixed with the electrolyte.
6.4 Water pressure

The water replenishment system must be operated with a water pressure in the water
line of 0.3 bar - 1.8 bar. Any deviations from the permissible pressure ranges will
affect the operation of the systems.
Water drop
Assembly height above battery surface is between 3 - 18 m. 1 m corresponds to 0.1

bar
Pressure water
The pressure regulating valve is adjusted to suit the system and must lie between 0.3
- 1.8 bar.
03.13 EN
15
6.5 Filling time
The filling time for a battery depends on the electrolyte level, the ambient temperature
and the filling pressure. Filling ends automatically. The water supply line must be
disconnected from the battery when the water has been filled.
6.6 Water quality

Z The quality of the water used to fill up electrolyte must correspond to purified or
distilled water. Purified water can be produced through distillation or ion
exchangers and is then suitable for the production of electrolyte.
6.7 Battery tubing

The tubing of the individual plugs is in accordance with the existing electric circuit. No
changes should be made.
6.8 Operating temperature

Batteries with automatic water replenishment systems should only be stored in rooms
with temperatures > 0°C, as otherwise the systems could freeze.
03.13 EN
16
6.9 Cleaning measures
The plug systems must only be cleaned with purified water in accordance with DIN
43530-4. No parts of the plugs must come into contact with solvent-based materials
or soap.
6.10 Service mobile vehicle

Mobile water filling vehicle with pump and filling gun to fill individual cells. The
immersion pump in the container generates the necessary filling pressure. The
service mobile must be at exactly the same height as the battery base.
03.13 EN
17
7 Electrolyte circulation
Electrolyte circulation ensures the supply of air during charging to mix the electrolyte,
thereby preventing any acid layer, shortening the charge time (charge factor approx.
1.07) and reducing the formation of gas during charging. The charger must be
suitable for the battery and electrolyte circulation.
A pump in the charger produces the necessary compressed air which is introduced
to the battery cells via a hose system. The electrolyte is circulated via the inlet air and
the electrolyte density level is constant over the entire length of the electrode.
Pump
In the event of a fault, e.g. if the pressure control system responds for an unknown
reason, the filters must be checked and replaced if necessary.
Battery connection
A hose is attached to the pump module which together with the charge leads is routed
from the charger to the charging connector. The air is passed on to the battery via the
electrolyte circulation coupling ducts in the connector. When routing make sure the
hose is not bent.
Pressure monitoring module
The electrolyte circulation pump is activated when charging begins. The pressure
monitoring module monitors the build up of pressure during charging. This ensures
that the required air pressure is provided for electrolyte circulation charging.
In the event of malfunctions such as:

– Battery air coupling not connected to circulation module (if coupling is separate) or
faulty.
– Leaky or faulty hose connections on battery or
– Intake filter contaminated
a visual error message appears on the charger.
03.13 EN
18
NOTE
If an installed electrolyte circulation system is seldom used or not used at all,
or if the battery is subjected to severe temperature fluctuations, the electrolyte
may flow back into the hose system.
XAttach a separate coupling system to the air inlet line, such as: locking coupling on
the battery side and through-coupling on the air supply side.
Schematic illustration
Electrolyte circulation on the battery and air supply via the charger.
03.13 EN
19
8 Cleaning batteries
Batteries and trays must be cleaned in order to
– maintain cell insulation and protect cells from ground or external conductive parts.
– Avoid damage from corrosion and stray currents.
– Avoid excessive and varying automatic discharge of the individual cells or block
batteries due to stray currents.
– Avoid electric sparking due to stray currents.
When cleaning the batteries make sure that:
– The assembly site chosen for cleaning is close to a drainage system for processing
the electrolytic rinsing water.
– All health and safety as well as water and waste disposal regulations are observed
when disposing of used electrolyte or rinsing water.
– Protective goggles and clothing are worn.
– Cell plugs are not removed or opened.
– Clean the plastic components of the battery, in particular the cell containers, only
with water or water-based cloths without any additives.
– After cleaning, the top of the battery is dried with suitable equipment, e.g.
compressed air or cloths.
– Any fluid that has entered the battery box must be suctioned off and disposed of in
accordance with the above-mentioned regulations.
03.13 EN
20
Cleaning the battery with a high pressure cleaner
Requirements
– Cell connectors tight, plugged in securely
– Cell plugs closed
Procedure
• Follow the high pressure cleaner's user instructions.
• Do not use any cleaning additives.
• Observe the permissible cleaning device temperature setting of 140°C.
Z This generally ensures that the temperature does not exceed 60°C at a distance of
30cm behind the outlet nozzle.
• Observe the maximum operating pressure of 50 bar.
• Observe a minimum distance of 30 cm from the top of the battery.
• The battery should be sprayed over its entire surface to avoid localised
overheating.
Z Do not clean one spot for more than 3 seconds with the jet to avoid exceeding the
maximum battery surface temperature of 60°C.
• After cleaning dry the battery surface with suitable materials e.g. compressed air or
cleaning cloths.
Battery cleaned.
03.13 EN
21
9 Storing the battery
NOTE
The battery should not be stored for longer than 3 months without charging as
otherwise it will no longer be functional.
If the battery is to be taken out of service for a long period, it should be stored fully
charged in a dry room protected from frost. To ensure the availability of the battery
the following charges can be selected:
– Monthly compensation charge for PzS and PzB batteries or 3-monthly full charge
for PzV batteries.
– Trickle charge for a charge voltage of 2.23 volts x no. of cells for PzS, PzM and PzB
batteries or 2.25 volts x no. of cells for PzV batteries.
If the battery is to be taken out of service for a long period ( > 3 months), it should, as
far as possible, be charged to 50% of its charge level and stored in a dry room
protected from frost.
10 Troubleshooting
If any faults are found on the battery or charger, contact the manufacturer's customer
service department immediately.
Z The operations required must be carried out by the manufacturer's customer

service department or a customer service organisation authorised by the
manufacturer.
11 Disposal
Batteries marked with the recycling symbol and the sign showing a
crossed-out rubbish bin should not be disposed of with ordinary
household waste.
Buy-back terms and type of recycling are to be agreed with the
manufacturer as described in § 8 of the battery legislation.
03.13 EN
22

Junghair

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Junghair

Uploaded by

Copyright:

Available Formats

EKS 513 - 515 / EKX 410 - 515 05.

0RGHO 2SWLRQ 6HULDOQR <HDURI

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

A Correct Use and Application ................................................... 11

B Truck Description .................................................................... 17

C Transport and Commissioning ................................................ 71

D Battery - Servicing, Recharging, Replacement ....................... 97

E Operation ................................................................................ 119

4.12 Diagonal travel......................................................................................... 225

10.4 Operator-specific settings (o) ................................................................. 387

F Industrial Truck Maintenance .................................................. 481

JH Traction Battery Operating Instructions

– Lifting, lowering and order picking of loads.

Z Special equipment and authorisation are required if the truck is to be used in

5 Adding attachments and/or accessories

The mounting or installation of additional equipment which affects or enhances the

Z The ground surface must comply with the VDMA guideline.

Item Travel direction

– If an error is detected by the controller the truck automatically brakes to a halt.

EKX 410 brake system:

– Vertically mounted, heavy-duty and maintenance-free threephase motor with no

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

– Generous entry room

– Electronic system with wear-free sensors.

– All hydraulic operations are controlled by a sturdy, maintenance-free AC motor with

– Mechanical rail guidance for precision guidance in narrow aisles.

Indicates optional equipment

4.1 Performance data

4.1.1 EKX 410 performance data

Component EKX 410

Component EKS 513 EKX 513

Component EKS 515k EKX 515k

Component EKS 515 EKX 515

4.2.1 EKX 410 dimensions with standard attachment

4.3.1 Standard mast version with telescopic mast (ZT)

EKS 515k EKS 515

EKS 515k EKS 515

Basic truck weight (excl. battery)

Truck Weight of basic truck

A Net weight of the industrial truck without battery

Formula for the EKX 410:

Formula for the EKS 513 - 515 / EKX 513 - 515:

EKS 513 EKS 515k EKS 515

EKS 513 - 515 / EKX 513 - 515

EKS 515k EKS 515

Vibration at driver's seat

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

– operating at +5°C to +40°C

– Ambient temperature in 24-hour mode: max. +25°C

4.9 Electrical requirements

Item Description Item Description

5.1.1 Serial number position

Example of how to calculate the maximum capacity:

4250 850 850 600

D (mm) 500 600 700

5.4 Jack contact points

Stability can also be affected by the following factors:

Safe lifting of the basic truck by crane with mast assembled

0RGHO 2SWLRQ 6HULDOQR <HDURI