LINDE H40D, H45D, H50D operations manual
Diesel truck
Original instructions
H40D, H45D, H50D
394 807 10 01 EN – 07/2011
Linde − Your Partner
Preface
g
With over 100
house machin
the world’s l
handling equ
for this succ
not only for t
nology, but a
ating costs,
than those of
The high quality of Linde products is also
matched by the quality of our service. With ten
production plants worldwide and an extensive
network of sales partners, we are at your
service round the clock and around the world.
Operating Instructions – 394 807 10 01 EN – 07/2011 I
,000 fork lift trucks and warees sold annually, Linde is one of
eading manufacturers of material
ipment. There are many reasons
ess: Linde products are renowned
heir innovative, cutting-edge tech-
lso for their low energy and operwhich are up to 40 per cent lower
their competitors.
Your local Li
complete pac
ranging from
of sales and s
appropriate
or lease-pur
with the flexi
your individ
Linde Material Handling GmbH
Carl-von-Linde-Platz
63743 Aschaffenburg
Telephone +49 (0) 6021 99-0
Fax +49 (0) 6021 99-1570
Mail: info@linde-mh.com
Web: http://www.linde-mh.com
nde partner can offer you a
kage from a single source;
expert advice on all aspects
ervice through, of course, to
finance options. Our leasing, hire
chase agreements provide you
bility to tailor decision-making to
ual business requirements.
Table of contents
1 Introduction
Your forklift truck ..................................................... 2
Proper use .......................................................... 3
Impermissible use .................................................... 3
Description of use and climatic conditions ................................... 3
Symbols used ....................................................... 4
Technical description .................................................. 4
Truck operation when using a shovel ...................................... 6
Receiving the industrial t
Legal requirements for marketing ......................................... 7
ruck ............................................ 6
2Safety
Safety guidelines .................................................... 10
Residual risks ...................................................... 11
Stability ........................................................... 12
In the case of tip-over ................................................. 12
Handling consumable
Competent person ................................................... 13
Regulations ........................................................ 13
Instructions for fit
Fork carriage emergency lowering ....................................... 15
Emergency exit with attached rear window ................................. 16
s ................................................ 12
ting attachments ....................................... 14
g
3Overview
Identification pl
General view ....................................................... 20
Operating devices ................................................... 21
Display unit ........................................................ 22
Switch panel ....................................................... 28
ates .................................................. 18
4 Operation
Service plan before initial commissioning .................................. 30
Running-in i
Operating Instructions – 394 807 10 01 EN – 07/2011 III
nstructions ............................................... 30
Table of contents
g
Pre-shift-checks ..................................................... 31
Standard equipment ................................................. 32
Entering and exiting the truck
Adjusting the standard driver’s seat and comfort driver’s seat .................... 32
Adjustingtheheight-adjustablecomfortdriver’sseat .......................... 34
Adjusting the luxury driver
Adjustingthearmrest ................................................. 39
Adjustingthesteeringcolumn ........................................... 40
Settingtheclock ..................................................... 40
Seatbelt .......................................................... 41
Drive engine (dual-pedal operation) ...................................... 43
Driving (dual-pedal opera
Drive engine (single-pedal operation) ..................................... 49
Driving (single-pedal operation) ......................................... 53
Steeringsystem ..................................................... 56
Brakesystem ....................................................... 56
Signal horn ........................................................ 58
Joystick with central le
Joystickwithsingleleveroperation ....................................... 65
Special equipment ................................................... 71
Depressurisation .................................................... 71
Driver’scab ........................................................ 72
Lighting ........................................................... 72
Windscreenwiper ................................................... 74
Window heater ...................................................... 77
Heating system, air conditioning ......................................... 78
Linde Forklift Data M
Adjustingthedriver’sseatwithrotatingdevice ............................... 88
Liftmastpositioning .................................................. 89
Working under load .................................................. 91
Beforetakingupaload ................................................ 91
Adjustingtheforkspread .............................................. 93
Takingupload ...................................................... 94
Travellingwithload .................................................. 95
Setting down loads ................................................... 96
Towcoupling ....................................................... 96
Before leaving the lift truck unattended .................................... 97
Beforeleavingthetruck ............................................... 97
Loading / Transpo
Securing the hose pulley against rolling up ................................. 98
Removingtheliftmast ................................................ 99
ver operation ...................................... 59
anagement (LFM) .................................... 81
rting ................................................ 98
........................................... 32
’sseat ......................................... 36
tion) .......................................... 46
IV Operating Instructions – 394 807 10 01 EN – 07/2011
Table of contents
Driving without the lift mast .............................................100
Loading ...........................................................100
Transportation by lorry or low
loading trucks ................................102
5 Maintenance
General information ..................................................104
Inspection and maintenance data ........................................105
Recommendations for cons
Inspection and maintenance overview ....................................108
Serviceplanasrequired ...............................................108
1000hserviceplan ................................................ . . 109
3000hserviceplan ................................................ . . 111
6000hserviceplan ................................................ . . 114
9000hServiceplan ................................................ . . 117
Engine ............................................................120
Checking the engine oil level ...........................................120
Change engine oil ...................................................121
Changing the engine oil filter ............................................123
Fuel ............................................................ . . 124
Draining water from th
Changing the fuel filter . ...............................................126
Cleanthefueltankventilationhose .......................................127
Checking the coolant
Changing the coolant . . ...............................................129
Checkingthecoolantconcentration ......................................131
Cleaning the water c
Checking the condition and secure positioning of the engine support and engine
mounting ........................................................134
Check condition of the ribbed vee belt .....................................135
Replacing ribbed V-
Checking the condition and tension of toothed belt ............................137
Renew the toothed belt and idler pulley ....................................139
Change the water pu
Changing the air filter cartridge, checking the vacuum-operated switch . . ..........139
Changing the air filter safety cartridge .....................................141
Check the dust disc
Changing the breather filter for the charge air pressure regulator .................142
Cleaningtheprefilter(specialequipment) ..................................143
Cleaning the oil b
Change the oil in the oil bath air cleaner (Optional) ............................144
ath air filter (special equipment) ............................143
umables ......................................105
efuelfilter. ........................................126
level .............................................128
oolerandhydraulicoilcooler,andcheckingthemforleaks ......133
belt ...............................................136
mp ...............................................139
hargevalve .........................................141
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Operating Instructions – 394 807 10 01 EN – 07/2011 V
Table of contents
g
Check suction and exhaust pipes for leaks .................................145
Regenerating the particle filter ..........................................146
Regenerating the changing par
Checkingtheparticlefiltersystem(specialequipment) ........................151
Draining water from the water trap at the changing particle filter (special equip-
ment) ........................................................... 152
Cleaning the water trap at th
Cleaning the pressure control device at the changing particle filter (special equip-
ment) ........................................................... 153
Gearbox ..........................................................154
Axle clamps and wheel motors
Checkingandadjustingthesidestopsonthedriveaxle ........................154
Checkingthedriveaxlebearingsforwear ..................................155
Checking the hydraulic pu
Chassis, bodywork and fittings ..........................................156
Cleaning the truck ...................................................156
Bonnet . . .........................................................156
Floorplate .........................................................158
Maintaining the heating system and air conditioning (special equipment) ...........159
Checking the condition
Check fastening for frame, tilt cylinders and steering axle .......................162
Checking and oiling other bearing points and joints ...........................162
Topping up the washer sy
Chassis frame ......................................................164
Changing a wheel ...................................................164
Tighten the wheel nut
Checkthetyresfordamageandforeignobjects ..............................165
Checkingthetyrepressure .............................................166
Checking the conditi
Cleaning and greasing the steering axle ...................................167
Checking the mountings of the steering cylinder and steering pivot pin . . . ..........168
Controls ..........................................................169
Checking the parking brake for correct operation . . ...........................169
Checking the pedals ..................................................169
Checking the bellow
Electrics ..........................................................171
Check the condition and secure positioning of electric cables, cable connectors and
connections ..................................................... . 171
Battery: Check con
Hydraulics .........................................................174
Change hydraulic oil ..................................................174
s ................................................165
onoftheantistaticbelt .................................167
sattheactuatinglever .................................170
dition,levelanddensityofacid ............................171
ticlefilter ...................................149
e changing particle filter (special equipment) ...........152
: checking the mountings .......................154
mp’s mounting on the engine ........................155
andcorrectfunctionoftheseatbelt .....................160
stemwatertank(specialequipment) ..................163
VI Operating Instructions – 394 807 10 01 EN – 07/2011
Table of contents
Hydraulicsystem:Checktheoillevel. .....................................175
Hydraulic system: changing the filter ......................................176
Check the bleeder valve on the h
Checkthehydraulicsystemforleaks .....................................180
Check tilt cylinder bearings for wear ......................................180
Check the tension of double hos
Load lift system .....................................................182
Workingontheliftmastandatthefrontofthetruck ...........................182
Cleaning and spraying the li
Lift mast, lift mast chains, lift cylinder and end stops: Check mounting, condition and
function ........................................................ . 186
Adjustingtheliftmastchain ............................................186
Check the forks and fork qu
Cleansideshift(specialequipment)andgrease,checkfastening .................189
Checking the slide guides on the sideshift (special equipment) for wear . . ..........190
Self-help ..........................................................191
Openingthecovertotheelectricalsystem ..................................191
Fuses for basic and special equipment ....................................192
Main fuses in engine comp
Diagnosticconnector .................................................193
Malfunctions during operation ...........................................194
Malfunctions, Causes a
Malfunctions,causesandremedies(hydraulicsystem) ........................199
Jumpstart ....................................................... . . 201
Towing .......................................................... . 202
Shutting down ......................................................205
Shuttingdownthetruck ...............................................205
Disposal of old truck
ndRemedies(dieselengine) ..........................196
s .................................................206
ydraulicoiltankforcorrectoperation .............179
es .......................................181
ftmastchain ...................................185
ick-releases ...................................188
artment .......................................192
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Operating Instructions – 394 807 10 01 EN – 07/2011 VII
Table of contents
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6 Technical data
Type sheet H 40, as at 07/2011 ..........................................208
Type sheet H 45, as at 07/2011 ..........................................21
Type sheet H 50/500, as at 07/2011 ......................................214
Type sheet H 50/600, as at 07/2011 ......................................217
Type sheet H 40 elevated dri
Type sheet H 45 elevated driver’s compartment, as at 07/2011 ..................223
Type sheet H 50/500 elevated driver’s compartment, as at 07/2011 ...............226
Type sheet H 40 container, a
Type sheet H 45 container, as at 07/2011 ..................................232
Type sheet H 50/500 container, as at 07/2011 ...............................235
Type sheet H 50/600 conta
Truck configuration ..................................................241
Tyre variants and rim sizes .............................................242
Load capacity diagrams
Additional capacity rating plate for attachments ..............................247
Noise emission values ................................................248
Vibration character
istic values for bodily vibrations ...........................249
ver’s compartment, as at 07/2011 ..................220
s at 07/2011 ..................................229
iner, as at 07/2011 ...............................238
and lift mast data as at 07/2011 .......................244
1
Annex
7 Circuit diagram
Wiring diagram .....................................................264
Basic equipment for diesel with pump injection engine — Sheet 01 ................264
Basic equipment
Basic equipment for diesel with pump injection engine — sheet 03 ................268
Special equipment sheet 01 — working spotlight . . ...........................270
Special equipm
sion ............................................................ 272
Special equipment sheet 03 — Heating system, air conditioning, flashing/rotating
beacon, reversing signal, interior lighting/clipboard lighting ...................274
Special equipment sheet 04 — hazard warning system for reverse travel, truck deacti-
vation,mastpositioning .............................................276
Special equip
Special equipment sheet 06 — Higher lighting, 12 V socket, diesel filter water trap
warning ......................................................... 280
VIII Operating Instructions – 394 807 10 01 EN – 07/2011
s
for diesel with pump injection engine — sheet 02 ................266
ent sheet 02 — Windscreen wipers, seat heater, seat with air suspen-
ment sheet 05 — particle filter, radio . ...........................278
Table of contents
Special equipment sheet 07 – Truck data management, LPG volume display . . . .....282
Special equipment sheet 08 – LPG volume display for volumetric filling with shut-off
valve, changing particle filter, camera system .............................284
Special equipment sheet 09 — ba
centrebrake/taillight ...............................................286
Special equipment sheet 10 — third auxiliary hydraulics with third joystick ..........288
Special equipment sheet 11 — Lighting, direction indicator and hazard warning sys-
tem,brakelight .................................................. . . 290
Special equipment sheet 12 —
hydraulics and double auxil
Hydraulic circuit diagram ..............................................294
Traction,workingandsteeringhydraulics ..................................294
Accumulator ..................................................... . . 296
ttery main switch with display unit power supply, rear
single lever for lifting/lowering, tilting, single auxiliary
iaryhydraulics ................................292
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Operating Instructions – 394 807 10 01 EN – 07/2011 IX
1
Introduction
1 Introduction
Your forklift truck
Your forklift truck
offers optimum economic efficiency, safety
and driving comfort. It is primarily down to
you to maintain these characteristics for a
long time and take advantage of the resulting
benefits.
During manufacture:
• all safety requirements of t
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.
These operating instruct
thing you need to know abou
driving and maintenance.
The attachment operating instructions are enclosed for trucks that are delivered from the
factory with an attachment. Before commissioning a truck with an attachment, you must
check that loads are handled securely. Depending on the type of attachment, it may be
necessary to make adjustments, e.g. pressure settings or adjusting stops and operating
speeds. See the attachment operating instructions for the corresponding instructions.
The instructions for operation of the attachment must also be observed.
Carry out the specified work regularly, at the
due times and using the consumables envisaged for this purpose in accordance with the
inspection and maintenance overview. Please
make sure you record the work performed in
the registration document for the industrial
truck; this is essential for any warranty claims.
The designations use
left, right) always r
position of the parts
as the drive directio
forwards).
Servicing work not described here will require
specialist knowledge, measuring devices and
frequently also special tools. Please ask your
authorised dealer to carry out this work.
efer to the installation
described, with forwards
n for the truck (fork arms
he relevant EC
ions contain every-
t commissioning,
d in the text (front, back,
Servicing should only be carried out by qualified personnel approved by Linde (specialists).
With orders for parts, please specify the
following along with the parts numbers:
Truck model:
Chassis number/year of manufacture:
Handover date:
The production number must also be specified
for parts from the following units: engine, lift
mast, hydraulic variable displacement pump,
drive axle and steering axle.
Engine number:
Lift mast number:
Lift mast lift:
Hydraulic variable
displacement pump
number:
Drive axle number
Steering axle
number:
When taking over the truck, this data should
be copied from the identification plates of the
units into these operating instructions.
NOTE
:
In the event of repairs, only use genuine Linde
spare parts. This is the only way to guarantee
that your truck remains in the same technical
condition as at the time of reception.
Please address all queries and orders for
spare parts relating to your truck only to
your authorised dealer, stating your mailing
address.
Linde is cons
development
understandi
are subject t
tantly engaged in the further
of its products. We ask for your
ng that figures and technical data
o technical modification in terms of
2 Operating Instructions – 394 807 10 01 EN – 07/2011
Introduction 1
Description of use and climatic conditions
form, equipment and expertise in the interest
of progress.
For this reason, no claims can be asserted
on the basis of the following data, figures and
descriptions in these operating instructions.
Proper use
The truck is used for moving and lifting the
loads indicated on the capacity rating plate.
Please pay particular attention to:
• The VDMA brochure on "Rule
use of industrial truck
operating instruction
• Regulations for driving on public roads, as
well as any country-specific restrictions on
winter road conditions
• Specific measures for using the industrial
truck in operating areas with magnetic fields
s
s for proper
s", supplied with these
Impermissible use
The operating compa
manufacturer, is li
manner that is not pe
It is not permitted to use the truck:
• for taking passengers
• in areas where ther
explosion
ny or driver, and not the
ableifthetruckisusedina
rmitted.
e is a risk of fire of
These operating instructions must not be
reproduced, translated or made accessible to
third parties—including as excerpts—except
with the express written approval of the
manufacturer.
that have magnetic flux densities greater
than 5 mT
• Other specific national re
It is essential that operating personnel and
repair personnel observe the rules for the
proper use of industrial trucks.
Modifications, in particular attachments or
conversions, are not permitted to be made to
the industrial truck without the manufacturer’s
approval.
The user, and not the man
for any hazards caused
• for stacking/unsta
slopes
• For stepping onto the fork arms when the lift
mast is raised
• If the maximum load capacity is exceeded
gulations.
ufacturer, is liable
by improper use.
cking operations on
Description of u
Normal use
• Indoor and outdoor use
• Ambient temperature in tropical and Nordic
regions ranging from -15 °C to 50 °C
• Start capabili
• Maximum start time of 20 seconds
• Use at up to 2000 metres above sea level.
Operating Instructions – 394 807 10 01 EN – 07/2011 3
se and climatic conditions
tyat-15°Cto50°C
Special use (pa
rtly with special mea-
sures)
• Use, e.g. in the event of abrasive dust (such
as AL203), lint, acid, leach, salt, corundum,
incombustible substances
• Ambient temperature in tropical regions up
to 55 °C
• Start capabil
• Use at up to 3500 metres above sea level.
ity to -25 °C
1 Introduction
Technical description
Symbols used
The terms DANGER, WARNING, CAUTION,
NOTE and ENVIRONMENT NOTE are used
in these operating instructions for notes on
particular hazards or for unusual information
that needs to be highlighted:
DANGER
Means that failure to comply can cause risk to life
and/or major damage to property.
WARNING
Means that failure to comply can cause risk of
serious injury and/or major damage to property.
CAUTION
Means that failure to comply can cause risk of
material damage or destruction.
Technical description
The forklift trucks in the 394 series allow
loading and palletising to be performed for
loadsupto4twithH40,upto4.5twithH45
and up to 5 t with H 50-500, at a load distance
of 500 mm.
Details on the exact lift-height-specific maximum loads are available in the load capacity
diagram.
The trucks are eco-friendly and their quiet
operational noise and low emission levels
benefit both the driver and the environment.
Their distinguishing features are the compact
design and small turning radius. For this
reason, the trucks are particularly well-suited
to narrow entrances and operational areas
where space is at a premium.
Engine
The drive engine is a 4-cylinder, four-stroke
diesel engine with turbocharging and state-of-
NOTE
Means that particular attention is drawn to
combinations of technical factors which may
not be evident even to a specialist.
ENVIRONMENT NOTE
The instructions listed
with as otherwise enviro
here must be complied
nmental damage may
result.
CAUTION
This label is found on the truck in
the areas where particular care and
attention are required.
You should refer to the appropriate
sectionintheseoperatinginstructions.
For your safety, additional symbols are also
used. Please heed the various symbols.
the-art pump injection technology. It powers
the truck’s hydraulic pumps and varies its
speed depending on the load. The engine is
cooled by means of a closed coolant circuit
with expansion tank.
Forced circulation lubrication with an oil pump
in the oil sump is used for engine lubrication.
The combustion air is cleaned by means of a
dry air filter with a paper insert. Diesel engines
with state-of-the-art engine technology are
used for:
• High torque
• Low fuel consumption
• Low exhaust emissions
• Low particulate emissions
• Low noise levels
Hydraulic system
The drive unit consists of a hydraulic variable
displacement pump, two hydraulic fixed
4 Operating Instructions – 394 807 10 01 EN – 07/2011
Introduction 1
Technical description
displacement wheel motors (assembled as
a drive axle unit), as well as a hydraulic pump
(fixed displacement pump) for the working
and steering hydraulics. Drive direction and
driving speed are regulated by means of two
accelerator pedals via the hydraulic variable
displacement pump.
The hydraulic fixed displacement wheel
motors in the drive axle are supplied by the
hydraulic variable displacement pump and are
used to power the drive wheels via two side
gearboxes.
Operation
One accelerator pedal eac
and reverse travel (dual p
used to simultaneously re
variable displacement pu
speed. The hydrostatic dr
driving speed to be contin
both directions, ranging
maximum speed. The dualmeans that operation of t
safe, non-fatiguing and
The driver always has both hands free for
steering and controlling operational movements. This results in fast reversing and efficient stacking.
An optional version is also available whereby
the driving speed is regulated by an accelerator pedal (single pedal operation) and the
drive direction controlled by means of a drive
direction switch.
To control the operati
ing, lowering and tilt
ating lever (joystick
for actuation of addi
erational movements
using two or four joys
tion version).
h for forward travel
edal operation) is
gulate the hydraulic
mp and the engine
ive enables the
uously varied in
from standstill to the
pedal control
he truck is simple,
efficient.
onal movements of lift-
ing, there is only one actu-
). Another joystick is fitted
tional attachments. Op-
canalsobecontrolled
ticks (single lever opera-
Linde Load Control
The truck’s Linde Load Control (LLC) control
electronics system enables:
• Millimetre-precise and secure load handling
• Effortless finger-tip control of all lift mast
functions
• Drive and lifting functions ar
separate.
e entirely
Linde Truck Control
The truck’s Linde Truck Control control
electronics system (LTC) offers:
• Reliable control unit
• A high level of safety thank
monitoring systems
• Automatic, load-dependent control of
engine speed
• Protection from dust and dirt though use of
a fully enclosed housing.
s to multiple
Brakes
The hydrostatic drive i
brake. This means that
maintenance-free. Tw
incorporated in the wh
as the parking brake. W
switched off, the mult
meaning that the truck
function. Always appl
when parking the truck
s used as the service
the service brake is
o multi-disc brakes
eel motors are used
hen the engine is
i-disc brakes engage,
has an automatic brake
y the parking brake
.
Steering
The steering is a hydrostatic steering system,
under 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 can also be operated
when the engine has been switched off.
Lift mast
The free-view lift mast enables:
• Ideal visibility
• Full load capacity up to maximum lift heights
• Enormous residual load capacity
due to slim lift mast profiles
Operating Instructions – 394 807 10 01 EN – 07/2011 5
1 Introduction
Receiving the industrial truck
• Maintenance-free storage of the lift mast
and tilt cylinder via rubber-cushioned
linkage points
• Electric tilt angle limitation.
Electrical system
The electrical system is powered by the
three-phase alternator with 12 V DC voltage. A
12 V battery with 88 Ah is installed for starting
the engine. It is located under the driver’s seat
in the engine compartment.
Truck operation when using a shovel
When operating the truck with a shovel, stall
protection can be activated by your authorised
dealer.
In this case, extreme load
engine due to the associa
decrease leads to a sligh
the working hydraulics.
Receiving the industr
Before the industrial
it undergoes a thoro
order to guarantee t
and that it contains
specified in the orde
In order to prevent complaints from occurring
further down the line, the exact condition
of the industrial truck and the integrity of
the equipment are checked and the proper
handover/acceptance of the truck is confirmed
by the dealer.
NOTE
In trucks that lea
mast, an addition
mitation is locat
tor pedal (dual-
ve our factory without a lift
al stop screw for speed li-
ed under the reverse accelera-
pedal operation) or under the
ing of the drive
ted engine speed
t delay in executing
ial truck
truck leaves our factory,
ugh inspection process in
hat it is in perfect condition
all of the equipment
r.
For a period of extended l
engine, the joystick mus
zero position in order t
hydraulics again.
accelerator pedal (si
This must be removed
mast; see the sectio
aliftmast.
The following techn
each industrial tru
• Operating instructions for the truck
• Operating instructions for the attachment
• EC declaration of c
• Safety rules for the use of industrial trucks
• Registration document for the industrial
NOTE
oading of the
t be switched to the
o release the working
ngle-pedal operation).
after installing the lift
n entitled Driving without
ical documents belong to
ck:
(only applies to trucks delivered from the
factory with an attachment)
ompliance
(VDMA)
truck, which is issued by authorised dealers
as part of the handover.
6 Operating Instructions – 394 807 10 01 EN – 07/2011
Legal requirements for marketing
Declaration
Linde Material Handling GmbH
Carl-von-Linde-Platz
D-63743 Aschaffenburg, Germany
We declare that the machine
Introduction 1
Legal requirements for marketing
Industrial tru
Model
complies with the most recent version of machinery directive 2006/42/EC.
Personnel a
see EC declaration of conformity
Linde Mat
ck
uthorised to compile the technical documents:
erial Handling GmbH
EC declaration of conformity
The manufacturer declares that the truck complies with the requirements of the EC machinery directive and any other EC directives, if
applicable, that are valid at the time of marketing. This is confirmed by the EC declaration
of conformity and by the CE labelling on the
nameplate.
The EC declaration of conformity document
is delivered with the truck. The declaration
according to these operating instructions
according to these operating instructions
shown explains the conformity with the requirements of the EC machinery directive.
An independent structural change or addition
to the truck can compromise safety, thus
invalidating the EC declaration of conformity.
The EC declaration of conformity must be
carefully stored and made available to the
responsible authorities if applicable. It must
also be handed over to the new owner if the
truck is sold on.
Operating Instructions – 394 807 10 01 EN – 07/2011 7
1 Introduction
Legal requirements for marketing
8 Operating Instructions – 394 807 10 01 EN – 07/2011
2
Safety
2 Safety
Safety guidelines
Safety guidelines
It is essential that operating personnel and
repair personnel observe the" rules for the
proper use of industrial trucks" enclosed with
these operating instructions.
Examples of those listed are:
• Operating industrial trucks
• Driving licence
• Driveways and working areas
• Rights, duties and rules of behaviour for the
driver
• Special operating areas
• Information regarding setting off, driving
and braking
• Information for maintenance and repair
• Regular tests
• Disposal of greases, oils and batteries
The operating company or the person it has
commissioned must ensure that the driver
understands all safety information and that
all guidelines and safety regulations are
observed.
During training, the driver must familiarise
themselves with the following:
• The operating conditio
areas
• The specific technical characteristics of the
industrial truck
• The operation of attachments
Practise driving, con
ations with an unloade
completely mastered.
industrial truck be us
Safety information
DANGER
The industrial truck must not be used by unauthorised persons.
Only trained persons and those authorised for
operation may have access to the industrial truck.
ns of the working
trol and steering oper-
d truck until they are
Only then can a loaded
ed for practice.
DANGER
In operating areas with magnetic fields that have a
magnetic flux density greater than 5 mT, unintentional truck and lift mast movementscannot be entirely
excluded under unfavourable circumstances.
For magnetic fields with magnetic flux densities
greater than 5 mT, components developed especially for this purpose must be used.
Contact your authorised dealer.
DANGER
Safety systems (e.g. the seat switch) are there for
safety.
Safety systems must never be disabled, regardless
of the kind.
DANGER
Any additional bores or welding to the overhead
guard will compromise its rigidity.
It is therefore strictly prohibited to drill holes in the
overhead guard 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.
CAUTION
Different functions are supported by gas springs.
Gas springs are under a high internal pressure of
up to 300 bar.
They must only be removed when not under compression and must not be opened without instructions. Any kind of damage, lateral forces, buckling,
temperatures in excess of 80° C and heavy contamination must be avoided under all circumstances.
Damaged or defective gas springs must be replaced immediately.
Contact your authorised dealer.
10 Operating Instructions – 394 807 10 01 EN – 07/2011
Safety 2
Residual risks
WARNING
In trucks with an accumulator, serious injuries can
occur if the accumulator is not properly handled.
Before starting work on the accumulator it must be
depressurised.
Contact your authorised dealer.
WARNING
Depending on the duration of use and
operating time, components carrying
exhaust gases and exhaust air may
become hot.
Protective equipment must therefore
be worn.
WARNING
Thetruckworkingareamustbesufficientlylit.
If it is insufficiently lit, working spotlights must be
installed to ensure that the driver can see properly.
Residual risks
Despite careful work and compliance with
all applicable standards and regulations, the
possibility of other dangers when using the
industrial truck cannot be entirely excluded.
The industrial truck and its possible attachments comply with current safety regulations.
Nevertheless, even when the truck is used for
its proper purpose and all instructions are followed, some residual risk cannot be excluded.
Even beyond the narrow danger areas of the
industrial truck itself, a residual risk cannot
be excluded. Persons in the area around the
industrial truck must exercise a heightened
degree of awareness, so that they can react
immediately in the event of any malfunction,
incident or breakdown.
CAUTION
Various pieces of special equipment are connected
to the special "speed reduction" function. This is
simply an assistance function, on which the driver
must not solely rely during operation.
The driver is always responsible for safe operation.
CAUTION
If drivers have active medical equipment, e. g. pace
makers or hearing aids, these may be impaired.
Check with a doctor or the medical equipment
manufacturer whether the equipment is sufficiently
protected against electromagnetic interference.
NOTE
If your truck is equipped with a fire extinguisher, make sure that you familiarise yourself
with it in case of an emergency. Handling information is provided on the fire extinguisher.
DANGER
Persons in the vicinity of the industrial truck must
be instructed with regard to the dangers that arise
through use of the truck.
These operating instructions also contain additional
safety regulations.
Residual dangers can include:
• Escape of consumables due to leakages or
the rupture of lines, hoses or containers,
• Risk of accident when driving over difficult
ground such as gradients, smooth or
irregular surfaces, or with poor visibility,
• Risk of falling, tripping, slipping etc. during
movement of the industrial truck, especially
in the wet, with leaking consumables or on
icy surfaces,
• Risk of fire and explosion due to the battery
and electrical voltages,
• Human error,
• Disregarding the safety regulations,
• Risk caused by unrepaired damage,
Operating Instructions – 394 807 10 01 EN – 07/2011 11
2 Safety
Handling consumables
• Risk caused by insufficient maintenance or
testing,
• Risk caused by using the wrong consumables.
Stability
Stability is guaranteed if your industrial truck is
used according to its intended purpose.
Stability will not be guaranteed in the event of:
• cornering at excessive sp
• moving with the load raised,
• moving with a load that is protruding to the
side (e.g. sideshift),
eeds,
In the case of tip-over
• turning and driving diagonally across
descents or ascents,
• driving on descents or asc
on the downhill side,
• loads that are too wide,
• driving with a swinging load,
• ramp edges or steps.
ents with the load
• Stay buckled up
•Don’tjump
• Hold on tight
•Bracefeet
• Lean away
Handling con
ENVIRONMENT NOTE
Consumables must be handled properly
and in accordance with the manufacturer’s
instructions.
• Consumables should only be stored in
containers complying with applicable
regulations and at the locations stipulated.
• Do not brin
contact wi
• When topping up consumables, use only
clean containers.
12 Operating Instructions – 394 807 10 01 EN – 07/2011
sumables
g flammable consumables into
th hot objects or a naked flame.
The stability of your industrial truck is ensured
if used properly and as intended. Should the
industrial truck tip over during an unapproved
application or due to incorrect operation,
always follow the instructions depicted above.
• Observe the manufacturer’s instructions
relating to safety and disposal.
• Avoid spill
• Remove any spilled fluid immediately with a
suitable binder and dispose of it according
to applicable regulations.
• Old and contaminated operating materials
should be disposed of according to the
regulations.
• Comply wit
• Before performing greasing, filter changes
or any work on the hydraulic system,
ing.
h the statutory provisions.
Safety 2
Regulations
carefully clean the area around the part
involved.
• Dispose of used spare parts in an environmentally friendly manner.
WARNING
The penetration of pressurised hydraulic fluid into
the skin, e.g. due to leakage, is hazardous. If an
injury of this type occurs, always consult a doctor.
Protective equipment must be worn.
Competent person
A competent person is a specialist in the field
of industrial trucks who has:
• Successfully completed training, as at least
a service engineer for industrial trucks
• Many years of professional experience with
industrial trucks
• Knowledge of the accident prevention
regulations
• Knowledge of the relevant national technical regulations
Regulations
Periodic safety inspection
Periodic safety inspections are required in
order to maintain the function and security of
the industrial truck.
Comply with the national regulations for your
country.
In Europe, the national laws are based
on the directives 95/63/EC, 99/92/EC and
2001/45/EC. These stipulate that periodic
safety inspections of the industrial truck must
be carried out by competent personnel, in order to ensure proper condition.
WARNING
The improper handling of coolant and coolant additives presents a risk to health and the environment.
Observe the manufacturer’s instructions without
fail.
The competent person is able to assess the
condition of industrial trucks in terms of health
and safety.
Operating Instructions – 394 807 10 01 EN – 07/2011 13
2 Safety
Instructions for fitting attachments
There is a recommendation setting out the
scope of the periodic safety inspection —FEM
4.004 of the European Industrial Truck Association— which defines a test log to document
the current safety inspection and an inspection
sticker for the next safety inspection. The next
safety inspection date is shown by the year
number (3) on an adhesive label (2), which
changes colour every year and is found on a
label (1).
The scope of the safety inspection is added
by the manufacturer in accordance with
the specific truck type. Please ask your
authorised dealer to carry out this work.
Diesel engine emissions
Diesel engine emissions i
hazardous materials. The
allowed to infiltrate the a
If trucks with diesel engines are used in fully
or partially enclosed spaces, this must first be
reported to the relevant occupational health
and safety authorities. Operating instructions
must be displayed in the working areas.
The national regulations must be observed
without fail.
nclude carcinogenic
se should not be
ir in workplaces.
Checking the particle filter system
Particle filter syste
and tested every 6 mon
person. The test resu
enclosed with the rep
national regulation
Instructions for fi
To depressurise th
fitting an attachme
for the auxiliary h
using an accumulat
depressurised
See the section entitled "Depressurisation".
14 Operating Instructions – 394 807 10 01 EN – 07/2011
ms must be maintained
thsbyacompetent
lts must be recorded and
ort book. Observe the
s for your country.
tting attachments
e oil in the lines before
nt, the hydraulic system
ydraulics can be connected
or (Special equipment)
WARNING
Improper handling of the accumulator may lead to
serious injuries.
Before starting work on the accumulator, it must be
depressurised. Contact your authorised dealer.
Fork carriage emergency lowering
If there is a malfunction, the fork carriage can
be lowered manually.
¾ Remove floormat.
DANGER
Risk of accident or danger to life
when lowering the fork carriage with
fork arms.
People are not allowed to stand in the
vicinity of the fork arms when they are
being lowered.
During lowering, leave the socket
wrench on the threaded stud (1) on
the valve block (3) to enable lowering
to be interrupted at any time.
¾ Insert the 8 mm WAF socket wrench
through the opening in the bottom plate.
¾ Using the socket wrench slowly rotate
the threaded stud (1) approx. 3 turns
anti-clockwise until the fork carriage has
been completely lowered.
¾ Open the bonnet.
¾ Open the bottom plate and secure it in
place.
¾ Undo the self-locking nut (2) about 2 turns.
Safety 2
Fork carriage emergency lowering
Operating Instructions – 394 807 10 01 EN – 07/2011 15
2 Safety
Emergency exit with attached rear window
¾ Screw the threaded stud (1) back in clock-
wise. Otherwise it will not be possible to lift
the fork carriage using the joystick.
Tightening torque 10 Nm.
¾ Retighten the self locking nut
Tightening torque 9.5 Nm
NOTE
After emergency lowering
med three times, a new thre
locking nut must be used.
¾ Close the bottom plate and bonnet.
¾ Insert the floormat.
(2).
has been perfor-
aded stud with self
1
3
2
d3941386
Emergency exit wi
th attached
rear window
If a truck with a
window breaks d
driver may poss
at the side. In t
driver can exit
For this purpos
broken with an e
¾ Bend open split pin (1) from the support
mounting (2) under the rear wiper motor.
WARNING
Glass splinters may cause injuries.
Remove glass splinters carefully.
¾ Take the emergency hammer (3) out of the
support mounting and carefully break the
rear window.
¾ Climb out carefully.
n attached front and rear
own in a narrow aisle, the
ibly be unable to exit the truck
he event of acute danger, the
the truck via the rear window.
e, the rear window must be
mergency hammer.
3
2
1
t3921371
16 Operating Instructions – 394 807 10 01 EN – 07/2011
3
Overview
3 Overview
Identification plates
Identification plates
1 Nameplate
9
Lift mast n
10
Serial number (stamped into the
front right of the junction plate on
the overhead guard)
11
Drive axle identification plate
12
Engine
18 Operating Instructions – 394 807 10 01 EN – 07/2011
umber (adhesive label)
identification plate
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