Operation Manual

Electric Walk-Behind Truck

Series
d100 - d1200 ASM

Your truck
Sichelschmidt GmbH
P.O. Box 320 Series: d _______ ASM
D-58291 Wetter
Tel. +49 (0)2335/6309-0 Nom. load capacity: _________ kg
Fax +49 (0)2335/630988 Serial No. _________
e-mail: [email protected]
www.sichelschmidt.de Year of manuf.: _________

d_1-12_ASM_1726_e.doc 08.04
 Your contact:

If the vehicle or individual parts of the vehicle are sold or made available to third
parties, you must notify your Sichelschmidt dealer and Sichelschmidt GmbH of this
fact in writing immediately.
Notification of all changes to a vehicle over and above the repair or replacement of
similar components (e.g. installation of another pump, changes to the load carrier)
must be given to your Sichelschmidt dealer and to Sichelschmidt GmbH immediately.
If you find any passages in this manual that could be misunderstood or are
incomplete, please notify your Sichelschmidt dealer and Sichelschmidt GmbH
immediately in writing.
You should not comply with any instructions that are obviously incorrect.
 OPERATION MANUAL
INTRODUCTION

This Operation Manual contains a description of the Sichelschmidt forklift truck series
d … ASM plus all associated assemblies.
Section 1 describes the basic conditions for operation of the vehicle.
Section 2 describes the technical aspects of the vehicle in such a way as to give you
a good overview of the layout and function of each of the assemblies and their inter-
action.
Section 3 contains the specifications
Section 4 describes how to operate the vehicle.
Section 5 provides you with an overview of necessary maintenance.
Pictograms denote important information for operating and maintenance personnel:
Identifies important information to which the operating or maintenance
personnel should pay particular attention.
Identifies work or operating procedures during which current environ-
mental and waste disposal regulations must also be observed.
Identifies work and operating procedures which must be strictly adhered
to in order to avoid personal injury, or damage to or destruction of the
vehicle and other property.

Scope of the operation manual

This operation manual applies to the entire d … ASM series.

Most of the text, in particular general advice and advice on safety, is universally
applicable.
Where passages of text apply only to a specific series, the text is indented and
clearly marked, and the extension … ASM is left out. In the case of passages of text
applicable to more than one series you will find several marks.

d100 Mark for the passages applicable to the d 100 ASM.

d400 Mark for the passages applicable to the d 400 ASM.

d400B Mark for the passages applicable to the d 400B ASM (special version with
base lift).

d500 Mark for the passages applicable to the d 500 ASM.

d600 Mark for the passages applicable to the d 600 ASM.

d1200 Mark for the passages applicable to the d 1200 ASM.

Illustrations and diagrams used serve merely to elucidate the text and do not claim to
be unambiguous or to show the truck as actually delivered.

EIN_1-12_ASM_1726_e.doc 08.04 I
OPERATION MANUAL
INTRODUCTION

Table of contents
Section Topic Section-Page

1 General operating instructions........................ 1-1

1.1 Intended use................................................................... 1-1
1.2 Improper use.................................................................. 1-1
1.3 Owner’s duties............................................................... 1-1
1.4 Ancillary equipment...................................................... 1-2
1.5 Documentation............................................................... 1-2
1.6 Definitions...................................................................... 1-2
1.6.1 Residual risks................................................................. 1-2
1.6.2 Operating instructions..................................................... 1-2
1.6.3 Operation manual........................................................... 1-2
2 Technical description....................................... 2-1
2.1 General description of vehicle..................................... 2-1
2.2 Description of vehicle layout........................................ 2-1
2.3 Description of running gear.......................................... 2-1
2.4 Description of driving process ………………………... 2-1
2.5 Description of lifting gear.............................................. 2-2
2.6 Description of brake functions..................................... 2-3
2.7 Description of safety devices....................................... 2-3
2.8 Control and display elements....................................... 2-4
3 Specifications................................................... 3-1
3.1 Grease - oil - brake fluid specifications....................... 3-1
3.2 Consumption figures..................................................... 3-1
4 Operation........................................................... 4-1
4.1 Vehicle operation safety regulations........................... 4-1
4.1.1 Operator’s rights and duties............................................ 4-1
4.1.2 Danger zone.................................................................... 4-1
4.1.3 Vehicle stability................................................................ 4-1
4.2 Transport and commissioning..................................... 4-2
4.2.1 Transport......................................................................... 4-2
4.2.2 Commissioning................................................................ 4-2
4.3 Battery............................................................................. 4-2
4.3.1 Safe handling of batteries................................................ 4-2
4.4 Putting vehicle into operation...................................... 4-3
4.4.1 Direction of travel and operator’s position........................ 4-3
4.4.2 Starting vehicle................................................................ 4-3
4.5 Drive mode...................................................................... 4-4
4.5.1 Safety in drive mode....................................................... 4-4
4.5.2 Driving……………………………………………………….. 4-4
4.5.3 Changing direction.......................................................... 4-6
4.5.4 Braking............................................................................ 4-6
4.5.5 Steering……………………………………………………… 4-6

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 OPERATION MANUAL
INTRODUCTION

4.6 Lifting loads................................................................... 4-7

4.6.1 Safety when lifting........................................................... 4-7
4.6.2 Maximum load capacity.................................................. 4-7
4.6.3 Picking up load............................................................... 4-7
4.6.4 Putting down load........................................................... 4-11
4.6.5 Tilting mast…………………………………………………. 4-13
4.6.6 Mast reach………………………………………………….. 4-13
4.7 Parking the truck………………………….……………… 4-14
5 Maintenance...................................................... 5-1
5.1 Safety regulations for maintenance............................ 5-1
5.1.1 Work on electrical system............................................... 5-1
5.1.2 Work on hydraulic system............................................... 5-1
5.1.3 Work on lifting device...................................................... 5-1
5.2 General hints on maintenance..................................... 5-1
5.3 Maintenance plan........................................................... 5-2

EIN_1-12_ASM_1726_e.doc 08.04 3
 OPERATION MANUAL
GENERAL INSTRUCTIONS

1 General operating instructions

1.1 Intended use
The Sichelschmidt Electric Trucks are suitable for lifting, transporting and stacking
properly palletized or suitably secured loads. The maximum permitted load or maxi-
mum permitted height, stated on the vehicle itself, is binding. The vehicle may only
be driven on even, non-slippery surfaces and within the prescribed pathways. Driving
on slopes is only permitted as stipulated in the technical specifications. The vehicle is
not certified for road use and so may only be used within the company. It may only
be operated under normal atmospheric conditions, i.e. not in overly dusty atmos-
pheres and at temperatures between -10 °C and
+ 40 °C. This operation manual describes, how, where and with the observance of
which conditions the vehicle may be used and operated. Only such use is deemed to
be intended use. Intended use also includes performing maintenance and service
work within the periods stipulated.

1.2 Improper use

Any use of the vehicle other than the use described in this operation manual is
deemed to be improper use. In particular, overloading with loads that are too heavy
or one-sided is prohibited. Also prohibited are the transporting of persons, driving at
inconsiderate speed, driving outside marked pathways, picking up and transporting
incorrectly palletized or secured loads, picking up and transporting liquid containers
which are not adequately secured against spills, pushing or pulling with the vehicle,
and operation in unsuitable environmental conditions.
The vehicle may not be operated if damage it has suffered jeopardizes overall safety.
The vehicle may not be operated in hazardous locations.
Sichelschmidt GmbH is not liable for damage resulting from violation of the above
conditions.
If designed with initial lift, suitable pallets – e.g. Euro pallets - may also be picked up
crosswise. In that case, however, mast lift is no longer permitted.

1.3 Owner’s duties

It is the duty of the owner to ensure that the vehicle is used only by trained operators
and only in the proper manner and in accordance with the relevant regulations. The
owner further has a duty to use qualified personnel to perform the maintenance and
service work within the prescribed intervals.
In addition, he is responsible for providing informative operating instructions and for
carrying out obligatory inspections under the Accident Prevention Regulations (annu-
ally).

1.4 Ancillary equipment

No ancillary equipment which influences or enhances vehicle performance may be
fitted without written permission from the Sichelschmidt GmbH. Local authority per-
mission may also be required. Fitting or attaching parts that influence vehicle stability
is prohibited.

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OPERATION MANUAL
GENERAL INSTRUCTIONS

In the event of an unauthorized change in the construction or of an addition to the

vehicle, safety may be inadmissibly jeopardized, consequently rendering the
EU Certificate of Conformity and the Sichelschmidt GmbH Operating Permit void.

1.5 Documentation
Every Sichelschmidt truck is accompanied by an operation manual. This operation
manual should be handled carefully and made accessible to the operator,
maintenance and service personnel, and the owner.
If the operation manual is lost, the owner must immediately request a replacement
from Sichelschmidt GmbH.
In addition to the operation manual, the company owning operation instructions, the
technical documentation of battery and charging station manufacturers, i. n. the
technical documentation of ancillary equipment, all national and international
standards and regulations and guidelines of testing and supervisory institutes must
be observed for truck operation and servicing.

1.6 Definitions
1.6.1 Residual risks
Residual risks are risks typical of the product (e.g. risks resulting from the vehicle’s
own weight) which can occur even when the vehicle is used in accordance with the
stipulations of the ´Directive on the due and intended use of forklift trucks (FFZ)` and
other safety regulations. Some of these risks are not foreseeable and are therefore
not dealt with in this Operation Manual. The avoidance of these risks is the responsi-
bility of the owner or operator of the forklift truck.

1.6.2 Operating instructions

Operating instructions are binding instructions to be put down in writing by the com-
pany owning or operating the forklift truck relating to the company-specific operation
of the vehicle. These instructions should also cover potential risks not apparent to the
manufacturer of the forklift truck or residual risks.

1.6.3 Operation Manual

This Operation Manual is the documentation shipped with the forklift truck which gov-
erns the due and intended use of the vehicle.

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 OPERATION MANUAL
TECHNICAL DESCRIPTION

2 Technical Description
2.1 General description of vehicle
The trucks in the d ... ASM series are Walk Behind Trucks which have different lifting
devices and load capacities.
The drive unit in all the series is largely identical. The number and design of the
operating elements may differ, however.
Duplex free lift, duplex clear view and duplex free lift/clear view masts are used as
lifting device.
They are powered by PzB batteries with a rated voltage of 24V and different
capacities.

2.2 Description of vehicle layout

The vehicle consists of a drive unit, which contains the drive, the hydraulic pump and
the complete electrical system. A front unit is screwed onto the drive unit and serves
as battery carrier. The front unit also contains the lifting device.

2.3 Description of running gear

The running gear consists of a drive wheel, two support wheels and two or four load
wheels.
The single-wheel driving gear is mechanically connected to the drive motor. The
steering tiller is screwed to the drive motor. In this way the steering movement is
transmitted from the tiller handle via the tiller lever and the motor to the single-wheel
driving gear and hence to the drive wheel.

2.4 Description of driving process

The direction switch and a safety brake switch are situated on the tiller head. The
vehicle is driven by operating the direction switch and turning the steering tiller. The
vehicle can only be driven when it is ready for operation, i.e. when it is switched on.

Moving in direction of tiller Moving in direction of forks

= moving forwards = moving in reverse
Reverse

0-position

Forwards

The travel speed as well as the braking effect is proportional to the turning angle of
the direction switch.

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OPERATION MANUAL
TECHNICAL DESCRIPTION

2.5 Description of lifting gear

The vehicle is fitted with a mast whose design varies. In the case of the duplex mast
model, two sections slide into one another on rollers. Depending on the mast design,
the cylinders are centred between the mast sections, or in the case of the clear view
model - which provides a better view of the load lifting device - on the side next to the
mast sections.
In the free lift version the lifting device can be raised a certain amount without the
inner section of the mast being extended. This allows lifting in low spaces without
any change in the vehicle height. These designs can be optionally varied, with three
cylinders being used.
In the initial lift version the entire mast is lifted by means of a rod running under the
forks.

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 OPERATION MANUAL
TECHNICAL DESCRIPTION

2.6 Description of brake function

Parking brake: The pallet truck is brought to a halt by an electromagnetic spring-
loaded brake located on the drive-motor shaft. When the truck is ‘par-
ked’, electric power is cut off and the friction faces of the brakes are
pressed together by compression springs. If the direction switch is now
operated, electric power is returned and the brake’s friction faces are
‘drawn apart’ by an electromagnet. The brake is ‘freed’.
Service brake: by regenerative braking. Information on the current position of the
drive switch is passed to the control, which either increases or de-
creases the motor speed and so slows the truck down.

2.7 Description of safety device

Tiller head safety brake switch:

An integral part of the tiller head (3-1) is a safe-
3-1 ty brake switch (3-2) which prevents the opera-
tor from being crushed while working. If the sa-
fety brake switch is operated the vehicle acce-
lerates in the forks direction for as long as the
safety brake switch is depresses (max. for 3
sec.). Upon release of the safety brake switch
the vehicle brakes. Before restarting the vehicle
3-2 the direction switch (3-3) must first be set in the
zero position.
3-3 Fig 3 The safety button is deactivated when the truck
is moving in the direction of the forks and when
the tiller is in either of its end positions.

Optional equipment:
The trucks can be fitted with speed reduction proportional to lift height. In this case
the truck can be moved only at creep speed from a specific lift height. The crawl
speed mode is independent of this feature..

Trucks with an emergency stop button and main relay will be shut down automatically
after the tiller has been in its upper end position for about 120 seconds. The truck can
be reactivated by moving the tiller out of the upper end position.

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OPERATION MANUAL
TECHNICAL DESCRIPTION

2.8 Control and display elements

7-4

7-4

Tiller head safety brake switch (7-1)

− for the safety of the operator.

Direction switch (7-2)

− for selecting direction of travel.
− for controlling travel speed.
7-1
Depending to equipment with sensoric levers
7-3 (8a-3) or via a rocker switch (7-3) for operating
7-2
the hydraulic functions.
Fig 7
Tiller(7-4)
− for steering the vehicle.

Horn button
− as signalling device

Battery charge indicator (8-1).

− displays residual battery capacity
Fig. 8a
8a-1 Hour meter (8-2)
− shows the actual hours of operation (driving
of lifting) in minutes and hours.
8-4 Sevicezähler
− for monitoring service intervals. When a
preset value is reached, the counter starts
to flash. Time continues to be added up,
however.

Ignition switch (8-3)

− protects against unauthorized use.
Position 0: All electrical functions are swit-
ched off.
Position I and non-activated emergency stop
8-3
button:
Vehicle control voltage is swit-
8-1
ched on.
8-2
Battery plug contact(8-4)
Fig 8 − for rapidly disconnecting battery in emer-
gencies
− for charging the battery

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 OPERATION MANUAL
SPECIFICATIONS

3 Specifications
3.1 Grease/oil/brake fluid specifications

It is imperative that a mix of sodium-saponified greases and lithium- or calcium-

saponified greases be avoided.

Abbr. BP Shell Esso Aral Fina Bechem ÖMV

H-LP 46* Tellus-Öl NUTO Vitam Hydran
H Hydraulic H-LP 68 46* H46* GF46* (HV)46 DIN 51525 HLP 46*
oil H-LP H-LP-D46* or or or or Hydran H-LP 46 or
H-LP-D68 Tellus-Öl NUTO Vitam (HV)68 HLP 68
68 H68 GF68

Transmis- Transmis- Omala Öl Spartan Degol BG Giran 100

G sion oil also sion oil 100 100 100 C-LP 100 C-LP 100 HST
suitable as GR-XP 100 C-LP 100 C-LP 100 C-LP100 100 EP
lubricating
C-LP 100
oil

K Anti- SU 2
corrosion
grease

Roller bea-
ring DIN
Plain ball 51502 KLK 2
S bearing Energrease Alvania Beacon 2 Bechem Typ
grease also LS 2 Fett R2 with EP Aralub HL Marson Rhus L474H Signum
suitable as or Ener-
lubricating with EP additive 2 EPL 2 (Li) M 283 or
grease LS- additive (Li), if nec- (Li) (Li) Plain bearing EPL 2
grease
EP 2 (Li), if nec- essary DIN 51502
(multi-
(Li) essary KPLF2K
purpose
grease) Bechem Typ
Rhus L2
(Li)

* preferable

3.2 Consumption figures

Hydraulic oil as per specifications approx. 7 l.
Battery fluids as per battery manufacturer’s instructions for use.

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 OPERATION MANUAL
OPERATION

4. Operation
4.1 Vehicle operation safety regulations

4.1.1 Operator’s rights and duties

The vehicle may only be driven by qualified operators.

The operator is responsible for the vehicle while it is in use. He must ensure that no
unauthorized persons operate the vehicle, that no-one is transported in or on the ve-
hicle, and that no-one steps onto the forks or any ancillary equipment.
It is the operator's responsibility to properly secure the vehicle after use.

4.1.2 Danger zone

The operator’s duties include monitoring the danger zone, which is defined as the
area in which persons or property are endangered by movements of the truck, a lift-
ing device or the load itself. The area that can be reached by a falling load, or falling
work equipment or equipment being lowered also falls within the danger zone.
Unauthorized persons must be shown out of the danger zone. If persons are in dan-
ger a timely warning signal must be given. If in spite of being requested to do so un-
authorized persons still do not leave the danger zone, operations must be ceased
immediately.

4.1.2 Vehicle stability

The stability of the vehicle has been tested in accordance with state-of-the-art tech-
niques.
The overturning moment may be exceeded if the vehicle is used in a manner contra-
dictory to its intended use, e.g.
− if the maximum permitted load capacity is exceeded,
− by driving on slopes and inclines with a gradient in excess of the maximum angle
stipulated in the technical specifications,
− travelling with a non-permitted load or with an incorrectly lifted load,
− travelling with a load lifted too high,
− braking hard,
− making technical modifications to the vehicle in a manner that has a negative im-
pact on vehicle stability (for instance, installing a lighter battery),
− exceeding the nominal load distance.
For this reason use as referred to above is prohibited.

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OPERATION MANUAL
OPERATION

4.2 Transport and commissioning

4.2.1 Transport
If the vehicle is to be lifted by crane for transport purposes, vehicle-specific transport
specifications must be obtained from the Sichelschmidt company. The unauthorized
establishment of supporting points is prohibited.

4.2.2 Commissioning
The vehicle is delivered ready for operation. Upon delivery the vehicle must be
checked for any damage or faults.
All operating equipment must be checked to ensure grease/oil/brake fluid levels are
sufficient. If necessary, replenish.
During the test drive all drive and lift functions must be tested. Defects
must be reported to the Sichelschmidt company.
Only after the successful testing of all functions may other operators be trained to
use the vehicle.

4.3 Battery
4.3.1 Safe handling of batteries
Only appropriately trained personnel may perform work (e.g. charging, maintaining,
replacing) on the batteries. This manual and the regulations of the battery and charg-
ing station manufacturers must be observed.

Smoking and naked flames are prohibited while handling batteries. Flammable sub-
stances, sparking and hot working equipment must be kept at a distance of at least 2
m from the area where the vehicle is parked for recharging. The space must be well
ventilated. Fire extinguishing equipment must be kept ready for use. When charging,
the battery cover must be open.

The batteries contain toxic, corrosive acid (dissolved sulfuric

acid). Protective clothing and safety goggles must therefore be
worn while performing any work on the battery. Contact with
battery acid must be avoided at all cost. If clothes, skin or eyes
should nevertheless come into contact with battery acid, the
corresponding body parts must be rinsed immediately with co-
pious amounts of clean water and the clothes must be
changed. If skin or eyes have been exposed, seek medical as-
sistance immediately. Spilled battery acid should be neutralized
immediately.

Used batteries carrying this sign are recyclable products and must be re-
cycled.

Used batteries which are not recycled must be disposed of as special

waste in compliance with current local environmental regulations.

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 OPERATION MANUAL
OPERATION

4.4 Putting vehicle into operation

4.4.1 Direction of travel and operator’s position

Operator´s
position

Tiller direction Fork direction

= forwards = reverse

The vehicle may only be operated from the tiller. The operator may not stand on the
lifting device.

4.4.2 Starting vehicle

Before the vehicle is switched on the pre-commissioning maintenance

must be carried out.

− Move the operating element for lifting/lowering to the end position.

⇒ The operating element should automatically return to its 0 position.
− Check the tiller for ease of movement.
⇒ The tiller lever should move easily from its uppermost to its lowermost position.
− Check the direction switch for ease of movement.
⇒ The direction switch should move easily between its two extremes and auto-
matically return to 0.
− Put the key in the ignition.
− Turn the key approx. 30°.
− Check the battery charging.
− The vehicle is now ready for operation.

The vehicle may not be operated if any one of the above functions fails to
perform.
A vehicle which is ready for operation must not be left unattended. If the
operator leaves the vehicle, he must park it correctly.

4.5 Drive mode

4.5.1 Safety in drive mode
The vehicle may only travel on the pathways designated by the owner. The operator
must observe company traffic regulations, always have a sufficiently clear view of the
operating area, and always look in the direction he is travelling. The load must be
properly palletized or secured in some other way.

BED_1-12_ASM_1726_e.doc 08.04 Section 4 Page 3

OPERATION MANUAL
OPERATION

In the following cases slow and careful driving can be crucial to safety:
− on bends,
− in narrow areas,
− between racks,
− in areas with a restricted view, e.g. gate entrances.
The transport of liquid containers requires particular attentiveness. When driving, the
operator must take care not to spill any liquid.
Only the operator at the tiller may perform any of the operating functions.
Except in emergencies, sudden braking and sharp turns are not permitted.
Entering aisles is only permitted if they are free of people and vehicles.
In areas with a gradient the load must be carried on the uphill side only. Turning,
travelling at an angle across or parking the vehicle on inclines are prohibited. On in-
clines, always travel at reduced speed and be permanently ready to brake at short
notice. Travelling on gradients with an angle of inclination in excess of the gradient
given in the technical specifications is prohibited.

4.5.2 Driving

The vehicle may only be driven by qualified operators.

Upper end position:

1. When the tiller is in this position, the
Working range parking brake is activated.
2. When the tiller is in this position, the
Upper end safety mode can be activated within a
position certain, specified period of time.

Working range:
When the tiller is in this position, the truck will
travel in the direction indicated by the direc-
Lower end tion selector switch and will accelerate or
position brake in accordance with the angle of deflec-
tion. The parking brake is activated when the
motor speed drops below a threshold value
of approx. 25 rpm.

Lower end position:

When the tiller is in this position the parking
brake is activated and the safety mode is de-
activated.

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 OPERATION MANUAL
OPERATION

Functional description:

− The tiller must be in the upper end position.

− Switch the truck on.
− Move tiller into the working range.
− Use the direction switch to select the direction of travel.

The travel speed is proportional to the deflection of the direction switch. A

rotation speed sensor on the travel motor is used to determine the actual
speed of travel. The travel control circuitry continuously compares the
value set at the direction switch with the effective speed at the drive. This
feedback system ensures that the travel speed will correspond to the
switch setting even when travelling up or down an incline.
If the tiller is moved into the upper or lower end position during travel, then
maximum braking force will be applied to stop the truck.

Safety mode:
The truck is equipped with a safety mode, making it possible to manoeuvre even in
tight spaces. In this mode the truck can only be moved in the direction of the forks
and at creep speed (about 20% of maximum travel speed).

Activating the safety mode:

The safety mode can only be activated with the truck at a standstill and with the tiller
in its upper end position. Once the tiller has been raised to its upper end position, the
direction switch must be moved towards the forks within a certain amount of time
(about 3 seconds). The truck will now move at reduced speed in the direction of the
forks. The safety mode is available across the entire working range, including the
tiller upper end setting. Braking via the upper end position is deactivated. Braking is
effected by deflecting the direction switch to the appropriate angle, or by moving the
tiller to its lower end position.

Deactivating the safety mode – three options:

• By putting the tiller in the lower end position
• By moving the tiller into the upper end position, putting the direction switch into
neutral and resuming travel with the tiller in its working range (first swing the tiller
out of the upper end position and then actuate the direction switch).
• On expiry of the enable time at the tiller's upper end position

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OPERATION MANUAL
OPERATION

− Position the tiller for the desired direction of travel.

When moving forward the operator controls the tiller with one hand on the
right or left handle while looking in the direction of travel.
Reverse

0-position

Forward

− Move the direction switch slowly and carefully to the desired direction of travel.

Make sure the pathways are clear and no-one is standing or sitting on the
forks.

The travel speed is proportional to the deflection of the direction switch.

4.5.3 Changing direction

− Brake the vehicle or let it roll to a halt from the current direction.
− Slowly turn the direction switch past the 0 position in the opposite direction.

Check for the presence of people or other obstacles in the newly selected
travel zone.

4.5.4 Braking
− Release the direction switch while the vehicle is in motion. The direction switch will
return to the 0 position. The vehicle will brake.
− Push the tiller to the uppermost position.

4.5.5 Steering
The tiller has an angle of steering lock of approx. 2x90°.

Moving forward the tiller is held with one hand and turned in the desired direction of
travel.

Moving in reverse (in fork direction) the tiller is held with both hands, with the opera-
tor looking towards the forks.

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 OPERATION MANUAL
OPERATION

4.6 Lifting loads

4.6.1 Safety when lifting

Only loads which do not exceed the effective load capacity of the vehicle may be
lifted and transported. The load must be properly palletized or otherwise secured
against shifting or falling off. The forks must be placed as far under the load as pos-
sible.

4.6.1 Maximum load capacity

The maximum load capacity of the vehicle is displayed on the vehicle's
identification plate.

The load center may not exceed the maximum permitted distance to load
center of the vehicle.

4.6.2 Picking up load

Before picking up a load the operator must satisfy himself that the load is
properly palletized and secured. If it is not, he is responsible for securing
the load against shifting immediately after lifting it. Added to this, the load
must not exceed the maximum permitted load capacity of the vehicle.

− Move carefully towards the load to be lifted.

− Move towards the load with the forks lowered as far as possible and
drive them under the pallet or load until the load is resting on the back
of the forks.

Check: In base lift operations the load wheels must not rest on
parts of the load carrier or pallet, as lifting would tear the pallet
apart.
The truck may not be used for lifting persons.
d100

− For base lift, slowly depress lower part

of rocker switch. The lifting speed
cannot be regulated.

⇒ The forks will be raised 125 mm.

Check: The load must be lifted high enough not to touch the floor.

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 OPERATION MANUAL
OPERATION

− Move carefully towards the load to be lifted.

− Move towards the load with the forks lowered as far as possible and
drive them under the pallet or load until the load is resting on the back
of the forks.
− In racking operations set the forks so that they are in alignment with the
pallet openings and slide them into the pallet.

Pallets lifted crosswise from a rack cannot be placed on the

ground.

Check: In initial lift operations the load wheels must not rest on
parts of the load carrier or pallet, as lifting would tear the pallet
apart.
Mast lift is not permitted for pallets lifted crosswise from the
d400 ground.
The vehicle may not be used for lifting persons.
d400B

− For mast lift, slowly move the right side

of the rocker to the lower contact sur-
face. Lift speed is proportional to the
deflection of the rocker.
Optional
− Pull the appropriately marked lever in
On the initial lift version direction of the tiller
there is a second rocker on
the left side of the tiller
head. − For initial lift, slowly move the left side
of the rocker to the lower contact sur-
face. Lift speed cannot be regulated.
Optional
− Pull the appropriately marked lever in
direction of the tiller

⇒ The forks will be lifted to the maximum lifting height while the rocker is
activated.
⇒ In initial lift operations the forks will be lifted approx. 125 mm.
Check: The load must be lifted high enough not to touch the floor.

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 OPERATION MANUAL
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− Move carefully towards the load to be lifted.

− When picking up loads from the ground, lower the forks until they are just
above the ground and position the truck so that the forks are in line with
the entries of the load.
− When picking up loads from racks, raise or lower the forks to the height
of the entries and position the truck so that the forks are in line with the
entries.
Loads picked up from the ground may not be wider than the
distance between the wheel arms.
When entering racks bear in mind the height of the wheel arms.

Excessively wide loads (wider than the distance between the

wheel arms) cannot be set down on the ground.

The truck may not be used for lifting persons.

In racking operations the load may only be raised far enough to
d500 allow it to be moved out without touching the rack.
If the forks are longer than the load, an appropriate amount of
space should be left free behind the load.

− For mast lift, slowly move the right side

of the rocker to the lower contact sur-
face. Lift speed is proportional to the de-
flection of the rocker.
Optional
− Pull the appropriately marked lever in
direction of the tiller

⇒ The forks will be lifted to the maximum lifting height while the rocker or
lever is activated.

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OPERATION MANUAL
OPERATION

− Move carefully towards the load to be lifted.

− When picking up loads from the ground, lower the forks until they are just
above the ground and position the truck so that the forks are in line with
the entries of the load.
− When picking up loads from racks, raise or lower the forks to the height
of the entries and position the truck so that the forks are in line with the
entries.
The truck may not be used for lifting persons.
In racking operations the load may only be raised far enough to
allow it to be moved out without touching the rack.
If the forks are longer than the load, an appropriate amount of
space should be left free behind the load.
d600
− For mast lift, slowly move the right side
of the rocker to the lower contact sur-
face. Lift speed is proportional to the
deflection of the rocker.
Optional
− Pull the appropriately marked lever in
direction of the tiller

⇒ The forks will be lifted to the maximum lifting height while the rocker or
lever is activated.
Check: The load must be lifted high enough not to touch the floor.

− For mast lift, slowly move the right side

of the rocker to the lower contact sur-
face. Lift speed is proportional to the
deflection of the rocker.
d1200 Optional
− Pull the appropriately marked lever in
direction of the tiller

⇒ The forks will be lifted to the maximum lifting height while the rocker or
lever is activated.
Check: The load must be lifted high enough not to touch the floor.

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4.6.4 Putting down load

Before putting a load down the operator must satisfy himself that the stor-
age facility is appropriate as regards dimensions and load-carrying capac-
ity.
Before lowering the forks the operator must satisfy himself that there are
no people, objects or body parts of other personnel between the load and
the floor.

Move carefully towards the storage facility.

− To lower, slowly depress upper part of

d100 rocker switch. The lowering speed
cannot be regulated.

Move the vehicle out from under the load or pallet.

Move carefully towards the storage facility.

For mast lift:
− To lower the load carrier, move the right
side of the rocker switch slowly towards
the upper contact surface. The load will
lower in proportion to the deflection of
the rocker switch.
Optional
− Lower the load to transport height by
d400 On the initial lift version pushing the appropriately marked lever
there is a second rocker on away from you.
d400B the left side of the tiller
head.
− To lower in initial lift mode, move the
left side of the rocker switch slowly to-
wards the upper contact surface. The
lowering speed cannot be regulated.
Optional
− Lower the load to transport height by
pushing the appropriately marked lever
away from you.

Move the vehicle out from under the load or pallet.

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OPERATION MANUAL
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Move carefully towards the storage facility.

− To lower the load carrier, move the right

side of the rocker switch slowly towards
the upper contact surface. The load will
lower in proportion to the deflection of
d500 the rocker switch.
d600 Optional
− Lower the load by pushing the appro-
priately marked lever away from you.

Move the vehicle out from under the load or pallet.

Move carefully towards the storage facility.

− To lower the load carrier, move the right

side of the rocker switch slowly towards
the upper contact surface. The load will
lower in proportion to the deflection of
the rocker switch.
d1200 Optional
− Lower the load to transport height by
pushing the appropriately marked lever
away from you.

Move the vehicle out from under the load or pallet.

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4.6.5 Tilting mast

Before tilting the mast, make sure the load cannot shift.
When tilting the mast, watch that it cannot clip anything.

With mast tilted backwards

⇒ better hold on the load in drive mode

To tilt the mast backwards, carefully pull the appropriately

d600 marked lever in the direction of the tiller.

d1200
With mast tilted forwards
⇒ easier to pick up and set down load

To tilt the mast forwards, carefully push the appropriately

marked lever in the carrier direction.

The maximum mast tilt is dictated by the stroke of the tilting

cylinder, which mechanically limits it.

4.6.6 Mast reach

− Move carefully, with mast retracted, towards the load to be lifted.
− When picking up loads from the ground, lower the forks until they are
just above the ground and position the truck so that the forks are in line
with the entries of the load.
− When picking up loads from racks, raise or lower the forks to the height
of the entries and position the truck so that the forks are in line with the
entries.
d1200 − Carefully move the appropriately marked lever in the
direction of the load until the load is resting against the back
of the forks.
The truck may not be used for lifting persons.
See the truck owner's instructions for lifting different types of
loads.
If the forks are longer than the load, an appropriate amount of
space should be left free behind the load.

− Carefully move the appropriately marked lever in the direction of the

tiller until the load has been raised far enough.

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OPERATION MANUAL
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When picking up loads that are larger than the distance

between the wheel arms, the load must be raised to a height
above the height of the wheel arms before the mast is retracted.
In racking operations the load may only be raised far enough to
allow it to be moved out without touching the rack.
− Carefully move the appropriately marked lever in the
direction of the tiller until the mast has been fully retracted.
d1200
− In racking operations move the truck plus load out of the rack until the
load can be lowered without obstruction.
− Lower the load to transport height by pushing the appropriately marked
lever away from you.
− Check: The load must be lifted high enough not to drag along the floor.
− The truck can be moved in the manner described in point 4.5.

4.7 Parking the vehicle

Before leaving the vehicle it must be parked as described below. This also
applies even if the operator leaves the vehicle (i.e. it is no longer under his
immediate control) only briefly.

− Drive the vehicle to a suitable spot.

A suitable spot for parking the vehicle is a place with an even surface and sufficient
carrying capacity, where forklift trucks are permitted and where parking the vehicle
will not obstruct or endanger anyone or anything (e.g. other forklifts).

− Lower the forks as far as possible.

− Push the tiller to its upper end position.
− Turn the ignition key to the 0 position, remove it from the ignition and deposit it in
accordance with company rules.

On inclines measures must also be taken to prevent the truck accidentally rolling
away.

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 OPERATION MANUAL
MAINTENANCE

5. Maintenance
5.1 Safety regulations for maintenance

A knowledge of general regulations (e.g. UVV safety regulations, principles for testing
forklift trucks, etc.) as well as a knowledge of certain standards and directives (e.g.
requirements governing explosion-proof equipment) is required.

− After the work has been completed the forklift truck must be thoroughly
inspected, tested and test driven prior to its going back into operation.
All the functions of the forklift truck must be operated several times
without anything unusual being noticed.

5.1.3 Work on the electrical system

Only electrotechnical professionals as defined in the VDE 0100 may work on the
electrical system. Before they start work they must take all necessary measures to
avoid accidents caused by electric currents. Unless necessary for special reasons,
the key must be removed from the ignition during work on the electrical system, the
vehicle must be chocked, and the battery plugs disconnected.

5.1.4 Work on the hydraulic system

Only hydraulics professionals may work on the hydraulic system. Unless necessary
for special reasons, the key must be removed from the ignition during work on the
hydraulic system, the vehicle must be chocked and the hydraulic system must be
depressurized and cool (less than 40°C).

5.1.5 Work on the lifting device

Before commencing work on the lifting device, all assemblies which might shift or fall
by themselves must be secured by taking appropriate measures. If the forks are
raised, they must be secured against accidental lowering by, for instance, placing a
block of hardwood under the forks.

5.2 General hints on maintenance

Thoroughly performed maintenance of the vehicle is the best basis for its functional
safety and increases the life expectancy of all assemblies. The amount of work re-
quired for this is small in comparison with the breakdowns that can occur as a result
of not performing the necessary maintenance. For this reason the maintenance ac-
tivities listed in the maintenance plan must be carried out.

A malfunctioning vehicle poses a threat to persons and property.

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OPERATION MANUAL
MAINTENANCE

5.3 Maintenance plan

After the first 30, 60, 90, 120, 150, 210 − Tighten all screws visible on the outside
and 240 operating hours. and accessible after removal of covers
in accordance with torque table.
After the first 60, 120, 180 and 240 oper- − Check entire hydraulic system for leaks.
ating hours. − Check all unions are screwed on well.
− Check hydraulic hoses for damage.

Maintenance interval Maintenance activity

Prior to every start Check battery plug system.
The plugs and cable must be undamaged. The battery
cable must not be bent or worn.
Check load rollers.
Remove extraneous matter from the load rollers. If cracks
or cuts deeper than 2 mm are found in the load rollers,
replace load rollers.
Check drive wheel tire.
Remove extraneous matter from the drive wheel try. If
cracks or cuts deeper than 3 mm are found in the drive
wheel tire, replace the tire.
Check frame.
Tighten loosen bolt connections. If cracks are visible in the
welding seams, take the vehicle out of service immedi-
ately.
Check lifting device.
The lifting device must be replaced if cracks or excessive
reductions in cross section are detected or if the forks are
bent.

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 OPERATION MANUAL
MAINTENANCE

Weekly, or after max. 30 Check lifting cylinder.

operating hours Check the lifting cylinder for leaks.
Check the surface of the piston rod for damage and to en-
sure it is clean. Clean it if necessary.
Make sure the hydraulic connections are securely fas-
tened and check for leaks
Check battery.
Observe the Instructions for use from the battery manufac-
turer as well.
Check safety devices.
Check performance of the tiller head safety brake switch.
Check performance of the tiller gas spring.
Check function of the microswitch at the tiller joint.
Checking signs.
The certification signs and identification plates must be in
place and easily legible.
Monthly, or after max. Check wheels
120 operating hours Check diameter of the drive wheel, support rollers and the
load wheels. If the wheels are excessively worn of dam-
aged, replace the wheels.
Initial lift rod linkage (optional).
Lubricate the initial lift rod linkage. Check for damage.
Tiller
Lubricate tiller joint. Check tiller mounting.
Check forks.
Measure the width and the height of the forks. Replace,
when the profile is too less.
Check lift/lower operating elements
Check operating elements action for proper functioning
and ease of movement. Clean if necessary.
Check drive actuators.
Check drive switch for proper functioning and ease of
movement. Clean if necessary.
Check tiller head handle.
The two rubber handles must be in place, undamaged,
and provide a good grip (no remnants of grease). Replace
if necessary.
Service battery.
See the Instructions for use from the battery manufacturer
for the necessary maintenance work.

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OPERATION MANUAL
MAINTENANCE

Quarterly, or after max. Check wheel hub bearing.

400 operating hours Check for excessive play.
Lubricate the bearing.
Check hydraulic system.
Check hydraulic hoses for damage.
Check metal hydraulic lines for damage and corrosion.
Check hydraulic connections are tight.
Check electrical system.
Check all visible cable for damage. Make sure all electrical
connections are securely fastened and conductiv.
Check hydraulic oil level. If necessary replenish.
Check lifting device guides.
Check movement of guide rollers. Adjust if necessary.
Grease mast sections.
Check lifting chains.
Check the chains for excessive elongation.
Check chain fastenings. Check that cotter pins, lock nuts
and similar securing elements are in place and properly
fastened.
Check mast attachments.
Check guide rollers onthe cylinders for play.
Check that initial lift cylinder (optional) is securely at-
tached.
Check and lubricate initial lift guides (optional).
Check special fork model (e.g. with removable tip) for
proper performance.
Check brake performance.
Check regenerative braking.
Check spring loading of parking brake.
Annually, or after max. Replace hydraulic oil.
1400 operating hours Service battery.
See the Instructions for use from the battery manufacturer
for the necessary maintenance.
UVV test
At least once a year and following major repairs.

Section 5 Page 4 08.04 WART_1-12_ASM_1726_e.doc