WARNING!

Before using your Votex Bison EGH, read this manual carefully!

ATTENTION!
Please use this manual only for the machine with the machine number written in the lower right
corner of this page!

OPERATING INSTRUCTIONS
Votex Bison EGH
EGH 4T to 30T
Only applicable to the Votex
Bison EGH with
MACHINE NUMBER:
Votex Bison Material Handling B.V.
5150098
De Geestakkers 6
5591 RC Heeze
The Netherlands
For your own safety, please read the operating
instructions carefully before using your pallet truck!

It is very important that this manual is carefully read before using your pallet truck, so it
can be used in a safe and efficient way.
In this manual, you will find information concerning the safety and operating
instructions, as well as a daily maintenance program for optimal use of your pallet truck.

Safety instructions and important explanations are indicated by the following graphics:

Used before safety instructions which must be observed to avoid danger to

personnel.

Used before notices which must be observed to avoid material damage.

Used before notices and explanations.

Used to indicate standard equipment.

Used to indicate optional equipment.

Only people who are aware of needed the driver’s instructions, are allowed to operate
this machine.

Your employer is responsible to provide you the knowledge needed to operate the
machine safely. Please, do not hesitate to ask your supervisor for instructions if you have
any doubts or insecurities operating this machine.

Please, operate the pallet truck with regard to all the safety warnings in this manual and
the warnings applied on the pallet truck, so that accidents can be prevented.

Votex-Bison Material Handling BV

Our trucks are subject to ongoing development. Votex Bison reserves the right to alter the design,
equipment and technical features of the truck. No guarantee of particular features of the truck
should therefore be inferred from the present operating instructions.

Votex Bison EGH 4T – 30T Operating Instructions

Table of Contents

Page

General Safety Prescriptions ……………………………………1

Correct Application……………………………………………….5

Truck Description………………………………………………….6

Transport and Commissioning………………………………….14

Battery Maintenance, Charging & Replacement…………..16

Operation……………………………………………………………20

Truck Maintenance……………………………………………….22

Votex Bison EGH 4T – 30T Operating Instructions

General Safety Prescriptions
Safety Instructions

Please follow the safety instructions in this manual carefully, to prevent

accidents.

After delivery, check if all the safety and protection devices are working
accordingly. Before you use your pallet truck, please make sure to do the
daily check of your machine, further instructions to be found in the chapter
Truck Maintenance. The pallet truck should not be taken into use if any of the
safety or protection devices are not operable.

Also, before using the machine check if all the decals on the pallet truck are
clearly visible.

The battery must be securely fixed in the battery case. The battery in the
battery case must have the same weight as the weight indicated on the
machine plate (chapter Truck Description).

When the pallet truck is damaged in any way or not working accordingly, it
should not be used. This warning also applies to any repairs or adjustments
that are done without written preapproval of manufacturer Votex Bison.

This pallet truck is built and designed as a machine used lifting and
transporting in combination with the intended pallet and it should not be used
for anything else.

When the pallet truck is to be used in environments with extreme temperature

conditions, it must be equipped with the right adjustments.

It is not permitted to use your pallet truck for any other purposes than the ones
stated above, especially not the following:
 In environments with a high fire and explosion risk caused by dust or gas
containing air.
 As tow truck for other vehicles.
 To tow away other pallet trucks or vehicles that are used for
transporting cargo.
 To lift or transport people.

1
Responsibilities of the driver

 The pallet truck should only be operated by persons who have are
aware of the needed driver’s instructions and who have read the
operating instructions thoroughly.
 Every country has it’s own safety regulations and application
instructions for this kind of machinery. The operator of this pallet truck is
obligated to be aware of those regulations and operate with regard to
these regulations while handling the pallet truck. If the regulations in this
manual are contradictory to the local regulations, the local regulations
should be applied.
 For pallet truck with additional insurance coverage, the insurance cost
and coverage, are those that in correspondence with legal regulations
in the environment in which the machine is operated.
 Accidents that result into damage to persons, environment or
equipment should be directly reported to an executive. This also goes
for almost-accidents and discovered defects and faults with regard to
the pallet truck.
 Operate the pallet truck alert, with care and in full awareness of the
responsibilities that come with operating this kind of machinery.
 Make sure the truck operator is ensured with regard to the local
legislation.
 With regard to skidding risk, never operate the pallet truck with greasy
hands.

Working space

As far as available, use roads that are designated for loading machinery.
Drive this pallet truck only on steady and level floors, e.g. on asphalt or
concrete floors.

Keep in mind, that the ground should be able to hold the weight of the pallet
truck (including battery) plus the max permitted load weight of the truck.

Please mind any irregular obstacles and damages in the working space that
could cause injuries or material damage while operating the pallet truck.

Any inconvenience that is caused by the presence of other people in the

working space is prohibited, because it may lead to injuries. E.g. people
moving in the operating space of the pallet truck or goods standing in the
operating space.

2
Driving the pallet truck

 Steadily drive the pallet truck away from its designated parking spot.
 Drive/operate the truck in a controlled motion with full awareness of
surrounding conditions. Sudden braking and curving should be avoided
in a higher speed.
 On slopes, operate the pallet truck in reduced speed and the load
facing downwards. Turning on slopes is prohibited.
 On slippery grounds, drive in reduced speed to prevent the pallet truck
from spinning or falling over.
 Adjust the driving speed of the machine to the obtained traffic
regulations. Watch out for pedestrians and order loading equipment.
When the view is obstructed by the load, the driving speed should be
reduced.
 When the load is blocking the view, always operate the truck with the
load facing backwards.
 When your sight is reduced, ask one of your colleagues to give you
directions, to reduce damage and injury risks.
 When there are people in the operating space of the pallet truck, be
prepared to turn of the pallet truck at any moment.
 Keep a sufficient distance from any machine driving in front of your
pallet truck.
 When operating the pallet truck on a loading bridge, keep a proper
distance from the edges. When the required distance from the edge is
marked, always keep the pallet truck within the lines.
 Use the horn to make people in the environment aware of the
presence of the pallet truck, especially when overtaking a person.
 Give way to loaded trucks at crossroads and narrow aisles.
 The transportation of people is strictly forbidden.
 Before you drive the pallet truck onto a loading bridge, make sure that
the load is securely fastened and that the total weight of the pallet
truck (including load and battery) does not exceed the capacity of the
loading bridge. Drive slowly and carefully on the bridge and mind your
distance to the edges.
 When loading this pallet truck onto another vehicle, please make sure
that this vehicle is securely fastened and check the (hand)brake.
 Before driving onto a lift, make sure that the lift is capable of holding
the pallet truck, the load weight and driver. Drive onto the lift with the
load facing forward and make sure there are no other people present
in the lift.

3
Handling cargo

 Operate the pallet truck carefully when loading or unloading cargo.

 Only handle load that does not exceed the max capacity of the pallet
truck.
 Transport only load that is stabile and securely and carefully packed.
 Handle long or high cargo with extra care.
 Make sure that the centre of gravity of the load is always higher than the
load centre of the pallet truck.

Turning off your pallet truck

 When turning off your pallet truck, make sure the forks rest on the floor and
that the brakes are fastened.
 When available, park the pallet truck in a designated parking spot.
 Never leave the key in the ignition lock when turning the machine off for a
longer period of time.
 Never turn off the pallet truck when on an inclined plane.
 Never park the pallet truck in front of an emergency exit.
 Never park the pallet truck in a place where it will obstruct other traffic or
working activities.

Handling the battery

 Handle battery and connectors with care. Instructions on changing and

handling the battery can be found in the chapter Battery maintenance,
charging and replacement.
 When working with the battery, always wear protective goggles.
 Make sure that the weight of the battery is the same as the battery weight
indicated on the machine plate.
 Make sure that the battery is securely fastened in the battery container.

Maintenance and repairs

For proper the maintenance of the pallet truck, please check the chapter on truck
maintenance. In this chapter you will find a maintenance schedule that is designed
to prevent the pallet truck from breaking down or causing accidents. Installing,
maintaining and repairs must be only preformed by qualified personnel or Votex
Bison mechanics.

Only spare parts that are preapproved by Votex Bison should be used for the pallet
truck.

All modifications and conversions that change or reduce functions of the pallet truck
are prohibited.

4
  Correct Application

The truck described in the present operating instructions is an industrial truck

designed for lifting and transporting loads.

It must be applied, operated and serviced in accordance with the instructions

contained in the present manual. All other types of use lie beyond the scope
of application and can result in damage to personnel, the truck or property. In
particular, avoid overloading the truck with loads which are too heavy or
placed on one side. The data plate attached to the truck or the load chart
are binding for the maximum load capacity. The industrial truck must not be
used in fire or explosion endangered areas, or areas threatened by corrosion
or excessive dust.

Proprietor responsibilities: For the purposes of the present operator manual 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 to be the person who, in
accordance with existing contractual agreements between the owner and
user of the industrial truck, is charged with operational duties.
The proprietor must ensure that the industrial truck is used only for the purpose
it is intended for and that danger to life and limb of the user and third parties
are excluded. Furthermore, accident prevention regulations, safety
regulations and operating, servicing and repair guidelines must be followed.
The owner must ensure that all truck users have read and understood these
operating instructions.

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’s customer service
department.

Attaching accessories: The mounting or installation of additional equipment

which affects or enhances the performance of the industrial truck requires the
written permission of the manufacturer. In some cases, local authority
approval shall be required. Approval of the local authorities however does not
constitute the manufacturer’s approval.

5
Truck Description
Application
The truck is designed for transporting goods on level surfaces. The truck can lift open
bottom or diagonal board pallets as well as roll cages beyond the area above the
load wheels. The capacity is shown on the capacity plate, for details see further in
this chapter.

Truck types, capacity and motor output:

Type Capacity Motor output

EGH 4T 4.000 kg 2,5 kW
EGH 10T 10.000 kg 2,5 kW
EGH 20T 20.000 kg 3 kW
EGH 30T 30.000 kg 6 kW
(2x 3 kW)
EGH 40T 40.000 kg 6 kW
(2x 3 kW)

6
General truck description

Drive system
The drive system is operated by an electrically driven AC motor. Changing the
driving speed can be managed by using the drive switch that is placed on the tiller
head.
Because of the three-point design (one drive wheel and two load wheel sets), the
pallet truck has a very stable support system.

Steering system
The steering system will be electrically empowered as soon as the tiller head
generates a move to left or right.
The steering angle is defined by limit switches. If the steering system may fail, the
machine can also be mechanically driven. But this is only meant to move the pallet
truck to a safer location if needed.

Brake system
The braking system consists of an electrically driven magnet brake. This brake will be
activated when the tiller head is released or pushed downward, or by turning off the
machine. When there is a failure during the operation of the machine, the brake
system will also be activated.
When the opposite driving direction is activated during driving, there will be a
backflow send to the motor. First, the speed will be reduced to zero, then the
machine will continue to drive into the other direction. Also, if the drive direction
switch is not operated, there will be a backflow send to the drive motor, which will
cause the machine to stop.
A safety switch is put on the top of the tiller head, to prevent people from getting
stuck between the machine and immobile obstacles.

Frame
The frame consists of three joint constructions.
The first one is the drive-part, which contains the drive system, controls and
hydraulics. The second part is the battery container, which holds the battery. And the
last one is the lifting system, on which the cargo can be loaded.

Lifting system
The hydraulic installation consists of a hydraulic aggregate, which operates the
cylinders that moves the lifting system.
The aggregate is operated by switches on the tiller head.

7
Assemblies and functional description

Pos. Description
1 Load wheels
2 Type plate / Load diagram
3 Lid battery container
4 Emergency stop button
5 Ignition lock
6 Battery indicator
7 Tiller head
8 Drive unit
9 Lift/load unit
10 Battery container
Calibration switch (blue)

8
Version Specifications

Technical modifications and additions reserved.

Performance data for standard trucks

Description EGH 10T EGH 20T EGH 30T EGH 40T EGH 4 T

Q Capacity 10.000 20.000 30.000 40.000 4.000 kg

Load centre
C distance 625 mm

Travel speed km/h

with/without 3/5
load
Lift speed cm/sec
with/without -
load
Lower speed cm/sec
with/without -
load
Max. grade
ability ( 5 min) 3/2 %
with/without
load

9
Dimensions

Pos. Description EGH 10T

5150024
1 Truck width 700 mm
2 Truck length (6 +7) 2390 mm
3 Distance between forks 240 mm
4 Width across forks 700 mm
5 Truck height 880 mm
6 Truck length without forks 1140 mm
7 Fork length 1250 mm
8 Load centre 625 mm
9 Drivers platform - mm
10 Wheelbase 1730 mm
11 Fork height from ground 135 mm
Q Capacity 10000 kg

10
EG Declaration of conformity

The pallet truck comes with a EG declaration of conformity. Below an example

of what A Votex Bison EG declaration of conformity looks like.

The machine type, machine number and date ought to be filled out and this
declaration must be signed by an authorized representative of Votex Bison
Material Handling.

11
EN norms

Noise level: 70 dB(A)

in accordance with EN 12053.
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 driver’s ear.

Electromagnetic Compatibility (EMC):

The manufacturer confirms that equipment complies with tolerance levels for
electromagnetic emissions and resistance as well as static electricity discharge
testing in accordance with EN 12895 including the normative
procedures contained therein.

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

made without the written agreement of the manufacturer.

Conditions of use
Ambient temperature
- during operation 5°C to 40 °C

Special equipment and authorisation is required if the truck is to operate

constantly below 5 °C or in a cold store or in extreme temperatures or conditions
of fluctuating air humidity.

12
Decals

On the pallet truck you will find several warning decals. In this paragraph you will find
the description of the warning signs:

When handling the pallet truck, be

careful to not let your hands get
stuck in the machine.

Make sure that you or bystanders will not get

stuck between the machine and a wall or any
other immobile object.

Operate the machine with care. Before

handling the machine, read the
manual.

Make sure to take the key out of the

ignition lock.

If any of the decals become unreadable, it is advised to replace them. The warning
signs can be ordered at Votex Bison with the article reference in the lower right
corner.

13
Truck data plate

The load handler must be raised to check the data plate.

Votex Bison EGH Machine plate Example

Description
1 Machine type
2 Machine number
3 Year of Manufacturing
4 Capacity / Load centre
5 Weight of machine with battery
6 Battery weight
7 Battery voltage

14
Transport and Commissioning

Lifting by crane
Only use lifting gear with sufficient capacity
(Loading weight = net weight + battery weight; see truck data plate).

Attach the crane slings to the strap points so that the truck cannot slip. Lifting
slings should be fastened to the harness in such a way that they do not come
into contact with any parts of the truck when it is being raised.

Using the truck for the first time

Only operate the truck with battery current. Rectified AC current will damage
the electronic components.

To prepare the truck after delivery or transport the following tasks must be
carried out:

– Make sure the truck is fully equipped and in a satisfactory condition.

– Install battery (where required). Do not damage battery cable.
– Charge the battery (see Chapter Battery maintenance).
– If the customer uses a maintenance-free battery, the discharge indicator
setting must match the battery type (manufacturer’s service department to
check).
– Start up the truck in accordance with instructions (see Chapter Operation).

15
 Operating the truck without its own drive system (emergency operation)

This operating mode is not permitted when negotiating inclines and gradients.

If the truck has to be moved after a failure has rendered it immobile, proceed
as follows:
– Set the isolator “OFF”.
– Set the key switch “OFF” (“0”) and remove the key.
– Prevent the truck from rolling away.
– Remove the front panel (1) (see Chapter Truck maintenance).
– Pull up the anchor plate by screwing in three M8 screws (at least 35 mm long)
as far as the stop.

The brake is now released and the truck can move.

On reaching your destination, ensure that the brake is restored to its initial state.
The truck must never be parked with the brakes released.

– Remove the screws (2).

The brake is now applied again.

16
Battery Maintenance, Charging & Replacement
Safety regulations for handling acid batteries

Park the truck securely before carrying out any work on the batteries (see
Chapter Operation).

Maintenance personnel: Batteries may only be charged, serviced or replaced

by trained personnel. The present operator manual and the manufacturer’s
instructions concerning batteries and charging stations must be observed
when carrying out the work.

Fire protection: Smoking and naked flames must be avoided when working
with batteries Wherever a truck is parked for charging there shall be no
inflammable material or operating fluids capable of creating sparks within 2
metres around the truck. The area must be well ventilated. Fire protection
equipment must be provided.

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. Batteries with non insulated terminals must be covered with
a non slip insulating mat.

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.

Before closing the battery panel make sure that the battery lead cannot be
damaged.

Batteries contain an acid solution which is poisonous and corrosive. Therefore,

always wear protective clothing and eye protection when carrying out work
on batteries. Avoid all contact with battery acid.
Should however clothing, skin or eyes come in contact with acid the affected
parts should be rinsed with plenty of clean water - where the skin or eyes are
affected call a doctor immediately. Immediately neutralise any spilled battery
acid.

The weight and dimensions of the battery have considerable affect on the
operational safety of the truck. Battery equipment may only be replaced with
the agreement of the manufacturer.

17
 Battery types
The battery weights can be taken from the battery data plate.

Depending on the particular model, the EGH can be fitted with different
battery types (see chapter Truck description).

Batteries with non insulated terminals must be covered with a non slip
insulating mat. When replacing or installing batteries, ensure that the battery is
correctly secured in the battery compartment of the truck.

When replacing or installing batteries, ensure that the battery is correctly

secured in the battery compartment of the truck.

Exposing the battery

– Park the truck securely (see Chapter Operation).

– Open the battery panel (2). To do this hold the panel by the handle mould (1)
and lift it up.
– Where necessary remove the insulating mat from the battery.

18
 Charging the battery

To charge the battery, the truck must be parked in a closed and properly
ventilated room. When charging, the tops of the battery cells must be exposed
to provide sufficient ventilation. Do not place any metal objects on the
battery. Check plug connections for visible signs of damage. All safety
instructions given by the battery and battery charger manufacturers must be
strictly observed.

Charging the battery with a stationary charger

– Disconnect the battery connector from the truck connector.

– Expose the battery.
– Connect the battery connector with the charging lead of the stationary
charger.
– Turn on the charger.

19
 Battery removal and installation

Changing the battery from the top

The truck must be level. To prevent short circuits, batteries with exposed
terminals or connectors must be covered with a rubber mat. Place the battery
connector or the battery cable in such a way that they will not get caught on
the truck when the battery is removed.

When transporting batteries using a crane, ensure that the crane and lifting
equipment is of adequate capacity (the battery weight is indicated on the
battery data plate on the battery container). The crane lifting gear must exert a
vertical pull. The hooks of the lifting gear must never fall into the battery cells.

– Expose the battery (see photos).

– Disconnect the battery connector from the truck connector.

Place the battery cable on the tray that it can not be severed when the
battery is pulled out.

– Strap the crane lifting gear to the eyes on the side of the battery.
– Pull the battery up out of the container.

Installation is the reverse order. When reinstalling the battery, note the proper
installation position and make sure the battery is connected correctly. Place
the battery cable on the tray so that it cannot be severed when the battery is
inserted.

– After installing the battery, check all cables and plug connections for visible
signs of damage.

Closely the battery panel slowly and carefully. Do not reach between the
battery panel and the chassis.

20
Operation
Safety Regulations for the Operation of Forklift Trucks

Driver authorisation
The forklift 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, obligations and responsibilities:

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 operator manual.
The driver shall be afforded all due rights. Safety shoes must be worn for
pedestrian operated trucks.

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
forklift 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 industrial
truck without the necessary training and authorisation to do so. The driver must
never disable or adjust safety mechanisms or switches.

Hazardous area: A 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.

Unauthorised persons must be kept away from the hazardous area. Where
there is danger to personnel, a warning must be sounded with sufficient
notice. If unauthorised personnel are still within the hazardous area the truck
shall be brought to a halt immediately.

Safety devices and warning signs: Safety devices, warning signs and warning
instructions shall be strictly observed.

21
Operating the truck

Before operating the pallet truck, the daily check up must be done.

This check up contains:

 Checking for any damage on the pallet truck
 The functioning of the drive, brake and steering system
 Wheel damage
 Functioning of all operating means, emergency button, tiller head and
switches
 Lift mechanism
 Condition of the battery, the water level and if the battery is charged
enough.
 Functioning of the horn

The machine can be turned on by the ignition key. By holding the tiller head
in horizontal position, the brakes will be released and the pallet truck will be
able to drive.

With the driving switch on the drive shaft, the forwards as well as the
backwards driving speed can be chosen.

Braking with the machine can be managed in three ways:

1. Stop using the drive switch, the machine will brake because of the
backflow to the drive motor.
2. Activate the opposite driving direction, the machine will brake
because of the backflow to the drive motor.
3. Pull/push the tiller head down/up. This will activate the magnet brake.

If the safety switch on the head of the drive shaft is switched on, the machine
will always drive in load direction. This to prevent the truck operator from
getting stuck between the pallet truck and a wall or immobile object.

The lift direction can be chosen by operating the rocker switch on the tiller
head.

The display shows the total operating hours of the machine as well as the
battery condition. The red LED next to the display will light up in the case of a
failure in the steering system.

When this happens, turn the machine off and wait one minute before
switching it on again. If this does not solve the failure, the pallet truck cannot
be operated anymore. Contact your dealer.

A list of the different blink/failure codes is included in the manual. Please

consult the failure codes for possible solutions (the list can be found under tab
10)

22
Truck Maintenance
Operational Safety and Environmental Protection
The servicing and inspection duties contained in this chapter must be
performed in accordance with the intervals indicated in the maintenance
checklists.

Any modification to the forklift truck assemblies, in particular the safety

mechanisms, is prohibited. The operational speeds of the truck must not be
changed under any circumstances.

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. Used parts, oils and fuels must be disposed of in
accordance with the relevant environmental protection regulations. For oil
changes, contact the manufacturer’s specialist department.

After inspection and maintenance work, carry out the operations listed in the
“Recommissioning” section (see Section 6.5).

Maintenance Safety Regulations

Maintenance personnel:
Industrial trucks must only be serviced and maintained by the manufacturer’s
trained personnel. The manufacturer’s service department has field
technicians specially trained for these tasks. We therefore recommend a
maintenance contract with the manufacturer’s local service centre.

Lifting and jacking up:

When an industrial truck is to be lifted, the lifting gear must only be secured to
the points specially provided for this purpose. When jacking up the truck, take
appropriate measures to prevent the truck from slipping or tipping over
(e.g. wedges, wooden blocks). You may only work underneath a raised load
handler if it is supported by a sufficiently strong chain.

Cleaning:
Do not use flammable liquids to clean the industrial truck. Prior to cleaning,
implement all necessary safety measures to prevent sparking (e.g. through
short circuits). For battery-operated trucks, the battery connector must be
removed. Only weak suction or compressed air and non-conductive antistatic
brushes may be used for cleaning electric or electronic assemblies.

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.

After cleaning the truck, carry out the activities detailed in the
“Recommissioning” section.

23
Electrical System:
Only suitably trained personnel may operate on the truck’s electrical system.
Before working on the electrical system, take all precautionary measures to
avoid electric shocks. For battery-operated trucks, also de-energise the truck
by removing the battery connector.

Welding:
To avoid damaging electric or electronic components, remove these from
the truck before performing welding operations.

Settings:
When repairing or replacing hydraulic, electric or electronic components or
assemblies, always note the truck-specific settings.

Tyres:
The quality of tyres affects the stability and performance of the truck. When
replacing tyres fitted at the factory, only use the manufacturer’s original spare
parts. Otherwise the data sheet specifications of the truck cannot be
guaranteed. When changing wheels and tyres, ensure that the truck does not
slew (e.g. when replacing wheels always left and right simultaneously).

Hydraulic hoses:
The hoses must be replaced every six years. When replacing hydraulic
components, also replace the hoses in the hydraulic system.

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.

Hydraulic load wheel calibration:

When the machine is equipped with hydraulic load wheels, a calibration
button is mounted on the dash. When the lifting height left and right is
different, air in the cylinders may cause the problem and recalibration with an
unloaded machine is necessary. Therefore lift and lower the load part of the
machine completely with the blue “calibration button” enabled several times.

The service intervals stated are based on single shift operation under normal
operating conditions. They must be deduced accordingly if the truck is to be
used in conditions of extreme dust, temperature fluctuations or multiple shifts.

During the run-in period – after approx. 100 service hours – the owner must
check the wheel nuts/bolts and re-tighten if necessary.

24
Maintenance intervals

Daily:
 Check the battery condition
 Check the machine for any damage and technical failure
 Check brake, drive, emergency button and tiller head function
 Check the wheels for damage and filth

Weekly:
 Check the fluid level in the battery. The battery may only be filled after
charging
 Check the battery connectors
 Check for oil leakage

Quarterly (200 hours):

 Check the magnet brake for signs of wear and clean the brake system
with compressed air
 Check whether the contactors of the relays are in good condition
 Check the margins of the toothed wheels (of the steering system) and
grease them
 Check the hydraulic system for leakage and oil level
 Clean the machine with compressed air
 Replace the oil in the drive system (Once after 200 hrs, after that yearly
or 2500 hrs) Oil to be used: SAE 80-90 / 0,7 litre

Yearly (1000 hours):

 Check for burn in damage in the collector of the drive and steering
motor
 Grease the bearing of the drive motor
 Grease the rolls and turning points of the lifting system
 Replace the hydraulic oil (BP TP 46)
 Check the cylinders for leakage and other damage
 Establish the correct margins for the brake system (0,3 mm) and check
the brakes for wearing damage.
 Check the electric system for any loose contacts.
 Replace the oil in the drive system
 Check the battery for leakage

25