Operating instructions

Model: VH-WS 12.5/30

Serial no.:

http://www.genkinger-hubtex.com mail to: info@genkinger-hubtex.com

Genkinger-HUBTEX. GmbH Postfach 11 20 Tel.: (07381) 186-0

D- 72521 Münsingen Fax.: (07381) 186 49
B40_0229GB.doc 21.06.2007
General

General

READ AND OBSERVE THESE DIRECTIONS FOR USE!

Only suitably trained specialist personnel who have received instruction at the machine in accordance with the
directions for use may be permitted to work with the truck.

Any liability or warranty claims are excluded in the event that:

C The instructions contained in these directions for use are not observed,
C The machine is incorrectly operated, cleaned or maintained,
C Functional modifications or conversion work are performed without the consent of the manufacturer,
C Non-original spare parts are used.

Declaration:

I have read and understood these directions for use and in particular the safety instructions.

Name Date Signature

2 21.06.2007 B40_0229GB.doc
 Declaration of conformity

Declaration of conformity

EC declaration of conformity
in accordance with machine directive 98/37EG, Annex II A
The manufacturer / vendor

Genkinger-HUBTEX. GmbH
Postfach 11 20
D 72521 Münsingen
Tel +49 7381 186 0 e-mail: info@genkinger-hubtex.com
Fax +49 7381 186 49 www.genkinger-hubtex.com

hereby declares that the following product

Make Electric pedestrian fork high-lift pallet truck

Product designation VH-WS 12,5/30
Serial number See nameplate
Year of construction 2007

complies with the regulations of the following directives, including any amendments applicable at the time of
declaration.

EC Directive 98/37/EC

Issue date
Harmonized standards DIN EN ISO 12100-1 04 - 2004

DIN EN ISO 12100-2 04 - 2004

DIN EN 1175-1 11 - 1998

DIN EN 1726-1 11 - 1999

DIN EN 60204-32 06 - 1999

Münsingen, 24.09.2007

A. Winter
(Chief Executive Officer)

B40_0229GB.doc 21.06.2007 3
Table of Contents

Table of Contents

General ...................................................................................................................................... 2
Declaration of conformity........................................................................................................... 3
Table of Contents ...................................................................................................................... 4
Safety Instructions ..................................................................................................................... 5
Basic principles ..................................................................................................................... 5
Used symbols and pictograms .............................................................................................. 6
General.................................................................................................................................. 7
Organizational details, personnel, areas of competence...................................................... 8
General safety principle ...................................................................................................... 10
Product-specific hazards..................................................................................................... 10
Product description.................................................................................................................. 11
View..................................................................................................................................... 11
Intended application of the pallet truck / high-lift pallet truck .............................................. 12
Load capacity diagram ........................................................................................................ 12
Nameplate ........................................................................................................................... 12
Signs attached to the truck.................................................................................................. 13
Product and performance data............................................................................................ 14
Ambient conditions.............................................................................................................. 15
Weights and measures ....................................................................................................... 15
Transport ................................................................................................................................. 16
Commissioning ........................................................................................................................ 17
Operation................................................................................................................................. 18
Operator's Controls ............................................................................................................. 18
Safety elements: ................................................................................................................. 19
Initial test drive .................................................................................................................... 20
Driving: ................................................................................................................................ 21
Driving using the ride-on platform ( options ) ..................................................................... 22
Braking ................................................................................................................................ 23
Hooting ................................................................................................................................ 23
Lifting and lowering ............................................................................................................. 24
Load pick-up........................................................................................................................ 25
Transporting loads .............................................................................................................. 26
Before leaving the truck unattended ................................................................................... 26
Driving on slopes................................................................................................................. 27
Maintenance and repair........................................................................................................... 28
Organizational measures, personnel deployment............................................................... 28
Troubleshooting instructions ............................................................................................... 29
Directions for use of the drive batteries .............................................................................. 31
Battery charging .................................................................................................................. 32
Requirements for maintenance personnel / areas of competence ..................................... 33
Maintenance – daily / prior to use ....................................................................................... 35
Servicing - monthly.............................................................................................................. 37
Servicing - 6-monthly .......................................................................................................... 39
Servicing – annually / 2 years / 6 years .............................................................................. 41
Oil change ........................................................................................................................... 42
Lubricant table..................................................................................................................... 43
Adjusting the load chains .................................................................................................... 44
Care and maintenance of load chains ................................................................................ 45
Temporary decommissioning .............................................................................................. 47
Recommissioning after extended standstill periods............................................................ 47
Final decommissioning........................................................................................................ 47
Logbook ................................................................................................................................... 49

4 21.06.2007 B40_0229GB.doc
 Safety Instructions

Safety Instructions
This chapter provides information to the user on residual risks and dangers when using the product in
compliance with its intended purpose. Generally applicable safety instructions which must be observed are
listed.

Specific safety instructions relating to particular operating circumstances or situations are provided in the
following at the beginning of the relevant instructions or in chapters describing the situations in question.

Basic principles
C Although this product is in compliance with the state of the art and the generally accepted rules of
technology, certain hazards can arise.
C Only operate the product when in flawless condition in compliance with the operating instructions.
C The user is obliged throughout all phases of the product's service life, starting at the planning stage, for
ensuring its safe integration in its environment and for minimizing residual risks.
C Only suitably trained specialist personnel may work at the machine who have received instruction at the
machine in accordance with the directions for use. The operating instructions must be understood
(responsibility, monitoring).

Any liability or warranty claims are excluded in the event that:

C The instructions contained in these directions for use are not observed,
C The machine is incorrectly operated, cleaned or maintained,
C Functional modifications or conversion work are performed without the consent of the manufacturer,
C Non-original spare parts are used.

These operating instructions must be supplemented to include instructions based on existing nationally
applicable regulations relating to accident prevention and environmental protection.


%

B40_0229GB.doc 21.06.2007 5
Safety Instructions

Used symbols and pictograms

Alongside the text and pictures, these operating instructions contain various symbols designed to draw attention
to the safety requirements. They are in compliance with the ISO 3864 and ANSI Z535 standards.

Their appearance is generally as follows:

Signal words
- Classification
Significance
according to ANSI Z
535.4
Warning of an immediate threat of danger!
DANGER Failure to observe this warning will result in fatal or extremely serious
injury.

Warning of a potentially occurring hazardous situation.

WARNING Failure to observe this warning could result in fatal or extremely serious
injury.

Warning of a potentially occurring hazardous situation.

CAUTION
May only be used to warn against potential material damage.

Other definitions:

Denotes application tips and other useful information.

NOTE
Warns against hazardous situations.

Warns against a potentially damaging situation.

IMPORTANT
Failure to observe this warning can result in material damage.

Used symbols and pictograms

Possible personal or material Riding on transport devices is

damage prohibited !

Danger of crushing ! Do not walk under raised loads!

Lashing points for truck transport

Wear safety shoes IMPORTANT

6 21.06.2007 B40_0229GB.doc
 Safety Instructions

General

W o r k p l a c e s, h a z a r d o u s a r e a s

See "product-specific hazards" page 10

Warning signals

See "product identification" page 13

B40_0229GB.doc 21.06.2007 7
Safety Instructions

Organizational details, personnel, areas of competence

What needs to be done? Who is responsible for execution?

- Commissioning
- Selection and instruction of personnel
- Assignment of powers of authorization
- Instruction and monitoring
- Analysis of operational hazards
- Implementation of minimized risk operation
- Definition of work areas
- Determination and release of travel routes
- Identification of hazard areas on designated travel routes
using customary road signs and if applicable additional - Head of the area of responsibility
warning signs
- Periodic repetition of personnel instruction
- Evaluation of faulty procedures
- Evaluation of occurred faults
- Notification of any occurred faults
- Notification of any occurred faults and defects in the
product / manufacturer's operating instructions to the
manufacturer and assurance of availability
- Set-up and operation of the pallet truck / high-lift pallet
truck
- Reporting and registration of faults
- Arranging for maintenance and repairs - Operator (skilled personnel1)
- Cleaning and care
- Securing the pallet truck / high-lift pallet truck against
unauthorized third party use (pulling out the key)
- Operation of the pallet truck / high-lift pallet truck
- Reporting faults
- Arranging for maintenance and repairs
- Operator (instructed personnel2)
- Cleaning and care
- Securing the pallet truck / high-lift pallet truck against
unauthorized third party use (pulling out the key)
- Mechanical operations - Mechanic (skilled personnel1)
- Electrical work - Electrician (skilled personnel1)
- Battery maintenance - Skilled personnel1
- Annual inspection of the pallet truck / high-lift pallet truck - Servicing (expert 3)
- Transport - Skilled transport personnel
- Maintenance - Service Genkinger-HUBTEX Co.
- Qualified and instructed specialist
- Repairs
personnel
1)
As per DIN 31000: Skilled personnel are persons whose specialist training, skill and experience and also knowledge of the
applicable regulations permits them to appraise work carried out under their instructions and recognize any possible hazards.“
2)
As per DIN 31000: Instructed personnel are persons who have been instructed and if necessary received appropriate training
regarding the work to be performed and any possible hazards which could arise in case of incorrect conduct, and who have been
informed about the necessary safety equipment and safety measures.“
3)
As per BGV D27 §37: Specialist personnel are persons who due to specialist training and experience have extensive knowledge in
the field of transport trucks and who are sufficiently familiar with the valid statutory occupational safety regulations, accident
prevention regulations, guidelines and generally accepted rules of technology to be able to judge whether transport trucks are in a
safe working condition.

8 21.06.2007 B40_0229GB.doc
 Safety Instructions

D U T Y TO R E P O R T faults and damage

The head of the respective field of responsibility is obliged to provide immediate notification.
This does not include occurrences of an insignificant nature.
Occurrences must be logged and evaluated in the attached "logbook".
Logbook suggestion ¹ see annex to the operating instructions.

P R O H I B I T I O N on modifications and conversions

Modifications of any kind are prohibited on principle. Modifications may only be performed in cooperation with
and with the consent of the manufacturer. As the approval of and execution of modifications must be traceable,
adequate records must be kept. Verifications must be stored in a safe and proper manner; they will be required
in the event of damage or for inspection by the Trading Standards Authorities or the Employers' Liability
Insurance Association.

%

B40_0229GB.doc 21.06.2007 9
Safety Instructions

General safety principle

It is inadmissible:
- For persons to walk or stand under the raised load pick-up unit, irrespective of the laden or unladen status
of the truck.
- To stand on the load pickup unit and to use the high-lift pallet truck as a hoisting platform.
It is prohibited:
- To step or reach into moving parts of the high-lift pallet truck such as the mast, shift units, load pick-up
devices, attachments etc.
- For protective gear or safety features to be bypassed or removed.
- Functional modifications or conversion work without the agreement of the manufacturer.

Product-specific hazards

which can occur in the event of incorrect operation of the high-lift pallet truck or use for any other than its
intended application.

CAUTION

Shearing and crushing areas are

unavoidable in the entire working
area of the machine.
Danger of injury. For this reason,
only the operator may be permitted
to remain in the working area of
the equipment. The work station
for the operator is the drawbar.

10 21.06.2007 B40_0229GB.doc
 Product description

Product description
This chapter imparts basic information about the product and its use as prescribed.

3
View 1
4
Options
Pallet truck / high-lift pallet truck with 2
ride-on platform

13 8 10 7 9

14

12

15

16

1 Mast 9 EMERGENCY STOP button

2 Drawbar with drawbar head 10 Hand lever switching valve
3 Load chains 11
4 Lift cylinder 12 Pulse control system
5 Load pick-up forks 13 Hooter
6 Load rollers 14 Hydraulic unit
7 Key-operated switch 15 Travel drive
8 Battery controller 16 Steering rollers

B40_0229GB.doc 21.06.2007 11
Product description

Intended application of the pallet truck / high-lift pallet truck

For the lifting, lowering and transportation of loads in accordance with the specifications on the nameplate
and the load capacity diagram
The use of the truck is restricted to level surfaces
For use in closed buildings

The pallet truck / high-lift pallet truck is not intended for:

Use in explosive atmospheres!
Continuous use in cold stores.

Conformity

....... in respect of safety, legislation, statutory requirements, directives, standards (general and country-specific)
and quality requirements is hereby certified.

Load capacity diagram

Nominal load capacity

Lift height

Load centre
of gravity

Nameplate

12 21.06.2007 B40_0229GB.doc
 Product description

Signs attached to the truck

optional

Resttragfähigkeit [kg]

B40_0229GB.doc 21.06.2007 13
Product description

Product and performance data

Drive system
Operating voltage: 24 V
Battery version: 2x12V 70 Ah
Drive motor: 24 V / 1.2 kW
Drive control: Threephase control
Brake
Counter current brake: By means of pulse control

Parking - A supplementary spring-powered brake

Emergency brake: activated by releasing or pressing down
the drawbar
Lifting device
Lift motor 24 V / 2.0 kW
Lift / lower by means of pushbutton
from the drawbar head.

Carriage
Drive wheel dia. 250 x 80 mm polyurethane
Steering roller dia. 100 x 50 mm polyurethane
Load rollers dia. 80 x 85 mm polyurethane
Charger
Charger Integrated charger
Mains connection: 230 V 50 Hz 16 A mains fuse
The charger switches off automatically on completion of the charging process

Incline: The maximum traversable incline for the truck is:

unladen = 10%
laden = 6%

14 21.06.2007 B40_0229GB.doc
 Product description

Ambient conditions

from +15 °C
Temperature
to +50 °C

Degree of humidity ≤ 70 %

Admissible floor incline

• laden max. 0.5 %

• unladen1) max. 2.0 %

Weights and measures

Intrinsic weight including

m See nameplate kg
battery

1)
When traversing between differing buildings etc.

WARNING!

The real load capacity of the high-lift pallet truck lies within the responsibility of the user.
This depends upon the operator, the condition of the floor and the high-lift pallet truck,
and on the frequency of maintenance intervals.

%

B40_0229GB.doc 21.06.2007 15
Transport

Transport

Only attach lifting gear in the marked

locations

CAUTION
Only use lifting gear and loading cranes with sufficient loading capacity!
For the truck weight, refer to the rating plate.

Never lift the truck at the drawbar !

DANGER
When loading the truck, ensure that there are no persons located underneath or in
the direct vicinity!

16 21.06.2007 B40_0229GB.doc
 Commissioning

Commissioning

IMPORTANT!

We recommend:
Before commissioning the high-lift pallet truck, carry out a completeness check on the model
and inspect the condition of the parts.

Delivery complete with drive battery

• In its as-delivered condition, the high-lift pallet truck is immediately ready to use after the removal of the
packaging material.
♦ The battery is filled and charged,
Inspect the battery capacity on the battery controller display.
♦ The hydraulic unit tank is filled,

WARNING!
Pedestrian-controlled transport trucks are only to be used by persons who are adequately briefed in
their control and have proved their competence for handling the vehicle to the person authorized by
the owner.
The first test drives should always be carried out on a level and spacious surface.
We recommend:
Have the operator practice the driving and steering movements and the control of the load pick-up
unit until these functions are securely mastered.
Only then may transportation and the retrieval and storage of products for transportation be
undertaken.

WARNING!
The driver is responsible for the pallet truck/ high-lift pallet truck during working hours.
He must not allow unauthorized personnel to operate the truck.
When leaving the truck unattended, it must be secured against unauthorized use
(by pulling out the starter key!).

B40_0229GB.doc 21.06.2007 17
Operation

Operation 7 6 6 7

3 4 5 3

9 10 8 2

Operator's Controls

1 Drawbar head 7 "Lower" pushbutton

2 EMERGENCY STOP button 8 Key-operated switch
3 Rotary switch for forward and reverse travel 9 Battery controller
4 Horn pushbutton 10 Hand lever switching valve
5 Safety reverse button
6 "Lift" pushbutton

18 21.06.2007 B40_0229GB.doc
 Operation

Safety elements:

When actuated, the red panic button on the

drawbar head brings about a brief switchover
to reverse travel and then stops the travel
movement.

If travel or lift movements can no longer be

stopped using the operating elements, the
entire energy supply can be interrupted by
hitting the EMERGENCY STOP button.

Guards integrated in the tiller head protect

hands against the risk of crushing

B40_0229GB.doc 21.06.2007 19
Operation

Initial test drive

WARNING!
Pedestrian-controlled transport trucks are only to be used by persons who are adequately briefed in
their control and have proved their competence for handling the vehicle to the person authorized by
the operator.
The first test drives should always be carried out on a level and spacious surface.
We recommend:
Have the operator practice the driving and steering movements and the control of load pick-up unit
without a load until these functions are securely mastered.
Only then may transportation and the retrieval and storage of products for transportation be
undertaken.

WARNING!
The driver is responsible for the pallet truck / high-lift pallet truck during working hours.
He must not allow unauthorized personnel to operate the vehicle.
When leaving the truck unattended, it must be secured against unauthorized use
(by pulling out the starter key!).

General:
The pallet truck / high-lift pallet truck is equipped with an electronic pulse control.
The electronic pulse control system enables completely smooth and stepless forwards and reverse travel.
The speed of travel can be controlled proportionally via the rotary switch on the drawbar head.
The control system allows reversal braking.

20 21.06.2007 B40_0229GB.doc
 Operation

Safety when driving

WARNING

• The pallet truck / high-lift pallet truck is intended for

use on level surfaces.
When travelling on sloping surfaces, there is a risk
that the truck could tip over!
• The maximum traversable incline is indicated in the
product description.
When negotiating greater inclines, the truck cannot
be reliably braked.
• Never traverse across inclines or attempt to turn
when on an incline. This could result in the truck
tipping over!
• Keep a sufficient distance from the truck.
This will help prevent risk of injury.

CAUTION
Driving:
• For this reason, travel paths must demonstrate
sufficient load-bearing capacity for the loaded truck.
In the event of unsuitable floor conditions, damage
can result to the floor or the truck.

• Pull up the red panic knob on the EMERGENCY

STOP button.
• Insert the key in the key-operated switch and turn to
the right.
• Tilt the drawbar into the drive position. This releases
the parking brake.
• Turn the rotary switch at the drawbar head to the
required direction of travel. The truck drives off
slowly and smoothly.
• The greater the deflection of the rotary switch, the
greater the truck speed.
• If released, the rotary switch turns back to the
neutral starting position.
• If the drawbar is released, it hinges back to its
vertical starting position. This causes the truck to
decelerate and the parking brake to be activated.
• Swivelling the drawbar steers the truck.

B40_0229GB.doc 21.06.2007 21
Operation

Driving using the ride-on platform ( options )

Pallet truck / high-lift pallet truck with ride-on platform

Version for trucks under 6 kph travelling speed.

CAUTION
• When riding, avoid any jerky steering or braking movements which could
unsteady anyone riding on the platform.
• Reduce your travelling speed before negotiating a corner. The occurring
centrifugal force could be too great and unsteady anyone riding on the
platform.

• Remember the larger turning circle of the truck when negotiating

corners.Take particular care to avoid obstacles in the area of the travelling
truck, which could pose a risk of injury.

22 21.06.2007 B40_0229GB.doc
 Operation

Braking

1 = Upper brake range

2 = Drive range The integrated pulse control system permits counter
3 = Lower brake range current braking action.
This is achieved by turning the rotary switch on the
drawbar head in the opposite direction to the direction of
travel. Once the truck has come to a standstill, release
the rotary switch. If the rotary switch is not released, the
truck moves off again in the opposite direction to travel
direction prior to braking.

The parking brake is automatically activated when the

drawbar is in the vertical position.

Forwards Reverse
Main direction of travel

Hooting

The pushbutton for operating the hooter is on the upper

side of the drawbar head.

B40_0229GB.doc 21.06.2007 23
Operation

Safety when lifting and lowering

WARNING
Stepping or reaching into moving parts of the high-lift pallet truck such as the mast, shift
units, load pick-up devices, attachments etc. is prohibited.
It is also prohibited to stand in the area of the load pick-up unit during lifting and lowering
movements.
Moving parts can give rise to a risk of injury.

The following are generally valid for the lifting and lowering procedure:
• The red operating button of the EMERGENCY STOP pushbutton must be pulled upwards
• The key must be inserted in the key-operated switch and turned to the right
• Lifting and lowering movements are initiated by pressing the pushbuttons on the drawbar head.

Lifting and lowering

24 21.06.2007 B40_0229GB.doc
 Operation

Load pick-up

CAUTION!
• Before picking up loads, ensure that the vehicle load
capacity is not exceeded.
• The rated load capacity and lift heights are shown on
the load capacity diagram and must be observed.
• Ensure that loads to be picked up are arranged in a
compact, stable manner. Prevent the load slipping or
falling off.
• Loads must not protrude into the mast area.
• Loads must always be picked up centrally in the
lengthways and crossways direction.
• Once loaded onto the forks, the load may not protrude
more than 50 mm over the fork ends.

1000 = 1000kg

B40_0229GB.doc 21.06.2007 25
Operation

Transporting loads

CAUTION!
• Only ever lift loads to a minimal height for transportation!
• For safety reasons (vision), only ever transport loads
when travelling forwards.
• Forward or reverse travel with a raised load is only
admissible when loading or unloading onto or from
storage racks.
• Loads may only be loaded or unloaded onto or from
storage racks when on a level surface.
• All journeys without a load must be undertaken with the
forks in the lowered position.

qr

Before leaving the truck unattended

• Always park the vehicle away from traffic routes, on a level surface.
• Fully lower the load pick-up unit.
• Extract the key from the key-operated switch and keep secure.

26 21.06.2007 B40_0229GB.doc
 Operation

Driving on slopes

CAUTION!

• If a slope has to be negotiated with the truck, this

is only admissible with the load facing
downwards.
• Traversing a slope crosswise is inadmissible.
• The maximum traversable incline is indicated in
the product description.

WARNING!

This method of travel is prohibited !

B40_0229GB.doc 21.06.2007 27
Maintenance and repair

Maintenance and repair

Organizational measures, personnel deployment

Fields of competence

What needs to be done? Who is responsible for execution?

- Mechanical operations - Mechanic (skilled personnel1)

- Electrical work - Electrician (skilled personnel1)

- Transport - Transport specialist

- Maintenance
- Service Genkinger-HUBTEX Co. GmbH
- Qualified and instructed specialist personnel
- Repairs

No. Indication Cause Remedy by

01

02

03

04

05

28 21.06.2007 B40_0229GB.doc

In the event of defects, the vehicle must be brought to a standstill until the cause of the defect has been
ascertained and remedied. Defects may only be remedied by skilled staff.
Troubleshooting instructions
Defect Cause
• Defective fuses
• Electrical connection
interrupted
Lifting not possible
• No oil
• Battery discharged
Failure to reach lift • Insufficient hydraulic oil
height
Jerky lift movement • Air in the system
• Lowering valve leaking
Load pick-up unit
lowers of its own • Overpressure valve
volition leaking
Drive motor will not • Contactor stuck
switch off • Pulse control defective
• Battery discharged
• Defective fuses
Truck will not drive
• Pulse control defective
• Switches at drawbar
bearing defective
• Secondary fuse in
charger defective
Battery does not • Battery is exhausted,
charge up overload safeguard has
tripped
• Charger defective
B40_0229GB.doc 21.06.2007
Maintenance and repair
Remedy By whom?
• Exchange the control fuse
• Exchange the unit fuse
• Check the cable
• Battery discharged
Mechanic
• Top up hydraulic oil
(Type see lubrication table)
• Recharge battery Electrician
• Top up hydraulic oil with load pick-up unit
Mechanic
lowered
• Open the venting screw on the lift cylinder
when the fork is lowered and lift until the
Mechanic
emerging oil is free of air bubbles. Close
the venting screw again.
• Lower using a jerking motion at maximum
speed (lower – release lever – lower)
• Lift as far as the end stop with brief Mechanic
overflow of the overpressure valve
(flushing through)
• Exchange contactor
Electrician
• Pulse control defective
• Recharge battery
• Exchange fuses for drive motor
• Exchange the control fuse
Electrician
• Exchange the pulse control system
• Exchange switch
• Exchange fuse
• Exchange battery Electrician
• Exchange charger
29
Maintenance and repair

30 21.06.2007 B40_0229GB.doc
 Maintenance and repair

Directions for use of the drive batteries

In the event of failure to observe the provided directions, repairs performed using non-original spare parts, any
attempt to perform unauthorized repairs or modifications, or the use of additives to electrolytes (so-called
enhancers), any warranty claim will be null and void.

Observe the directions for use and ensure that they are placed in a visible location in the
loading area.
Only ever perform work on batteries under the instruction of skilled personnel.

When performing work on batteries, always wear goggles and protective clothing.
Observe the accident prevention regulations and the stipulations of DIN VDE 0510, VDE 0105
Part 1.

Smoking is prohibited.
Never allow naked flames, sparks or smouldering material in the vicinity of the battery due to
the risk of fire and explosions.

Rinse off any acid splashes in the eyes or on the skin using plenty of clear water.
Then consult a doctor without delay. Rinse out acid from contaminated clothing using water.

Avoid short circuits due the risk of fire and explosions.

Caution ! As the metal components of the battery cells are always under tension, never place
any foreign objects or tools on the battery.

Electrolyte is highly caustic.

Never tilt the battery.

Only use approved lifting and transport devices such as hoisting gear in compliance with VDI
3616.
Lifting hooks must not be permitted to cause any damage to cells, terminals or connecting
cables.

Old batteries bearing this symbol are reusable commodities and must be sent for recycling.
Old batteries which are not sent for recycling must be disposed of as special waste in
compliance with all the relevant regulations.

B40_0229GB.doc 21.06.2007 31
Maintenance and repair

Battery charging

The charge status of the

battery is indicated on the
battery controller

The automatic charging process is

started by plugging the charging
cable into a socket.
Once the battery is completely
charged, the charger switches off.

AC 230V / 50Hz

32 21.06.2007 B40_0229GB.doc
 Maintenance and repair

Maintenance and repairs

This chapter contains instructions on how to maintain the truck in correct working order.
Ensuring troublefree operation and avoiding unplanned standstill periods are only possible with correct
execution of the specified maintenance work.

Requirements for maintenance personnel / areas of competence

What needs to be done? Who is responsible for execution?

- Maintenance - Service Genkinger-HUBTEX Co. GmbH

- Repairs - Qualified and instructed personnel

Customer Service Information

Genkinger-HUBTEX. GmbH
Postfach (P. O. Box) 11 20
D-72521 Münsingen

Tel.: +49 73 81 – 1 86 – 18
Fax: +49 73 81 – 1 86 - 52
E-mail: ersatzteile@genkinger-hubtex.com

B40_0229GB.doc 21.06.2007 33
Maintenance and repair

1.6

1.1

1.4

1.5

1.3

1.2

1.7

34 21.06.2007 B40_0229GB.doc
 Maintenance and repair

Maintenance – daily / prior to use

Servic Assembly / Performed
Fig. Action Wearing parts Ident no.
ing Component by
Entire high-lift pallet Check condition, clean when
truck required
Check for leaks (oil drips under the
Hydraulic system
vehicle)
• General
Tighten threaded joints
1.1 Safety reverse Does the travel direction switch
button from forwards to reverse when this
is actuated?

1.2 EMERGENCY Is the energy supply interrupted ?

STOP button

1.3 Key-operated switch Is the energy supply interrupted ?

1.4 Load pick-up unit Visual inspection for damage
Before each use

Check function

Operator
Check braking path, has this
Daily

changed since the last inspection?

Does the drawbar hinge back into
Service and parking
1.5 its vertical neutral position and is
brake
the vehicle braked when this
happens?
Is the vehicle braked with the
drawbar horizontal?
Visual inspection for mechanical
1.6 Load chain Load chain
damage
Battery (daily) • Inspect the charge status of the
WARNING battery at the battery controller,
Observe top up the charge if necessary
the safety See product
1.7 • Keep upper surface of the
regulations description
battery clean and dry
• Is the battery secured against
slippage?

If defects are detected during checking, they are to be reported immediately to the
responsible qualified personnel or to Customer Service.

IMPORTANT
Do not clean the truck with running water, high-pressure cleaners or solvents.

B40_0229GB.doc 21.06.2007 35
Maintenance and repair

2.4

2.1

2.2 2.3 2.2

36 21.06.2007 B40_0229GB.doc
 Maintenance and repair

Servicing - monthly
Servic Assembly / Performed
Fig. Action Wearing parts Ident no.
ing Component by
Check for wear
2.1 Load wheels Exchange < D -8 mm load Wheels
wheel
Check for wear
2.2 Steering rollers Exchange < D-5 mm steering Wheels

Mechanic
monthly7

roller
Exchange wheel at diameter < D-10
2.3 Drive wheel Drive wheel
mm
Inspect the entire load pick-up
2.4 Load pick-up device device for cracks Inform after-
sales services

7
In multiple shift operation, suitably shorter maintenance intervals are required.

B40_0229GB.doc 21.06.2007 37
Maintenance and repair

3.3

3.2

3.4

3.5

3.1

38 21.06.2007 B40_0229GB.doc
 Maintenance and repair

Servicing - 6-monthly
These servicing jobs require special knowledge and may only be carried out by qualified and instructed
personnel.

Maint Performed
Assembly /
enanc Fig. Action by Wearing parts Ident no.
Component
e
Hydraulic system See
3.1 • Oil level •
Check, top up if required Hydraulic oil lubricant
• Oil condition •
Check, change if necessary table
Check chain and chain connection

Qualified and instructed personnel

for mechanical damage.
Check for play (slack chain)
3.2 Load chain Load chain
(incl monthly service)

If necessary, treat with chain spray.

See also "Maintenance and care of
6-monthly7

load chains“
Clean and lightly grease the inside
3.3 Mast
of the mast profile
Check for lateral play of the mast See
3.4 Mast / load fork (with dual mast) and load fork (do Guides Spare parts
not lift load fork completely) list
Does the vehicle travel straight
when the drawbar is upright
Is the steering locking angle limited
3.5 Steering
to approx. 90 °
Is the control cable at the drawbar
pivot point OK?
7
In multiple shift operation, suitably shorter maintenance intervals are required.

B40_0229GB.doc 21.06.2007 39
Maintenance and repair

4.0

4.3
4.4

5.1

4.1
4.2

40 21.06.2007 B40_0229GB.doc
 Maintenance and repair

Servicing – annually / 2 years / 6 years

These servicing jobs require special knowledge and may only be carried out by qualified and instructed
personnel.

Maint Performed
Assembly /
enanc Fig. Action by Wearing parts Ident no.
Component
e
Accident prevention inspection by
Entire high-lift pallet authorized expert according to
4.0
(incl. 6-monthly service)

truck inspection logbook

BGG 939

Service Genkinger-HUBTEX Co.

Electro- Brake, complete
4.1 Check brake travel
Annually

magnetic brakes 7
Carbon brushes in
4.2
the drive motor7 Check for wear,
Carbon brushes
Carbon brushes in exchange if necessary
4.3
lift motor 7
4.4 Motor wiring Is the wiring to the motor OK?

Every
Oil change. Tank capacity approx.
2 5.1 Hydraulic unit 7 Hydraulic oil
6 litres
years
Every
6 Hydraulic system Change all hydraulic hoses Hydraulic hoses
years
7
In multiple shift operation, suitably shorter maintenance intervals are required.

Wearing parts, as well as auxiliary materials and supplies are

excepted from the warranty.

B40_0229GB.doc 21.06.2007 41
Maintenance and repair

Oil change

Venting
screw • Fully lower the load pick-up unit.
• Operate the EMERGENCY-STOP button and
remove the key.
• Remove the vent plug
• Suction off the oil through the opening in the
vent plug
• Fill with clean hydraulic oil
• Tank capacity approx. 6 litres.
• Screw in the vent plug.
• Lift and lower the load pick-up unit several
times.
• Lower the load pick-up unit and release the
vent plug at the lift cylinders by around 1 turn.
• Fully lift the load pick-up unit.
As soon as the emerging oil is free of bubbles,
close the vent plug again.
Collect the emerging oil using a cleaning cloth.
• Used oil must be disposed of in an
environmentally safe manner.

IMPORTANT

The hydraulic unit must not be switched

on without a filled oil tank.
Allowing the system to "run dry" can
destroy the pump.

Id.-Nr.
70500592

Lubricants
See "lubricant table"

42 21.06.2007 B40_0229GB.doc
 Maintenance and repair

Lubricant table
Die Betriebssicherheit und Wirtschaftlichkeit unserer Flurförderzeuge hängt in hohem Maße von der Güte der zu verwendenden Schmierstoffe ab.
The reliability and economy of our transport trucks are dependent on the quality of used lubricants.
The under mentioned lubricants are approved.

Schmierstellen
Points of
Lubrication

Hydraulik
Hydraulics
a) Fußpumpen Aral Vitam GF 22 BP Energol HLP-HM 22 Astron HLP 22 NUTO H 22
a) foot pumps Aral Vitam DE 22 Actis HLPD 22 HLPD-OEL 22

b) Elektr. Pumpen Aral Vitam GF 46 BP Energol HLP-HM 46 Astron HLP 46 NUTO H 46

b) electric pumps Aral Vitam DE 46 Actis HLPD 46 HLPD-OEL 46
Getriebe
Gears

a) Schneckengetriebe Aral Degol BG 220 BP Energol GR-XP 220 Falcon CLP 220 SPARTAN EP 220
a) worm gears *Aral Getriebeöl EP *BP Energear Hypo 90 *Dearon EP-A *ESSO GEAR OIL
SAE 85W-90 *BP Energear EP SAE 90 SAE 85 W-90 GP-D 85 W-90
*ESSO GEAR OIL
oder GP 85 W-90
or
b) Zahnradgetriebe Aral Degol BG 100 BP Energol GR-XP 100 Falcon CLP 100 SPARTAN EP 100
b) spur gears *Aral Getriebeöl EP *BP Energear EP *Dearon EP-A *ESSO GEAR OIL
SAE 80W SAE 80 W SAE 80 W GP-D 80 W
*ESSO GEAR OIL
GP 80 W
Sonstige Aral Degol BG 100 BP Energol GR-XP 100 Falcon CLP 100 SPARTAN EP 100
Ölschmierstellen *Aral Getriebeöl EP *BP Energear EP *Dearon EP-A *ESSO GEAR OIL
Other oil lubricated SAE 80 W SAE 80 W SAE 80 W GP-D 80 W
points *ESSO GEAR OIL
GP 80 W
Fettschmierstellen *Aral Aralub HL 2 *BP Mehrzweckfett L 2 Glissando 20 BEACON 2
Grease lubricating point *Aral Mehrzweckfett *BP Langzeitfett *Dealit EP 2 *EXXON
BP Energrease LS 2 MEHRZWECKFETT

Schmierstellen
Points of
Lubrication

Hydraulic system
Hydraulics
a) Fußpumpen *RENOLIN MR 5 VG 22 LAMORA HLP 32 Mobil DTE 22 OEST Hydrauliköl H-LP 22
a) foot pumps *RENOLIN B 5 VG 22 OEST Hydrauliköl 22 DD

b) Elektr. Pumpen *RENOLIN MR 15 VG 46 LAMORA HLP 46 Mobil DTE 25 OEST Hydrauliköl H-LP 46
b) electric pumps *RENOLIN B 15 VG 46 Hydraulikoel HLPD 46 OEST Hydrauliköl 46 DD
Getriebe
Gears

a) Schneckengetriebe RENOLIN Klüberoil *Mobilube OEST Gearol C-LP 220

a) worm gears CLP 220 / PLUS GEM 1-220 GX 85W-90-A *OEST Mehrzweck-
RENOGEAR MP 90 Mobilgear 630 Getriebeöl SAE 85W-90
RENOLIN Mobilgear SHC 220
oder CLP 150 / PLUS
or
b) Zahnradgetriebe RENOGEAR MP 80 Klüberoil *Mobilube OEST Gearol C-LP 100
b) spur gears GEM 1-100 GX 85W-90-A *OEST Mehrzweck-
Mobilgear 627 Getriebeöl SAE 80 W
Sonstige * RENOGEAR MP 80 Klüberoil *Mobilube OEST Gearol C-LP 100
Ölschmierstellen RENOLIN GEM 1-100 GX 85W-90-A *OEST Mehrzweck-
Other oil lubricated CLP 100 / PLUS Mobilgear 627 Getriebeöl SAE 80 W
points
Fettschmierstellen RENOLIT MP CENTOPLEX 2 Mobilux 2 *OEST Mehrzweckfett
Grease lubricating point RENOLIT LZR 2 Mobilgrease HP 222 GOC 190
RENOLIT FWA 160 OEST Langzeitfett
LT 200 EP
*) Auch an Tankstellen bzw. Vertragswerkstätten erhältlich / obtainable from service stations

Die vorstehenden Gesellschaften verfügen über einen schmiertechnischen Dienst, dessen Fachingenieure Sie jederzeit in allen
Schmierungsfragen beraten.
These companies and their agencies maintain a technical service, whose advice on all lubrication problems is available free of charge.
Genkinger-HUBTEX. GmbH 72525 Münsingen
Tel.: +49 (0) 73 81/1 86-0 http://www.genkinger-hubtex.com info@genkinger-hubtex.com

B40_0229GB.doc 21.06.2007 43
Maintenance and repair

Load chain

Chain holder

Adjusting nut

Lock nut

Safety split pin

Adjusting the load chains

If the load pick-up unit fails to reach the correct end height despite a correct oil level, or if the load chain
demonstrates noticeable play (slackness) when the load pick-up unit is lowered, the load chain requires
retensioning.

• Lift the load pick-up unit until the chain holder is in a suitable location.
• Pull out the starter key.
• Release the lock nut at the chain holder. The safety split pin at the chain holder must not be removed!
• Fully lower the load pick-up unit.
• By turning the adjusting nut, the load chain can now be tensioned until any slackness is taken up. If it is no
longer possible to tension the load chain, it must be exchanged (customer services).
• Switch the truck back on.
• Lift the load pick-up unit until the chain holder is in a suitable location.
• Tighten the lock nut again at the chain holder.

44 21.06.2007 B40_0229GB.doc
 Maintenance and repair

Care and maintenance of load chains

When used under normal conditions, the load chains should be relubricated after every 250 hours of
operation; in case of heavy soiling, extreme effects of moisture or continuous heavy-duty operation, this
should be performed after only 100 hours of operation.
If exposed to corrosive media, the chain should be immediately cleaned and lubricated.

Chain lubrication, chain conservation

Flyer chains are correctly lubricated and in a flawless condition if:

- There is no external adhering dirt
- Touching the chain leaves a trace of oil on the finger. This ensures that the chain links are sufficiently
lubricated.

Lubricant type

Always use a low-viscosity mineral machine or motor oil / synthetic oil. Select a lubricating oil which retains its
low viscosity at all occurring ambient temperatures. Under normal temperature conditions, lubricating oils with a
viscosity of SAE 20 to SAE 40 may be used.

Lubricating methods

The lubricating product can be applied using a brush, paintbrush or compressed air spray device. When using
with spray cans, ensure that the following basic requirement is fulfilled:
- After the thinning agent has evaporated, the viscosity must comply with the above recommendation
(lubricant type).

Chain cleaning

If the chain becomes so soiled during operation that penetration of the lubricant is no longer guaranteed, the
chain must be cleaned.
This may only be done using paraffin derivatives such as diesel fuel, petroleum or cleaning benzene.
Before cleaning with steam jets, using cold cleaners or even caustic or acidic agents, sufficient warning must be
given. These can result directly in chain damage.

If it is not possible to avoid cleaning the chains with a steam jet, please contact our customer
services.

B40_0229GB.doc 21.06.2007 45
Maintenance and repair

Chain inspection

When used as a lift stacker, inspections must be performed at least once a year. In heavily soiled conditions
and when used in continuous heavy-duty operation, every three months.

Test characteristics - We recommend observing the following points:

1. Odour formation
2. Surface rust
3. Link rust
4. Link stiffness
5. Twisted bolts
6. Loose chain bolts
7. Inadmissible external wear
8. Damage
9. Broken link plates
10. Broken bolts
11. Soiling
12. Chain extension
Even with optimum lubrication, it is not possible to avoid chain extension.
Exposure to wear takes place only in the area of the chain which is guided over the chain wheel /
deflecting wheel. Consequently when measuring wear, only this area needs to be checked.
In accordance with currently applicable regulations, a chain is deemed to be worn when it has extended by
3% (i.e. 30 mm over 1 metre) of its original length.
If safety concerns are paramount or if a possible hazard depends on the condition of a single chain, we
consider it necessary to exchange the chain already when it reaches 2% extension over its original length.

Measurement process
To measure wear extension, the part of the chain which runs over the chain wheel/deflector wheel is moved to
the extended area. Using a measure, measure out a piece of chain measuring around 1 metre in length.
The number of pitches lying inside the measured area multiplied by the nominal chain pitch produces the
nominal measurement.
The length by which this measurement is exceeded equals the degree of wear, which may not exceed a
maximum of 3% over the nominal length.
A 3% wear extension has been reached when a used chain measures the same length over just 33 links as a
new chain over 34 links.

Exchanging the chain

If two chains are used as a pair in the truck in question, always exchange both chains at the same time.
Mounting and removing chains must be performed with the same degree of care exercised when working with a
safety element.

Chain repairs must only ever be performed by authorized specialist personnel.

We do not recommend lengthening safety lift chains, as an inserted chain link is not pre-stretched.

Assembling chain sections with different silver label numbers will result in forfeiture of the
manufacturer's warranty.

46 21.06.2007 B40_0229GB.doc
 Maintenance and repair

Temporary decommissioning
If the truck is decommissioned for operational reasons for periods of longer than 2 months, the following points
must be carried out:

7 Jack up the truck so that all the wheels are off the ground.
This prevents permanent deformation of the wheels.
6 Thoroughly clean the truck.
6 The lift device may have be supported by a suitable underlay in order to release the tension on the load
chains.
6 Check the hydraulic oil level, top up if necessary.
6 Lubricate the truck.
6 Apply a thin film of oil and grease to all bright and moving parts.
6 The storage location for the truck must be dry, out of danger of frost and free of dust.
6 Do not use plastic film to cover the truck, as otherwise there is a risk of condensation forming.

Additional measures to be performed on trucks with integrated electronics

6 Disconnect the batteries from the truck's electrical system.
6 Charge the batteries.
6 Clean the battery head and pole terminals.
6 Grease the pole terminals with a small amount of terminal grease.
6 Check the level of the electrolyte, top up if necessary
(not applicable when using maintenance-free or gel batteries).
6 Repeat the battery charge process every 90 days, charge gel batteries every six months.
6 Spray exposed electrical contacts using a suitable contact spray.

Recommissioning after extended standstill periods

6 Thoroughly clean the truck and lubricate.
6 Remove the applied layer of protective grease.
6 Check the oil tank and hydraulic oil for condensation, if applicable carry out an oil change.
6 Check the hydraulic hoses for brittleness.
6 Check the functional characteristics of the truck, in particular the safety equipment.

Additional measures to be performed on trucks with integrated batteries

6 Disconnect the batteries from the truck's electrical system.
6 Charge the batteries.
6 Check the level of the electrolyte, top up if necessary
(not applicable when using maintenance-free and gel batteries).

Final decommissioning
If a defective truck can no longer be repaired so as to permit adherence to valid safety regulations in
accordance with its intended application, then the truck must be decommissioned.
The truck dismantled into its individual components (steel, plastic, electronics, operating materials and supplies
etc.) must be disposed of in compliance with the valid environmental regulations.

B40_0229GB.doc 21.06.2007 47
Maintenance and repair

IMPORTANT

Only use the listed operating materials and supplies.

Only use spare parts which are included in the spare parts list.
Failure to observe these instructions may potentially result in unforeseeable personal injury and damage to
property.

Circuit diagrams, drawings

Assembly drawings, parts lists, circuit diagrams etc. form part of the scope of delivery.
Should you have any questions in this regard, please contact us.

Repairs

We can also supply you with original spare parts at short notice. The order form is attached.
What can we do for you ?

Repair service - information

Genkinger-HUBTEX. GmbH
Postfach 11 20
D - 72521 Münsingen
Tel.: 073 81 1 86- 18
Fax: 073 81 1 86- 52
mail to: ersatzteile@genkinger-hubtex.com

48 21.06.2007 B40_0229GB.doc
 Logbook

Logbook

Please inform our customer services in the event of any faults.

Thank you for your notification.

Genkinger-HUBTEX. GmbH
Postfach 11 20
D - 72521 Münsingen
Tel. +49 073 81 1 86- 18
Fax +49 073 81 1 86- 52
mail to: ersatzteile@genkinger-hubtex.com
Internet: http://www.genkinger-hubtex.com

B40_0229GB.doc 21.06.2007 49
Logbook

No. Symptom Cause Effect Measures undertaken

50 21.06.2007 B40_0229GB.doc
 Logbook

For instruction, training, evaluation of incidents

Topic
Day

from:

to:

Participants: First name Surname Signature

1. Instructor

For instruction, training, evaluation of incidents

Topic
Day

from:

to:

Participants: First name Surname Signature

1. Instructor

B40_0229GB.doc 21.06.2007 51