LINDE H25D, H30D, H35D User Manual

Operating Instructions
Diesel forklift truck

H25D, H30D, H35D

393 807 1001 EN – 06/2006

Linde - Your Partner

Preface

g

With over 100,000 fork lift trucks and ware­house machines sold annually, Linde is one of
the world’s leading manufacturers of material
handling equipment. There are many reasons
for this success: Linde products are renowned
not only for their innovative, cutting-edge tech­nology, but also for their low energy and oper­ating costs, which are up to 40 per cent lower
than those of their competitors.

Thehighquali
matched by the
production pl
network of sal
service round

Your local Linde partner can offer you a
complete package from a single source;

Operating Instructions – 393 807 1001 EN – 06/2006 I

ty of Linde products is also

quality of our service. With ten

ants worldwide and an extensive

es partners, we are at your
the clock and around the world.

ranging from expert advice on all aspects
of sales and service through, of course, to
appropriate finance options. Our leasing, hire
or lease-purchase agreements provide you
with the flexibility to tailor decision-making to
your individual business requirements.

Linde Materia
Schweinheimer
63743 Aschaffen
Telephone +49 (0)
Fax [phone]­Mail: info@linde­Web: http://www.li

l Handling GmbH & Co. KG

straße 34

burg

6021 99-0

1570

mh.com

nde-mh.com

Table of contents

1 Introduction

Your forklift truck ..................................................... 2

Intended use ........................................................ 2

Symbols used ....................................................... 2

Technical specification ................................................. 4

Truck operation with a bucket ............................................ 5

Truck takeover ....................................................... 5

Initial operation ...................................................... 6

2Safety

Safety regulations .................................................... 8

In the case of tip-over .................................................. 9

Handling fluids and lubricants ............................................ 9

Experts ........................................................... 10

Operation of industrial trucks in plant area .................................. 10

Regulations ........................................................ 10

Determination and assessment of haza

Instructions for fitting attachments ....................................... 12

rds from use of industrial trucks ............ 11

g

3Overview

Rating plates ....................................................... 14

General view ....................................................... 16

Controls .......................................................... 17

Indicator unit ....................................................... 18

4 Operation

Running-in instructions ............................................... 22

Checks before starting work ............................................ 22

Standard equipment ................................................. 22

Adjustingthedriver’sseat .............................................. 22

Adjustthesteeringcolumn ............................................. 25

Settingtheclock ..................................................... 26

Lapseatbelt ....................................................... 26

Drive motor (two-pedal operation) ........................................ 28

Operating Instructions – 393 807 1001 EN – 06/2006 III

Table of contents

g

Driving (double-pedal operation) ......................................... 31

Drive motor (single-pedal operation) ...................................... 33

Driving (single-pedal operatio

Steeringsystem ................................................. .... 40

Brakingsystem ..................................................... 41

Horn ............................................................. 42

Liftingsystemandattachments(centralleveroperation) ....................... 43

Liftingsystemandattachments(singleleveroperation) ........................ 46

Special equipment ................................................... 50

Lifting system and attachments (single lever operation with 3rd additional hy-

draulics) .......................................................... 50

Adjustingtheswivelseat .............................................. 53

Adjustthedriver’sair-sprungseat ........................................ 54

Mastpositioning ..................................................... 56

Lighting ........................................................... 58

Windscreenwiper ................................................... 60

Heating, air conditioning ............................................... 62

Truck Data Management (LFM) ......................................... 64

Working under load .................................................. 69

Beforetakingupaload ................................................ 69

Adjustingtheforkspread .............................................. 70

Loading ........................................................... 71

Transportingaload .................................................. 72

Unloading ......................................................... 73

Towcoupling ....................................................... 74

Loading / Transport .................................................. 74

Securing the hose reel against rewinding .................................. 74

Dismantlingtheliftmast ............................................... 75

Driving without a mast ................................................ 76

loading . . ......................................................... 77

Transportwithlorryorlow-bedtrailer ..................................... 79

Before leaving the truck unattended ...................................... 79

n) ......................................... 37

5 Servicing

Inspection and maintenance overview .................................... 82

General information .................................................. 82

Workonthemastandfrontpartofthetruck ................................. 83

Initial operation ..................................................... 86

Checksbeforestartingwork ............................................ 86

Maintenance after the first 50 hours ...................................... 86

IV Operating Instructions – 393 807 1001 EN – 06/2006

Table of contents

Inspection and maintenance as required . . . ................................ 86

Inspection and maintenance work every 500 to 1000 operating hours * or every

year ........................................................... ... 87

Inspection and maintenance ever

Inspection and maintenance every 6000 hours or every 3 years . ................. 88

Inspection and maintenance every 9000 hours or every 4 years . ................. 88

Inspection and maintenance data ........................................ 8

Consumable materials recommendations . . ................................ 89

Checks prior to starting work ............................................ 92

Fuel ........................................................... ... 92

Bonnet ........................................................... 93

Engineoil ......................................................... 95

Coolant ........................................................... 96

Tyres ............................................................. 98

Check the third auxiliary hydraulic function and safety system (option) . ............ 99

Inspection and maintenance as required ...................................10

Baseplate ....................................................... . . 101

Changing wheels ....................................................102

Tighten the wheel bolts . ...............................................103

Cleanthelifttruck ....................................................103

Cleantheventhosetothetank ..........................................104

Cleanandlubricatetheliftchainsl .......................................105

Change the air filter element ............................................105

Change the air filter safety element .......................................106

Checkthedustdischargevalve .........................................106

Cleantheprefilter ....................................................107

Cleanandchecktheradiatorandhydraulicoilcoolerforleaks ...................107

Regenerate the soot filter ..............................................109

Change the oil in the oil bath air cleaner (Optional) ............................111

Topping up washer system water tank (special equipment) .....................111

Drainthefuelfilter ...................................................112

Lubricate the steering axle bearings ......................................113

Checkthetyresfordamageandforeignobjects ..............................113

Check the seat belt for condition and proper operati

Servicing the air conditioning (special equipment) ............................114

Inspection and maintenance every 500 to 1000 operating hours or once a year ......116

Changing motor oil ...................................................116

Cleantheradiatorandhydraulicoilcooler ..................................118

Clean wet type air cleaner (Optional) ......................................118

Checkcoolantconcentration ...........................................119

Hydraulicsystem:Checktheoillevel .....................................120

y 3,000 operating hours or every 2 years .......... 87

on .........................113

g

8

1

Operating Instructions – 393 807 1001 EN – 06/2006 V

Table of contents

g

Check correct operation of breather valve on the hydraulic oil tank ................121

Battery:checkcondition,acidlevelandacidspecificgravity ....................122

Change the fuel filter .................................................124

Engine oil filter change ................................................125

Check condition of the ribbed vee belt .....................................126

Check toothed belt condition and ten

Checkthesootfiltersystem(option) ......................................128

Check electrical cables, cable connectors and cable terminals for condition and secure

attachment ..................................................... ...129

Check the pedals ....................................................130

Checkandoilotherpivotsandjoints ......................................130

Check the control unit for proper operation .................................131

Renew the air filter element, check the

Cleanandgreasethesteeringaxle .......................................132

Clean sideshift (special equipment) and grease, check fastening .................133

Clean and lubricate fork arm adjuster (spe

andlubricate .......................................................133

Mast, lift chains, lift cylinders and end stops: Check for security, condition and proper

operation ..........................................................135

Adjusttheliftchainlength ..............................................135

Check the tension of double hoses .......................................137

Checktheforksandforkquick-releases ...................................138

Check the engine mounting for condition and security .........................138

Checking fastening for frame, tilt cylinders

Axleclampsandwheelmotors,checkingfastening ...........................139

Checkthesteeringcylinderandkingpinforsecurity ..........................140

Check,adjustthedriveaxlelateralstops ...................................140

Checkthecombustionairintakeandexhaustpipesforleaks ....................141

Checkthehydraulicsystemforleaks .....................................141

Check the operation of the parking brake ..................................142

Inspection and maintenance every 3000 operating hours or every 2 years ..........143

Hydraulicsystem:renewthefilters .......................................143

Change the air filter safety element .......................................145

Renew the ribbed V-belt ...............................................146

Renewthetoothedbeltandidlerpulley ....................................147

Check the drive axle mounting for wear ....................................147

Check tilt cylinder bearings for wear ......................................148

Check the hydraulic pump security at the engine . . ...........................148

Check slide guides on sideshift (special equipment) f

Inspection and maintenance every 6000 operating hours or every 3 years ..........150

Change hydraulic oil ..................................................150

sion ..................................127

vacuumswitch .........................131

cial equipment), check fastenings Clean

andsteeringaxle ....................139

orwear ....................148

VI Operating Instructions – 393 807 1001 EN – 06/2006

Table of contents

Inspection and maintenance every 9000 operating hours or every 4 years ..........152

Replacethewaterpump ............................................. . . 152

Changing coolant ....................................................152

Troubleshooting .....................................................155

Openingtheelectricalsystemcover ......................................155

Fuses for basic- and special equip

Mainfuseintheenginecompartment .....................................156

Diagnosticconnector .................................................157

Jumpstart ...................................................... . . . 157

Emergency lowering of fork carriage ......................................158

Emergency exit for trucks with rear screen . ................................159

Towinginstructions ..................................................160

Placingtheforklifttruckintostorage ......................................162

Disposalofoldvehicles ...............................................163

Malfunctions during operation ...........................................164

Faults, causes, remedies (diesel engine) . . ................................166

Hydraulic system troubleshooting guide . . . ................................169

ment ....................................155

6 Technical data

Technical data ......................................................172

Type sheet H 25, Edition 12/2005 ........................................172

Type sheet H 30, Edition 12/2005 ........................................175

Type sheet H 35, Edition 12/2005 ........................................178

Load diagrams and lift mast data Edition 12/2005 ............................181

Noiseemissiondata ..................................................183

Frequency characteristics for human body vib

rations ..........................184

g

Operating Instructions – 393 807 1001 EN – 06/2006 VII

Table of contents

g

Annex

7 Wiring diagrams

Wiring diagram (standard equipment) sheet 1 ...............................196

Wiring diagram (standard equi

Wiring diagram (standard equipment) sheet 3 ...............................200

Wiring diagram (option) sheet 1 .........................................202

Wiring diagram (option) sheet 2 .........................................2

Wiring diagram (option) sheet 3 .........................................206

Wiring diagram (option) sheet 4 .........................................208

Wiring diagram (option) sheet 5 .........................................21

Wiring diagram (special equipment) page 6 .................................212

Wiring diagram (special equipment) page 7 .................................214

Hydraulic circuit diagram ..............................................216

pment) sheet 2 ...............................198

04

0

VIII Operating Instructions – 393 807 1001 EN – 06/2006

1

Introduction

1 Introduction

Symbols used

Your forklift truck

offers optimum efficiency, safety, reliability
and comfort. It is now up to you to maintain
these characteristics for as long as possible
and to take advantage of the resulting benefits.

During manufacture:

• all safety requirements of the
directives were observed

• all conformity assessment procedures
stipulated in the applicable directives were
carried out.

This is attested by the CE mark shown on the
nameplate.

This operating manual contains
you need to know about commissio
driving and maintenance.

A number of special equipment items have
their own operating manuals, which are sup­plied along with this equipment. Please ob­serve the information for operation depending

relevant EC

everything

ning,

Intended use

The lift truck is designed for transporting and
stacking the loads stated in the load capacity
diagram. In particular

• we refer to the VDMA "Guidelines for the
normal and proper use of industrial trucks"
(or BITA for UK market),

• the safety rules of your tr

• the special measures required for driving on
public roads in accordance with the C.U.R.,

• other local regulations.

ade association,

on the version of your forklift truck and carry
out the specified work regularly, at the due
times and using the working materials envis­aged for this purpose according to the inspec­tion and maintenance overview programme.
Please make sure you record the work per­formed in the registration document for the
industrial truck; only in this manner will you
retain your warranty claims.

The designations used in the text: front - back

- left - right - always refer to the installation
position of the parts described with forwards
as the direction of travel (fork arms forwards)
for the forklift truck.

In the case of servicing work
here, specialist knowledge
ments and frequently also sp
required. Please ask your au
to carry out this work.

Servicing should only be carried out by quali­fied staff authorised by Linde (specialists).

The rules for the intended and approved use
of industrial must be followed under all circum­stances by the responsible persons, espe­cially by the operator and service personnel.

The user, and not Linde, is responsible for
any danger arising from applications not
authorised by the manufacturer.

If you desire to use the tru
not mentioned in the manua
supplement it for this pur
contact your authorised

No changes, particularly no modifications and
additions, may be made to the truck without
the approval of the manufacturer.

not described

, measuring instru-

ecial tools are
thorised dealer

ck for applications

l and convert or

pose, please first

dealer.

Symbols used

The precautions WARNING, CAUTION, AT­TENTION, NOTE and ENVIRONMENTAL
NOTE in this manual are provided to indicate

2 Operating Instructions – 393 807 1001 EN – 06/2006

special hazards or unusual information requir­ing special identification:

Introduction 1

Symbols used

DANGER

indicates hazards that may result in personal injury
or death and/or substantial damage to the product.

WARNING

indicates hazards that may result in personal injury
and/or substantial damage to the product.

CAUTION

indicates hazards that may result in damage to or
destruction of the product.

NOTE

Identifies technical information requiring
special attention because the connection may
not even be obvious to skilled personnel.

ENVIRONMENT NOTE

The information contained here
observed, otherwise environme

in must be
ntal damage

may occur.

CAUTION

This label is affixed on the truck at
the places needing your special
attention.

Read the related material in this
manual.

For your safety other symbols are also used.
Please note the different symbols.

Operating Instructions – 393 807 1001 EN – 06/2006 3

1 Introduction

Technical specification

Technical specification

Forklift trucks in the 393 series are designed to
handle loading and palletising operations for
loads up to 2.5 t with H 25, up to 3 t with H 30
and up to 3.5 t with H 35.

Details on the exact lifting height-specific
maximum loads are available in the load
diagram.

The forklift trucks are eco-fr
quiet operational noise and lo
emissions benefit both the dri
environment. They excel on acc
compact design and a small turn
and they are fully container
this reason, the forklift tr
well-suited for narrow alle
areas where space is at a prem

Motor

A 4-cylinder, four-stroke diesel motor with
turbocharging is installed as the drive motor.
It drives the forklift truck’s hydraulic pump
at a speed to match the load. The motor is
cooled by means of a closed coolant circuit
with remote expansion reservoir.

Pressure circulation lubrication with an oil
pump in the oil sump is used to lubricate the
motor. The combustion air is cleaned by
means of a dry air filter with a paper insert.
Diesel motors with state-of-the-art technology
areusedfor:

• high torque

• low fuel consumption

• low exhaust emissions

• low particulate emissions

• low noise values

Hydraulic system

The travel drive consists of a hydraulic vari­able-displacement pump, two hydraulic con­stant wheel motors (assembled as a drive axle
unit) as well as a hydraulic pump (fixed-dis­placement pump) for the operating and steer­ing hydraulics. The direction of travel and

iendly and their

w level of

ver and the

ount of their

ing radius,

compatible. For

ucks are particularly

ys and operational

ium.

speed are regulated by means of two accel­erator pedals via the hydraulic variable-dis­placement pump.

The hydraulic constant wheel motors in
the drive axle are supplied by the hydraulic
variable-displacement pump and they power
the drive wheels.

Operation

One accelerator pedal each for
travel and reversing (two-ped
is used to regulate both the hyd
displacement pump and simult
motor speed. The hydrostatic
the speed to be continuously v
directions, ranging from sta
maximum speed. The dual-peda
means that operation of the fo
both simple and reliable.

The driver always has both hands free for
steering and control of the work movements.
Fast reversing and energy-saving stacking is
the result.

An optional version is also available whereby
the speed is regulated by an accelerator pedal
(single-pedal operation) and the direction of
travel controlled by means of a travel direction
switch.

To control the work movement
lowering and tilting, there
lever (joystick). Another j
operate additional attachm
movements can also be contro
joysticks (single-lever op

forward

al operation)

raulic variable-

aneously the

drive enables

aried in both

ndstill up to

lcontrol

rklift truck is

s, lifting,
is only one operating
oystickisfittedto

ents. Working

lled using two

eration version).

Linde Truck Control

The forklift truck’s Linde Truck Control (LTC)
enables:

• sensitive, smooth driving and reversing,

• automatic regulation of moto
match respective power requi
hydraulics,

• faster service through self diagnosis,

• maximum operational reliability.

r speed to

red by the

4 Operating Instructions – 393 807 1001 EN – 06/2006

Introduction 1

Truck takeover

Brakes

The hydrostatic drive is used as a service
brake. This in turn means that the service
brake is maintenance free. Two multi-disc
brakes integrated into the wheel motors are
used as a parking brake. When the motor is
switched off the multi-disc brakes engage,
this in turn means that the forklift truck has an
automatic braking function. To operate the
parking brake when switching off the forklift
truck the parking brake handle must always be
engaged.

Truck operation with a buck

If the truck is operated wit
anti-stall device can be ac
authorised dealer.

In this case the working hydraulics will op­erate with a slight delay due to the drop in
engine speed when the engine experiences
extremely heavy loads.

h a bucket, the

tivated by your

et

Steering

The steering is a hydrostatic steering system,
with which the steering wheel acts on the
steering cylinder to actuate the rear wheels.
If the power applied to the steering wheel is
increased, the steering system can also be
operated when the motor has been switched
off.

Electrical system

The electrical system is power
the alternator with 12 V d.c. vo
battery with 88 Ah has been inst
starting the motor. It is loca
driver’s seat in the motor com

NOTE

With a longer sustained loa
the joystick must be put to
to release the working hyd

ed through
ltage. A 12 V

alled for

ted under the

partment.

d on the engine,
the neutral position
raulics again.

Truck takeover

Every Linde lift truck undergoes careful in­spection before leaving the factory in order
to make sure that it will be in good condition
and fully equipped as ordered when delivered.
Your authorised Linde dealer is under obliga­tion to re-inspect the truck before delivery and
to hand it over in full working order.

In order to avoid later complaints and incon­venience to customers, you are requested to
ascertain that the truck is in satisfactory condi­tion and fully equipped at the time of delivery
and to acknowledge the correct installation
of the truck in the manufacturers certificate of
conformity.

Linde pursues a policy
ment in the design and m

Operating Instructions – 393 807 1001 EN – 06/2006 5

of continuous improve-

anufacture of its

products. The illustrations and technical de­tails referring to design, fittings and engineer­ing of lift trucks are subject to change or mod­ification as a result of technological progress
by Linde.

Linde is therefore unable to consider any
claims based on the specifications, illustra­tions and descriptions contained in this Oper­ating Instructions manual.

Please submit all enqui
fork truck orders for sp
Linde representative,
correct delivery addre

For repairs use only original Linde spare parts.
Only in this way can it be guaranteed that
your Linde fork lift truck maintains its original
technical standard.

ries concerning Linde

are parts to your local
making sure to give the
ss.

1 Introduction

Initial operation

These operating instructions or excerpts
thereof may only be copied, translated or
transmitted to third parties after prior written
approval by the manufacturer.

When ordering spare parts, please specify the
part number and state the following truck data:

Lift truck model:

Serial number/year
of manufacture:

Handover date:

Additionally, specify the serial number of the
engine, mast, hydrostatic hydraulic pump
and drive axle when ordering parts for these
assemblies.

Engine number:

Mast number:

Mast stroke:

Hydraulic pump
number:

Drive axle number:

This information can be found on the type
plates on the truck. We recommend that you

transfer this information to this manual for
ease of future reference.

NOTE

When a forklift truck without a ma
from our factory, it is fitted wit
stop screw to limit the speed. T
is located under the reverse ac
(two pedal operation) or under
pedal (one pedal operation). T
screw must be removed when the m
mounted. To do this, loosen the
screw and unscrew it along with
nut (see also: Driving without

The following technical documents belong to
each fork lift truck:

• Operating Instructions manua

• EC Declaration of Conformity (The man­ufacturer certifies that the industrial truck
conforms to EC directives for machines.)

• Rules for the Normal and Proper use of
Industrial Trucks or Booklet for Users of
Industrial and Rough Terrain Trucks (VDMA

• or BITA for UK market)

st is delivered

h an additional

his stop screw
celerator pedal
the accelerator
his additional

ast is

hexagonal

the hexagonal

mast).

lforthetruck

Initial operation

¾ Check the engine oil level

¾ Check the coolant level in the expansion

reservoir

¾ Refuelling

¾ Check condition, electrolyte level and acid

density of the battery

¾ Check the tyre inflation pressure

¾ Tighten the wheel nuts

6 Operating Instructions – 393 807 1001 EN – 06/2006

¾ Check the hydraulic oil level

¾ Check the brake system

¾ Check the steering system

¾ Check the lifting device and attachments

¾ Regenerate the soot filter (option)

¾ Check the third auxiliary hydraulic function

and safety system

2

Safety

2 Safety

Safety regulations

Safety regulations

This "rules enclosed with this operating
manual refer to the correct use of industrial
trucks." They must be brought to the attention
of the persons responsible, in particular to
those persons concerned with operating and
maintaining the trucks, before working with or
on the trucks.

The operating company must ensure that the
driver understands all the safety information.

Please comply with the regulat
e. g.

• Operation of industrial trucks,

• Rules for driveways and the area of opera­tion,

• Right, duties and rules of behav
driver,

• Special operating areas,

• Information regarding setting in motion,
driving and braking,

• Information for maintenance and

• Periodic checks,

• UVV inspections,

• Disposal of oils, greases and batter

• Other hazards.

As the operating company or responsible
person, ensure that all regulations and safety
rules that are applicable to your industrial
trucks are complied with.

When training a fork-lift truck driv
already been trained to BGV D 27, the

• special features of the Linde fork lift truck
(dual-pedal control, central joystick, stop
pedal),

• and any special attachments,

• special features of operation and wor
area,

must be practised sufficiently by training,
driving, switching and steering, so that they
are fully mastered.

ions and rules,

iour for the

repair,

ies,

er who has

king

Only then should training on fork lift access to
the racking commence.

Safety information

DANGER

Safety devices (e.g. the seat switch) are there for
your safety.

Safety devices - of whatever kind - must never be
disconnected.

DANGER

When retrofitting a 3rd additional hydraulic system,
using solutions other than those recommended by
the truck manufacturer will render EC conformity
null and void and is therefore expressly forbidden.

Trucks may only be retrofitted with a 3rd additional
hydraulic system with the approval of the truck
manufacturer.

DANGER

It is forbidden to connect any safety-critical func­tions such as a ball clamp or swivel of a fluid con­tainer to any third additional hydraulic system that
may be fitted.

So as to prevent inadvertent opening of the clamp or
swivel, the additional function should be connected
to the first additional hydraulic system.

DANGER

Any additional drilled holes or welding to the driver’s
protective roof will compromise its strength.

It is therefore strictly forbidden to drill holes in the
driver’s protective roof or to weld to it.

CAUTION

Welding operations on other parts of the vehicle
can cause damage to the electronics.

Therefore before performing any welding, always
disconnect the battery and all connections to the
electronic control units.

8 Operating Instructions – 393 807 1001 EN – 06/2006

Safety 2

Handling fluids and lubricants

WARNING

It is the coolant temperature that determines when
the fan on the cooler starts up. This means that the
fan can even start up automatically if the ignition is
switched off.

When performing work in the engine compartment,
wait until the engine has cooled down.

In the case of tip-over

• Stay buckled up

• Don’t jump

• Hold on tight

• Brace feet

•Leanaway

WARNING

Depending on the duration of
operation and use, components
carrying exhaust gases and exhaust
air can become hot.

Therefore wear protective clothing

WARNING

The fork lift truck working area must be adequately
lit.

If it is insufficiently lit, floodlights must be installed
to ensure that the driver can see properly

The stability of your truck is ensured if used
properly and as intended. Should the truck
tip over during an unapproved application or
due to incorrect operation, always follow the
instructions depicted below.

Handling fluids and lubricants

ENVIRONMENT NOTE

Always handle fluids and lubricants as re­quired and as specified by the manufacturer.

• Only store fluids and lubricants in approved
containers at specified storage places.

• As they could be inflammable, do not allow
contact with hot objects or a naked flame.

• Only use clean containers when replenish­ing fluids and lubricants.

• Follow the manufacturer’s safety and
disposal instructions.

Operating Instructions – 393 807 1001 EN – 06/2006 9

• Do not spill fluids.

• Remove any spillage immediately with a
suitable binding agent and dispose of as
specified.

• Also dispose of used or contaminated fuels
and lubricants as specified.

• Follow laws and regulations.

• Clean the area surrounding the part in
question before lubrication, filter renewal
or repairs in the hydraulic system.

• Discard replaced parts in a way friendly to
the environment.

2 Safety

Regulations

WARNING

Do not allow hydraulic oil under pressure, for
example at a leak, to penetrate the skin. Medical
aidisrequiredifsuchaninjuryoccurs.

Wear protective gear.

WARNING

Improper handling of coolants and coolant additives
puts your health and the environment at risk.

Observe manufacturer´s directions.

Experts

Experts are persons with a special training and
experience in servicing and testing industrial
trucks and familiar with the applicable worker’s
protection rules, safety regulations, directives
and generally recognised rules of the art

(DIN and VDE standards, technical rules of
members of the EU or EEA agreements) so
that they can give a qualified assessment
of the safe operating condition of industrial
trucks.

Operation of industrial trucks in plant area

Many plant areas are so-called limited public
traffic areas. In this sense, we would like to
advise you to check your company liability
insurance coverage, to ensure that possible

claims for damages caused by your truck
in limited public traffic areas in relation to
third parties are included in the insurance
coverage.

Regulations

Safety inspection

The accident prevention rules in some coun­tries require that the fork lift truck must be
checked periodically for proper operation by
trained personnel. Please contact your autho­rised dealer for this inspection.

Diesel engine emissions

In Germany, fork trucks equipped with diesel
engines must conform to TRGS 554. Ac­cording to this regulation, diesel engine emis­sions are hazardous materials causing can­cer. They should not get into the air at the
workplace, if possible. If trucks equipped with

diesel engines are used in totally or partially
enclosed spaces, the labour protection au­thority must first be notified. Appropriate no­tices must be posted in the work areas (refer
to TRGS 554 for an example).

Soot filter inspection

The responsible authorities specify that soot
filters must be inspected and serviced every
six months by an expert. The results of the
inspection must be recorded in a "Diesel
Engine Emissions Inspection Certificate" and
attached to the log book (eg truck’s safety
inspection logbook).

10 Operating Instructions – 393 807 1001 EN – 06/2006

Safety 2

Determination and assessment of hazards from use of industrial trucks

Determination and assessment of hazards from use of industrial
trucks

Check note

Hazard Action

Industrial truck
equipment does not
comply with local
provisions

Lack of skills and
qualification of driver

Lack of skills and
qualification of driver

Usage by unauthorised
persons

Industrial truck not in a
safe condition

Impaired visibility
through load

Contamination of
respiratory air

Contamination of
respiratory air

Impermissible usage
(improper usage)

Impermissible usage
(improper usage)

Impermissible usage
(improper usage)

When filling up with a)
diesel

When filling up with b)
fuel gas

When charging traction
batteries

Check

Driver training (sit-on
and stand-on industrial
trucks)

Instruction for pedestrian­controlled trucks

Access with key only for
appointed staff

Recurrent testing and
rectification of defects

Deployment planning

Assessment of diesel
exhaust gases

Assessment of fuel gas
exhaust gases

Issue of operating
instructions

Written notice of
instruction to driver

UVV-BGV D 27, observe
operating manual and
VDMA leaflet

UVV-BGV D 27, observe
operating manual and
VDMA leaflet

UVV-BGV D 27, observe
operating manual and
VDMA leaflet

UVV-BGV D 27, observe
operating manual, VDMA
leaflet and VDE 0510

X = actioned

- = not
concerned

Notes

If in doubt, consult
competent factory
inspectorate or
employers’ liability
insurance association

UVV-BGV D 27 - § 7,
BGG 925 driver permit
VDI 3313

UVV-BGV D 27 - §§ 9,
37, BGG 918

UVV-BGV D 27 - § 12

TRGS 554

MAK list (maximum work­place concentrations list)

UVV-BGV D 27 - § 5

UVV-BGV D 27 - §7

VDE 0510: In particular
a) ventilation b) insulation
value

Operating Instructions – 393 807 1001 EN – 06/2006 11

2 Safety

Instructions for fitting attachments

In the Federal Republic of Germany the Ger­man Law on Health and Safety at Work (Arb­SchG) states that it is up to the Employer to
assess which hazards are associated with
the work of employees and which Health and
Safety measures are required (§ 5 ArbSchG).
The result must be documented (§ 6 Arb­SchG). In the case of industrial truck deploy­ments involving similar hazard situations it is
permitted to summarise the results . In coun­tries outside the Federal Republic of Germany
the country-specific regulations must be ob­served. With the list we are helping you to
comply with these regulations. The construc­tion and equipment of industrial trucks comply
with the Machinery Directive 98/37/EC and
are identified by the CE mark accordingly.
This means that they do not fall under the
scope involved in the assessment of hazards,
and nor do attachments due to their own CE
marking . The operator must however select
the type and equipment of industrial trucks so
as to comply with the local provisions for de­ployment.

Instructions for fitting attachments

To depressurise the oil in the pipes be­forefitting an additional hydraulic attachment
to the hydraulic system, a pressure receiver
(special equipment) can be used.

In order to ensure the safe usage of industrial
trucks we not only supply every industrial
truck with a copy of the operating manual but
also with the leaflet of the VDMA (German
Engineering Federation) specifying the rules
for the proper usage of industrial trucks "Rules
for the Proper Use of Industrial Trucks".

The list specifies key hazards which are most
frequently the cause of accidents in the event
of non-compliance. If other major hazards are
involved at a specific plant , they must be listed
additionally.

In many plants the conditions o
industrial trucks are by and la
that the hazards can be summar
list. The pronouncements of t
liability insurance associa
each case as regards this topi
taken into account.

For this consult the section "Operate attach­ments".

f use for

rge similar so

ised in one

he employers’

tion competent in

c should also be

12 Operating Instructions – 393 807 1001 EN – 06/2006

3

Overview

3 Overview

Rating plates

Rating plates

1 Nameplate
9 Lift mast number (stick-on label)
10 Chassis number (stamped into the rear wall

of the driver’s protective roof)
11 Rating plate for drive axle
12 Rating plate for engine

14 Operating Instructions – 393 807 1001 EN – 06/2006

NOTE

The CE mark confirms compliance with the EC
machinery directive and with all regulations
applicable to fork lift trucks .

Overview 3

Rating plates

1 Nameplate
2 Manufacturer
3CEmark
4 Serial No. / build year)
5 Tare weight
6 Battery voltage
7 Nominal load capacity
8 Type

Operating Instructions – 393 807 1001 EN – 06/2006 15

3 Overview

General view

General view

1Mast
2 Lift cylinder
3 Composite instrument
4 Tilt cylinders
5 Toggle switch for auxiliary functions (op-

tional)
6 Steering wheel/hydrostatic power steering
7 Control lever (joystick)
8 Operator’s seat
9 Electrical system cover
10 Fuses (behind the electrical system cover)
11 Counterweight
12 Steering axle

16 Operating Instructions – 393 807 1001 EN – 06/2006

13 Maintenance access covers
14 Chassis and overhead guard
15 Engine bonnet
16 Step for mounting and dismounting
17 Fuses (in the engine compartment)
18 Wheel motor, left
19 Handwheel for adjusting steering column
20 Fork carriage
21 Fuses, forks
22 Forks
23 Forks, locking
24 Lift chain (only for duplex or triplex mast)

Controls

4

3

2

1

Overview 3

Controls

56 879

10

11

18

12

d3921508

14151617

1 Parking brake handle
2 Handwheel for adjusting steering column
3 Combined lever for wiper/washer and

blinker (option)
4 Steering wheel/hydrostatic power steering
5 Signal button
6 Ignition switch with ignition key
7 Cubby hole
8 Control lever (joystick) for working hy-

draulics
9 Control lever (joystick) for auxiliary hy-

draulics (attachments) (option)

Operating Instructions – 393 807 1001 EN – 06/2006 17

10 Symbol label for auxiliary hydraulics (attach-

11 Symbol label for working hydraulics
12 Operator’s seat armrest
13 Operator’s seat
14 Forward accelerator
15 Brake pedal
16 Reverse accelerator
17 Backrest cushion adjuster (option)
18 Plate "Guaranteed acoustic power level"

13

ments) (option)

3 Overview

Indicator unit

Indicator unit

1 Indicator unit
2 Hydraulic oil temperature indicator
3 Battery charge indicator
4 Engine oil pressure indicator / Engine oil

level indicator (special equipment)
5 Electrical control system fault
6 Engine temperature indicator
7 Load / overload indicator (special equip-

ment)
8 not assigned
9 Level display (special equipment)
10 Hydraulic oil micro-filter indicator (special

equipment)
11 Fuel tank level display
12 Display
13 not assigned
14 Display operating hours

(2) Hydraulic oil temperature indicator (colour
red)

Lights up when the specified temperature
limit is reached. A buzzer sounds when the
permissible temperature limit is reached.

• Insufficient oil in the hydraulic system

• Incorrect oil used

• Oil filter clogged

• Oil cooler clogged

• Switch buzzer off with the reset button (19).

(3) Battery charge indicator (colour red)

15 Symbol operating hours
16 Display time
17 Symbol service interval exceeded
18 Function push-button
19 Reset button
20 Symbol parking brake applied
21 Symbol "do not start the engine"
22 Symbol operating hours (until next service

shown for only 4 sec on display field (14))
23 Symbol lift mast position sensing
24 Text field
25 Glow plug indicator
26 Air filter induction pressure indicator
27 Coolant water level display (special equip-

ment)
28 not assigned

Lights up when there is a fault in the battery
charger system.

• Ribbed vee belt broken or ribbed vee belt

tension too slack

• Ribbed vee belt tensioner defective

• Cable defective

• Alternator defective

• Charge controller or controller switch

defective.

(4) Engine oil pressure indicator / Engine oil
level indicator (special equipment) (colour
red)

18 Operating Instructions – 393 807 1001 EN – 06/2006

Overview 3

Indicator unit

When engine lubricating oil pressure is
too low this indicator lights up, and also a
buzzer sounds. In addition the text field (24)
displays the text
downwards indicates that the engine oil level
is too low.

• Insufficient oil in the crankcase

• Engine too hot

• Incorrect oil used

• Internal leakage in the lubricating oil circuit

• Top up with engine oil

• Switch buzzer off with the reset button (19).

(5) Electrical control system fault (colour red)

Lights up when an electrical contro
fault is present, and displays a fau
text field (24).

(6) Engine temperature indicator (colour red)

Lights up when the specified temperature
limit is reached. A buzzer sounds when the
permissible temperature limit is reached.

• Fan motor defective

• Thermostatic switch defective

• Radiator clogged

• Leakage in the coolant circuit

• Coolant level too low

• Switch buzzer off with the reset button (19).

(7) Load / overload display (special equ
ment)

Symbol lights up orange when load is normal.

DANGER

Symbol lights up red when overloaded.

Set down load immediately.

• Consult load diagram.

(8) not assigned

(9) Level display (colour yellow) (special
equipment)

Lights up when the coolant level is below the
minimum.

• Top up the coolant.

Oil A double arrow pointing

l system

lt code in

ip-

Please contact your authorised dealer.

(10) Hydraulic oil micro-filter indicator (colour
yellow) (special equipment)

Lights up when the micro-filter r
maintenance.

• Micro-filter clogged, exchange it.

(11) Fuel tank level display (colour depending
on the level, green or red

• Shows the current fuel tank level.

(13) not assigned

(14) Display operating hours

Shows the operating hours of the fo
This indicator is an shows the fork
operating hours and indicates the
and maintenance work to be perform

NOTE

If a defective indicator unit is exc
the operating hours up to that poi
recorded. Note the data on an embo
attached near the indicator unit
the option of subsequently updat
indicator unit. Please contact y

equires

rklift truck.
lift truck’s
inspection

ed.

hanged,
nt must be

ssed strip

. There is also

ing the new

our authorised

dealer.

(15) Symbol operating hours

Flashes when operating hours are
counted (only when the ignition i
engine speed exceeds 500 rpm

(16) Display clock

24-hour clock display

Can be adjusted using buttons (18) a

Resetting to 12-hour clock display is possible
using a diagnostic tester. Please contact your
authorised dealer.

(17) Symbol service interval exceeded

If the number of operating hours unt
service is less than or equal to 0, th
flashes for 10 sec every time the veh
started, and then lights up contin

Adjustment and reset of the intervals can be
performed only using the diagnostic tester

being

sonandthe

)

nd (19.)

il the next

e symbol

icle is

uously.

Operating Instructions – 393 807 1001 EN – 06/2006 19

3 Overview

Indicator unit

provided for this purpose. Please contact your
authorised dealer.

(18) Function push-button

Assignment depending on version

(19) Reset button (special equipment)

To adjust the time, switch off the warning
buzzer and other functions depending on the
version.

(20) Symbol parking brake

Lights up when the parking brake is applied.

(21) Symbol "do not start the engine"

Lights up when the engine has stall

NOTE

.

ed.

It is essential to leave the ignition switched on
until this symbol has gone out (depending on
the oil temperature this may be between 15
and 50 seconds). Then attempt to restart the
engine.

(22) Symbol operating hours until

After the ignition has been switched on,
display field (14) shows the operating hours
until the next service (counting backwards).

Symbol (22) lights up. After 5 seconds symbol
22 goes out and indicator (14) automatically
switches to the operating hours of the forklift
truck; the operating hours symbol (15) flashes.

next service

(23) Symbol lift mast position sensing (special
equipment)

Lights up when the function "lift mast position
sensing" is enabled .

(24) text field

Serves as a display field. Please contact your
authorised dealer for interpretation of fault
codes.

(25) Glow plug indicator (colour yellow)

Lights up whilst the glow plugs are
up, then goes out.

Flashes if there an engine fault or engine
management fault occurs. Please contact
your authorised dealer.

(26) Air filter induction pressure indicator
(colour yellow)

Lights up when the air filter is exc
clogged.

• Air filter clogged, exchange it.

(27) Coolant water level display (colour
yellow) (special equipment)

Lights up when the coolant level is b
minimum.

• Top up the coolant.

(28) not assigned

warming

essively

elow the

20 Operating Instructions – 393 807 1001 EN – 06/2006

4

Operation

4 Operation

Standard equipment

Running-in instructions

The lift truck can be operated at full speed
directly. Avoid sustained high loads on the
working hydraulic system and the travel
drive in the first 50 hours of operation. The
wheel fasteners must be tightened before the
commissioning and after each wheel change.

Checks before starting work

¾ Check the fuel level

¾ Check the engine oil level

¾ Check the hydraulic oil level

Standard equipment

Adjusting the driver’s seat

WARNING

An incorrect adjustment of the seat can cause back
injury. Do not operate the seat adjusting devices
while operating the truck.

Before each start-up of the truck and with each
change in driver, set the weight setting to the indivi­dual weight of the driver and check if all settings are
correctly engaged. Do not place any objects in the
vicinity of the controls.

Thereafter at least every 100 operating hours.
Tighten opposite wheel fasteners to a torque
of

front:

rear:

¾ Check the coolant level

¾ Check the tyre pressures

170 Nm

460 Nm

22 Operating Instructions – 393 807 1001 EN – 06/2006

Horizontal adjustment

¾ Lift lever (2) up and pull it.

¾ Move the driver’s seat on the sli

backwards or forwards to give th
the best position in relation to
wheel and the accelerator pedal

¾ Re-engage the lever.

de rails

edriver

the steering

s.

Backrest adjustment

¾ Push up and hold the backrest adjuster (1).

¾ Move the backrest forward and bac

comfortable sitting position fo
found.

¾ Release the backrest adjuster (1).

k until a

r the driver is

Adjusting the lumbar support (option)

¾ Turn knob (3) until a comfortable sitting

position is achieved.

Turning the knob anticlockwise makes the
backrest arch outwards.

Turning the knob clockwise returns the back­rest to its original position.

d3921352

Operation 4

Standard equipment

1

2

3

6

Adjusting for the operator’s weight

¾ Turn the adjusting handwheel (5) to set the

cushioning to the weight of the driver.

The adjustment range from 50 kg to 130 kg is
visible at the weight range indicator (4).

To reduce the weight, turn the handwheel
anticlockwise.

To increase the weight, turn the handwheel
clockwise.

Operating Instructions – 393 807 1001 EN – 06/2006 23

5

4

d3921353

4 Operation

Standard equipment

Adjusting the seat angle of tilt (option)

¾ Lift the handle (6).

The seat is tilted to the desired
applying or taking off one’s wei
ously.

Adjusting the seat position (

¾ Lift the handle (9).

The desired position is reached by simultane­ously sliding the seat forward or back.

Adjusting the backrest extension (option)

¾ Push the backrest extension (7

for an individual adjustment.

Turning the seat heating on/off

¾ Toggle the switch (8) on or off.

NOTE

Long sitting puts excessive strain on the spinal
column. Prevent strain with regular, light exer­cising.

position by

ght simultane-

option)

)upordown

(option)

7

9

8

d3921354

Adjusting the armrest on the operator’s
seat

NOTE

The armrest on the operator’s s
automatically by spring press

eat is raised

ure after the

handwheel (1) is loosened.

24 Operating Instructions – 393 807 1001 EN – 06/2006

Operation 4

Standard equipment

¾ Sit down on the operator’s seat and loosen

the handwheel (1).

¾ Push the armrest (3) down against the force

of the spring until a comfortable position for
the arm is reached.

¾ Tighten the handwheel (1).

¾ Loosen the handwheel (2) and slide the

armrest (3) back and forth until the control
lever (4) is easily accessible.

¾ Tighten the handwheel (2).

Adjust the steering column

DANGER

If the clamping screw is loose, safe driving is not
possible.

The steering column may only be adjusted when
the truck is stationary.

Tilt adjustment

¾ Loosen the clamping screw (2) in counter-

clockwise direction.

¾ Move the steering wheel (1) to the desired

position.

¾ Tighten the clamping screw (2) in clockwise

direction.

4

3

2

1

d3921416

1

Height adjustment (Optional)

¾ Loosen the clamping screw (2) counter-

clockwise.

¾ Pull the steering wheel (1) upwards, or push

it downwards, to the desired position.

¾ Tighten the clamping screw (2) clockwise.

Operating Instructions – 393 807 1001 EN – 06/2006 25

2

t3921369

4 Operation

Standard equipment

Setting the clock

NOTE

The time is shown in the 24 hour mode.
Change to 12 hour mode with diagnostic unit.
Please contact your authorised dealer for this
service.

¾ Depress both buttons (2) and (3) simultane-

ously for 3 seconds.

The hour readout in the time dis

NOTE

The setting of the hours or minutes can be
adjusted slowly with button (2) by tipping it or
fast by holding it.

¾ Depress button (2) to set the h

¾ Depress button (3) to confirm the hour set-

ting.

Now the minute readout blinks.

¾ Depress button (2) to set the mi

¾ Depress button (3) to confirm the setting of

the minutes.

play (1)blinks.

ours.

nutes

1

3

2

d3921348

Lap seat belt

Applying the lap seat belt

DANGER

It is dangerous to leave the truck in
an uncontrolled manner.

Therefore always keep buckled up
when operating the truck! Only one
person may be fastened with the
seat belt.

WARNING

The proper operation of the lap belt must be gua­ranteed.

Therefore do not let the belt get twisted, caught
or tangled. Protect the lock and retractor against
foreign objects, damage and dirt.

26 Operating Instructions – 393 807 1001 EN – 06/2006

NOTE

Cabins with closed solid doors or guards com­ply with the safety requirements for driver
restraint systems. The lap seat belt can be ap­plied optionally. However, it must be applied
when driving with the doors open or removed.
PVC doors are not considered to be an opera­tor restraint system.

The automatic blocking system locks the belt
when the truck tilts heavily. The belt can then
no longer be pulled out of the retractor. To
loosen the automatic blocking system of the
truck, drive off the slope carefully.

During the operation of the truck (eg driving,
operation of the mast, etc), sit as far back as
possible so that the back contacts the back­rest. The retractor’s automatic blocking sys­tem sufficient freedom of movement during
normal truck operation.

¾ Pull the lap seat belt (1) gent

retractor on the left.

¾ Place the belt over the thighs, not over the

abdomen.

¾ Engage the tongue (2) in belt lock (4).

¾ Check seat belt tension.

The belt should be snug on the body.

ly from the

Operation 4

Standard equipment

5

1

4

Opening the lap seat belt

¾ Press the red button (5) on the lock (4).

¾ Return the tongue (2) to the retr

with the hand.

NOTE

actor (3)

2

3

d3921415

If the belt is retracted too fast the automatic
blocking system can be triggered when the
tongue hits the case. The belt can not be
pulled out with the usual force.

Operating Instructions – 393 807 1001 EN – 06/2006 27

4 Operation

Standard equipment

Drive motor (two-pedal operation)

Starting motor

DANGER

Risk of poisoning!

Do not allow motor to run in unventi­lated rooms.

NOTE

Where possible, avoid starting up the motor
frequently and short service periods to en­sure that the combustion engine attains its
operating temperature. Frequent cold-starts
encourage wear.

¾ The joystick must be in neutral.

¾ Sit down on the driver’s seat.

¾ Fasten the seat belt.

¾ Place both feet on the accelerator pedals

(4).

¾ Parking brake handle (1) engaged, (motor

will only start when parking brake handle is
engaged).

¾ Insert switch key (2) into the ignition and

starting switch and turn from the zero posi­tion to position "I" .

The electrical system is switched on.

1

2

3

d3921417

28 Operating Instructions – 393 807 1001 EN – 06/2006

4

4

Operation 4

Standard equipment

¾ Check the indicator unit (3).

NOTE

After switching on the ignition the indicator unit
will perform a self-test . The displays all light
up for approx. 2 seconds and the operating
hours until the next service are displayed for
5 seconds in the indicator unit (3) display field
(11). During this time symbol (12) remains
lit. After 5 seconds the display reverts auto­matically to the operating hours. If the buzzer
sounds (particulate filter unit fault), check the
lamps (see Diesel motor faults, cause, reme­dies). If the buzzer continues to sound, please
contact your local authorised dealer.

The following controls light up:

• Symbol (9) parking brake engaged,

• Motor oil pressure indicator (

• Battery charge indicator (5),

• Glow plug indicator (13).

¾ Wait until the glow plug indicat

out

¾ Turn switch key to position "II".

As soon as the motor starts

¾ release the switch key.

Symbol (7) will flash on and off.

CAUTION

For vehicles with particulate filter units only. If the
exhaust is very smoky and remains so, switch off.
Please contact your authorised dealer.

Every time the engine is started, watch the exhaust
pipe outlet for about 5 seconds.

6),

or (13) goes

13

12

11

10

3

56

7

9

8

d3921349

If motor fails to start

¾ After the glow plugs have heated up, keep

turning the starter motor until the motor runs
at idling speed . Depending on the vehicle,
the temperature and the altitude, this can
take more than 1 minute.

If the motor stalls, the symbol" Do not start the
motor"(10) will appear.

Operating Instructions – 393 807 1001 EN – 06/2006 29

4 Operation

Standard equipment

¾ Always leave ignition switched on until sym-

bol extinguishes (between 15 und 50 sec­onds depending on oil temperature).

¾ Then try to restart.

When trying to start the motor, wa
for min. 1 minute to protect the ba
motor still does not start at th
consult: Malfunctions, Cause

The Charging and Motor oil pressure symbols
must extinguish once the motor starts to run
smoothly.

Motor speed is regulated automatically de­pending on the load on the motor.

NOTE

Do not allow motor to warm up at id
Under load drive truck at a brisk
motor will warm up quickly.

Switchingoffthemotor

CAUTION

For motors with a turbocharger, the high speed of
the turbocharger shaft (approx. 100 000 rpm at
full load) could cause the shaft bearing to run dry
through lack of lubrication thus damaging it.

Do not switch off motor under full load, but rather
allow to run on for a few minutes at low speed.

it each time
ttery. If the

e third attempt,

s and Remedy.

ling speed.

speed . The

¾ Take your feet off the accelerator pedals

(3).

¾ Move switch key (2) into zero position.

NOTE

1

2

The brake becomes active when the motor is
switched off.

¾ Pull up parking brake handle (1).

¾ Remove the switch key (2) when leaving the

truck.

d3921418

30 Operating Instructions – 393 807 1001 EN – 06/2006

3

3

Driving (double-pedal operation)

WARNING

Driving on gradients over 15 % is generally not
allowed due to the specified minimum brake ap­plications and the stability values. Contact your
authorised dealer before driving on steeper gradi­ents. The climbing ability values given in the data
sheet have been derived from the drawbar pull and
apply only for crossing obstacles and short diffe­rences in height.

Always adapt your driving style to the conditions
of the roadway (rough surfaces, etc.), especially
hazardous work zones and the load.

WARNING

If mirrors are used, please note the rear-view mirror
is only provided for observing the traffic area to the
rear.

If you are reversing, therefore, always look over the
shoulder in the direction your are reversing.

CAUTION

Possibly fitted side doors must be protected against
damage.

Therefore always ensure both side doors are closed
and locked before driving.

Operation 4

Standard equipment

NOTE

The truck can only be driven with the operator
seated.

¾ Start the engine.

¾ Raise the forks slightly and tilt the mast

back.

Operating Instructions – 393 807 1001 EN – 06/2006 31

4 Operation

Standard equipment

¾ Push the parking brake handle (1) down.

Forward travel

¾ Depress the right accelerator (2) gently.

Truck speed depends on how far the
depressed.

NOTE

Flooring the accelerator does n
speed as maximum acceleration i

pedal is

ot increase the

s controlled

automatically.

Reversing

¾ Depress the left accelerator (4) gently.

The truck willreverse slowly or fast, depending
on how far the accelerator is depressed.

Changing the direction of travel

¾ Release the depressed accelerat

The hydrostatic drive will act as service brake.

¾ Depress the accelerator for the opposite

direction of travel.

The truck will now accelerate in th
direction.

¾ Keep both feet on the accelerators to main-

tain easy control over all truck movements.

The accelerators can be operated directly.
The hydrostatic drive will brake the truck to a
full stop and then accelerate it in the opposite
direction of travel.

or.

e selected

d3921419

1

4

3

2

32 Operating Instructions – 393 807 1001 EN – 06/2006

Starting on gradients

¾ Fully depress the brake pedal (3).

¾ Push the parking brake handle (1

¾ Release the brake pedal half way.

¾ Depress accelerator (2) or (4).

¾ Slowly release the brake pedal fu

The brake is released and the truck will drive
without rolling back.

) down.

lly.

Stopping

¾ Release the depressed accelerator slowly.

The hydrostatic drive will act as s

¾ When stopping on gradients, keep both feet

on the accelerators and compensate drive
slippage by lightly depressing the accelera­tor in the "upslope" direction of travel.

¾ Depress the brake pedal (3) for a long stop.

¾ When dismounting form the truck w

engine running, for example, to b
form some actions in close vicini
truck (opening a gate, unhitchin
etc.), always pull the parking br
(1) and release the seat belt. In c
longer stop, shut down the engine
the parking brake handle (1).

¾ Remove the ignition key when leaving the

truck unattended.

ervice brake.

ith the

riefly per-

ty of the

gatrailer,

ake handle

ase of a

and pull

d3921419

Operation 4

Standard equipment

1

4

3

2

1

Drive motor (single-p

edal operation)

d3921419

4

3

2

Starting motor

DANGER

Risk of poisoning!

Do not allow motor to run in unventi­lated rooms.

Operating Instructions – 393 807 1001 EN – 06/2006 33

4 Operation

Standard equipment

NOTE

Where possible, avoid starting up the motor
frequently and short service periods to en­sure that the combustion engine attains its
operating temperature. Frequent cold-starts
encourage wear.

¾ Sit down on the driver’s seat.

¾ Fasten the seat belt.

¾ Move the operating lever (hydra

direction of travel (5) into neu

ulics and

tral.

5

d3921361

¾ Place foot on accelerator pedal (4).

¾ Parking brake handle (1) engaged, (motor

will only start with parking brake handle
engaged).

¾ Insert switch key (2) into the ignition and

starting switch and turn from the zero posi­tion to position "I".

The electrical system is switched on.

34 Operating Instructions – 393 807 1001 EN – 06/2006

1

d3921420

2

3

4

Operation 4

Standard equipment

¾ Check the indicator unit (3).

NOTE

After switching on the ignition the indicator unit
will perform a self-test. The displays all light up
for approx. 2 seconds and the operating hours
until the next service are displayed for 5 sec­onds in the indicator unit (3) display field (12).
During this time symbol (13) remains lit. After
5 seconds the display reverts automatically
to the operating hours. If the buzzer sounds
(particulate filter unit fault), check the lamps
(see Diesel motor faults, cause, remedy). If
the buzzer continues to sound, please contact
your local authorised dealer.

The following controls light up:

• Symbol (10) Parking brake engaged

• Motor oil pressure indicator (

• Battery charge indicator (6),

• Glow plug indicator (14).

¾ Wait until the glow plug indicat

out

¾ Turn switch key to position "II".

As soon as motor starts,

¾ release switch key.

Symbol (8) flashes on and off.

CAUTION

Only for vehicles with particulate filter units. If the
exhaust is very smoky and remains so, switch off
the motor. Please contact your authorised dealer.

Every time the engine is started, watch the exhaust
pipe outlet for about 5 seconds.

7),

or (14) goes

14

13

12

11

3

67

8

10

9

d3921359

If motor fails to start

After the glow plugs have heated up, keep
turning the starter motor until the motor runs
at idling speed. Depending on the vehicle,
the temperature and the altitude, this can take
more than 1 minute.

If the motor stalls, the symbol " Do not start
motor"(11) will appear.

Operating Instructions – 393 807 1001 EN – 06/2006 35

4 Operation

Standard equipment

¾ Always leave ignition switched on until sym-

bol extinguishes (between 15 und 50 sec­onds depending on oil temperature).

¾ Then try to restart.

When trying to start the motor, wa
for min. 1 minute to protect the ba
motor still does not start at th
consult: Malfunctions, Cause

The Charging and Motor oil pressure symbols
must extinguish once the motor runs smoothly.

Motor speed is regulated automatically de­pending on the load on the motor.

NOTE

Do not allow motor to warm up at id
Drive truck, under load, at a bri
motor will reach operating stat
quickly.

Switching off motor

CAUTION

For motors with a turbocharger, the high speed of
the turbocharger shaft (approx. 100 000 rpm at
full load) could cause the shaft bearing to run dry
through lack of lubrication thus damaging it.

Do not switch off motor under full load, but rather
allow to run on for a few minutes at low speed.

it each time
ttery. If the

e third attempt,

s and Remedy.

ling speed.

sk speed. The

e temperature

¾ Take foot off accelerator pedal (3).

36 Operating Instructions – 393 807 1001 EN – 06/2006

1

d3921421

2

3

¾ Move direction of travel lever (4) into neu-

tral.

¾ Move switch key (2) into zero position.

NOTE

The brake becomes active when the

motor is

switched off.

¾ Pull up parking brake handle (1).

¾ Remove the switch key (2) when le

aving the

truck.

Driving (single-pedal operation)

WARNING

Driving on long gradients over 15 % is generally
not allowed due to the specified minimum brake
applications and the stability values. Contact your
authorised dealer before driving on steeper gradi­ents. The climbing ability values given in the data
sheet have been derived from the drawbar pull and
apply only for crossing obstacles and short diffe­rences in height.

Always adapt your driving style to the conditions
of the roadway (rough surfaces, etc.), especially
hazardous work zones and the load.

Operation 4

Standard equipment

4

d3921362

WARNING

If mirrors are used, please note the rear-view mirror
is only provided for observing the traffic area to the
rear.

If you are reversing, therefore, always look over the
shoulder in the direction your are reversing.

CAUTION

Possibly fitted side doors must be protected against
damage.

Therefore always ensure both side doors are closed
and locked before driving.

Operating Instructions – 393 807 1001 EN – 06/2006 37

4 Operation

Standard equipment

NOTE

The truck can only be driven with the operator
seated.

¾ Start the engine.

¾ Raise the forks slightly and tilt the mast

back.

¾ Push the parking brake handle (

Forward travel

¾ Push the direction lever (4) forward.

¾ Depress the accelerator (3) gently.

Truck speed depends on how far th
depressed.

NOTE

Flooring the accelerator does no
speed as maximum acceleration is
automatically.

1) down.

e pedal is

t increase the

controlled

1

Reversing

¾ Pull the direction lever (4) back.

¾ Depress the accelerator (3) gently.

The truck willreverse slowly or fa
on how far the accelerator is depre

Changing the direction of trave

¾ Release the accelerator.

The hydrostatic drive will act as service brake.

38 Operating Instructions – 393 807 1001 EN – 06/2006

st, depending

ssed.

l

d3921422

2

3

¾ Move the direction lever (4) to the opposite

direction of travel.

The truck will now accelerate in the selected
direction.

The direction lever can be moved d
the opposite direction. The hydr
will brake the truck to a full st
celerate it in the opposite dir

irectly to

ostatic drive

op and then ac-

ection of travel.

Starting on gradients

¾ Fully depress the brake pedal (2).

¾ Push the parking brake handle (1) down.

¾ Release the brake pedal half way.

¾ Depress the accelerator (3).

¾ Slowly release the brake pedal fully.

The brake is released and the truck will drive
without rolling back.

Operation 4

Standard equipment

4

d3921362

1

Stopping

¾ Release the accelerator slowly.

The hydrostatic drive will act as service brake.

3

¾ When stopping on gradients, keep the foot

on the accelerator, move the direction lever
(4) to the "upslope" direction of travel and
compensate drive slippage by depressing
the accelerator slightly.

¾ Depress the brake pedal (2) for a long stop.

¾ When dismounting form the truck with the

engine running, for example, to briefly per­form some actions in close vicinity of the
truck (opening a gate, unhitching a trailer,
etc.), always pull the parking brake handle
(1) and release the seat belt. In case of a
longer stop, shut down the engine and pull
the parking brake handle (1).

Operating Instructions – 393 807 1001 EN – 06/2006 39

d3921422

2

4 Operation

Standard equipment

¾ Remove the ignition key when leaving the

truck unattended.

Steering system

Steering

The hydrostatic steering system means that
the level of effort required to turn the steering
wheel is very low. This is particularly advanta­geous when palletising in narrow aisles.

¾ Starting and driving.

¾ Turn the steering wheel to the left and right

as far as it will go.

Apply sufficient force to move the steering
wheel beyond the limit stop making sure that
the position of the wheels on the steering axle
does not change.

DANGER

The forklift truck must not be driven if the steering
system is defective.

If the steering is stiff or has too much play, contact
your local authorised dealer.

d3921423

Turning radius

H25 2420mm

H30 2444mm

H35 2476mm

40 Operating Instructions – 393 807 1001 EN – 06/2006

Braking system

Service brake

¾ Allow accelerator pedals (1) to move to the

neutral position.

The hydrostatic drive acts as th
brake. Slow or quick release of
erator pedals to the neutral po
the braking action to be sensit
from gentle to hard braking.

NOTE

For emergency braking, apply the STOP pedal
(2) located between the accelerator pedals.
This causes a full brake application.

eservice

the accel-

sition allows

ively controlled,

Operation 4

Standard equipment

Stop pedal

NOTE

The stop pedal (2) is not a sensitive service
brake but a sharply applied parking brake. Its
use whilst driving should be avoided, because
this can cause the drive wheels to lock and
in certain circumstances can cause the load
to slip from the fork arms. In unfavourable
situations the engine can also stall. A wait of
about 30 seconds must then elapse to allow
the variable pump in the traction drive to re­turn to a neutral setting . It is recommended
that drivers familiarise themselves with the
function and action of this brake without any
load on the forklift truck. For this purpose they
should choose a route without any other traf­fic, and drive at low speed.

Parking brake

Themulti-discbrakesare
brake of the fork-lift tru

used as the parking

ck.

d3921424

1

2

1

Operating Instructions – 393 807 1001 EN – 06/2006 41

4 Operation

Standard equipment

Apply the parking brake

¾ Pull the parking brake handle (3) upwards.

The symbol on the indicator unit

Release the parking brake

NOTE

The multi-disc brake will release only if the
engine is running.

¾ Release parking brake handle (3) down-

wards.

The symbol on the indicator unit will go out.

DANGER

The forklift truck must not be driven if the braking
system is defective.

Should there be any defects or wear apparent in
the braking system, please contact your authorised
dealer at once.

Horn

Operating the horn

When operating at blind corners and junctions,
a horn serves as warning signal.

¾ Press the horn button ((1)) on the steering

wheel to sound the horn.

will light up.

3

d3921425

42 Operating Instructions – 393 807 1001 EN – 06/2006

Lifting system and attachments (cen­tral lever operation)

WARNING

With the moving lift mast or any
attachment there is a risk of the driver
getting caught in between.

Therefore never reach or step into
the lift mast or the space between
the lift mast and the vehicle. The
lifting system and attachments
should only ever be used for their
proper purpose. Drivers must be
instructed in the handling of the lifting
system and attachments. Bear the
maximum lift height in mind.

NOTE

When working with a bucket, see "forklift truck
operation using a bucket".

NOTE

With the central lever version, use of the oper­ating lever in an intermediate position (approx.
45°) will activate both functions at the same
time (e.g. lifting and tilting).

¾ Take note of the switching symbols with

arrows.

The operating lever should always be op­erated carefully, never jerkily. Moving the
operating lever determines the lifting, lower­ing and tilt speed . After the operating lever is
released, it automatically returns to its initial
position.

Operation 4

Standard equipment

NOTE

The lifting system and attachments only func­tion with the motor running and the driver’s
seat under load.

d3931329

Operating Instructions – 393 807 1001 EN – 06/2006 43

4 Operation

Standard equipment

Tilt lift mast forwards

¾ Move operating lever (1) forwards.

Tilt lift mast backwards

¾ Pull back operating lever (1) .

Lift fork carriage

DANGER

When lifting the lift mast there is an increased risk
of falling and crushing.

For this reason it is not permitted to step onto the
fork arms when lifted without a protective cage .

¾ Move operating lever (1) to the right.

Lower fork carriage

¾ Move operating lever (1) to the left.

Operate attachments

Attachments can be fitted to the truck as spe­cial equipment (e.g. sideshift, clamps etc.).
Take note of the operating pressure and op­erating manual for the attachment. Another
operating lever is attached for operation.

d3921370

1

2

NOTE

Before fitting an attachment, the depressuri­sation circuit (special equipment) can be used
to depressurise the hydraulic system for the
additional hydraulics so that the union nuts on
the fork carriage can be opened.

¾ Switch off the engine.

¾ Switch on the ignition.

¾ Operate the lever for the respective addi-

tional hydraulics several times.

¾ Unscrew the union nuts on the fork carriage.

¾ Screw on hoses for attachment or connect

plug-in couplings.

44 Operating Instructions – 393 807 1001 EN – 06/2006

CAUTION



Attachments affect the load capacity and stability of
the forklift truck.

Attachments which are not supplied with the forklift
truck should only be used when the authorised dea­ler has checked that safe operation is ensured by
the allocation in terms of load capacity and stability .

¾ Take note of the switching symbols with

arrows.

NOTE

For every attachment device, a plate stating
the load capacity of the truck must be affixed
beside the load diagram in the top left of the
driver’s protective roof, and a symbol label
for the relevant attachment must be affixed
behind the operating lever.

Operate sideshift

NOTE

In order to prevent damage, do not activate the
sideshift when the fork arm is on the ground.

¾ Move operating lever (2) to the left.

Sideshift moves to the left.

¾ Move operating lever (2) to the right.

Sideshift moves to the right.

Operation 4

Standard equipment

1

2

d3931328

Activate the clamp

¾ Move operating lever (2) forwards.

Clamp opens.

¾ Pull back operating lever (2).

Clamp closes.

Activate the fork arm adjustment device

NOTE

d3921370

In order to prevent damage, do not activate
the fork arm adjustment device with a load or
the fork arm on the ground. Do not use the fork
arm adjustment device as a clamp.

Operating Instructions – 393 807 1001 EN – 06/2006 45

4 Operation

Standard equipment

¾ Move operating lever (2) forwards.

Fork arms move outwards.

¾ Pull back operating lever (2).

Fork arms move inwards.

Lifting system and attachments (sin­gle lever operation)

WARNING

With the moving lift mast or any
attachment there is a risk of the driver
getting caught in between.

Therefore never reach or step into
the lift mast or the space between
the lift mast and the vehicle. The
lifting system and attachments
should only ever be used for their
proper purpose. Drivers must be
instructed in the handling of the lifting
system and attachments. Bear the
maximum lift height in mind..

NOTE

When working with a bucket, see "forklift truck
operation using a bucket".

46 Operating Instructions – 393 807 1001 EN – 06/2006

¾ Take note of the switching symbols with

arrows.

The operating lever should always be op­erated carefully, never jerkily. Moving the
operating lever determines the lifting, lower­ing and tilt speed . After the operating lever is
released, it automatically returns to its initial
position.

NOTE

The lifting system and attachments only func­tion with the motor running and the driver’s
seat under load.

Lift fork carriage

DANGER

When lifting the lift mast there is an increased risk
of falling and crushing.

For this reason it is not permitted to step onto the
fork arms when lifted without a protective cage .

¾ Pull back operating lever (1) .

Lower fork carriage

¾ Move operating lever (1) forwards.

Operation 4

Standard equipment

Tilt lift mast forwards

¾ Move operating lever (2) forwards.

Tilt lift mast backwards

¾ Pull back operating lever (2).

Operate attachments

Attachments can be fitted to the truck as spe­cial equipment (e.g. sideshift, clamps etc.).
Take note of the operating pressure and oper­ating manual for the attachment. One or more
additional operating levers are fitted for oper­ating the attachments.

NOTE

Before fitting an attachment, the depressuri­sation circuit (special equipment) can be used
to depressurise the hydraulic system for the

Operating Instructions – 393 807 1001 EN – 06/2006 47

4 Operation

Standard equipment

additional hydraulics,so that the union nuts on
the fork carriage can be opened.

¾ Switch off the engine.

¾ Switch on the ignition.

¾ Operate the lever for the respective addi-

tional hydraulics several times.

¾ Unscrew the union nuts on the fork

¾ Screw on hoses for attachment or connect

plug-in couplings.

CAUTION

Attachments affect the load capacity and stability of
the forklift truck.

Attachments which are not supplied with the forklift
truck should only be used when it has been che­cked by the authorised dealer that safe operation is
ensured by the allocation in terms of load capacity
and stability .

¾ Take note of the switching symbols with

arrows.

NOTE

For every attachment device, a plate stating
the load capacity of the truck must be affixed
beside the load diagram in the top left of the
driver’s protective roof, and a symbol label
for the relevant attachment must be affixed
behind the operating lever.

carriage.

Operate sideshift

NOTE

In order to prevent damage, do not activate the
sideshift when the fork arm is on the ground.

48 Operating Instructions – 393 807 1001 EN – 06/2006

¾ Move operating lever (3) forwards.

Sideshift moves to the left.

¾ Pull back operating lever (3).

Sideshift moves to the right.

Activate the clamp

¾ Move operating lever b forwards.

Clamp opens.

¾ Pull back operating lever (4).

Clamp closes.

Activate the fork arm adjustment device

NOTE

In order to prevent damage, do not activate
the fork arm adjustment device with a load or
the fork arm on the ground. Do not use the fork
arm adjustment device as a clamp.

¾ Move operating lever (4) forwards.

Fork arms move outwards.

¾ Pull back operating lever (4).

Fork arms move inwards.

Operation 4

Standard equipment

Operating Instructions – 393 807 1001 EN – 06/2006 49

4 Operation

Special equipment

Special equipment

Lifting system and attachments (sin­gle lever operation with 3rd addi­tional hydraulics)

WARNING

With the moving lift mast or any
attachment there is a risk of the driver
getting caught in between.

Therefore never reach or step into
the lift mast or the space between
theliftmastandthetruck. The
lifting system and attachments
should only ever be used for their
proper purpose. Drivers must be
instructed in the handling of the lifting
system and attachments. Bear the
maximum lift height in mind.

NOTE

When working with a bucket, see "forklift truck
operation using a bucket".

¾ Take note of the switching symbols with

arrows.

The operating lever should always be oper­ated carefully, never jerkily. The excursion of
the operating lever determines the lifting, low­ering and tilt speed . After the operating lever
is released, it automatically returns to its initial
position.

NOTE

The lifting system and attachments only func­tion with the motor running and the driver’s
seat under load.

Lift fork carriage

DANGER

When lifting the lift mast there is an increased risk
of falling and crushing.

For this reason it is not permitted to step onto the
fork arms when lifted without a protective cage.

50 Operating Instructions – 393 807 1001 EN – 06/2006

¾ Pull back operating lever (1).

Lower fork carriage

¾ Move operating lever (1) forwards.

Tilt lift mast forwards

¾ Move operating lever (2) forwar

ds.

Tilt lift mast backwards

¾ Pull back operating lever (2).

Operate attachments

The forklift truck is equipped with three addi­tional functions (e.g. fork adjustment, rotating
unit, sideshift etc.). Take note of the operating
pressure and operating manual for the attach­ment. Two other operating levers are then
attached for operation . Operating lever (5) is
used to operate two attachments, which are
controlled via toggle switch (4).

NOTE

Before fitting an attachment,
tion circuit (special equipme
to depressurise the hydraulic
additional hydraulics, so tha
the fork carriage can be opened

a depressurisa-

nt) can be used

system for the

t the union nuts on

.

Operation 4

Special equipment

¾ Switch off the engine.

¾ Switch on the ignition.

¾ Operate the lever for the respective addi-

tional hydraulics several times.

¾ Unscrew the union nuts on the fork carriage.

¾ Screw on lines for attachment or

plug-in couplings.

CAUTION

Attachments affect the load capacity and stability of
the forklift truck.

Attachments which are not supplied with the forklift
truck should only be used when it has been che­cked by the authorised dealer that safe operation is
ensured by the allocation in terms of load capacity
and stability .

Operating Instructions – 393 807 1001 EN – 06/2006 51

connect

4 Operation

Special equipment

¾ Take note of the switching symbols with

arrows.

NOTE

For every attachment a plate stat
capacity of the forklift truck wi
must be affixed above the switc
the top right in the driver’s pr
a symbol label for the relevant
behind the operating lever and
right next to the toggle switch

Operate fork adjustment

¾ Move operating lever (1) forwards.

Fork arms move outwards.

¾ Pull back operating lever (1).

Fork arms move inwards.

Operate rotating unit

¾ Press left side (2) of toggle switch (3).

Green switch illumination lit up.

¾ Move operating lever (5) forwards.

Unit moves anticlockwise.

¾ Pull back operating lever (5).

Unit moves clockwise.

ing the load

th attachment

h console on

otective roof and

attachment
on the left and

(4) .

52 Operating Instructions – 393 807 1001 EN – 06/2006

Operate sideshift

¾ Press right side (4) of toggle switch (3).

Orange switch illumination lit

¾ Move operating lever (5) forwards.

Sideshift moves to the left.

¾ Pull back operating lever (5).

Sideshift moves to the right.

up.

Adjusting the swivel seat

CAUTION

The driver’s seat should not turn when the truck is
being operated.

Make sure, therefore, that the swivel is locked.

Operation 4

Special equipment

The swivel seat allows better view to the rear
when reversing for long periods. It is recom­mended to set the seat to the straight-ahead
position for long periods of travel in the forward
direction. The swivel is maintenance-free.

¾ Pull up the locking lever(1).

This releases the swivel and allows the seat to
be swivelled 17° to the right, lockable in the 0°
and 17° positions.

¾ Engage the locking bolt (1) audibly.

Operating Instructions – 393 807 1001 EN – 06/2006 53

4 Operation

Special equipment

Adjust the driver’s air-sprung seat

WARNING

Incorrect seat adjustment may cause injury to the
driver’s back. The adjustment controls for the dri­ver’s seat should not be used during operation.

On each occasion, before starting up the vehicle
and changing drivers adjust for the individual weight
of the driver. Adjust the driver’s seat only when the
vehicle is stationary.

Adjust for the driver’s weight

¾ Sit on the driver’s seat.

¾ Check the weight adjustment in viewing

window (3).

The correct selection of the driver’s weight has
been made when the arrow (4) is within the
centre clear area of the viewing window.

¾ Adjust as necessary for the driver’s weight

• Lift lever (2) upwards (5) = increase weight
setting

• Push lever (2) downwards (6) = decrease
weight setting

Longitudinal adjustment

¾ Lift lever (1) upwards.

¾ Move the driver’s seat on the slide rails

backwards or forwards to give the driver
the best position in relation to the steering
wheel and the accelerator pedals.

¾ Allow lever to click back into place.

54 Operating Instructions – 393 807 1001 EN – 06/2006

Adjust the seat angle

¾ Lift lever 2 and hold it there.

Whilst holding the lever, press
or release it to move the seat to t
position.

on the seat

he desired

Adjust the seat height

¾ Lift lever 1 and hold it there.

Whilst holding the lever, slide the seat for­wards or backwards to move the seat to the
desired position.

Seat heater

NOTE

The maximum temperature is pre-set.

¾ Switch (1) turns the seat heater ON and

OFF.

• 0 = seat heater OFF

• I = seat heater ON

Adjust lumbar support

The lumbar support enables optimum config­uration of the seat back contour to the driver’s
body.

¾ Turn the handwheel (2) upwards.

The convexity of the upper lumbar support can
be adjusted individually.

¾ Turn the handwheel (2) downwards.

The convexity of the lower lumbar support can
be adjusted individually.

Operation 4

Special equipment

Operating Instructions – 393 807 1001 EN – 06/2006 55

4 Operation

Special equipment

Adjust the seat back

¾ Lift lever (2) and hold it there.

¾ Move the seat back backwards and

wards until a comfortable sitti
the driver is found.

¾ Release lever (2).

Adjust the headrest

¾ Push in or pull out the headrest (1) and

adjust it individually.

Mast positioning

Programming

The tilt angle sensors allow the programming
of a certain mast angle of tilt. When this func­tion is actuated the indicator symbol (1) illumi­nates.

¾ Tilt the mast to the desired angle.

for-

ng position for

1

d3921357

56 Operating Instructions – 393 807 1001 EN – 06/2006

Operation 4

Special equipment

¾ Push the pushbutton (2) front left in the arm

rest longer than 2 seconds.

The tilt angle is now permanently stored. As
acknowledgement, a twin tone is heard and
the light in the push button (2) blinks often for
short intervals.

The mast angle of tilt in relati
is stored. The tilt of the mast i
ground depends on various fact
tyre wear, tyre inflation pres
evenness and gradient of the gr

on to the vehicle

n relation to the

ors such as

sure, load, un-

ound.

To operate

NOTE

The mast positioning feature serves to support
the driver and makes work more relaxing. The
operator always has the responsibility for and
control of the selection of the desired mast
position.

¾ Depress the push button (2)

left in the arm rest. Lamp in
illuminates and the mast po
vated.

¾ Operate joystick to reach the stored angle

of tilt. (For safety reasons, tilting is only
possible in the direction of the stored angle
of tilt and must be reactivated with each
mast positioning).

After reaching the programmed tilt, the mast
remains stationary and a tone is heard in the
composite instrument.

¾ Release joystick or depress

(2) shortly again. The lamp i
extinguishes and the mast po
is deactivated.

¾ The mast can now be operated normally

with the joystick.

¾ Depress pushbutton (2) shortly again. Pro-

grammed tilt is again actuated.

shortly, front

push button

sitioning is acti-

push button
n the button

sition sensing

2

t3921358

2

t3921358

Operating Instructions – 393 807 1001 EN – 06/2006 57

4 Operation

Special equipment

Lighting

NOTE

The arrangement of the individual switches
on the right hand overhead console may vary
depending on the version. Please take note of
the symbols for the switches.

Switch on interior lighting

¾ Press toggle switch (1).

Switch on lighting

¾ Move toggle switch (2) to cen

Side lights and licence plat
switched on.

¾ Switch toggle switch (2) as far as it will go.

Dipped beam, side lights and licence plate
lights are switched on.

Switch on working headlights

¾ Press toggle switch (3) or (4) (depending on

the version) .

Switch on hazard warning lights

¾ Press toggle switch (8).

tre position.

e light are

2345 6 7 8

1

9

d3921516

Switch on rotating flashing l

Depending on the equipment there are two
different versions.

Version 1 (single stage switch):

¾ Press toggle switch (9).

The rotating flashing light is always switched
on.

Version2(twostageswitch):

¾ Move toggle switch (9) to centre

The rotating flashing light is switched on only
when reversing.

¾ Switch toggle switch (9) as far as it will go.

The rotating flashing light is al
on.

58 Operating Instructions – 393 807 1001 EN – 06/2006

ight

position.

ways switched

Switch on turn indicator lights

¾ Move operating lever (10 ) on steering

wheel forwards.

The flashing lights flash on the

right. Indicator

lamp (11) flashes.

¾ Move operating lever (10 ) on steering

wheel backwards.

The flashing lights flash on the left. Indicator
lamp (11) flashes.

Attach additional consumers

DANGER

The driver’s protective roof is a safety part.

It is therefore not permitted to perform drilling or
welding on the driver’s protective roof .

CAUTION

Any additional electrical consumers to be retrofit­ted (lights, seat heaters etc.) should be installed
using the unoccupied connections of the harness
provided for this purpose . Other connections going
beyond the scope envisaged are only permitted
after consultation with your authorised dealer.

Such work should only be carried out by trained
competent staff using functional and appropriate
materials subject to compliance with the applicable
rules and regulations .

Operation 4

Special equipment

Operating Instructions – 393 807 1001 EN – 06/2006 59

4 Operation

Special equipment

Windscreen wiper

Switch on the front windscreen wiper

¾ Move operating lever (10) on steering wheel

from centre position upwards.

The front windscreen wiper will
the lever is in this position.

¾ Move operating lever (10) on steering wheel

from centre position downwards.

The front windscreen wiper will run in intermit­tent mode.

¾ Switch toggle switch (5) as far as it will go.

¾ Move operating lever (10) on steering wheel

from centre position downwards.

The front windscree
ous mode.

n wiper will run in continu-

run as long as

Switch on the rear wi

¾ Move toggle switch (6) to centre position.

¾ Move operating lever (10) on steering wheel

from centre position upwards.

The rear windscreen wi
the lever is in this pos

¾ Move toggle switch (6) to centre position.

¾ Move operating lever (10) on steering wheel

from centre position downwards.

The rear windscreen wiper will run in intermit­tent mode.

¾ Switch toggle switch (6

¾ Move operating lever (10) on steering wheel

from centre position downwards.

The rear windscreen wiper will run in continu­ous mode. The front windscreen wiper will run
in intermittent mode.

60 Operating Instructions – 393 807 1001 EN – 06/2006

ndscreen wiper

per will run as long as

ition.

) as far as it will go.

2345 6 7 8

1

9

d3921516

Switch on the roof windscreen wiper

¾ Move toggle switch (7) to centre position.

¾ Move operating lever (10) on stee

from centre position upwards.

The roof windscreen wiper will run as long as
the lever is in this position.

¾ Move toggle switch (7) to centre position.

¾ Move operating lever (10) on steer

from centre position downwards.

The roof and front windscreen wipers are in
intermittent mode.

¾ Switch toggle switch (7) as far as it will go.

¾ Move operating lever (10) on steer

from centre position downwards.

The roof windscreen wiper is in continuous
mode. The front windscreen wiper is in inter­mittent mode.

ring wheel

ing wheel

ing wheel

Switch on the wiper/washer system

¾ Switch on relevant windscreen wiper.

¾ In addition, push the operating lev

as far as it will go.

The pre-selected wiper/washer system will
run as long as the lever is in this position.

er (10) in

Operation 4

Special equipment

Operating Instructions – 393 807 1001 EN – 06/2006 61

4 Operation

Special equipment

Heating, air conditioning

Switch on heating

¾ Turn switch (3).

The blower is switched on to any o
flow settings.

Operating elements

• Rotary knob (1) for setting the vent positions
for windscreen defrosting - positions for
windscreen defrosting - footwell ventilation

• Rotary knob (2) for temperature c

• Rotary switch (3) for setting blower

• Interior air vents (4)

Windscreen defrosting

¾ For maximum windscreen defrostin

• rotary knob (2) to the end position on the
right

• Turn rotary knob (1) to the windscreen de­frosting position (max. position on the left)

• rotary switch (3) to setting level 3

• interior air vents (4) to open, louvres for­wards.

For standard heating operation the following
rules apply:

• Select the temperature using the rot
knob (2) (end position on the left → co
end position on the right → hot)

• Use the blower switch (3) (setting level 1 to

3), air distribution vent (rotary knob (1)) and
interior air vents (4) to select the tempera­ture / temperature distribution you require

f three air

ontrol

gsetthe

ary

ld /

1

d3921478

2

3

1

2

0

3

4

Switch on air conditioning

CAUTION

The moving parts must be lubricated and the com­pressor prevented from seizing.

Therefore switch on the air conditioning briefly
every 3 months. In addition the air conditioning
must be serviced once a year by an authorised ser­vice centre, preferably before the season starts,
and a record must be kept of the servicing. Other­wise, warranty claims will be voided.

62 Operating Instructions – 393 807 1001 EN – 06/2006

NOTE

It is normal that condensate can build up in
the hoses and under the vehicle when the air
conditioning is in use.

¾ Turn switch (8).

The blower is switched on to any of three air
flow settings.

Operating elements

• Rotary knob (5) for setting the ve
for windscreen defrosting - foot

nt positions

well ventila-

tion

• Rotary knob (6) for temperature control

• Toggle switch (7) for switching on the air
conditioning

• Rotary switch (8) for setting blow

er

• Cab air vents (9)

Operation 4

Special equipment

5

67

8

1

2

0

3

9

NOTE

The air conditioning only works when the
engine is running and the blower switch is
switched to setting 1, 2 or 3. The fan in the roof
switches on when necessary. It can come to a
standstill from time to time.

¾ Switch on the toggle switch (7).

Raising the temperature in the cab:

¾ Turn the rotary knob (6) clockwise

duce the blower speed using switch

and re-

(8).

Lowering the temperature in the cab:

¾ Close windows and doors, turn rotary knob

(6) anti-clockwise and increase the blower
speed using switch (8).

NOTE

To achieve maximum cooling in the c

•

the air conditioner must be switche

•

the rotary knob (6) must be fully to the left,

•

the blower must be set to its highest setting,

•

the windows and doors must be closed.

ab:

d on,

NOTE

On cool, humid days, the heater and air con­ditioning can be used to dehumidify the air

d3921505

Operating Instructions – 393 807 1001 EN – 06/2006 63

4 Operation

Special equipment

in the cab (operate the heater and air condi­tioning simultaneously). The vehicle heater
counteracts the cooling effect. This ensures a
pleasant temperature inside the cab and pre­vents the windows misting up.

Truck Data Management (LFM)

Truck data acquisition

The truck data input terminal (1) is located at
the front left overhead guard leg.

The terminal has a keypad (3)
With the standard setting, a
ber assigned to the operato
authorised personnel can o
The truck can only be starte
number and maybe a conditio
ing on the setting) has been

NOTE

The PIN number can be enlarged from 5 to 8
digits. Before entry of the PIN number, please
request your truck pool manager to give you
the number of digits of the PIN number and the
setting of the truck.

with 12 keys.

5-digit PIN num­r ensures that only
perate the truck.

d after this PIN

n code (depend-

entered.

Condition code

NOTE

The code indicates the state of the truck.

The following code numbers are available:

0

= Truck in working order

1

= Request Service (truck cannot be started)

2

= Request Maintenance (truck can be

started)

3

= Driving problem

4

= Lifting problem

5

= Steering problem

6

= Damaged in accident

7

= User defined

8

= User defined

64 Operating Instructions – 393 807 1001 EN – 06/2006

9

= User defined

The condition codes

7,8,9

can be defined
by the user as he chooses. Please contact
your truck pool manager for the definition of
these condition codes.

NOTE

If you notice one of these conditions (eg driv­ing problem) only after you have first logged in
with condition code

0

(truck in working order),

you must first log out.

¾ Turn the rotary knob (2) anticlockwise as far

as possible.

¾ Log in again with the condition

message

(driving problem)

Operation 4

Special equipment

3

Truck data acquisition - defau
(PIN number and condition code

lt setting

)

Logging in and starting the truck:

¾ Engage the parking brake.

¾ Press any key to take the terminal into oper-

ation.

The green LED (2) flashes.

¾ Enter your PIN number

0 0 0 0

and condition code.

(factory setting =

On a truck in proper working order this is there­fore the following PIN No:

0 0 0 0 0 0

.

NOTE

In case the incorrect PIN number was entered,
it can be corrected after pressing the key

*

(4)

with the asterisk.

¾ Confirm the entry by pressing the#(3) key.

Green LED (2) is illuminated steadily.

0

Operating Instructions – 393 807 1001 EN – 06/2006 65

4 Operation

Special equipment

NOTE

If the red LED (1) comes on, an incorrect PIN
number was entered. Press the key
the asterisk and enter the correct number.
After more than three incorrect inputs (fac­tory setting), the red LED (1)and the green
LEDs (2) flash. A valid PIN input is disabled
for 10 minutes. The disable period can be ter­minated by entering a special PIN number.
Please contact your pool manager.

¾ Turn the rotary knob (7) clock

possible and start the truck.

NOTE

If the truck does not start pr
tempt, the starting procedu
until the rotary knob (5) is r

operly at the first at-

re can be repeated

eturned to zero and
the PIN number is deleted fro
the expiration of the delay p

NOTE

eriod.

If the green (2) and red (1) LEDs are both illu­minated steadily, the data must be read out.
Please inform your pool manager at once.

*

(4) with

wise as far as

m memory after

Turning the truck off and log

¾ Turn the rotary knob (5) anticlockwise as far

as possible.

The engine is turned.

NOTE

After a delay period (factor
onds), the red LED (1) illumi
then the green (2) and red (1)
3 seconds. During this time t
started at any time. The LED
the PIN number is deleted fr
delay time can be set betwee
and 10 minutes with the FDE c
software. Please contact y

ging out:

y setting = 10 sec-

nates briefly and

LED flash about
he truck can be
s then go out and

om memory. The

n 10 seconds

onfiguration

our authorised

dealer.

Pressing the#(3) after the engine is turned
off terminates the delay period at once and the
PIN number is deleted from memory.

66 Operating Instructions – 393 807 1001 EN – 06/2006

Truck data acquisition - special setting
(PIN number)

Logging in and starting the truck:

¾ Engage the parking brake.

¾ Press any key to take the terminal into oper-

ation.

The green LED (2) flashes.

0

¾ Enter your PIN number (factory s

0 0 0 0

).

NOTE

etting =

In case the incorrect PIN number was entered,
it can be corrected after pressing the key

*

(4)

with the asterisk.

#

e

¾ Confirm the entry by pressing th

Green LEDs (2) is illuminated steadily.

NOTE

(3) key.

If the red LED (1) comes on, an incorrect PIN
number was entered. Press the asterisk

*

(4)
and enter the correct number. After more than
three incorrect inputs (factory setting), the
red LED (1)and the green LEDs (2) flash. A
valid PIN input is disabled for 10 minutes. The
disable period can be terminated by entering a
special PIN number. Please contact your pool
manager.

¾ Turn the rotary knob (7) clock

possible and start the truck.

wise as far as

Operation 4

Special equipment

NOTE

If the truck does not start pro
tempt, the starting procedur
until the rotary knob (5) is r
the PIN number is deleted fro
the expiration of the delay p

NOTE

perly at the first at-

e can be repeated

eturned to zero and

m memory after

eriod.

If the green (2) and red ((1)) LEDs are both
illuminated steadily, the data must be read
out. Please inform your pool manager at once.

Turning the truck off and log

Operating Instructions – 393 807 1001 EN – 06/2006 67

ging out:

4 Operation

Special equipment

¾ Turn the rotary knob (5) anticlockwise as far

as possible.

The engine is turned off.

NOTE

After an delay period (factory se
onds), the red LED (1) comes on b
then the green (2) and red (1) LE
about 3 seconds. During this ti
can be started any time. The LED
and the PIN number is deleted fr
The delay time can be set betwee
onds and 10 minutes with the dia
Please contact your authorise

Pressing the#(3) after the engine is turned
off terminates the delay period at once and the
PIN number is cleared.

tting = 10 sec-

riefly and

Ds flash for

me the truck

s then go out

om memory.

n10sec-

gnostic unit.

d dealer.

68 Operating Instructions – 393 807 1001 EN – 06/2006

Working under load

Before taking up a load

Before taking up a load, check the load capac­ity diagram above the switch console on the
top right in the driver’s protective roof.

The max. permissible load is determined by
the distance of the centre of gravity of the load
from the fork back of the fork arms and the lift
height.

DANGER

The values specified in the lifting capacity diagram
or plate apply to compact homogeneous loads and
must not be exceeded as this will impair the stability
of the forklift truck and the strength of the fork arms
and lift mast.

When using attachments, observe the lifting capa­city plate for each attachment device.

NOTE

Take the load restriction into account and con­sult your authorised dealer

•

before transporting off-centre or swinging

loads

•

before transporting loads with the lift mast

tilted forward or the load not close to the
floor

•

loads involving a large centre of gravity

distance

•

before using attachments and additional

equipment

•

before transporting loads in a wind force of

6andupwards.

Example

Load centre-of-gravity distance: 650 mm

Load height to be lifted: 6500 mm

¾ Trace a vertical line from a load distance of

650 mm to its point of intersection with the
line for a lift height of 6500 mm.

¾ At the point of intersection with the horizon-

tal line read off the max. permissible load to
the left.

The maximum load in this example is 1700 kg.

Operation 4

Working under load

t3921383

1 Max. weight of permissible loads in kg
2 Lift height in mm
3 Series designation of the forklift truck with

max. load capacity and lift mast series

4 Distance between centre of gravity of load

and fork back in mm

Operating Instructions – 393 807 1001 EN – 06/2006 69

4 Operation

Working under load

The same procedure should be followed for
other lift heights und centre of gravity dis­tances. The values calculated refer to both
fork arms and a uniformly distributed load.

Wheel-slide protection chains

CAUTION

Mounting wheel-slide protection chains alters the
wheel freedom and load capacity of the forklift truck

Before wheel-slide protection chains are mounted
the standard fork carriage must be replaced by a
special fork carriage that is installed 40 mm further
forward. All other load capacity data on the basic
load capacity diagram and on the additional load
capacity plate must be reduced by 100 kg. This
load capacity reduction remains necessary even if
wheel-slide protection chains are not fitted.

¾ In addition, attach plate (5) alongside the

basic load capacity diagram.

Adjusting the fork spread

NOTE

The load centre should be in the centre be­tween the forks.

70 Operating Instructions – 393 807 1001 EN – 06/2006

¾ Raise the fork quick-release levers(1).

¾ Move the forks further apart or closer to-

gether depending to the size of the load to
be lifted.

Make sure that both forks are equa

lly distant

from the truck centre.

¾ Allow the quick-release levers to engage in

a notch on the fork carriage.

Loading

DANGER

Increased danger of falling and being squeezed.

Standing on the lifted forks without the appropriate
cage protection is therefore prohibited.

Operation 4

Working under load

1

d3921429

DANGER

The loads must be picked up so that they do not
project beyond the loading area of the truck, and
will not fall over or off.

If needed, a load backrest (option) must be used.

DANGER

No persons are allowed to stand under the picked
up load when the load is raised.

Only drive with the load lowered and the mast tilted
back.

¾ Approach the load to be picked up carefully

and as exactly as possible.

Operating Instructions – 393 807 1001 EN – 06/2006 71

4 Operation

Working under load

¾ Set the mast vertical.

¾ Lift or lower the fork carriage to the required

height.

¾ Drive carefully into the centre o

to be picked up. Carefully drive t
forward under the centre of the lo
the load contacts the fork-fac
while taking care not to dislod
loads.

¾ Lift the fork carriage until the load is clear of

the ground.

f the load

he truck

ad until

e, if possible,

ge adjacent

d3921430

¾ Observe the load/ov

(option) (2)in the c

DANGER

If the overload warning symbol comes on red during
lifting,

¾ lower the load at once.

¾ Check the admissible weight of the load using

the load capacity diagram.

¾ Backupthetruckuntiltheloadisclear.

¾ Tilt the mast back.

erload indicator light

omposite instrument.

Transporting a load

NOTE

In goods traffic, the sender must load and,
if necessary, secure the goods to be trans­ported safely. Therefore pay attention to
proper stacking and make sure the packages,
pallets, etc are not damaged. The carrier is
responsible for safe loading.

2

d3921509

72 Operating Instructions – 393 807 1001 EN – 06/2006

¾ Do not drive with a laterally displaced load

(eg with a sideshifter).

¾ Carry the load close to the ground.

¾ On inclines, always travel with t

hill, never drive or maneuvre acr

he load up-

oss a slope.

¾ Work with a guide if visibility is restricted.

¾ Iftheloadtobetransportedisstackedso

high that no unobstructed view in direction
of travel is ensured, the truck may only be
driven with the load trailing.

Unloading

DANGER

Never park the truck and leave it unattended with
theload/forkcarriageraised.

fork carriage ablassen TO forks on the ground auf­liegen.

Operation 4

Working under load

d3921431

¾ Carefully approach the racking receiving

the load.

¾ Lift the fork carriage to the required height.

¾ Set the mast to the vertical position (load

horizontal).

¾ Note the mast position sensing symbol (1)

on the display if your truck is fitted with auto­matic mast positioning.

¾ Carefully drive into the racking.

¾ Carefully lower the load onto the racking

until the forks are free.

¾ Reverse the truck.

Operating Instructions – 393 807 1001 EN – 06/2006 73

1

d3921357

4 Operation

Loading / Transport

Tow coupling

NOTE

The tow coupling is used only for towing light
trailers inside the plant. (Observe the applica­ble safety guidelines and VDI.)

¾ Turn the handle ((1)) of the tow pin 90° to

the rear and then lift it up.

¾ Place the drawbar eye into the c

sleeve (2).

¾ Press down the tow pin against spring pres-

sure, turn 90° degrees and let engage in the
retainer.

oupling

1

2

d3921373

Loading / Transport

Securing the hose reel against rewinding

If a single attachment is installed, a hose reel
(1) is installed underneath the floor plate (in
case of two attachments a mirror-inverted
second one (5) is also installed.

WARNING

The hose reels are spring-tensioned

and must always be secured against rewinding:

• Before the hose couplings at the mast union
can be disconnected (eg for removal of the
mast or the hose reel itself).

• Whenever the hose reels in the vehicle are
being serviced.

74 Operating Instructions – 393 807 1001 EN – 06/2006

WARNING

Do not open the reel locking mechanism on the
removed hose reel.

If so, the spring tension must first be reduced to 0.
Please contact your authorised dealer.

¾ Open the bonnet.

¾ Open the floor plate and secure it.

¾ hex head screw (3) to the Hose reel (1) in

direction of travel right) with key (SW 10)
against the stop in gesicherte position (6)
turn.

The pawl (2) points opposite to the direction of
travel and the pin (8)is visible; the hose reel is
secured against turning.

Operation 4

Loading / Transport

5

1

¾ If two attachments are installed, also turn

the pawl (4) of the second hose reel (5) to
the locked position(6).

¾ Disconnect the hoses before removing the

mast.

CAUTION

If the mast is extended with the pawl in action, the
hose lines can not be damaged (ratchet effect).
When the mast is lowered again, however, the
hoses are not reeled in and can therefore suffer
damage.

The reel locking mechanism may only be released
after the mast has been installed (hoses reconnec­ted). For this set the pawl(s) back to the free-whee­ling position (7) (pawl visible).

Dismantling the lift mast

This work should only be performed by spe­cialist staff working for your authorised dealer .

4

8

3

d3921481

2

3

d3921468

2

6

7

Operating Instructions – 393 807 1001 EN – 06/2006 75

4 Operation

Loading / Transport

DANGER

The spring elements on the drive axle are pretensi­oned.

Before dismantling the tilt cylinders, the lift mast
must be tilted back 2 °.

DANGER

The lift mast may fall off during
transport.

Do not move under overhead loads!

¾ Fix the lifting gear to the traverse on the

outer mast of the lift mast at the top.

¾ When dismantling the lift mast, place the tilt

cylinders on a suitable piece of timber and
secure with a steel strap.

CAUTION

After dismantling the lift mast or tilt cylinders, the
potentiometer for the tilt angle is misaligned.

The potentiometer for the tilt angle thus has to be
readjusted after reinstalling the lift mast . When
doing so, the parking brake should be applied for
safety reasons, and any restriction in terms of the
tilt angle taken into account. Please contact your
authorised dealer.

d3921469

Driving without a mast

CAUTION

When driving without a mast the speed of the truck
should be reduced for safety reasons.

Before removing the mast, therefore, install an ad­ditional stop screw under the reverse accelerator
(double-pedal operation) or accelerator (single-pe­dal operation) to limit the truck speed.

¾ Shut the engine off.

76 Operating Instructions – 393 807 1001 EN – 06/2006

¾ Install a M8 X 20 hex head screw (3) half as

high as the M8 hexagonal nut (2) (DIN 6330,
6331, 6334).

¾ Screw a hexagonal nut (2) on the existing

M8 hex head screw (1) until hex head screw
(3) contacts hex head screw (1).

¾ Lock the hexagonal nut (2).

¾ Remove the mast.

Remove the additional stop after the mast is
refitted.

loading

Lifting the truck with a crane

DANGER

When loading the truck by crane make sure no per­sons are within the working range of the crane! Do
not exceed the hoisting weight on the manufactu­rer’s plate.

Do not step under elevated loads. Only use lifting
slings and a crane of sufficient capacity.

Operation 4

Loading / Transport

3

2

1

d3921520

WARNING

When hoisting the truck with a crane the tilt cylin­ders and the cover plate at the counterweight can
get damaged.

Fully lower the mast, fully retract the tilt cylinders
and lift the truck with it slanting forward.

¾ Attach the lifting slings at the points pro-

vided.

The fastening points are not marked on your
truck.

Operating Instructions – 393 807 1001 EN – 06/2006 77

4 Operation

Loading / Transport

¾ Place a round sling ((2)) (min. capacity 3000

kg) around the lower edge of the counter­weight.

¾ Use edge protectors on sharp edges.

¾ Wrap a round sling ((3)) (3000 kg c

capacity minimum) around the cro
ber on the outer upright of the m

¾ Attach all the ends to the crane hook (1).

¾ Make sure the safety (4) is closed.

NOTE

When the truck is being hoisted, t
should not rub against the sides
head guard and any attachments p
fitted.

arrying

ss mem-

ast.

he slings

of the over-

ossibly

Hoisting the truck with lifting

CAUTION

If the truck is not hoisted vertically, the eyebolts can
break off.

The truck may be hoisted with eyebolts only if the
appropriate lifting gear (3) is used with which the
chains (2, 6) lead straight up from the eyebolts (1,

7).

¾ Hook the chains (6) (min. capacity 3000 kg)

into the eyebolts (7) at the counterweight.

¾ Hook the chains (2) (min. capacity 3000 kg)

into the eyebolts (1) at the mast.

¾ Make sure the safety(5) is closed.

NOTE

eyes

When the truck is being hoisted, the slings
should not rub against the sides of the over­head guard and any attachments possibly
fitted.

78 Operating Instructions – 393 807 1001 EN – 06/2006

Transport with lorry or low-bed trailer

¾ Lower the mast.

¾ Engage the parking brake.

¾ Chock the truck.

¾ Tie the truck down.

Operation 4

Loading / Transport

d3921499

Before leaving the t

¾ Deposit the load or l

¾ Tilt the mast slightly forward.

The forks must contact the ground.

¾ Pull the parking brak

¾ Shut the engine off.

¾ Removetheignitionkey(2).

ruck unattended

ower the fork carriage.

e handle (1) up.

d3921432

1

2

Operating Instructions – 393 807 1001 EN – 06/2006 79

4 Operation

Loading / Transport

80 Operating Instructions – 393 807 1001 EN – 06/2006

5

Servicing

5 Servicing

Inspection and maintenance overview

Inspection and maintenance overview

General information

Your truck will remain operational only if the
maintenance and checks are carried out
regularly and according to the information
and instructions in the operating manual.
The maintenance may only be performed
by qualified authorised personnel. This work
can be carried out by your authorised dealer
under a service contract.

Ifyouwishtodotheworkyourself,werec­ommend that the first three customer service
checks be carried out by your distributor’s
mechanic in the presence of the responsible
mechanic in your workshop so that your staff
can receive the appropriate instruction.

When servicing the truck, it m
a level surface and the wheels
the engine and remove the igni

When working on the truck with the fork
carriage and mast elevated, secure them
against inadvertent lowering.

When working on the front part of the truck,
secure the mast against tilting back.

No changes, particularly no m
additions, may be made to the t
the approval of the manufactu

Perform a functional check and trial run after
every servicing.

WARNING

Possibly fitted side doors can close during the
servicing, so that personnel can get caught in the
door.

Fort this reason both doors must be opened and
secured against closing.

ustbeplacedon

secured. Stop
tion key.

odifications and

ruck without

rer.

The truck must always be properly labelled.

Missing or damaged type plates and/or self-adhe­sive labels must be replaced. Refer to the parts
catalogue for their location and part number.

Follow the precautions for handling fluids and
lubricants.

When operating the truck under extreme
conditions (ie extreme heat or cold, very dusty
environment, etc), the intervals given in the
maintenance schedule should be reduced
accordingly.

Maintenance intervals

Under certain conditions it is possible to
change the intervals of certain services listed
in the maintenance schedule. Please use
the specified engine oil and coolant in this
case. The required qualities are specified
in the recommended lubricants section.
The inspection and maintenance intervals
depend on the operating and duty conditions
of the truck. Under heavy-duty conditions we
recommend shorter intervals. Please contact
your authorised dealer.

CAUTION

ENVIRONMENT NOTE

NOTE

82 Operating Instructions – 393 807 1001 EN – 06/2006

Work on the mast and front part of the truck

DANGER

When working on the front part of the truck, there
is a danger of getting squeezed in and of the mast
lowering accidentally.

Before carrying out any work on the raised mast
and fork carriage, be sure that the following safety
precautions are observed. These safety precauti­ons are only sufficient for the general maintenance
on your truck (inspections and lubrication services).
For repairs (eg replacement of chains or removal
of the lift cylinder) further safety precautions are
required. Please contact your authorised dealer.

Securing against tilting back

The mast must be secured against tilting back
accidentally.

¾ Tilt the mast back completely.

¾ Shut the engine off.

¾ Remove the ignition key.

Standard mast

METHOD OF OPERATION: When the in­ner upright is lifted, the chain pulleys are also
moved upwards thereby raising the fork car­riage at a 2:1 ratio.

Servicing 5

Inspection and maintenance overview

Securing the raised standard mast

DANGER

Check the chain load capacity.

Choose a chain with a sufficient load capacity for
the mast in question. Do not exceed the maximum
height of lift.

¾ Extend the mast.

Operating Instructions – 393 807 1001 EN – 06/2006 83

d3921437

5 Servicing

Inspection and maintenance overview

¾ Fasten the chain around the cross member

of the outer upright (1) and the cross mem­ber of the inner upright(2).

¾ Lower the inner upright until it is held by the

chain.

Duplex mast

NOTE

The advantage of this mast vers
the special free lift height ca
in spaces with a low ceiling (ce
ships).

METHOD OF OPERATION: The fork carriage
is raised to the special free lift height by the
centre cylinder via the chain pulley. It moves
at twice the rate of the centre cylinder. The
inner upright and the fork carriage are then
raised together by the two outer cylinders. The
centre cylinder is mounted on the extendible
inner upright.

Securing the raised duplex mast

DANGER

Check the chain load capacity.

Choose a chain with a sufficient load capacity for
the mast in question. Do not exceed the maximum
height of lift.

ion is that

nbeusedeven

llars, wagons,

1

2

d3921482

¾ Extend the mast.

84 Operating Instructions – 393 807 1001 EN – 06/2006

¾ Fasten the chain around the cross member

of the outer upright (1) and the cross mem­ber of the inner upright(2).

¾ Lower the mast until it is held by the chain.

¾ Fully lower the fork carriage.

Triplex mast

METHOD OF OPERATION: The fork carriage
is raised to the special free lift height by the
centre cylinder via the chain pulley. Then the
two lift cylinders raise the inner upright. When
the inner upright is fully extended, two further
lift cylinders raise the intermediate upright,
which is raised together with the inner up­right and fork carriage. The centre cylinder is
mounted on the extendible inner upright.

Securing the raised triplex mast

DANGER

Check the chain load capacity.

Choose a chain with a sufficient load capacity for
the mast in question. Do not exceed the maximum
height of lift.

Servicing 5

Inspection and maintenance overview

1

2

d3921483

¾ Extend the mast.

¾ Fasten the chain around the cross member

of the outer upright(1) and of the intermedi-

1

ate upright(2).

¾ Lower the mast until it is held by the chain.

¾ Fully lower the fork carriage.

2

d3921484

Operating Instructions – 393 807 1001 EN – 06/2006 85

5 Servicing

Inspection and maintenance overview

Initial operation

¾ Check the engine oil level

¾ Check the coolant level in the expansion

reservoir

¾ Refuelling

¾ Check condition, electrolyte level and acid

density of the battery

¾ Check the tyre inflation pressure

¾ Tighten the wheel nuts

Checks before starting work

¾ Check the fuel level

¾ Check the engine oil level

¾ Check the hydraulic oil level

Maintenance after the first 50 hours

¾ Check the parking brake for proper opera-

tion.

¾ Tighten the wheel fasteners.

¾ Check the hydraulic system, drive axle,

hydraulic pumps and lines for leaks (visual
inspection).

¾ Check the hydraulic oil level

¾ Check the brake system

¾ Check the steering system

¾ Check the lifting device and attachments

¾ Regenerate the soot filter (option)

¾ Check the third auxiliary hydrau

and safety system

¾ Check the coolant level

¾ Check the tyre pressures

¾ Check the mast, lift chain, lift cylinder and

stops for condition, security and proper
operation.

¾ Clean the lift chain, adjust a

chain spray.

¾ Check the electric lines and cable connec-

tions for condition and security.

¾ Drain water from the fuel filter.

lic function

nd lubricate with

Inspection and maintenance as required

¾ Clean the lift truck

¾ Wheel change

¾ Clean the vent hose to the fuel tank

¾ Clean and lubricate the lift chains

¾ Renew the air filter element (

hours minimum)

¾ Renew the air filter safety element (every

3000 hours minimum)

¾ Check the dust discharge valve

¾ Clean the prefilter

86 Operating Instructions – 393 807 1001 EN – 06/2006

every 1000

¾ Drain the fuel filter

¾ Regenerate the soot filter

¾ Clean and check the radiator and hydraulic

oil cooler for leaks

¾ Change the oil in the oil bath air cleaner

¾ Tighten the wheel fasteners w

ers (after each servicing or r
100 hours minimum)

¾ Check the tyres for damage and foreign

objects

heel fasten-

epair, every

Servicing 5

Inspection and maintenance overview

¾ Lubricate the steering axle bearings (every

1000 hours minimum)

¾ Check the lap seat belt for condition and

proper operation

¾ Service the air conditioner

Inspection and maintenance work every 500 to 1000 operating hours * or every year

¾ Change motor oil (once a year at least)

¾ Change motor oil filter (onc

¾ Check coolant concentration

¾ Hydraulic system: Check oil level

¾ Check bleed valve on hydrauli

proper operation

¾ Change fuel filter

¾ Check function of control unit

¾ Check fastening of frame, tilt c

steering axle

¾ Check fastening of axle clamps and wheel

motors

¾ Check and lubricate pedals

¾ Check condition of ribbed V-belt

¾ Check condition and tension of toothed belt,

replace if necessary

¾ Clean water and hydraulic oil cooler

¾ Check particulate filter system

¾ Check condition of electric cables, cable

connectors and connections and that they
are securely fitted

¾ Battery: Check condition, acid level and

electrolyte density (even for maintenance­free battery)

¾ Check and lubricate other bearing

joints

e a year at least)

c tank for

ylinders and

sand

¾ Clean and lubricate steering axle

¾ Sideshift: Clean and lubric

fastening

¾ Fork adjustment device: Clean and lubri-

cate, check fastening

¾ Check fork arms and arm safety devices

¾ Check condition of lift mast,

lift cylinders and end stops,
secure fastening and proper o

¾ Adjust lift mast chain, spray with chain spray

¾ Change air-cleaner cartridge, check vac-

uum-operated switch

¾ Check condition of motor brack

mounting and check for secure a

¾ Check intake and exhaust lines for signs of

leaks

¾ Check hydraulic system for signs of leaks

¾ Check parking brake for proper

¾ Check fastening of steering cylinder and

steering-knuckle pin

¾ Check and adjust side stops on drive axle

¾ Check pretension of double hoses

¾ Clean oil bath air cleaner

* Depending on fuel, coolants and lubricants,
driving style and service conditions. Refer
also to Recommendations for fuel, coolant
and lubricants.

ate, check

lift mast chain,

also check for

peration

et and motor

ttachment

operation

Inspection and maintenance every 3,000 operating hours or every 2 years

¾ Change feed / pressure / suction filter and

breather of hydraulic system

Operating Instructions – 393 807 1001 EN – 06/2006 87

¾ Change ribbed V-belt

¾ Change safety cartridge of air f

ilter

5 Servicing

Inspection and maintenance overview

¾ Check tilt cylinder bearing for wear

¾ Check drive axle bearing for wear

¾ Hydraulic pump on engine: check f

Inspection and maintenance e

¾ Renew the hydraulic oil

Inspection and maintenanc

¾ Change the coolant pump ¾ Change the coolant G12

Inspection and mainten

Assembly

Nr.

Engine Engine oil

1

2 Fuel tank Diesel

3

Cooling system Antifreeze / drinking water

4 Hydraulic system Hydraulic oil

Battery

5

Tyres

6

7

Wheel fasteners,

8

Lift chains / mast channels

Air conditioning

9

astening

very 6000 hours or every 3 years

e every 9000 hours or every 4 years

ance data

Aids / fluids and lubricants

Distilled water As needed

Air

tighten

Linde chain spray As needed

Refrigerant

¾ Change toothed belt and tension pulley (at

latest after 5 years)

¾ Check slide guides on sideshift for wear

¾ Check fork arm adjustment device

and tear

Filling capacity / settings

With heater / air conditioning

conditioning approx. 9.0 L

Height of lift up to 5000 mm

Height of lift from 5000 mm
to 6900 mm approx. 25.5 L

Height of lift from 6900 mm
to 8000 mm approx. 28.0 L

See sticker on inside of

for wear

approx. 4.5 L

approx. 40.0 L

approx. 11.0 L

Without heater / air

approx. 24.0 L

overhead guard

Front: 170 Nm

Rear: 460 Nm

1600 g

88 Operating Instructions – 393 807 1001 EN – 06/2006

Consumable materials recommendations

Diesel fuel

Only diesel fuels to EN 590 with a cetane
number (CN) not less than 51 may be used.
The fuel sulphur content must not exceed
350 mg/kg.

If the only diesel fuel availab
content above the value permis
EN 590, the engine oil change in
be reduced as follows:

• At a sulphur content more than 350 mg/kg
and less than 2000 mg/kg = engine oil
change interval 300 operating hours.

• At a sulphur content more than 2000 mg/kg
= engine oil change interval 150 operating
hours.

NOTE

If the sulphur content of the diesel fuel is
more than 350 mg/kg, as well as performing
oil changes more frequently, an oil to VW
standard 505 00 / 505 01 / 506 00 / 506 01
must be used.

NOTE

As the ambient temperature fall
characteristics of diesel fuel
paraffin segregation. If "summ
are used at low ambient temper
can lead to problems. Therefo
colder part of the year cost-r
diesel fuels are available, w
be used at temperatures down t

In winter, use only winter diesel fuel, so
that the fuel lines do not become blocked
with segregated paraffin waxes. At very
low temperatures even winter diesel fuel
can suffer from this problem of segregation.
Please contact your authorised dealer.

CAUTION

When using bio-diesel fuel (RME to DIN 51606/pro­visional standard), some important points must be
considered.

Please contact your authorised dealer.

le has a sulphur

sible for

tervals must

s, the flow

s reduces due to

er" diesel fuels

atures, this

re during the

esistant "winter"

hich can reliably

o about -22 °C.

Servicing 5

Inspection and maintenance overview

Hydraulic oil

NOTE

The working temperature is the critical factor
to be considered in selecting the correct oil for
hydrostatic drives. The recommendations for
oils given below can only be taken as guide
values.

Hydraulic oil recommendations for standard
use:

Hydraulic oil ISO - L - HM 68 to ISO 6743 - 4 or
HLP ISO VG 68 to DIN 51524.T.2 (factory
filling) average sustained oil temperature
60 °C - 80 °C.

Hydraulic oil recommendations for heavy-duty
use:

Hydraulic oil ISO - L - HM 100 to ISO 6743 - 4
or HLP ISO VG 100 to DIN 51524, T.2 for
heavy-duty and multi-shift use, operation in
hot climates or at high ambient temperatures,
average sustained oil temperature over 80 °C.

Hydraulic oil recommendations for normal and
heavy-duty use:

Hydraulic oil ISO - L - HV 68 to ISO 6743 - 4
or HVLP ISO VG 68 to DIN 51524, T.3 (multi­grade oil)

Bio-hydraulic oil

Highly biodegradable hydraulic fluid

Aral Forbex SE 46

CAUTION

Bio-oils must not be mixed with mineral-based oils.

No recommendations for other fluids from other
manufacturers can be made at the present time.

NOTE

If in doubt, we recommend obtaining the ad­vice of your authorised dealer. Recommen­dations made by representatives from the
mineral oil industry should also be agreed with

Operating Instructions – 393 807 1001 EN – 06/2006 89

5 Servicing

Inspection and maintenance overview

your authorised dealer. Manufacturer’s ap­proval has been granted only for the oils listed
above. If they are mixed with other hydraulic
fluids or other hydraulic fluids are used, highly
expensive damage may result.

Lubricating grease

Linde heavy-duty grease, lithium-saponified
with EP active ingredients and MOS
ignation as per DIN 51825-KPF 2N-20 (order
no. see spare parts list).

Mixing with lubricating greas
soap basis other than lithium i

.Des-

2

etypeswitha

s not permitted .

Coolant

CAUTION

Refer to the coolant specifications!

Use only coolant G12 A8D to VW specification
TL-VW 774D (factory filling) or G 12 A8F to VW
specification TL-VW- 774F.

Temperature

25°C 40 % 60 %

30°C 45 % 55 %

35°C 50 % 50 %

40°C 60 % 40 %

Coolant
additive

Drinking
water

Long life engine oils to VW standard 506 00 or
506 01. These oils are available exclusively in
viscosity SAE 0W-30.

Oil change every 1000 hours or every 12
months

The engine is factory-filled wit
engine oil for 1000 operating h

Engine oil for oil change every 500 operating
hours

Engine oils to VW standard 505 00 and 505 01
are approved. For viscosity see table.

This engine oil must be changed eve
erating hours.

Engine oil for oil change every 300 operating
hours

Engine oils of qualities API CD and
ACEA B2 / B3, together with high-quality
API-C and ACEA-B classes are also ap­proved. Viscosity - see table

This engine oil must be changed ev
erating hours.

¾ When topping up the various oils may be

mixed with each other, however the oil
change interval is then determined by the
oil of the lowest quality.

h a good quality

ours.

ry 500 op-

ery 300 op-

Refrigerant for air conditioning system

R134a

Battery grease

Acid-free lubricating grease (terminal grease).

Chain spray

Linde chain spray (order no. see spare parts
list).

Engine oil

Specification and viscosity of engine oil for oil
change every 1000 operating hours

90 Operating Instructions – 393 807 1001 EN – 06/2006

Since a good engine oil is a pre-requisite for
problem-free operation and a long working
life for the engine, use only good quality
engine oil even when topping up and also
at oil change . Due to their limited viscosity