F12-F16-F18

CONTENTS

Chapter 1

INTRODUCTION .......................................................................................................................................... 1.1

- Foreword .................................................................................................................................................... 1.2
- Important information ................................................................................................................................. 1.3
- After sales service ...................................................................................................................................... 1.4
 Service ..................................................................................................................................................... 1.4
 Spare parts .............................................................................................................................................. 1.4
 Warranty .................................................................................................................................................. 1.4
 Responsibility........................................................................................................................................... 1.4
 Transport ................................................................................................................................................. 1.5
- Vehicle identification .................................................................................................................................. 1.6
 Model ....................................................................................................................................................... 1.6
 Chassis number ....................................................................................................................................... 1.6
 Manufacturer's plate ................................................................................................................................ 1.7
 Lifting capacity plate ................................................................................................................................ 1.7

Chapter 2

SAFETY ........................................................................................................................................................ 2.1

- Basic safety remarks .................................................................................................................................. 2.3
- Safety of the operator and of bystanders ................................................................................................... 2.9
- Lubricants - hygiene and safety instructions .............................................................................................. 2.14
- Behaviour in emergency cases .................................................................................................................. 2.17
- Safety equipment of the "C.V.S. Lift Truck" ............................................................................................... 2.19

Chapter 3

DRIVER'S CAB ............................................................................................................................................ 3.1

- Cab ............................................................................................................................................................. 3.2
 Doors ....................................................................................................................................................... 3.2
 Main controls ........................................................................................................................................... 3.3
 Front left control panel ............................................................................................................................. 3.4
 Analog instrument panel .......................................................................................................................... 3.5
 Digital instrument display (option) ........................................................................................................... 3.6
 Front right instrument panel (with fuses) ................................................................................................. 3.7
 Front right instrument panel (with thermal circuit breakers) .................................................................... 3.8
 Side right control panel (Lift trucks with forks)......................................................................................... 3.9
 Side right control panel (Lift trucks with spreader) .................................................................................. 3.10
 Side right control panel with JOYSTICK (option) .................................................................................... 3.11

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Chapter 4

VEHICLE'S CONTROLS .............................................................................................................................. 4.1

- Driver's seat ............................................................................................................................................... 4.2
- Pneumatic driver's seat .............................................................................................................................. 4.3
- Seat belts ................................................................................................................................................... 4.4
- Steering wheel adjustment ......................................................................................................................... 4.5
- Right side control panel position adjustment ............................................................................................. 4.6
- Main switch................................................................................................................................................. 4.7
- Emergency engine cut-off .......................................................................................................................... 4.7
- Parking brake operation ............................................................................................................................. 4.8
- External lights control stalk ........................................................................................................................ 4.9
- Window washer/wiper controls .................................................................................................................. 4.10
- Heater and blower ...................................................................................................................................... 4.11
- Auxiliary heater "AIRTRONIC" (option) ...................................................................................................... 4.12
- Electronic Climate System E.C.S. ............................................................................................................. 4.14
- Operation of the digital display ................................................................................................................... 4.17
 Use of the menus .................................................................................................................................... 4.18
 Maintenance menu .................................................................................................................................. 4.22
 Diagnosis screens ................................................................................................................................... 4.23
- Working and signalling lights ..................................................................................................................... 4.24
- "Optional" Controls ..................................................................................................................................... 4.27
- General remarks ........................................................................................................................................ 4.27

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Chapter 5

VEHICLE'S OPERATION ............................................................................................................................ 5.1

- Introduction................................................................................................................................................. 5.2
- First operation hours - Break-in.................................................................................................................. 5.3
- Checks before starting ............................................................................................................................... 5.4
- Engine ........................................................................................................................................................ 5.5
 Engine start.............................................................................................................................................. 5.5
 Pre-heater system ................................................................................................................................... 5.6
 Engine stop .............................................................................................................................................. 5.6
- Use of the vehicle ....................................................................................................................................... 5.7
 Vehicle start ............................................................................................................................................. 5.7
 Vehicle stop ............................................................................................................................................. 5.8
 Gearbox selector lever ............................................................................................................................ 5.9
 Autoshift transmission ............................................................................................................................. 5.10
 During the drive ....................................................................................................................................... 5.11
 Parking brake........................................................................................................................................... 5.12
* Drive axle "KESSLER" .......................................................................................................................... 5.13
* Emergency brake release drive axle "KESSLER" ................................................................................ 5.13
* Drive axle "MERITOR" .......................................................................................................................... 5.14
* Emergency brake release drive axle "MERITOR" ................................................................................ 5.14
 Use of the inching pedal .......................................................................................................................... 5.15
 Control levers (version lift trucks with Forks) ........................................................................................... 5.16
 Control levers (version lift trucks with Spreader) ..................................................................................... 5.17
 Joystick (option) ....................................................................................................................................... 5.18
 Spreader extension/retraction (20' – 40') ................................................................................................ 5.19
 Safety system override controls .............................................................................................................. 5.20
 Steering ................................................................................................................................................... 5.21
* Emergency steering pump .................................................................................................................... 5.21
 Emergency mast lowering ....................................................................................................................... 5.22
 Towing the vehicle ................................................................................................................................... 5.23
 Lifting the vehicle ..................................................................................................................................... 5.23
 Vehicle transport and handling ................................................................................................................ 5.24
* Lift truck loading .................................................................................................................................... 5.25

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Chapter 6

MAINTENANCE ........................................................................................................................................... 6.1

- Maintenance instructions. .......................................................................................................................... 6.2
- Spare parts ................................................................................................................................................ 6.3
- General maintenance information .............................................................................................................. 6.3
- General safety rules ................................................................................................................................... 6.4
- During maintenance ................................................................................................................................... 6.6
- Hygienic safety rules .................................................................................................................................. 6.7
- Engine ........................................................................................................................................................ 6.10
 Lubrication ............................................................................................................................................... 6.11
* Oil and filter ........................................................................................................................................... 6.12
* Oil filter .................................................................................................................................................. 6.13
* Closed circuit engine vent system ....................................................................................................... 6.14
 Timing system.......................................................................................................................................... 6.15
 Injection ................................................................................................................................................... 6.15
 Drive belts ................................................................................................................................................ 6.16
 Cooling fan............................................................................................................................................... 6.17
- Air intake system ........................................................................................................................................ 6.18
 Turbocharger ........................................................................................................................................... 6.18
 Air cleaner................................................................................................................................................ 6.19
- Fuel system ................................................................................................................................................ 6.22
 Engine fuel filter ....................................................................................................................................... 6.22
 Fuel prefilter (water/fuel separator) ......................................................................................................... 6.23
 Bleeding of the fuel system ..................................................................................................................... 6.24
 Manual priming pump .............................................................................................................................. 6.26
 Fuel tank .................................................................................................................................................. 6.27
- Cooling system ........................................................................................................................................... 6.28
 Radiator ................................................................................................................................................... 6.28
 Coolant filter (if fitted) .............................................................................................................................. 6.29
 Coolant change ....................................................................................................................................... 6.30
 Antifreeze percentage check ................................................................................................................... 6.31
- Exhaust system .......................................................................................................................................... 6.32
 Catalytic converter ................................................................................................................................... 6.32
- Windshield washer system......................................................................................................................... 6.33
- Transmission .............................................................................................................................................. 6.34
- Propeller shaft ............................................................................................................................................ 6.38
- Drive axle ................................................................................................................................................... 6.39
 Differential gear ....................................................................................................................................... 6.39
 Wheel gears............................................................................................................................................. 6.41
- Steering axle .............................................................................................................................................. 6.42
 Wheel hub bearings ................................................................................................................................. 6.42
- Tyres and wheels ....................................................................................................................................... 6.44
 Tyre check ............................................................................................................................................... 6.44
 Wheel changing ....................................................................................................................................... 6.45
 Tyre specifications ................................................................................................................................... 6.48
 Inflating pressure ..................................................................................................................................... 6.48

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Chapter 6 (continuation)

- Mast............................................................................................................................................................ 6.49
 Chains...................................................................................................................................................... 6.51
* Lubrication ............................................................................................................................................. 6.51
* Tensioner adjustment ............................................................................................................................ 6.52
* Inspection .............................................................................................................................................. 6.53
* Cleaning ................................................................................................................................................ 6.55
- Hydraulic system ........................................................................................................................................ 6.56
 Hydraulic oil tank ..................................................................................................................................... 6.56
 Brake system ........................................................................................................................................... 6.59
* Accumulator .......................................................................................................................................... 6.60
* Brake pedal adjustment ........................................................................................................................ 6.60
 Hydraulic system for brake and inching pedal compensation ................................................................. 6.61

- Hydraulic cylinders ..................................................................................................................................... 6.61

- Air conditioning system .............................................................................................................................. 6.62
- Towing hook ............................................................................................................................................... 6.63
- Counterweights .......................................................................................................................................... 6.63
- Lubrication .................................................................................................................................................. 6.64
 Manual lubrication ................................................................................................................................... 6.64
 Centralised automatic lubrication ............................................................................................................ 6.65
- Electric system ........................................................................................................................................... 6.68
 Batteries ................................................................................................................................................... 6.68
 AC generator ........................................................................................................................................... 6.70
 Starter motor ............................................................................................................................................ 6.70
 Lighting system ........................................................................................................................................ 6.70
* Front light cluster ................................................................................................................................... 6.71
* Headlight beam alignment .................................................................................................................... 6.72
* Rear light cluster ................................................................................................................................... 6.73
* Working lights (20' – 40' ) ...................................................................................................................... 6.74
* Yellow flashing light ............................................................................................................................... 6.74
* Side box light and additional light in the cab (option) ........................................................................... 6.74
* Additional rear working lights ............................................................................................................... 6.75
* Additional front working lights .............................................................................................................. 6.76
* Spreader control lamps ......................................................................................................................... 6.76
* Roof lamp .............................................................................................................................................. 6.76
* Bulb table .............................................................................................................................................. 6.77
 Fuses [in the cab] .................................................................................................................................... 6.78
 Restorable fuses [in the cab] (option) ...................................................................................................... 6.79
 Fuses [in "QGS Box"] .............................................................................................................................. 6.80
 Location of electrical and electronic equipment ...................................................................................... 6.82
 Main electric cabinet "QGS Box" ............................................................................................................ 6.83
 Electronic system control unit "HEAD" .................................................................................................... 6.84
 Relays ...................................................................................................................................................... 6.84
 Control units and boards ......................................................................................................................... 6.85
- Cab ............................................................................................................................................................. 6.86
- General care and checks ........................................................................................................................... 6.87
- Tool kit ........................................................................................................................................................ 6.89
- Tightening torque tables............................................................................................................................. 6.90

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Chapter 7

LUBRICATION ............................................................................................................................................. 7.1

- Fuel, fluids and lubricants chart ................................................................................................................. 7.2
 Specifications of fuel, fluids and lubricants .............................................................................................. 7.2
 "NOTES" .................................................................................................................................................. 7.3
- Maintenance charts .................................................................................................................................... 7.5
 First maintenance steps .......................................................................................................................... 7.5
 Maintenance intervals .............................................................................................................................. 7.6
- Lubrication points of lift trucks with Forks .................................................................................................. 7.10
- Lubrication points of lift trucks with Spreader ............................................................................................ 7.12

Chapter 8

FIGURES AND DIAGRAMS ........................................................................................................................ 8.1

- Introduction................................................................................................................................................. 8.1
- Figures :
 Identification plates (standard vehicle) .............................................. Draw. 583480 .............................. 8.2
 Dimensions "F16" (with forks and cab in low position) ...................... Draw. 579839 .............................. 8.3
 Dimensions "F16" (with forks and cab in high position) .................... Draw. 579928 .............................. 8.4
 Dimensions "F16" (with Spreader) .................................................... Draw. 579827 .............................. 8.5
 Dimensions "F18" (with Spreader) .................................................... Draw. 580934 .............................. 8.6

- System diagrams:
 Hydraulic system
Steering, Lifting, Mast tilting .....................................................................................................Draw. 582106
 Variants of the hydraulic system ..............................................................................................Draw. 582134
 Options .....................................................................................................................................Draw. 582970
 Hydraulic diagram Brakes ........................................................................................................Draw. 581230

 Detailed wiring diagram - "F16" (with cab in low position)........................................................Draw. 584344

 Detailed wiring diagram - "F16 and F18" (with cab in high position) ........................................Draw. 586540

Chapter 9

SPECIFICATIONS ....................................................................................................................................... 9.1

- Introduction................................................................................................................................................. 9.1
- Technical data of the vehicle in standard execution ................................................................................. 9.2

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Chapter 10

MAINTENANCE REPORTS ......................................................................................................................... 10.1

- Introduction................................................................................................................................................. 10.1
 Maintenance reports ................................................................................................................................ 10.2

ENCLOSURES

- Electronic Control System “3B6 Model HEAD”

 Load limiter

- Transmission "ZF"
 Autoshift Transmission (shifting, speed etc.)
 "AEB" device (clutch backlash alignment)

ATTACHMENTS
- Spreader installed on the mast (if fitted)

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