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 +49 (0) 6021 99Mail: 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
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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
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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
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