MAX TRUCK 2T User manual

Instruction book
Maxtruck 2T
MAX TRUCK AB
June 20, 2016
REV:E
CL

INTRODUCTION
For safe operation of Maxtruck 2T handling indoors requires some knowledge contained in this
documentation. The information is presented in short and clear form.
Safety instructions and important explanations are marked by the following pictograms
Standing in front of instructions that must be
observed to avoid damage to property.
Standing in front of the safety instructions that
must be observed to avoid personal injury.
Standing in front of explanations and references.
Specifies that the operating manual must be read.
Available also as a small symbol on important
signs.
Specifies that the staff should not be staying
under raised tool or cargo.
Specifies that no passengers are allowed on the
truck and that the driver should always wear a
seat belt.
Specifies that one always for drivers to take the
key from the forklift when leaving the forklift to
help prevent unauthorized can utilize the truck.
This plate must alert the driver that he must
regularly monitor the tool is correctly installed
and locked into position for use.
This plate also sits on the forklift's exterior in a
larger size, indicates that staff are not allowed
beside the forklift during operation.

1
The manufacturer reserves the right to make changes within the scope of technical development
without simultaneously change this manual.
Max Truck AB
Byvägen 136B
SE-832 53 Frösön
Phone [phone]

2
Innehåll
A. VEHICLE DESCRIPTION............................................................................................................................5
Vehicle....................................................................................................................................................7
Performance.........................................................................................................................................14
EN-norms..............................................................................................................................................16
Load diagram........................................................................................................................................18
B. TRANSPORT AND FIRST START .........................................................................................................19
Crane transport ....................................................................................................................................19
Secure the vehicle during transport.....................................................................................................19
First start-up.........................................................................................................................................20
Towing Maxtruck 2T.............................................................................................................................20
C. BATTERY-SERVICE, CHARGING, CHANGE..........................................................................................21
Battery types ........................................................................................................................................22
Change of battery.................................................................................................................................23
Charging the battery ............................................................................................................................24
Battery charge indictor.........................................................................................................................24
D. OPERATION.......................................................................................................................................25
Safety rules for the operation of the vehicle .......................................................................................25
Repairs..................................................................................................................................................26
Danger zone .........................................................................................................................................26
Seatbelt ................................................................................................................................................29
Load handling .......................................................................................................................................31
Driving ..................................................................................................................................................32
Driving in slopes ...................................................................................................................................33
Steering wheel ratio to wheels.............................................................................................................34
Steering of Maxtruck 2T .......................................................................................................................34
Breaking the forklift..............................................................................................................................34
Operation of the lift functions..............................................................................................................35
Fork spread (optional equipment) .......................................................................................................36
Fork side shift (optional equipment)....................................................................................................36
Tool Changing Unlocking/locking.........................................................................................................36
Taking up, transporting lowering of load.............................................................................................37
Taking up the load................................................................................................................................37
Transport of load..................................................................................................................................37

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Lowering the load.................................................................................................................................38
Secured parking of the truck ................................................................................................................38
Trouble shooting ..................................................................................................................................39
E. MAINTENANCE OF FORKLIFT............................................................................................................40
Maintenance and Inspection................................................................................................................41
Lubrication Schedule............................................................................................................................44
Description of service and maintenance works ...................................................................................45
Preparing the truck for service and maintenance works .....................................................................45
Change hydraulic oil filter ....................................................................................................................46
Maintenance of seatbelt ......................................................................................................................46
Alarm codes presented on display .......................................................................................................49
Dimensions on Maxtruck 2T.................................................................................................................51
Technical data ......................................................................................................................................52

4
INTENDED USE
The vehicle handling described in this manual is a vehicle that is suitable for lifting and
transporting goods or any other data using additive utilities.
Maxtruck 2T is especially suited for indoor work, but can be operated outdoors on dry surfaces
composed of concrete or hard asphalt.
The vehicle may only be used, operated and maintained according to instructions in this
manual. Using the forklift for indications other than the intended is not appropriate and may
involve the risk of personal injury, property damage or other tangible damage. On truck-
ranking nameplate or load chart must be followed regarding maximum load capacity.
The user must ensure that damaged and / or difficult-readable load charts renewed.
The vehicle handling and outdoor shall not be used in the vicinity of flammable or explosive
substances or exposed to corrosion driving and extremely dusty environment.
User responsibility: Users under the user guide is the natural or legal persons who engage in
vehicle handling by themselves or through Agents. In special cases (leasing, renting) are
counted as users of the person assigned responsibility for running the vehicle for cargo
handling by agreement between the machine owner and the person / persons using the forklift.
The user must ensure that the forklift is only used appropriately so that operational staff or
third-party life and health are not compromised. In addition, the user is responsible to accident
prevention against accidents, other safety rules and instructions for operation, service and
maintenance are strictly followed. The user must ensure that all users of the forklift have read
and understand the instructions in these instructions.
If this manual is not observed, warranty will expire. The same applies if the client and / or third
parties without the consent of the manufacturer do not perform professional work on or change
to the product.
Mounting of accessories: all on or installation of additional equipment that is not supplied by
Max Truck AB, which results in interference or completion of the forklift functional parts
requires prior written approval from the Max Truck AB.
You may also need to obtain permission from local authorities.
Authorization document does not replace the approval of the manufacturer.
Connected trailer: Only by Max Truck AB allowable trailer may be connected to the vehicle.
With the trailer attached to the truck, it is only allowed to drive in control mode D2
conventional rear-wheel steered forklift when a trailer can´t follow the movement´s in the
steering mode D1.

5
A. VEHICLE DESCRIPTION
Application Description
Maxtruck 2T is an electrically powered forklift with traction on the front wheels and steering
on all four wheels. The driver is placed in a driver's seat with the controls on armrest panels and
with excellent visibility in all directions. The truck can handle loads for lifting, transporting
outside and inside the wheelbase.
The truck is a counterbalance truck with Omni-directional drive but with cargo uptake through
the right side positioned telescopic boom. The truck can also handle long goods (6 m or longer)
through narrow doors when it can move in all directions with and without load.
In addition, the pallets according to DIN 15142, boxes with sides of wire mesh according to
DIN 15144 and other pallets with cargo can be stacked and transported
The vehicle data and max. Load capacity:
Type Max. Load capacity *) Load distance Extended
Maxtruck 2T 2000 kg 500 mm 0
Maxtruck 2T 1000 kg 500 mm 1000
Maxtruck 2T 750 kg 500 mm 1500
Maxtruck 2T 500 kg 500 mm 2100
Extension relates mm extension of the telescoping boom
*) It is always load chart on the vehicle, applying

6
Description of units and functions
PICTURE OF THE TRUCK WITH POS. No.
POS. No. AND EXPLANATION

7
Vehicle
Steering (1)
The truck's steering wheel is of type multi-way steering wheel with a large knot that shows
direction D1 operation.
The control dial has a motor function at certain operating conditions can control the steering
wheel.
In D2 operating as normal rear wheel driven truck the driver must sense the position of the
steering wheel and then turn the wheel to the right position during drive. In this mode, the knob
on the steering wheel only as a means to turn the wheel right. D2 operation is limited steering
angle to 1.5 turns to the left and 1.5 turns to the right as on a conventional counterbalance
truck. The restriction is done by buzzer sounds if you turn the steering wheel too far or if you
turn the wrong direction from the end positions.
Driver seat (2)
The driver's seat is comfortable and adjustable in the longitudinal direction and the pedals are
adjustable in height. There is a weight adjustment for the weights of the drivers.
There are storage sites for documents and driver's personal items.
The operator controls the lifting functions using the right control panel and steering with the
left control panel. All-important lift functions are operated with a joystick on the right control
panel.
Control of the forklift operation in D2 steering mode occurs with steering wheel (multi turned)
on the left control panel. At Omni-directional D1 steering mode it is controlled by the steering
wheel on the left control panel plus two control pedals for the left foot for turning the truck
Right - Left.
Driver's protection roof (3)
Is designed to protect the operator from falling goods according to the requirements of standard
ISO 6055
Electronics (4)
State of the art 3ph AC technique used for all motors with data communication via CAN-Bus
system imposes minimized the cable system in the truck.
This brings advantages in terms of full monitoring for all control functions.
The complex microprocessor control is easy to use, secure and flexible.
Error analysis and programming are implemented very simply and above all quickly using a
separate PC.
Traction and break (5)
Front operation always gives the best traction force to the rear wheels when the truck carrying
the cargo.
At speed reduction, power is generated back to the battery from the traction motors. (Also, the
lift function generates power back when lowering the load)
This minimizes energy consumption. Mechanical brake hubs for faster deceleration or braking
if the power supply is lost.

8
Parking brake (6)
When the parking brake is activated, the forklift´s traction is blocked.
When the parking brake is released, the brake pedal is operated as normal service brake when
necessary. Normal speed reduction is via regeneration of power back to the battery when the
accelerator pedal is released.
Service brake (7)
Maxtruck 2T has a mechanical service brake in addition to the power generation service brake
controlled by the accelerator pedal. The service brake comprises a brake pedal acting on the
brake disc coupled to the drive shaft of the respective drive wheels. Disc brake's stopping
power is sufficient to slow down the truck with a full load in the maximum slope that the truck
may be driven in.
If the foot brake is affected during normal braking is reduced power regeneration automatically
when necessary to truck stability is not jeopardized by the rapid deceleration. At all braking
with the foot brake is up to the driver's responsibility not to slow down too quickly with the
load in the raised position, as this can affect the stability of the truck.
In normal braking through power generation the progress is monitored and controlled by the
truck's built-in security ASE system.
Hydraulic system (8)
The hydraulic system in Maxtruck 2T is different than all other trucks and therefore patented.
The system works with a pump for each main function of the lifting system which allows for
automatic control functions.
The hydraulic system has very high efficiency with low heat losses to the oil and therefore the
forklift just need 9 litres oil tank, which benefits the environment during oil changes.
The system works with custom pressure in all operating conditions to minimize the risk of oil
leakage from the truck and the noise level is also thereby low from the hydraulic system. All
systems are built to regenerate power back to the battery to optimize battery capacity.
Telescopic boom (9)
One of the objectives in the design of Maxtruck 2T was to improve visibility for drivers in all
operating modes with or without load. By ensuring 100% visibilities for the operator it can
minimize personal accidents. By right-positioned telescopic boom instead of truck frame and
the ability to run in all directions, the driver can drive the truck even with bulky cargo and
100% visibility for the driver.
Fork tool (10)
Maxtruck 2T is provided with a fork tool type ISO2A standard. As option it can be supplied
different types of tools that can be quickly fitted to the truck via the special tool holder.

9
Instrument panel (11)
The instrument panel is mounted on the driver's right side and contains following.
1- Display for information to the driver
2- Pushbutton to see alarm codes
3- Pushbutton to see running hours
4- Navigator button
5- Pushbutton for calibration menu
6- Pushbutton to see motor fault codes
7- Emergency stop button
8- Battery status indicator
9- Start key
10- Switch for head lamps

10
Presentation of the display unit pictures
The truck's display has the task of providing information to the driver while driving.
The images change depending on the current operating mode and the truck's status.
The picture shows the current operating mode in which (1) indicates that the truck is ready for
Omni-directional drive (D1). Upon failure of the control or operation switches the green
indicator goes too red.
The symbol A in (2) indicates that the hydraulic system is set for automatic controlled lift.
Turns red on failure of the hydraulic system.
The symbol (3) shows that the button under the symbol can be used to go in and check the
alarm codes. The symbol (4) indicates that the button under the symbol allows you to check the
operating time. The symbol (5) indicates that the parking brake is activated. The symbol (6)
indicates that the battery needs charging. The symbol (7) indicates that with the key under the
symbol you can go into the service mode. Only for service technician.
(8) Shows the actual weight of the load you have on the forks.
(9) Shows the forks tilt with respect to the horizontal.
The picture shows (1) that the truck is set up for forklift steering D2 (Control only with the rear
wheels)
(2) Indicates that the hydraulic system is in manual mode.

11
This display appears when the tool lock is open. Simultaneously, a continuous buzzer signal to
attract the driver's attention to lock tools. After locking it should be kept in lock command for
five seconds to turn the buzzer off.
This display appears during the start-up of the forklift to indicate that it is not fully ready.
When the picture changes to the normal display image, the truck can be activated for operation.
Technical data standard
Description Data Unit
H1 Height of forklift 1972 mm
H2 Max lifting height forks 4200 mm
H3 Max retraction of forks 2105 mm
H4 Free height over driver seat 1000 mm
H5 Driver seat height over floor 608 mm
H6 Free height under fork lift 99 mm
H7 Structure height at max lifting height 5037 mm
H8 Trailer connection height 450 mm
L1 Length inclusive standard forks 3290 mm
L2 Length exclusive forks 2177 mm
L3 Fork lift length when forks over cabin 1910 mm
L4 Load distance on forks 500 mm
L5 Wheelbase 1378 mm
B1 Total forklift width 1190 mm
B2 Track width front axle min / max 770/1000 mm

12
B3 Track width rear axle min/max 740/970 mm
B4 Width fork back 1200 mm
AB Width fork lift aisle 1200 pall long way 3500 mm
BB Width fork lift aisle 1200 pall crossway 3200 mm
R Turning radius 0 mm

13
MAXTRUCK 2T DIMENSIONS

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Performance
Description Data unit
Max load capacity 2000 kg
Load centre on forks 500 mm
Traveling speed max 16 km/h
Lifting speed with/without load 0.4 / 0.6 m/s
Max inclination with/without load 5 / 7 %
Acceleration with/without load 10 m 4,2 / 3,9 s
Weights
Description Data unit
Dead weight with batteries 3600 kg
Battery weight (2 x 300 kg) 600 kg
Axle load with max load, front / rear 4800 / 800 kg
Axle load without load, front / rear 1400 / 2200 kg

15
Tire and wheel equipment
Description Data unit
Max wheel hub front/rear Moulded steel hub
Max wheel tire PUR 90 Shore black non marking
Wheel dimensions Diameter 450 mm
Weight of wheel 45 kg
Front track min / max 770/1000 mm
Rear track min/max 740/970 mm

16
EN-norms
Continuous sound pressure level
Maxtruck 2T = 70 dB(A)
According to EN 12053 in accordance with ISO 4871.
The continuous sound pressure level is according to prescribed standards of an average value
calculated by reference to the sound pressure level while driving, lifting and idling. The sound
pressure level measured at the driver's ear.
Vibration: = 0,45 m/s2
According EN 13059
Electromagnetic compatibility (EMC)
The manufacturer confirms the compliance with the limit values for emitted electromagnetic
radiation and the influence of electromagnetic radiation as well as a test of the influence of
static discharge of electricity in accordance with EN 12895 and references to other standards
thus included.
Changes of electrical and electronic components and its function may be performed only after
written approval by the manufacturer.
Operating conditions
Ambient temperature when operating -20 C to +40 C
Industrial trucks shall be specially equipped and approved for continuous use in environments
with temperatures below +5 ° C or in cold stores with extreme temperatures and humidity.

17
Name plate, vehicle
Picture of name plate
For inquiries regarding the forklift, or when ordering spare parts please mention the type and
serial no according to the name plate above.

18
Load diagram
The vehicle's load chart indicates the carrying capacity in kg at different extensions on
telescopic boom. Also shows the total height at each extension.
The fork lift's payload monitored and limited completely automatically by the safety system.
Diagram lift capacity
Vertical axis and horizontal axis indicates the dimensions in meters.
The centre of gravity is assumed to be 500 mm on the forks.
Green line indicates the maximum extended for each payload.
This diagram is based on standard fork tool ISO 2 with 1150 long forks.
The weight of the standard fork tool is 135 kg.