Electric forklift truck

Original instructions

E20, E25, E30, E35

387 801 1501 EN – 12/2012

Linde − Your Partner
With over 100,000 fork lift trucks and ware-
house 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 tech-
nology, but also for their low energy and oper-
ating costs, which are up to 40 per cent lower
than those of their competitors.
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 – 387 801 1501 EN – 12/2012
Preface
g
Your local Linde partner can offer you a
complete package from a single source;
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 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
I
 Table of contents
g

1 Introduction
Your industrial truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Impermissible use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Description of use and climatic conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Technical description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Receiving the industrial truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Legal requirements for placing on the market ................................ 9
Service plan before initial commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2 Safety
Safety guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
In the case of tip-over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Emergency exit with attached rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Handling consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Competent person . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Fit attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fork carriage emergency lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Fork carriage emergency lowering for trucks with an elevated driver’s compart-
ment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3 Overview
Identification plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Truck overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Operating devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Display unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Switch panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

4 Operation
Instructions for running-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

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Pre-shift checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Standard equipment . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ 38
Entering and exiting the truck . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ 38
Adjusting the driver’s seat . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ 39
Adjusting the steering column . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ 42
Setting the time . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ 43
Seat belt . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ 44
Switching the truck on and off . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ 46
Driving (dual-pedal operation) . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ 48
Driving (single-pedal operation) . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ 51
Steering system . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ 54
Brake system . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ 55
Horn . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ 60
Joystick —Central-lever operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ 61
Joystick — Single-lever operation .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ 67
Emergency off switch . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ 74
Special equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Adjusting the driver’s seat equipped with air suspension . . . . . . . . . . . . . . . . . . . . . . . 74
Adjusting the driver’s seat with rotating device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Mast positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Steering angle display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Lift height restriction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Lifting system and attachments (single-lever operation with 3rd auxiliary hy-
draulics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Depressurisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
BlueSpot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Windscreen wipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Window heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Linde Forklift Data Management (LFM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Integrated charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Working under load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 116
Before load pick up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 117
Adjust fork arm distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 117
Load pick up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 119
Driving under load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 119
Setting down loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 121
Towing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 122

IV Operating Instructions – 387 801 1501 EN – 12/2012

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Before exiting the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Parking the truck securely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Loading / Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... .. 123
Removing the lift mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... .. 123
Driving without the lift mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... .. 124
Crane loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... .. 125
Transportation by lorry or low loading trucks . . . . . . . . . . . . . . . . . . . . . . . . . . . ... .. 126

5 Maintenance
General remarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Inspection and maintenance data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Recommendations for consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Inspection and maintenance overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
One-off service plan after 1000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Service plan for every 1000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Service plan for every 3000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Service plan for every 6000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. ............... .. 143
Checking the planetary transmission oil level .............. ............... .. 143
Checking the planetary transmission for leaks. ............. ............... .. 145
Changing the oil in the planetary transmission .............. ............... .. 146
Chassis, bodywork and fittings . . . . . . . . . . . . . . . . . . . . . .... ............... .. 149
Checking the mountings . . . . . . . . . . . . . . . . . . . . . . . . . . .... ............... .. 149
Cleaning the industrial truck . . . . . . . . . . . . . . . . . . . . . . . .... ............... .. 150
Opening and closing the battery hood . . . . . . . . . . . . . . . . .... ............... .. 151
Checking the condition and correct function of the seat belt .... ............... .. 153
Check the tilt cylinder bearings for wear . . . . . . . . . . . . . . .... ............... .. 154
Check and oil other bearings and joints . . . . . . . . . . . . . . . .... ............... .. 156
Other cleaning and greasing . . . . . . . . . . . . . . . . . . . . . . . .... ............... .. 156
Filling up the washer system / water tank . . . . . . . . . . . . . . .... ............... .. 157
Chassis frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 158
Checking the tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 158
Checking the condition of the antistatic belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 160
Wheel change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 161
Tightening the wheel fastenings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 162
Cleaning and lubricating the combined axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 163
Checking the drive axle heat sinks for contamination, cleaning if necessary . . . . . . . .. 164
Operating devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Checking the brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

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Check bellows on joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Checking and oiling the pedal group and linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Electrics / Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Checking the battery charge status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Charging the battery using an external battery charger . . . . . . . . . . . . . . . . . . . . . . . . 173
Active charging ventilation unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Battery replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Battery replacement — truck with elevated driver’s compartment . . . . . . . . . . . . . . . . . 184
Checking the main contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Adjusting the accelerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Checking the fans for function and contamination, and cleaning if necessary . . . . . . . . 189
Checking the condition and secure positioning of electric cables, cable connectors and
connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............... ............ 194
Checking oil level for hydraulic system . . . . . . . . . ............... ............ 194
Checking the hydraulic system for leaks . . . . . . . . ............... ............ 195
Changing the hydraulic oil . . . . . . . . . . . . . . . . . . ............... ............ 196
Checking the breather filter for leaks . . . . . . . . . . . ............... ............ 198
Changing the breather filter . . . . . . . . . . . . . . . . . ............... ............ 198
Checking the control unit for correct function . . . . . ............... ............ 199
Replacing the high-pressure filter . . . . . . . . . . . . . ............... ............ 200
Changing the suction filter . . . . . . . . . . . . . . . . . . ............... ............ 202
Check the tension of double hoses . . . . . . . . . . . . ............... ............ 203
Load lift system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Lift mast/protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Tightening the lift mast/ mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Lift mast — cleaning the chain and applying chain spray . . . . . . . . . . . . . . . . . . . . . . . 209
Lift mast — adjusting the chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Lift mast, chains, lift cylinder and end stops:Checking the mountings, condition and
function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Check fork arms and arm safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Cleaning and lubricating the sideshift (special equipment), checking the fastening . . . . 213
Checking the sideshift (special equipment) for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Checking the slide guides on the sideshift (special equipment) for wear . . . . . . . . . . . . 214
Cleaning and lubricating the fork prong positioner (special equipment), checking the
mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Checking the fork prong positioner (special equipment) for wear . . . . . . . . . . . . . . . . . 216
Self-help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Malfunctions during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Fuses - Basic equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

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Fuses -Special equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... . . 220

Diagnostic connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... . . 225
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... . . 226
Shutting down the industrial truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... . . 230
Disposal of old trucks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... . . 231

6 Technical data
Type sheet E 20/500, as at 01/2012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Type sheet E 20/600H, as at 01/2012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Type sheet E 25/500, as at 01/2012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Type sheet E 25/600 H, as at 01/2012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Type sheet E 25/500 L, as at 01/2012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
Type sheet E 25/600 HL, as at 01/2012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
Type sheet E 30/500, as at 01/2012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Type sheet E 30/500 L, as at 01/2012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Type sheet E 30/600 H, as at 01/2012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
Type sheet E 30/600 HL, as at 01/2012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
Type sheet E 35/500 L, as at 01/2012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
Type sheet E 35/500 HL, as at 01/2012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Type sheet E 30/600 HL, elevated driver’s compartment, as at 12/2012 . . . . . . . . . . . . 270
Truck configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
Tyre variants andrim sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
Load capacity diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Lift mast data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Lift mast data 387 series elevated driver’s compartment . . . . . . . . . . . . . . . . . . . . . . . 280
Additional capacity rating plate for attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
Vibration characteristics for bodily vibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
Noise emission values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

Operating Instructions – 387 801 1501 EN – 12/2012 VII

 1

Introduction
1 Introduction
Your industrial truck
Your industrial 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 the relevant EC
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 instructions contain every-
thing you need to know about commissioning,
driving and maintenance.
A number of items of special equipment have
their own operating instructions, which are
supplied along with these devices.
Please observe the operation information that
corresponds to your industrial truck version
and 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 per-
formed in the registration document for the
industrial truck; this is essential for any war-
ranty claims.
The designations used in the text: front - rear
- left - right - always refer to the installation
position of the parts described, with forwards
as the drive direction (fork arms forwards) for
the industrial truck.
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.
Servicing should only be carried out by quali-
fied personnel approved by the manufacturer
(specialists).
2 Operating Instructions – 387 801 1501 EN – 12/2012
With orders for parts, please specify the
following along with the parts numbers:
Industrial truck
model:
Production number /
year of manufacture:
Handover date:
The production number should also be speci-
fied for parts from the following units: lift mast,
drive axle and steering axle.
Lift mast number:
Lift mast lift:
Drive axle number:
Steering axle
number
When you receive the industrial 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 spare
parts from the manufacturer. This is the only
way to guarantee that your industrial 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 industrial truck
only to your authorised dealer, stating your
mailing address.
The company, i.e. the manufacturer, is con-
stantly engaged in the further development of
its products. We ask for your understanding
that figures and technical data are subject to
technical modification in terms of form, equip-
ment 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.
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.
Intended use
The industrial truck may only be used as
permitted.
The industrial truck is used for moving and
lifting the loads indicated on the capacity rating
plate.
Damages and defects
Damages and other defects to industrial trucks
or to attachments must be reported to the
Supervisor immediately. Industrial trucks and
attachments which are not safe to operate
may not be used until they have been properly
repaired.
Safety installations and switches may not be
removed or rendered unusable. Specified set-
tings may only be changed with the approval
of the manufacturer.
Danger areas
Danger areas are those areas in which
persons are in danger as a result of the
movements of industrial trucks, their operating
equipment, their load carrying devices (e.g.
their attachments) or the loaded goods. This
also includes the area which can be reached
by falling goods or lowering or falling operating
equipment and devices.
No other persons may stand in the danger
area of an industrial truck.
Working areas
Only the areas approved by the operator or his
representative may be used for transportation
purposes. Loads may only be deposited or
stored at the intended places.
In operating areas with magnetic fields that
have a magnetic flux density greater than 5
mT, unintentional truck and lift mast move-
ments cannot be entirely excluded under un-
favourable circumstances. In this case com-
Operating Instructions – 387 801 1501 EN – 12/2012
Introduction 1
Intended use
ponents developed especially for this purpose
must be used.
Driving routes
Driving routes shall be sufficiently paved,
level and free of objects. Drain channels and
railways crossings, etc., shall be levelled and,
if necessary, covered with ramps in such a way
that they can be driven over without bumps as
far as possible.
Industrial trucks shall only be used on routes
without sharp curves, excessive slopes and
gates which are too narrow or too low.
Inclines used by industrial trucks shall not ex-
ceed the limits specified by the manufacturer
and must have an adequately rough surface.
Level and smooth transitions at the upper and
lower end shall prevent the load from touching
the floor or causing damages to the chassis.
The admissible area and point load of driving
lanes or routes may not be exceeded. There
shall be an adequate clearance between the
highest parts of industrial trucks or the load
and the fixed parts of the surrounding areas.
The EU Directive 89/654/EEC (Minimum
Regulations for Health and Safety at Work)
shall be observed. The respective national
regulations apply for non-EU countries.
Danger points on driving lanes or routes shall
be secured or marked by the customary road
traffic signs and by additional warning signs, if
necessary.
When driving on public roads, the correspond-
ing regulations must be observed, as well as
country-specific restrictions for winter road
conditions.
Fire protection
The operator is responsible for adequate
fire protection in the vicinity of the industrial
3
1 Introduction
Impermissible use
truck. Depending on the form of use, he is
responsible for additional fire protection on the
industrial truck. Enquiries should be directed
to the responsible supervisory authority in
case of doubt.
Attachments
Attachments shall only be used as permitted.
The driver shall be instructed in the handling
of attachments.
The attachment operating instructions are en-
closed for trucks that are delivered from the
factory with an attachment. Before commis-
sioning a truck with an attachment, you must
check that loads are handled securely. De-
pending on the type of attachment, it may be
necessary to make adjustments, e.g. pres-
sure settings or adjusting stops and operating
speeds. See the attachment operating in-
structions for the corresponding instructions.
If attachments are not supplied with the indus-
trial truck, the specifications of the industrial
truck manufacturer and the attachment manu-
facturer must be observed.
The attachments and the connection of power
supplies for powered attachments may only
be made by specialists in accordance with
Impermissible use
DANGER
High risk of property damage, injury and death.
Avoid impermissible use.
The operating company or driver, and not the
manufacturer, is liable if the truck is used in a
manner that is not permitted.
The following list is exemplary and is not
intended to be exhaustive.
4 Operating Instructions – 387 801 1501 EN – 12/2012
the specifications of the manufacturer. The
proper functioning of the attachments shall be
checked after each installation before initial
use.
The permissible carrying capacity of the
attachments and the permitted load of the
industrial truck (carrying capacity and load
moment) combined with the attachments shall
not be exceeded., refer to additional capacity
rating plate.
Modifications, in particular attachments or
conversions, are not permitted to be made to
the industrial truck without the manufacturer’s
approval.
Trailers
Industrial trucks may only be used to tow trail-
ers if they are intended for this purpose by the
manufacturer and if they are fitted with the
appropriate trailer coupling. The maximum
towed load specified in the operating instruc-
tions for unbraked or braked trailers must not
be exceeded.
The towing industrial truck must be operated
in such away that safe driving and braking
of the towed vehicle is ensured for all driving
movements.
It is not permitted:
• To use the truck to transport people (if the
truck is not designed for this purpose)
• in areas where there is a risk of fire of
explosion
• for stacking/unstacking operations on
slopes
• To stand on the fork arms when raised
• To exceed the truck’s maximum load
capacity
• To increase the truck’s load capacity, e.g.
by attaching an additional weight.

Description of use and climatic conditions
Normal use
• Indoor and outdoor use
• Ambient temperature in tropical and Nordic
regions ranging from -10 °C to 40 °C
• Use at up to 2000 metres above sea level.
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.
Operating Instructions – 387 801 1501 EN – 12/2012
Introduction 1
Description of use and climatic conditions
Special use (partly with special mea-
sures)
• Ambient temperature in tropical regions to
40 °C
• Cold store version to -32 °C
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 here must be complied
with as otherwise environmental 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
section in these operating instructi-
ons.
For your safety, additional symbols are also
used. Please heed the various symbols.
5
1 Introduction
Technical description
Technical description
Electric forklift trucks in the 387 series are
designed to handle loading and palletising
operations for loads up to 2.0 t with the E 20,
2.5 t with the E 25, 3.0 t with the E 30 and 3.5 t
with the E 35.
NOTE
Please refer to each load capacity diagram for
the load centre of gravity data.
A driver’s compartment with the most up-to-
date ergonomic design and the energy-saving
digital controller (LDC) included as standard
ensure that this industrial truck is a valuable
piece of equipment.
It is characterised by a compact design,
good visibility, maximum stability against
overturning and cornering stability.
There is an electric forklift truck in this version:
Combined axle
E 20, E 25, E 30, E 35
If you require further information on the differ-
ent versions, please contact your authorised
dealer.
The combined axle ensures a large movement
range for the steering axle, good ground
contact and reliable handling for both inside
and outside operations, even when used on
inferior road surfaces.
The truck has an electric drive unit and an
electric motor with a hydraulic pump for the
steering and working hydraulics.
Drive
Front-wheel drive via two electric traction
motors combined in one compact axle with
automatic corner shift, which drive the right
and left-hand drive wheel via the respective
wheel gear.
The power required is supplied by the battery
installed in the truck.
6 Operating Instructions – 387 801 1501 EN – 12/2012
Thanks to the dual pedal system, continuously
variable control of forwards and reverse travel
is possible via the digital controller.
Steering
Kickback-free steering of the truck, which is
sensitive and virtually free of play, is carried
out manually using the small steering wheel
of the hydrostatic steering on the steering
cylinder of the steering axle.
Hydraulic system
The hydraulic system consists of an electric
motor with a hydraulic pump for the steering
and for the lift and tilt cylinders of the lift mast,
a hydraulic oil tank with a breather filter and
an oil dipstick, as well as a suction filter and
pressure filter.
Operation
With one accelerator pedal each for forwards
travel and reverse travel, the traction motors
are controlled steplessly from a standstill to
maximum speed in both drive directions.
The driver always has both hands free for
steering and controlling operational move-
ments.
This results in fast reversing and efficient
stacking.
A joystick is used to control the lifting, lowering
and tilting operational movements.
There is also another joystick for operating the
additional attachments.
If desired, all operational movements (lifting,
lowering and tilting) can also be controlled with
single lever operation.
Brakes
The truck is equipped with three independent
brake systems that act on the front axle:
 Introduction 1
Technical description

• The hydraulic service brake, which is These systems allow the truck to be secured
actuated by using the stop pedal. sufficiently against rolling away on gradients
• The electrohydraulic parking brake, which of up to 10%.
is activated manually by using the parking
brake switch. Electrical system
• The electric regenerative brake, or LBC
The well-protected electrical system is posi-
(Linde Brake Control) for energy recovery,
tioned at the front, under the right-hand truck
which is automatically actuated when the
console.
accelerator pedal is released or when the
drive direction is changed. On request, the The necessary energy is supplied by the 80V
LBC braking effect can be changed using battery built into the chassis.
the diagnostic program.
A hinged side access panel allows the battery
In addition, the truck has an automatic brake, to be changed quickly and easily.
which is activated after a short delay when the
accelerator pedal is released.

Operating Instructions – 387 801 1501 EN – 12/2012 7

1 Introduction
Receiving the industrial truck

Receiving the industrial truck

Before the industrial truck leaves our factory,
it undergoes a thorough inspection process in
order to guarantee that it is in perfect condition
and that it contains all of the equipment
specified in the order.
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.
CAUTION
Risk of overload on battery female connector.
For trucks that are supplied from the factory without
batteries, a battery female connector is also requi-
red in the MRC version for increased current-car-
rying capacity.
Contact your authorised dealer.
NOTE
In trucks that leave our factory without a
lift mast, additional stop screws for speed
limitation are located under the forwards
and reverse accelerator pedals (dual-pedal
operation) or under the accelerator pedal
(single-pedal operation). These must be
removed after installing the lift mast; see the
section entitled Driving without a lift mast.
The following technical documents belong to
each industrial truck:
• Operating instructions for the truck
• Operating instructions for the attachment
(only applies to trucks delivered from the
factory with an attachment)
• EC declaration of conformity
• Rules for proper use of industrial trucks
(VDMA)

8 Operating Instructions – 387 801 1501 EN – 12/2012

 Introduction 1
Legal requirements for placing on the market

Legal requirements for placing on the market

Declaration

Linde Material Handling GmbH

Carl-von-Linde-Platz
D-63743 Aschaffenburg, Germany

We declare that the machine

Industrial truck according to these operating instructions

Model according to these operating instructions

complies with the most recent version of machinery directive 2006/42/EC.

Personnel authorised to compile the technical documents:

see EC declaration of conformity

Linde Material Handling GmbH

EC declaration of conformity shown explains the conformity with the re-

The manufacturer declares that the truck com-
plies with the requirements of the EC machin-
ery directive and any other EC directives, if
applicable, that are valid at the time of plac-
ing on the market. 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
quirements 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 – 387 801 1501 EN – 12/2012 9

1 Introduction
Service plan before initial commissioning

Service plan before initial commissioning

Carried
out
 
Chassis frame
Check wheel fastenings and tighten.
Test the brake system (service and parking brake).
Check the steering system.
Electrics / Electronics
Battery: Check charge state, acid level and acid density.
Check the electrical system (e.g. lighting, warning units and any additional special
equipment).
Check traction functions (forwards and reverse travel).
Check the emergency stop switch.
Hydraulics
Hydraulic system: Check the oil level.
Subsequent tasks
Perform a test drive and functional test.

10 Operating Instructions – 387 801 1501 EN – 12/2012

 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
himself with the following:
• The operating conditions of the working
area
• The specific technical characteristics of the
industrial truck
• The operation of attachments
Practise driving, control and steering oper-
ations with an unloaded truck until they are
completely mastered. Only then may a loaded
industrial truck be used for practice.
Safety information
DANGER
The industrial truck must not be used by unauthori-
sed persons.
Only trained persons and those authorised for
operation may have access to the industrial truck.
12
DANGER
In operating areas with magnetic fields that have a
magnetic flux density greater than 5 mT, unintentio-
nal truck and lift mast movements cannot be entirely
excluded under unfavourable circumstances.
For magnetic fields with magnetic flux densities
greater than 5 mT, components developed espe-
cially 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
When retrofitting a 3rd auxiliary hydraulic system,
using solutions other than those recommended by
the truck manufacturer will render CE conformity
null and void, and is therefore expressly prohibited.
Industrial trucks may only be retrofitted with a 3rd
auxiliary hydraulic system with the approval of the
truck manufacturer.
DANGER
Any additional bores or welding to the overhead
guard on 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
Risk of overloading the battery female connector.
This means that only the embedded battery female
connector (MRC socket) that has been approved
by the manufacturer may be used.
Make sure that the correct battery female connector
is connected, especially after changing the battery.
Contact your authorised dealer.
Operating Instructions – 387 801 1501 EN – 12/2012

CAUTION
Welding operations on other parts of the truck can
cause damage to the electronics.
Therefore, always disconnect the battery and all
connections to the electronic controls beforehand.
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 com-
pression and must never be opened without instruc-
tions. Any kind of damage, lateral forces, buckling,
temperatures in excess of 80°C and heavy conta-
mination must be avoided under all circumstances.
Damaged or defective gas springs must be repla-
ced immediately.
Contact your authorised dealer.
WARNING
In trucks with an accumulator, serious injuries may
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 the operating time, components
carrying exhaust air may become
hot.
Therefore wear protective equip-
ment.
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 attach-
ments comply with current safety regulations.
Nevertheless, even when the truck is used for
its proper purpose and all instructions are fol-
lowed, some residual risk cannot be excluded.
Operating Instructions – 387 801 1501 EN – 12/2012
Safety 2
Residual risks
WARNING
The industrial truck working area must be adequa-
tely lit.
If it is not sufficiently lit, working spotlights must be
installed to ensure that the driver can see properly.
CAUTION
Various pieces of special equipment are connected
to the "speed reduction" special function. This is
simply an assistance function, and the driver must
not rely solely on this function during operation.
The driver is always responsible for safe operation.
CAUTION
If the driver has active medical equipment, e. g.
pace makers or hearing aids, these may be impai-
red.
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 extinguis-
her, make sure that you familiarise yourself
with it in case of an emergency. Handling in-
formation is provided on the fire extinguisher.
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.
13
2 Safety
Stability
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,
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 speeds,
• moving with the load raised,
• moving with a load that is protruding to the
side (e.g. sideshift),
In the case of tip-over
• Stay buckled up
• Don’t jump
• Hold on tight
• Brace feet
• Lean away
14
• 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,
• Risk caused by insufficient maintenance or
testing,
• Risk caused by using the wrong consum-
ables.
• turning and driving diagonally across
descents or ascents,
• driving on descents or ascents with the load
on the downhill side,
• loads that are too wide,
• driving with a swinging load,
• ramp edges or steps.
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.
Operating Instructions – 387 801 1501 EN – 12/2012
 Safety 2
Emergency exit with attached rear window

Emergency exit with attached

rear window
NOTE
If a truck with an attached front and rear
window breaks down in a narrow aisle, the
driver may not be able to exit the truck from the
side.
In the event of extreme danger, the driver can
exit the truck via the rear window.
The rear window can be opened for this
purpose:
 Actuate linkage (1) to the left.
Both interlocks on the rear window are un-
locked simultaneously via the linkage.
 Using light pressure at the bottom, push out
the window from inside until it remains in the
top position.
 Climb out carefully towards the rear.

Handling consumables
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 bring flammable consumables into
contact with hot objects or a naked flame.
• When topping up consumables, use only
clean containers.
• Observe the manufacturer’s instructions
relating to safety and disposal.
• Avoid spilling.
• 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 with the statutory provisions.
• Before performing greasing, filter changes
or any work on the hydraulic system,

Operating Instructions – 387 801 1501 EN – 12/2012 15

2 Safety
Competent person

carefully clean the area around the part WARNING

involved.
The improper handling of coolant and coolant addi-
• Dispose of used spare parts in an environ- tives presents a risk to health and the environment.
mentally friendly manner. Observe the manufacturer’s instructions without
fail.
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 The competent person is able to assess the
of industrial trucks who has: condition of industrial trucks in terms of health
• Successfully completed training, as at least and safety.
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 techni-
cal 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 or-
der to ensure proper condition.

16 Operating Instructions – 387 801 1501 EN – 12/2012

 Safety 2
Fit attachments

There is a recommendation setting out the

scope of the periodic safety inspection —FEM
4.004 of the European Industrial Truck Asso-
ciation— 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 inspections is added
by the manufacturer in accordance with
the specific truck type. Please ask your
authorised dealer to carry out this work.

Fit attachments
Only specialists are permitted to fit the at-
tachment and connect the energy supply for
power-driven attachments.

Mechanical connection
For hung attachments, the attachment and
fork carriage must be of the same class.

Class Load Load

As per capacity centre of a b c2 i2 h3
Design
ISO Truck gravity mm mm mm mm mm
2328 kg mm

400 and A 76
1 0 - 999 331 16 13 305
600 B 114

Operating Instructions – 387 801 1501 EN – 12/2012 17

2 Safety
Fit attachments

Class Load Load

As per capacity centre of a b c2 i2 h3
Design
ISO Truck gravity mm mm mm mm mm
2328 kg mm

1000 - 500 and A 76

2 407 16 13 381
2500 600 B 152

2501 - 500 and A 76

3 508 21.5 16 476
4999 600 B 203

5000 - A 127
4 600 635 25.5 19 597
8000 B 254

8001 - A 127
5 600 728 34 25 678
10999 B 257

Integrated attachments are made to match the

installed lift mast. When fitting attachments
retroactively, the correct attachment and
all necessary parts from the industrial truck
manufacturer—especially lift mast rollers and
chain holders—must be available.
Contact your authorised dealer.

Hydraulic connection
WARNING
Hydraulic system is under pressure. Risk of injury.
Wear protective equipment.

CAUTION
Damage to the hydraulic system through contami-
nation.
When connecting hydraulic lines, ensure they are
clean.

Before connecting hydraulic lines or hydraulic

couplings, the hydraulic system must be
depressurised.
Without depressurisation:
 Place a collection container underneath.
 Carefully release connection of the hy-
draulic lines.
When the pressure is reduced, hydraulic oil
escapes.

18 Operating Instructions – 387 801 1501 EN – 12/2012

 Safety 2
Fit attachments

 Disconnect hydraulic lines.

 Connect hydraulic lines to attachment.
With depressurisation: (special equipment)
 Depressurise the hydraulic lines as de-
scribed in section "Depressurisation".
 Disconnect hydraulic lines.
 Connect hydraulic lines to attachment.

Additional capacity rating plate

Attachments alter the load capacity and
stability of the truck. For each attachment,
an additional capacity rating plate must be
mounted where the driver can see it that
indicates the load capacity of the truck with
attachment; see section "Additional capacity
rating plate for attachments".
A symbol sticker for the relevant attachment
must be affixed behind the actuating lever.

Operating Instructions – 387 801 1501 EN – 12/2012 19

2 Safety
Fork carriage emergency lowering

Fork carriage emergency

lowering
In the event of a malfunction, it may be
necessary to lower the fork carriage manually.
The control valve block (3), located under-
neath the bottom plate on the right-hand side
of the truck, is equipped with an emergency
lowering screw (1). This is secured and sealed
with a self locking nut (2).
 Remove the rubber mat from the bottom
plate.
 Remove floor plate from truck.

DANGER
Risk of accident when lowering the 1 Emergency lowering screw
fork carriage. 2 Self locking nut
3 Control valve block
People must not stand near the fork
arms when they are being lowered.
Leave the socket wrench on the
emergency lowering screw to enable
lowering to be interrupted at any time.

Using an 8 mm AF socket wrench, slowly turn

the emergency lowering screw (1) max. three
turns anti-clockwise until the fork carriage is
fully lowered. In doing so, the locking device
of the self-locking nut is destroyed.

 Remove the old emergency lowering screw

(1) from the valve block, together with the
self-locking nut (2).
 Using an 8 mm AF socket wrench, turn the
new emergency lowering screw (1) to the
stop by applying 10 Nm, and secure with
new self-locking nut (2) (tightening torque
9.5 Nm).
 Install the bottom plate in the truck.
 Place the rubber mat on the bottom plate.

20 Operating Instructions – 387 801 1501 EN – 12/2012

 Safety 2
Fork carriage emergency lowering for trucks with an elevated driver’s compartment

Fork carriage emergency

lowering for trucks with an
elevated driver’s compartment
In trucks with an elevated driver’s compart-
ment, emergency lowering is performed using
a threaded rod.
 Release the rubber panelling (1) on the
right-hand side and fold it out to the left.
The threaded rod can be accessed via the
opening.

 Turn the knurled nut (4) under the support

bracket (3) downwards by about 20 mm (a
thumb’s width).
 Remove floor plate from truck.

DANGER
Risk of accident when lowering the
fork carriage.
People must not stand near the fork
arms when they are being lowered.
Leave the socket wrench on the
emergency lowering screw to enable
lowering to be interrupted at any time.

 Using the socket wrench, turn the nut (2)

clockwise until the fork carriage begins to
lower and is lowered fully.
 When the fork carriage is lowered, turn the
nut (2) back anticlockwise, and push the
threaded rod (1) downwards until the lever
(5) has returned to approximately the 5
o’clock position.

Operating Instructions – 387 801 1501 EN – 12/2012 21

2 Safety
Fork carriage emergency lowering for trucks with an elevated driver’s compartment

 Retighten the rim nut (4) by turning it

clockwise to the stop on the support bracket
(3).
As the locking device of the self-locking nut is
destroyed when the fork carriage is lowered
manually, the emergency lowering screw and
the self-locking nut under the lever (5) must be
replaced.
 Using an 8 mm AF socket wrench, turn the
new emergency lowering screw to the stop
by applying 10 Nm, and secure with new
self-locking nut (tightening torque 9.5 Nm).
Contact your authorised dealer.

22 Operating Instructions – 387 801 1501 EN – 12/2012

 3

Overview
3 Overview
Identification plate

Identification plate

1 Identification plate

24 Operating Instructions – 387 801 1501 EN – 12/2012

 Overview 3
Identification plate

NOTE
The CE mark confirms compliance with the EC
machinery directive and with all regulations
applicable to the truck.

1 Nameplate
2 Manufacturer
3 Model / Production no. / Year of manufac-
ture
4 Tare weight
5 Max. battery weight / min. battery weight
6 Ballast weight
7 Placeholder for data matrix code
8 CE mark
9 Nominal driving power
10 Battery voltage
11 Rated capacity

Operating Instructions – 387 801 1501 EN – 12/2012 25

3 Overview
Truck overview

Truck overview

1 Lift mast 13 Counterweight

2 Tilt cylinder 14 Step
3 Overhead guard 15 Pedals / reverse accelerator pedal
4 Display unit 16 Left wheel gear
5 Rear-view mirror 17 Fork carriage
6 Load capacity diagram 18 Sideshift
7 Switch panel / toggle switch for special 19 Fork arms
equipment 20 Lift mast chain
8 Rotating beacon 21 Front left working spotlight
9 Driver’s seat with armrest and operating 22 Steering column adjusting knob
console 23 Steering column
10 Rear flap 24 Flasher unit / windscreen wiper switch
11 Left tail light (LED) 25 Steering wheel
12 Towing pin 26 Handhold

26 Operating Instructions – 387 801 1501 EN – 12/2012

 Overview 3
Operating devices

Operating devices

1 Steering column adjusting knob 8 Horn signal button

2 Steering wheel 9 Armrest
3 Parking brake switch 10 Forward travel accelerator pedal
4 Key switch 11 Stop pedal
5 Emergency off switch 12 Reverse travel accelerator pedal
6 Joystick for working hydraulics 13 Driver’s seat with seat switch
7 Joystick for attachments (special equip-
ment)

NOTE
The switches for lighting, windscreen wipers
and the heating system (special equipment)
are located in the top right-hand area of the
overhead guard at the same level as the
display unit.

Operating Instructions – 387 801 1501 EN – 12/2012 27

3 Overview
Display unit

Display unit

28 Operating Instructions – 387 801 1501 EN – 12/2012

 Overview 3
Display unit

1 Display unit 19 Remaining travel time display for electric

2 Direction indicator light (green) forklift trucks active
3 Engine temperature at upper limit (red) 20 No function
4 Neutral warning light (red)/no function 21 Speed display (km/h / mph)
5 Error in electrical controller or integrated 22 Function key
battery charger (red) 23 Reset button
6 Drive direction forwards for single-pedal 24 Clock/remaining travel time/speed display
trucks (green) 25 No function
7 "Lift height restriction" special equipment 26 Parking brake activated
(green/red) or 27 Operating hours until next service
"Electronic joystick locked" (red) 28 Seat belt not fastened
8 Speed reduction activated (green) 29 Text field for error code
9 Assist (red) 30 Lift mast positioning activated (special
10 Drive direction backwards for single-pedal equipment)
trucks (green) 31 LCD display with backlight (orange)
11 Refer to truck documentation (yellow) 32 Neutral warning light (yellow)
12 Battery discharge indicator (green/red) 33 Rear cover monitoring
13 No function 34 Prewarning: engine temperature increasing
14 Steering position display active (yellow)
15 Operating hours display 35 Battery charging via integrated charger
16 Hour meter active finished — green (special equipment)
17 Service interval exceeded 36 Integrated charger in charging mode —
18 Clock display (am/pm) yellow (special equipment)

The display unit (1) is mounted to the top right-hand side of the overhead guard. It is positioned
within the driver’s field of vision and provides centralised information about all functions of the
truck. Once the key switch has been switched on, a self-test of the display unit is then performed.
During the self-test, all indicator lights and LCD displays are activated.

Display element
(2) Direction indicator light
(green)
(3) Indicator light (red),
engine temperature at upper
limit
Possible malfunctions
Function
Remedy
- The green direction indicator
light is used in trucks with
lighting devices to check for
activated direction indicators
- Lights up when the direction
indicator switch is actuated on
the steering wheel
- The red indicator light Fan motor faulty
illuminates if the permissible
temperature limit is reached at Thermal switch faulty
an engine or power module Switch off the buzzer via the
- The text display shows an reset button (22)
error code that enables the
corresponding component to
be located
- When the maximum
Contact your authorised dealer.
permissible temperature limit
is reached, the warning buzzer
built into the display unit is also
activated

Operating Instructions – 387 801 1501 EN – 12/2012 29

3 Overview
Display unit
Display element
(4) Neutral warning light
(red), no function
(5)Indicator light (red), error electrical controllers or during
in the electronic control unit
or integrated charger
(6) Indicator light (green),
drive direction forwards
(single-pedal version)
(7) Indicator light (green/red),
lift height restriction
function/error
or
"Electronically locked
joystick", green (special
equipment)
(8) Indicator light (green),
speed reduction activated
(special equipment)
(9) Indicator light (red)
"Assist"
(special equipment)
(10)Indicator light (green),
reverse drive direction in
single-pedal trucks
(11)Indicator light (yellow), due to an operating error or
refer to the truck documenta- malfunction An error code
tion
30
Possible malfunctions
Function
Remedy
The function can be pro-
- The red indicator light
grammed via the truck diag-
provides optional information
nostics.
about necessary servicing
Contact your authorised dealer.
- Lights up if errors occur in the
battery charger operation. Contact your authorised dealer.
Error code is displayed in the
text field (29).
- Lights up if the forwards
direction is selected via the
Contact your authorised dealer.
drive direction selector in
single-pedal trucks.
- Lights up (green) when the Faulty sensor system.
specified lift height is reached
Faulty joystick.
- Lights up (red) if an error
occurs in the sensor system
Indicator light goes out when
joystick is locked. Contact your authorised dealer.
Display lights up when joystick
is unlocked.
- The green indicator light
signals that the speed has
been reduced via an optional
switch
- The red indicator light
provides optional information Contact your authorised dealer.
about servicing.
- Lights up if the reverse
direction is selected via the
drive direction selector in
single-pedal trucks
Seat switch or FDE unit not
activated and accelerator pedal
actuated
- When the yellow indicator
Battery charger connected to
light lights up, this may be
system voltage and accelerator
pedal actuated
is usually shown in the text Tilt angle sensor alignment
display (29) in conjunction with process active
this indicator light. New truck control unit sensor
system not yet aligned.
Contact your authorised dealer.
Operating Instructions – 387 801 1501 EN – 12/2012

Display element
(12)Battery discharge
indicator — LED bar display
(green/red)
(13) Symbol for "particle
filter"
(14) Steering position display display
symbol display activated
(15) Operating hours display
(16) Operating hours active
symbol
(17) Service interval
exceeded symbol
Operating Instructions – 387 801 1501 EN – 12/2012
Overview 3
Display unit
Possible malfunctions
Function
Remedy
- Shows the current charge
status of the battery The
battery discharge status is
shown by an LED bar display
in the display unit.
- The 7 green LEDs go out
one after another as the
battery becomes increasingly
discharged
- Once the battery is 80%
discharged, the red LED with
the battery symbol lights up.
When the battery has
discharged even further
(residual battery capacity <
20%), the red LED flashes.
- No function
- The steering angle is shown
on the second line of the text
- If the steering angle display is
switched on, the symbol (14)
lights up in the display unit.
If a faulty display unit is
replaced, the operating hours
that have been incurred up to
that point must be recorded.
- Shows the operating hours of
Affix the information to an
the truck This display is used
embossed strip near the display
to show the truck’s operating
unit.
time and when performing
There is also the option of
inspection and maintenance
updating the new display unit
work.
at a later time.
The display can only be reset
using the diagnostic program.
Contact your authorised dealer.
- The hour meter symbol
flashes and the operating
hours are counted when the
truck is switched on and the
seat switch is activated
Implement the corresponding
Signals that the service interval service interval.
has been exceeded. Contact your authorised dealer.
31
3 Overview
Display unit
Display element
(18)Clock display symbol
(am/pm)
(19)Display for electric forklift
truck remaining travel time
active
(20) Symbol has no function
(21)Speed display (km/h /
mph)
(22) Function key
(23) Reset button
(24) Time /remaining travel
time/speed display
(25)"Do not start the engine"
symbol
(26)"Parking brake" symbol
(27)"Operating hours until
the next service" symbol
(28) Symbol for "Seat belt not
fastened"
(special equipment)
(29) Text field, error code
display
32
Possible malfunctions
Function
Remedy
The diagnostic program can be
For 12-hour format:
used to reset the display to a
am = morning
12-hour clock.
pm = afternoon
Contact your authorised dealer.
- Setting the time
- Scrolling through error
messages
- Setting the time
- Scrolling through error
messages
- Turning off the warning sound
The diagnostic program can be
- 24-hour clock display Can be
used to reset the display to a
adjusted via the (22) and (23)
12-hour clock.
push buttons.
Contact your authorised dealer.
- No function in electric trucks
- Lights up when the parking
brake is activated
-Goes out when the parking
brake is deactivated.
- Once the key switch has been
switched on, the display field
(17) shows the operating hours
until the next service (counting
down)
Symbol (27) lights up. After
5 seconds, the symbol (27)
goes out and the display (17)
switches automatically to the
truck’s operating hours — the
operating hours symbol (16)
flashes.
- Lights up if seat belt has not
Fasten the seat belt.
been fastened
- Display line 1: lift height
display error code
- Display line 2: steering
position display error code
Operating Instructions – 387 801 1501 EN – 12/2012

Display element
(30)"Lift mast positioning"
symbol (special equipment)
(31) LCD display with
backlight
(32) Indicator light (yellow),
"depressurisation of working
hydraulics"
(33) Indicator light (yellow), - For trucks with an integrated
"rear cover open"
(34)Indicator light (yellow), - The yellow indicator light is
charging via "integrated
charger" (special equipment) charger when the truck battery
(35) Indicator light (green),
battery charging via
integrated charger finished.
(36)Indicator light (yellow),
charging via integrated
charger (special equipment)
.
Operating Instructions – 387 801 1501 EN – 12/2012
Overview 3
Display unit
Possible malfunctions
Function
Remedy
- Lights up when the "Lift
mast positioning" function is
activated
- Illuminated display field for
various functions
- The neutral yellow indicator
light flashes and provides
information on whether all
conditions for depressurisation
of the working hydraulics have
been met
- The yellow indicator light
illuminates if the truck’s rear
flap is opened
Close the rear flap.
charger, this is monitored to
prevent the truck from being
driven if the charging cable is
still connected to the truck
- The yellow indicator light
illuminates when the truck
battery is being charged
activated by the integrated
is being charged
- The indicator light flashes
during the equalising charge
- The green indicator light is
activated by the integrated
charger when battery charging
has finished
- The indicator light flashes
during the maintenance
charge
- The indicator light is activated
directly by the integrated
charger
- The yellow indicator light is
activated by the integrated
charger when the truck battery
Contact your authorised dealer.
is being charged
- The indicator light flashes
during the equalising charge
33
3 Overview
Switch panel

Switch panel

1 Interior lighting (level 2), terminal board light 7 Front windscreen wiper / rear window wiper
(switch in centre position on level 1) - interval / on / wipe-wash
2 Standard or higher lighting 8 Roof panel wiper - interval / on / wipe-wash
3 Working spotlight position 1 / 2 without 9 Hazard warning light
lighting 10 Rotating beacon / flashing beacon
4 Working spotlight positions 3 / 4 or working 11 Screen heating push button
spotlight positions 1 / 2 with higher lighting 12 Depressurisation (special equipment)
5 Working spotlight position 5 / 6 or cross 13 Not assigned
beam 14 Not assigned
6 Working spotlight position 7/8 15 Not assigned

NOTE
The configuration of the switch panel and
arrangement of individual switches may vary
depending on the version. Please note the
switch symbols.

34 Operating Instructions – 387 801 1501 EN – 12/2012

 4

Operation
4 Operation
Instructions for running-in

Instructions for running-in

The truck can be run at high speeds straight
away.
However, in the first 50 operating hours avoid
subjecting either the working hydraulics or the
drive unit to high continuous loads.
And then every 100 operating hours.
The wheel fastenings should be tightened
crosswise with a torque of
front: 425 Nm

During the initial operating period and when- rear: 210 Nm

ever the wheels are changed, the wheel fas-
tenings must be tightened before starting
the truck, and then every 10 operating hours
thereafter, until they have settled and can be
tightened no further.
NOTE
Observe the tightening instructions on the tag
attached to the steering column

36 Operating Instructions – 387 801 1501 EN – 12/2012

 Operation 4
Pre-shift checks

Pre-shift checks
Carried
out
 
Chassis, bodywork and fittings
Check condition and correct operation of driver’s seat and seat belt.
Check that the adjustment of the steering column is secure.
Chassis frame
Check tyres and rims (profile, external damage, air pressure).
Test the service brake and parking brake.
Check the steering.
Electrics / Electronics
Battery: check the charge status.
Check the electrical system (e.g. lighting, horn, lifting functions and windscreen
wipers).
Hydraulics
Hydraulic system: check the oil level.
Check the truck for leaks (visual inspection).
Load lift system
Check the fork arms and arm safety devices.
Special equipment
Check the condition of the antistatic belt (only when using tyres that are not antista-
tic).
Check that the attachments are working correctly (observe the manufacturer’s
operating instructions).
Final tasks
Perform a test drive and functional test

Operating Instructions – 387 801 1501 EN – 12/2012 37

4 Operation
Standard equipment

Standard equipment
Entering and exiting the truck

WARNING
Entering and exiting the truck can result in injuries
to the feet or back.
Always face the truck when climbing in and out.

NOTE
Do not use the steering wheel or the joysticks
as an aid to get in or out of the cab.
 Use the handle (1) or the vertical bar (2) and
step (3).

Truck with elevated driver’s compart-

ment
In the "truck with elevated driver’s compart-
ment" version, two steps (1) and two han-
dles (2) serve as a safe mounting aid for climb-
ing into and out of the truck.

WARNING
Risk of accident and injury if you climb into or out of
the truck incorrectly.
Climb into or out of the truck carefully using the two
steps (1) together with the two handles (2). Never
jump off the truck.

38 Operating Instructions – 387 801 1501 EN – 12/2012

 Operation 4
Standard equipment

Adjusting the driver’s seat

WARNING
An incorrect seat setting may cause damage to the
driver’s back. The setting devices for adjusting the
driver’s seat should not be used during operation.
Before starting the truck and whenever changing
drivers, adjust the seat to match the driver’s weight
and make sure that the settings have all engaged
properly. Do not place any objects in the driver’s
rotation range.

Longitudinal adjustment
WARNING
There is a risk of crushing if the lever is grasped
fully.
Only grasp the lever by the trough provided for this
purpose.

 Pull lever (1) upwards.

 Move the driver’s seat backwards or for-
wards on the runners to give the driver the
most comfortable position in relation to the
steering wheel and the accelerator pedals.
 Allow lever (1) to click back into place.

Operating Instructions – 387 801 1501 EN – 12/2012 39

4 Operation
Standard equipment

Setting the driver’s weight

NOTE
Setting the individual driver’s weight must be
carried out with the driver’s seat under load.
 Swing the lever (2) out.
Move the lever to set the driver’s weight for the
suspension.
 The correct driver’s weight has been
selected when the arrow is in the centre
position of the inspection window (3).
Move the lever (2) upwards for a heavier
weight.
Move the lever (2) downwards for a lighter
weight.

NOTE
Sitting for lengthy periods places a major
burden on the spine. Try to compensate for
this by performing regular simple gymnastic
movements.

Adjusting the seat backrest

 Pull lever (4) up and hold.
 Move seat backrest (5) forwards or back-
wards until a comfortable sitting position for
the driver is found.
 Release lever (4) and allow seat backrest
(5) to click home in that position.

40 Operating Instructions – 387 801 1501 EN – 12/2012

 Operation 4
Standard equipment

Adjusting the lumbar support

 Move turning knob (6) to the left or right to
adjust the lumbar support as required.

NOTE
Take note of the symbol label affixed to the
rear of the seat backrest.

Switch on seat heater (special equip-

ment)
 Operating this switch (7) activates the seat
heater for the driver’s seat.

Operating Instructions – 387 801 1501 EN – 12/2012 41

4 Operation
Standard equipment

Adjusting the steering column

DANGER
Safe driving is not guaranteed with the clamping
screw open.
Only adjust the steering column when the vehicle is
stationary.
Before attempting to drive the truck, ensure that the
steering column is locked.

Swivel adjustment
 Undo the clamping screw (see arrow) by
turning it anticlockwise.
 Move the steering wheel into the required
position.
 Tighten the clamping screw by turning it
clockwise.

Height adjustment (special equipment)

 Undo the clamping screw (see arrow) by
turning it anticlockwise.
 Move the steering wheel into the required
position by pulling it upwards or pushing it
downwards.
 Tighten the clamping screw by turning it
clockwise.

42 Operating Instructions – 387 801 1501 EN – 12/2012

 Operation 4
Standard equipment

Setting the time

NOTE
The time is displayed in 24-hour format. It is
possible to change to 12-hour format using
the diagnostic device. Please contact your
authorised dealer.
 Press both push buttons (2) and (3) simulta-
neously for 3 seconds.
The hour figures in the time display (1) will
flash.

NOTE
The hours or minutes can be adjusted gradu-
ally by pressing push button (2) or quickly by
holding down the push button.
 Press push button (2) to set the hours.
 Press push button (3) to confirm the hours
setting.
Now the minutes display will flash.
 Press push button (2) to set the minutes.
 Press push button (3) to confirm the minutes
setting.

Operating Instructions – 387 801 1501 EN – 12/2012 43

4 Operation
Standard equipment

Seat belt
Fastening the seat belt
DANGER
There is a risk to life if the driver
leaves the vehicle in an uncontrolled
manner.
For this reason, the seat belt must
always be worn when operating the
truck!
The seat belt should only be worn by
one person.

WARNING
The seat belt must function perfectly.
For this reason, the belt should not become twisted,
trapped or tangled.
The belt buckle and belt retractor should be protec-
ted from foreign bodies, damage and dirt.

NOTE
Driver’s cabs with fixed closed doors or
bracket doors meet the safety requirements
for driver restraint systems. The seat belt can
also be used. It must, however, be fastened
when driving with doors that are open or have
been removed, or if there aren’t any doors.
PVC doors are not deemed to constitute driver
restraint systems.
The automatic blocking mechanism prevents
the seat belt from being extended whenever
the industrial truck is on a steep slope. It is
then not possible to pull the belt any further out
of the retractor.
To release the automatic blocking mecha-
nism, carefully move the industrial truck so
that it is no longer positioned on a slope.
While using the truck (e.g. driving, operating
lift mast etc.), adopt a sitting position as far
back as possible so that the driver’s back rests
against the seat backrest.
The automatic blocking mechanism of the
belt retractor offers sufficient freedom of
movement on the seat for normal use of the
truck.

44 Operating Instructions – 387 801 1501 EN – 12/2012

 Operation 4
Standard equipment

 Pull the seat belt (3) smoothly out of the belt

retractor (1) to the left.
 Position belt over the lap, not over the
stomach.
 Allow the latch plate (2) to snap into place in
the buckle (4).
 Check seat belt tension.
The belt must fit close to the body.

Unfastening the seat belt

 Push the red button (5) on the buckle (4).
 Manually return the buckle guide (2) to the
belt retractor (1).

NOTE
The automatic blocking mechanism may be
triggered if the web belt runs in too quickly and
the buckle guide strikes the housing. The web
belt cannot be pulled out with normal force.

Operating Instructions – 387 801 1501 EN – 12/2012 45

4 Operation
Standard equipment

Switching the truck on and off

Switching on the truck
 Sit on the driver’s seat (5).
 Fasten the seat belt.
 Actuate the stop pedal.

NOTE
Joysticks or single-levers must be in the
neutral position.
 Pull the emergency off switch (3).
 Insert the key (2) into the key switch and turn
clockwise from the zero position to position
"I".
The electrical system is switched on.
 Release the parking brake either by actuat-
ing the switch (1) or the accelerator pedals
(4) or (6).
The truck is now ready for use.
 Look at the display unit (7).

NOTE
After the key switch has been switched on,
display unit (7) performs a self-test. All
displays light up for approx. 4 seconds and the
operating hours (9) are shown in the display
unit. Symbol (8) flashes and hour meter (9) is
in operation. All indicator lights in the display
unit (7) go out after approx. 4 seconds, apart
from symbol light (10).

NOTE
The joysticks and/or accelerator pedals must
not be used until all indicator lights apart from
(10) have gone out. Otherwise the truck will
not function. To restart: switch the key switch
off and on again.

46 Operating Instructions – 387 801 1501 EN – 12/2012

 Operation 4
Standard equipment

Switching the truck off

NOTE
In trucks with an "active charging ventilation
unit" or an "integrated charger", the emer-
gency off switch must not be pressed as the
battery is discharged during prolonged down-
times.
 Take your feet off accelerator pedals (4)
and (6).
 Turn the switch key (2) anticlockwise to the
zero position.

NOTE
The braking effect of the automatic brake
holds the truck with a lowered load and/or
lowered lifting accessory on a clean floor
covering at a gradient of up to 10%.

Operating Instructions – 387 801 1501 EN – 12/2012 47

4 Operation
Standard equipment

Driving (dual-pedal operation)

WARNING
It is generally not permitted to drive on long gra-
dients over 15% due to specified minimum braking
and stability values. Please contact your authori-
sed dealer before driving on larger gradients. The
climbing capability values given in the type sheet
have been determined from the pulling force and
only apply when overcoming obstacles on the road-
way and for small height differences.
You should always adapt your driving to the conditi-
ons of the route used (unevenness etc.), especially
hazardous work areas and your load.

WARNING
Rear-view mirrors should not be used for reverse
travel.
Reverse travel is therefore only permitted when
looking directly behind you.

NOTE
Certain Linde forklift trucks (e.g. those with
a special container roof or a rotary seat)
have a reduced clearance between the seat
and overhead guard. For this reason, such
trucks should only be used by persons whose
normal operating posture is such that there is
a minimum of 30 mm clearance between their
head and the overhead guard.

CAUTION
Any side doors attached must be protected from
damage when driving.
Please therefore ensure that both side doors are
closed and locked before setting off.

NOTE
The truck can only be driven with the driver’s
seat under load.

NOTE
All actuating levers and accelerators pedals
must be in the neutral position before the truck
is switched on.

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 Operation 4
Standard equipment

 Sit down on the driver’s seat (5) (only then

is the seat switch under the driver’s seat
activated).
 Fasten the seat belt.
 Pull the emergency off switch (3).

 Insert switch key (2) into the switch lock and

turn clockwise to the stop.
Symbol (11) flashes and hour meter (12) is in
operation.
Battery discharge indicator (10) and all indica-
tor lights (7) light up in the display unit. (The
indicator lights go out after approx. 4 seconds,
apart from symbol light (13)).

NOTE
The actuating levers (joystick) and/or acce-
lerator pedals should not be used until the
indicator lights (13) have gone out. Otherwise
the truck will not function. To restart: switch
the switch lock off and on again.
 Lift the fork arms slightly and tilt the lift mast
back.
 Release the parking brake by actuating the
switch (1) or the foot pedals (4, 6).

Operating Instructions – 387 801 1501 EN – 12/2012 49

4 Operation
Standard equipment

Forward travel
 Carefully press the right accelerator pedal.
The green indicator light for forward travel
lights up.
The driving speed of the truck increases as the
actuation distance of the pedal increases.

NOTE
Pressing down the accelerator pedal hard is
to no advantage as the maximum acceleration
rate is controlled automatically.

Reverse travel
 Carefully operate the left accelerator pedal
(6).
The green indicator light for reverse travel
lights up.
The truck will reverse slowly or quickly de-
pending on the accelerator pedal position.

Changing the drive direction

 Release the actuated accelerator pedal.
 Operate the accelerator pedal for the
opposite drive direction.
The truck will be electrically braked until it
comes to a standstill and then accelerated in
the drive direction specified.
 Both feet should be left on the accelerator
pedals so that the truck is easily controlled
in every driving movement.

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 Operation 4
Standard equipment

Driving (single-pedal operation)

WARNING
It is generally not permitted to drive on long gra-
dients over 15 % due to specified minimum braking
distance and stability values. Please contact your
authorised dealer before driving on larger gra-
dients. The climbing capability values given in the
type sheet have been determined from the pulling
force and only apply when overcoming obstacles
on the roadway and for small height differences.
You should always adapt your driving to the condi-
tions on the route used (unevenness etc.), paying
particular regard to hazardous work areas and your
load.

WARNING
Rear-view mirrors should not be used for reverse
travel.
Reverse travel is therefore only permitted when
looking directly behind you.

NOTE
Certain Linde forklift trucks (e.g. those with
a special container roof or a rotary seat)
have a reduced clearance between the seat
and overhead guard. For this reason, such
trucks should only be used by persons whose
normal operating posture is such that there is
a minimum of 30 mm clearance between their
head and the overhead guard.

CAUTION
Any side doors attached must be protected from
damage when driving.
Please therefore ensure that both side doors are
closed and locked before setting off.

NOTE
The truck can only be driven with the driver’s
seat under load.

Operating Instructions – 387 801 1501 EN – 12/2012 51

4 Operation
Standard equipment

 Sit down on the driver’s seat (only then

is the seat switch under the driver’s seat
activated).
 Fasten the seat belt.
 Pull the emergency off switch (3).
 Insert key (2) into the key switch and turn
clockwise to the stop.
The symbol (11) in the display flashes and the
hour meter (12) is in operation.

The battery discharge indicator (10) and all

indicator lights (7) light up in the display unit
and then go out after approx. 4 seconds, apart
from symbol light (13).
 Lift the fork arms slightly and tilt the lift mast
back.

NOTE
If the red light in the brake switch lights up,
this means that the manual parking brake is
actuated. The drive function may only be used
on the truck once the manual parking brake
has been released. The brake is released and
the red light goes out when the brake switch is
actuated by pressing the "P" symbol.
 Actuate switch (1) (press "P symbol").
 Press the accelerator pedal (5).
The automatic brake is released and the truck
is ready for operation.

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 Operation 4
Standard equipment

Forward travel
 Move the direction selection lever (4)
forwards.
 Press the accelerator pedal (5) carefully.
Indicator light (8) lights up.
The parking brake is released and the truck is
ready for operation.
The driving speed of the truck increases as the
actuation distance of the pedal increases.

NOTE
Pressing down the accelerator pedal hard is
to no advantage as the maximum acceleration
rate is controlled automatically.

Reverse travel
 Move direction selection lever (4) back-
wards.
 Press the accelerator pedal (5) gently.
Indicator light (9) in the display unit lights up.
The parking brake is released and the truck is
ready for operation.
The truck will reverse slowly or quickly de-
pending on the accelerator pedal position.

Changing the drive direction

 Release accelerator pedal.
 Operate direction selection lever (4) for the
opposite drive direction.
The truck will now accelerate in the specified
direction.
The direction selection lever can be switched
over directly. The drive brakes the truck until
it comes to a standstill and then accelerates in
the opposite drive direction.

Operating Instructions – 387 801 1501 EN – 12/2012 53

4 Operation
Standard equipment
Steering system
The hydrostatic steering system means that
very little effort is required for the steering
wheel turning movement.
This is particularly advantageous when
palletising in narrow aisles.
 Start up and drive the industrial truck.
 Turn the steering wheel to the left and right
to the stop.
54
The steering wheel can be moved beyond
the stop if sufficient force is applied, without
the position of the wheels changing on the
steering axle.
DANGER
The industrial truck must not be driven if the steering
system is defective.
If the steering is stiff or has too much play, contact
your authorised dealer.
Operating Instructions – 387 801 1501 EN – 12/2012
 Operation 4
Standard equipment

Brake system

DANGER
Risk of accident or death if brake system is faulty.
Your industrial truck should not be used under any
circumstances if the brake system is faulty.
Should you notice any defects or wear to the brake
system, please contact your authorised dealer
immediately.

DANGER
The truck’s braking characteristics are influenced
by the viscosity of the oil, among other things.
Using a different oil (with a different viscosity) to
that prescribed by the manufacturer will affect the
braking characteristics and increase the risk of
accidents and risk to life.
Therefore, only use the oil prescribed by the manu-
facturer (see Recommendations for consumables).
Contact your authorised dealer.

Service brake via the stop pedal

The stop pedal (2) is positioned between the
accelerator pedals and is used for hydraulic
operation of the multi-disc brake.

NOTE
It is recommended that drivers familiarise
themselves with the function and effect of this
brake when there is no load on the truck. For
this purpose they should choose a route with
no other traffic, travelling at a low speed.
 Depress the stop pedal (2).
The braking efficiency will be greater or lower
depending on how hard the stop pedal is
pressed.

Operating Instructions – 387 801 1501 EN – 12/2012 55

4 Operation
Standard equipment

Electric regenerative brake

 Allow the accelerator pedals (1) or (3) to
move to the neutral position.
Slowly or quickly releasing the accelerator
pedals to the neutral position allows the
braking effect to be sensitively controlled,
from gentle to hard braking.
The LBC brakes the truck.
 Operate the accelerator pedal for the
opposite drive direction.

NOTE
If required, this function can be adjusted via a
diagnostic program so that the effect is greater
or less. Contact your authorised dealer.

NOTE
The regenerative brake increases the braking
effect of the service brake. For emergency
braking, press the stop pedal (2), which is
located between the accelerator pedals.

NOTE
When the emergency off switch is actuated,
the truck is braked (not braked fully).
DANGER
Possible risk of accident
Always use stop pedal (2) for emergency braking.

WARNING
Risk of accident
Depending on the charging state of the battery,
the electric regenerative brake may be insufficient
and result in the maximum permissible speed of
the truck being exceeded. For this reason, the
driving speed must be adapted to the respective
environmental conditions.

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 Operation 4
Standard equipment

Automatic brake
If the truck is braked to a standstill, the auto-
matic brake will become active after a short
time.
When the truck is standing on a clean floor
covering, the brake will hold the truck in
position on gradients of up to a maximum
of 10%.
The brake symbol "P" (see arrow) flashes in
the display unit.
When stopping on gradients, the truck is held
electrically until the automatic brake becomes
active.
 Actuate accelerator pedal again.
The brake is automatically released.

Applying the parking brake manually

The parking brake can be applied manually
using the brake switch (1) when the key
switch is switched on. When the key switch
is switched on and the truck is standing on a
clean floor covering, the parking brake holds
the truck in position on gradients of up to a
maximum of 15%.

NOTE
A manually activated parking brake must also
be switched off manually before driving the
truck again.

Operating Instructions – 387 801 1501 EN – 12/2012 57

4 Operation
Standard equipment

Actuate brake switch (1) by pressing the

"P" symbol (3) (red LED (2) in the switch
illuminates).

The brake symbol (see arrow) in the display

unit lights up permanently. The truck is
braked.
DANGER
Risk of accident and injury
Do not actuate brake switch (1) during travel.
Under some circumstances, the load can slip from
the fork arms if the parking brake is applied too
sharply.
Only actuate the brake switch (1) during travel
if emergency braking with the stop pedal is not
sufficient.

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 Operation 4
Standard equipment

 Actuate the brake switch (1) by pressing the

red LED symbol (2).
The red LED (2) in the brake switch (1) goes
out. The truck is ready for operation.

NOTE
When starting up the truck on a gradient, the
truck is held electrically once the parking brake
has been released, in order to prevent it from
rolling backwards.

NOTE
In safety-critical situations (e.g. when a worker
is in a raised workshop hoist), the parking
brake must be actuated manually using the
brake switch (1). This will result in all of the
drive functions being blocked.

Operating Instructions – 387 801 1501 EN – 12/2012 59

4 Operation
Standard equipment

Horn
The horn is used as a warning signal, e.g. at
blind spots and junctions.
The horn knob is easily accessible in the
armrest area.
 Push in the horn knob on the armrest (see
arrow) to sound the horn.

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 Operation 4
Standard equipment

Joystick —
Central-lever operation

WARNING
There is a risk of becoming trapped
between parts due to the moving lift
mast or the attachment.
Therefore, never reach into or enter
the lift mast or the area between the
lift mast and the truck.
The lifting system and attachments
should only ever be used for their
proper purpose.
Drivers must be instructed in the
handling of the lifting system and
attachments.
Take note of the maximum lift height.

Operating the lift and tilt attachments

NOTE
On the version with central lever operation,
moving the joystick to an intermediate position
(approx. 45°) will activate both functions at the
same time (e.g. lifting and tilting).
 Take note of the switching symbols with
arrows.
The joystick must always be operated gently,
never jerkily. Moving the joystick determines
the lifting, lowering and tilt speed. After the
joystick is released, it automatically returns to
its initial position.

NOTE
The lifting system and attachments only
function when the truck is switched on and
the driver’s seat is occupied (seat switch is
actuated).

Operating Instructions – 387 801 1501 EN – 12/2012 61

4 Operation
Standard equipment

Lifting the fork carriage

DANGER
There is an increased risk of falling and crushing
when lifting the lift mast.
For this reason, it is not permitted to step onto the
raised fork arms.

 Push joystick (1) to the right.

Lowering the fork carriage

 Push joystick (1) to the left.

Tilting the lift mast forwards

 Push the joystick (1) forwards.

Tilting the lift mast back

 Pull the joystick (1) backwards.

Operating the attachments

Attachments can be fitted to the truck as
special equipment (e.g. sideshift, fork prong
positioner, clamp etc.). Refer to the working
pressure and operating instructions for the
attachment. An additional joystick (cross
lever) is attached for operation.

NOTE
Before fitting an attachment, depressurisation
(special equipment) can be performed to
depressurise the hydraulic system for the
auxiliary hydraulics so that the connection
on the attachment can be connected to
the connection on the fork carriage (see
"Depressurisation" under special equipment).

62 Operating Instructions – 387 801 1501 EN – 12/2012

 Operation 4
Standard equipment

CAUTION
Attachments alter the load capacity and stability of
the truck.
Attachments that are not supplied with the truck
should only be used if the authorised dealer has
confirmed that the arrangement in terms of load
capacity and stability ensures safe operation.

NOTE
The methods of attachment operation descri-
bed here are examples. The configuration
of the joystick may vary depending on your
truck’s equipment.
 Take note of the switching symbols with
arrows.

NOTE
For every attachment, a label stating the load
capacity of the truck plus attachment (for a
description, see "Additional capacity rating
plate for attachments") must be affixed within
the driver’s range of vision and a symbol label
for the relevant attachment must be affixed
behind the joystick.

Operating the sideshift

NOTE
In order to prevent damage, do not activate
the sideshift when the fork arms are on the
ground.
 Push joystick (2) to the left.
Sideshift moves to the left.
 Push joystick (2) to the right.
Sideshift moves to the right.

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4 Operation
Standard equipment

Operating the fork positioner

NOTE
In order to prevent damage, do not activate
the fork prong positioner with a load, or with
the fork arms on the ground. Do not use the
fork prong positioner as a clamp.
 Push the joystick (2) forwards.
Fork arms move outwards.
 Pull the joystick (2) backwards.
Fork arms move inwards.

Operating the clamp

DANGER
Increased risk of accident from a falling load.
For attachments that perform a clamping function
(e.g. a bale clamp), a lockable joystick must be
used.
If your truck is not fitted with this equipment, please
contact your authorised dealer.

Version 1: Electronically locked

 Take note of the switching symbols with
arrows.

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 Operation 4
Standard equipment

 Push joystick (2) forwards by at least 40%

and then move to the zero position.

Joystick is unlocked for approx. one second

and the display (3) lights up in the display unit.

NOTE
If the joystick is not moved forwards within this
time period, it is locked again.
 Push the joystick (2) forwards.
Clamp opens.
Once the joystick has been released, it is
locked again within one second.
 Pull the joystick (2) backwards.
Clamp closes.

Version 2: Mechanically locked

NOTE
The joystick (single lever) is recognisable by
the somewhat wider design of the bellows.

Operating Instructions – 387 801 1501 EN – 12/2012 65

4 Operation
Standard equipment

 Take note of the switching symbols with

arrows.

 Unlock the joystick (4) (depending on the

version) by pressing the knob downwards.
 Push the joystick (4) forwards.
Clamp opens.
 Pull the joystick (4) backwards.
Clamp closes.
Once the joystick has been released, it is
locked again.

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 Operation 4
Standard equipment

Joystick —
Single-lever operation

WARNING
There is a risk of becoming trapped
between parts due to the moving lift
mast or the attachment.
Therefore, never reach into or enter
the lift mast or the area between the
lift mast and the truck.
The lifting system and attachments
should only ever be used for their
proper purpose.
Drivers must be instructed in the
handling of the lifting system and
attachments.
Take note of the maximum lift height.

 Take note of the switching symbols with

arrows.
The joystick must always be operated gently,
never jerkily. Moving the joystick determines
the lifting, lowering and tilt speed. After the
joystick is released, it automatically returns to
its initial position.

NOTE
The lifting system and attachments only
function when the truck is switched on and
the driver’s seat is occupied (seat switch is
actuated).

Operating Instructions – 387 801 1501 EN – 12/2012 67

4 Operation
Standard equipment

Lifting the fork carriage

DANGER
There is an increased risk of falling and crushing
when lifting the lift mast.
For this reason, it is not permitted to step onto the
raised fork arms.

 Pull the joystick (1) backwards.

Lowering the fork carriage

 Push the joystick (1) forwards.

Tilting the lift mast forwards

 Push the joystick (2) forwards.

Tilting the lift mast back

 Pull the joystick (2) backwards.

68 Operating Instructions – 387 801 1501 EN – 12/2012

 Operation 4
Standard equipment

Operating the attachments

Attachments can be fitted to the truck as
special equipment (e.g. sideshift, fork prong
positioner, clamp etc.). Refer to the working
pressure and operating instructions for the
attachment. One or two additional joysticks
are fitted for operating the attachments.

NOTE
Before fitting an attachment, depressurisation
(special equipment) can be performed to
depressurise the hydraulic system for the
auxiliary hydraulics so that the connection
on the attachment can be connected to
the connection on the fork carriage (see
"Depressurisation" under special equipment).

CAUTION
Attachments alter the load capacity and stability of
the truck.
Attachments that are not supplied with the truck
should only be used if the authorised dealer has
confirmed that the arrangement in terms of load
capacity and stability ensures safe operation.

NOTE
The methods of attachment operation descri-
bed here are examples. The configuration
of the joystick may vary depending on your
truck’s equipment.
 Take note of the switching symbols with
arrows.

NOTE
For every attachment, a label stating the load
capacity of the truck plus attachment (for a
description, see "Additional capacity rating
plate for attachments") must be affixed within
the driver’s range of vision and a symbol label
for the relevant attachment must be affixed
behind the joystick.

Operating Instructions – 387 801 1501 EN – 12/2012 69

4 Operation
Standard equipment

Operating the sideshift

NOTE
In order to prevent damage, do not activate
the sideshift when the fork arms are on the
ground.
 Push the joystick (3) forwards.
Sideshift moves to the left.
 Pull the joystick (3) backwards.
Sideshift moves to the right.

Operating the fork prong positioner

NOTE
In order to prevent damage, do not activate
the fork prong positioner with a load, or with
the fork arms on the ground. Do not use the
fork prong positioner as a clamp.
 Push the joystick (4) forwards.
Fork arms move outwards.
 Pull the joystick (4) backwards.
Fork arms move inwards.

Operating the clamp

DANGER
Increased risk of accident from a falling load.
For attachments that perform a clamping function
(e.g. a bale clamp), a lockable joystick must be
used.
If your truck is not fitted with this equipment, please
contact your authorised dealer.

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 Operation 4
Standard equipment

Version 1: Electronically locked

 Take note of the switching symbols with
arrows.

 Push joystick (5) (depending on the version)

forwards by at least 40% and then move to
the zero position.

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4 Operation
Standard equipment

Joystick is unlocked for approx. one second

and the display (6) lights up in the display unit.

NOTE
If the joystick is not moved forwards within this
time period, it is locked again.
 Push the joystick (5) forwards.
Clamp opens.
Once the joystick has been released, it is
locked again within one second.
 Pull the joystick (5) backwards.
Clamp closes.

Version 2: Mechanically locked

NOTE
The joystick is recognisable by the somewhat
wider design of the bellows.
 Take note of the switching symbols with
arrows.

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 Operation 4
Standard equipment

 Unlock the joystick (5) (depending on the

version) by pressing the knob downwards.
 Push the joystick (5) forwards.
Clamp opens.
 Pull the joystick (5) backwards.
Clamp closes.
Once the joystick has been released, it is
locked again.

Operating Instructions – 387 801 1501 EN – 12/2012 73

4 Operation
Special equipment

Emergency off switch

If the emergency off switch is actuated during
travel, the industrial truck is braked with
reduced braking torque. This minimises the
risk of a load being dropped.

Pulling the emergency off switch

 Pull the emergency off switch (1).
The emergency off switch is unlocked and the
electrical system is switched on. The truck is
ready for use.

Pushing the emergency off switch

 Push the emergency off switch (1).
Only the lift and drive functions of the truck are
deactivated by pressing the emergency off
switch.
WARNING
The battery voltage on the input side of the main
contactor remains connected when the emergency
off switch is actuated.
In order to de-energise the truck completely (e.g. for
maintenance work), the battery female connector
must be removed from the battery male connector.

Special equipment
Adjusting the driver’s seat equipped
with air suspension

WARNING
Incorrect seat adjustment may cause injury to the
driver’s back. The setting devices for adjusting the
driver’s seat should not be used during operation.
Before starting up the truck and whenever changing
drivers, adjust the seat for the individual weight of
the driver. Only adjust the driver’s seat when the
truck is stationary.

Setting the driver’s weight

 Sit on the driver’s seat.

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 Operation 4
Special equipment

 Check the weight adjustment in viewing

window (3).
The correct driver’s weight has been selected
when the arrow (4) is in the centre of the
inspection window.
 Adjust as necessary for the driver’s weight
• Lift lever (2) upwards (5) = increase weight
setting
• Push lever (2) downwards (6) = decrease
weight setting

Longitudinal adjustment
WARNING
There is a risk of crushing if the lever is grasped
fully.
Only grasp the lever by the trough provided for this
purpose.

 Lift lever (1) upwards.

 Move the driver’s seat backwards or for-
wards on the runners to give the driver the
most comfortable position in relation to the
steering wheel and the accelerator pedals.
 Allow lever to click back into place.

Adjust the seat angle

 Lift lever 2 and hold it there.
The seat surface is moved to the desired
position by applying pressure to the seat
surface or removing pressure from it.

Adjust the seat height

 Lift lever 1 and hold it there.
The seat surface can be moved to the desired
position by sliding the seat surface forward or
to the rear.

Seat heater

NOTE
The maximum temperature is pre-set.

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4 Operation
Special equipment

 Switch (1) turns the seat heater ON and

OFF.
• 0 = seat heater OFF
• I = seat heater ON

Adjusting the lumbar support

The lumbar support enables optimum config-
uration of the seat back contour to the driver’s
body.
 Turn the handwheel (2) upwards.
The convexity of the upper part of the backrest
can be adjusted individually.
 Turn the handwheel (2) downwards.
The convexity of the lower part of the backrest
can be adjusted individually.

Adjust the seat back

 Lift lever (2) and hold it there.
 Move the seat backrest forwards and
backwards to find a comfortable seat
position for the driver.
 Release lever (2).

Adjusting the backrest extension

 Push backrest extension (1) in or pull it out
for individual adjustment.

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 Operation 4
Special equipment

Adjusting the driver’s seat with

rotating device

CAUTION
The driver’s seat must not rotate while the truck is
in use.
It should therefore be ensured that the rotating
device is locked.

The driver’s seat with rotating device offers

better rear visibility during reverse travel over
long distances.
When driving forwards for long distances, it is
recommended that you return the seat to the
straight-ahead position.
The rotating device is maintenance free.
 Pull locking lever (1) backwards.
The rotating device is enabled and allows the
seat to be rotated 17° to the right. It can be
locked at 0° and at 17°.
 Turn the driver’s seat to the right and allow
the locking bolt to engage audibly in the
interlock.

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4 Operation
Special equipment

Mast positioning
The lift mast positioning function allows easy
activation of a previously programmed lift mast
tilt.
When the function is enabled, the symbol (see
arrow) lights up in the display unit.

Programming
The tilt angle sensor system allows a specific
lift mast tilt to be programmed.
When this function is enabled (special equip-
ment), the symbol (see arrow) lights up in the
display unit.

 Use the joystick (1) or single lever to tilt the

lift mast to the required angle.
 Push the push button (2) in the front-left
position of the armrest for longer than 2
seconds.
The tilt angle is now stored.
As confirmation, a double acoustic signal
sounds from the display unit and the light (3) in
the button (2) flashes briefly several times.
The lift mast tilt is stored in relation to the truck.
The lift mast tilt in relation to the ground
depends on various influencing variables:
• Tyre wear
• Tyre pressure with pneumatic tyres
• Load
• Unevenness and gradient of the ground

NOTE
Resetting the truck control unit parameters
(working hydraulics) to the factory setting

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 Operation 4
Special equipment

deactivates the lift mast positioning and it

must be switched on again. When the truck
is switched off, the lift mast position currently
stored is lost.

Operation

NOTE
The lift mast positioning function is designed
to aid the driver and is purely a comfort feature.
The responsibility and control for initiating the
required lift mast position always lie with the
driver.
 Briefly push the push button (2) in the
front-left position of the armrest.
The lamp (3) in the button (2) lights up and the
lift mast positioning function is switched on.
 Operate the joystick (1) and activate the
stored tilt angle.

NOTE
For safety reasons, tilting is possible only in
the direction of the stored tilt angle, and must
be reactivated for each lift mast positioning
operation.
After reaching the stored lift mast position, the
lift mast remains stationary and an acoustic
signal sounds in the display unit.
 Release the joystick (1) or push the button
(2) again briefly.
The light (3) in the push button goes out and
the lift mast positioning is switched off.
The lift mast can now be operated normally
using the joystick (1).
 Briefly push the push button (2) again.
Lift mast position identification is switched on
again.

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4 Operation
Special equipment

Steering angle display

Function
The steering angle display must be activated
using the diagnostic program.
When this function is enabled, the symbol (1)
lights up in the display unit.
The steering angle is shown as a bar display
across 11 segments in the second line of the
text display (2).
Please contact your authorised dealer.

Lift height restriction

The lift height restriction function enables the
lift to be stopped at a particular lift height.
The function is activated via a switch (6).
The required lift height is detected via two
further sensors, which must be attached to the
lift mast.
Please contact your authorised dealer.

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Special equipment

Lifting system and attachments (sin-

gle-lever operation with 3rd auxiliary
hydraulics)

WARNING
There is a risk of becoming trapped
between parts due to the moving lift
mast or the attachment.
Therefore, never reach into or enter
the lift mast or the area between the
lift mast and the truck.
The lifting system and attachments
should only ever be used for their
proper purpose.
Drivers must be instructed in the
handling of the lifting system and
attachments.
Bear the maximum lift height in mind.

 Take note of the switching symbols with

arrows.
 The joystick must always be operated
gently, never jerkily.
Moving the joystick determines the lifting,
lowering and tilt speed.
After the joystick is released, it automatically
returns to its initial position.

NOTE
The lifting system and attachments only
function with the truck switched on and the
driver’s seat occupied.

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4 Operation
Special equipment

Lifting the fork carriage

DANGER
Risk of falling and crushing.
Never allow people to be lifted on
either the forks, or on a pallet placed
on the forks.
If the truck is to be used for lifting
people then it must be fitted with
a purposely designed working
platform. Ensure that the platform,
platform securing method and
platform interlocks have been
approved for the truck.
Please contact your local distributor.

 Pull the joystick (1) backwards.

Lowering the fork carriage

 Push the joystick (1) forwards.
 Take note of the switching symbol with
directional arrows.

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Tilt the lift mast forward.

 Push the joystick (2) forwards.

Tilt the lift mast backwards

 Pull the joystick (2) backwards.

 Take note of the switching symbol with

directional arrows.

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4 Operation
Special equipment

Operating attachments
Attachments can be fitted to the truck as
special equipment (e.g. sideshift, clamps,
fork prong positioner etc.).
Refer to the working pressure and operating
instructions for the attachment.
One or two additional joysticks are fitted for
operating the attachments.

DANGER
Risk of accident with attachments that perform a
clamping function and have a non-lockable joystick.
For attachments that perform a clamping function
(e.g. a bale clamp), a locked joystick must be used.
The joystick is recognizable by the somewhat wider
design of the bellows.
If your truck is not fitted with this equipment, please
contact your authorised dealer.

NOTE
Before fitting an attachment, depressurisation
(special equipment) can be performed to
depressurise the hydraulic system for the
auxiliary hydraulics so that the connection
on the attachment can be affixed to the
connection on the fork carriage.
 Slide the switch interlock of the relevant
switch downwards.
 Operate the switch for single auxiliary
hydraulics (couplings on the right of the fork
carriage) and the switch for double auxiliary
hydraulics (couplings on the left of the fork
carriage).
 Unscrew the union nuts on the fork carriage.
 Screw on the connecting lines from the
attachment or connect the plug connectors.
Depressurisation via the switches can be
performed only on trucks with quick-release
couplings.

NOTE
When the auxiliary hydraulics is operated, it
is necessary to wait a few seconds before it
can be depressurised again via the switches.

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Otherwise an error will occur and the lift mast

will no longer be able to be actuated. In this
case, switch the switch lock off and on again.

NOTE
Depressurisation can also be performed using
the diagnostics software. Please contact your
authorised dealer.
Take note of the switching symbols with
arrows.

NOTE
For every attachment, a label stating the load
capacity of the truck plus attachment must be
attached to the switch console on the top right
of the overhead guard, and a symbol sticker
for the relevant attachment must be attached
behind the joystick.

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

NOTE
This operation of attachments described
here are examples. The configuration of the
actuating levers may vary depending on your
truck’s equipment.
 Take note of the switching symbols with
arrows.

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Special equipment

Operating the sideshift

NOTE
In order to prevent damage, do not activate
the sideshift when the fork arms are on the
ground.
 Push the joystick (3) forwards.
Sideshift moves to the left.
 Pull the joystick (3) backwards.
Sideshift moves to the right.

 Take note of the switching symbol with

directional arrows.

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Actuating the fork arm positioner

NOTE
In order to prevent damage, do not activate
the fork prong positioner with a load, or with
the fork arms on the ground. Do not use the
fork prong positioner as a clamp.
 Push the joystick (4) forwards.
Fork arms move outwards.
 Pull the joystick (4) backwards.
Fork arms move inwards.

 Take note of the switching symbol with

directional arrows.

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4 Operation
Special equipment

Operating the clamp

 Depending on the version, unlock the joy-
stick (5) by pressing the knob downwards.
 Push the joystick (5) forwards.
Clamp opens.
 Pull the joystick (5) backwards.
Clamp closes.
Once the knob has been released, the joystick
is automatically locked again.

 Take note of the switching symbol with

directional arrows.

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Special equipment

Depressurisation
When changing hydraulic components or
connecting operating equipment to the quick-
release couplings of the working hydraulics,
the hydraulic system must be depressurised.
Depressurisation takes place via a push
button in the overhead console. This releases
the pressure from the hydraulic system without
activating the pump motor.
For activation of depressurisation, the follow-
ing conditions must be fulfilled:
• Seat switch activated
• Parking brake applied
• Truck stopped.
• No movement of steering wheel
• Joysticks in neutral position
To depressurise the auxiliary hydraulics, the
push button must be unlocked and pressed
(neutral yellow warning light flashes in the
display unit).
The joystick for the corresponding auxiliary
hydraulics must be actuated at the same time.
The current depressurisation status is shown
by the neutral yellow warning light in the
display unit.
• Flash — ready for depressurisation via the
joysticks
• Steady light — pressure reduction in the
auxiliary hydraulics
• Flash — auxiliary hydraulics are depres-
surised
If the push button for depressurisation is
pressed and the accumulator is emptied, the
accumulator is charged once to make pilot
pressure for valve activation available in the
valve block.
After the key switch has been turned off and
back on again, the pump is controlled normally
once more for accumulator charging and the
yellow warning light goes out in the display
unit.

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4 Operation
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NOTE
In trucks with quick-release couplings for the
auxiliary hydraulics, the depressurisation
push button is installed in the truck as a
standard feature. Depressurisation via the
truck diagnostics is also possible. Contact
your authorised dealer.

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Special equipment

Lighting

NOTE
The arrangement of the individual switches on
the overhead console may vary depending on
the version. Please note the switch symbols.

Switching on the clipboard light

 Move the toggle switch (1) to the centre
position (setting 1).

Switching on the interior lighting

 Press the toggle switch (1) to the end
position (setting 2).

NOTE
The clipboard light remains in switch setting 2
and is also switched on.

Switching on the side lights, dipped

beams and licence plate lamp

NOTE
The side lights, dipped beams and the di-
rection indicator are incorporated in the front
headlights.
 Move the toggle switch (2) to the centre
position (setting 1).
The side lights and licence plate lamp are
switched on.
 Press the toggle switch (2) to the end
position (setting 2).
The dipped beams, side lights and licence
plate lamp are switched on.

Switching on the front working spotlights

 Activate the toggle switch (3).
The lower front working spotlights are
switched on.
 Activate the toggle switch (4).

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4 Operation
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The upper front working spotlights are

switched on.
 Activate the toggle switch (5).
The upper front working spotlights on the
bridge piece are switched on.

Switching on the rear working spotlights

 Press the toggle switch (6) to the end
position (setting 2).
The rear working spotlights are switched on.

Switching on the working spotlights for

reverse travel
 Move the toggle switch (6) to the centre
position (setting 1).
For reverse travel, the rear working spotlights
will turn on.

Switching on the hazard warning system

 Activate the toggle switch (9).

Switching on the rotating beacon /

flashing beacon
Depending on the equipment there are three
different versions.
Version 1
 Activate the toggle switch (10).
The rotating beacon is always in operation.
Version 2
 Switch on the key switch.
The rotating beacon is in operation.
Version 3
 Switch on the key switch and press the
reverse pedal.
The rotating beacon is in operation for reverse
travel only.

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Switching on the direction indicators

 Switch flasher unit (1) on the steering wheel
upwards.
The direction indicators flash on the right. The
indicator light (2) in the display unit flashes.

 Switch flasher unit (1) on the steering wheel

downwards.
The direction indicators flash on the left. The
indicator light (2) in the display unit flashes.

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Special equipment

Rear lights

NOTE
The two rear light clusters contain the stop
light, the rear light and the direction indicator.

1 Left reflector (red)

2 Left rear light
3 Left brake light/rear light (red)
4 Left direction indicator (white)
5 Right rear light
6 Right stop light / rear light (red)
7 Right direction indicator (white)
8 Right reflector (red)

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Special equipment

BlueSpot
"BlueSpot" is a visual warning unit to enable
early detection of trucks in driving areas with
low visibility (such as drive lanes, high racks),
as well as at blind junctions.

"BlueSpot" is mounted on a support on

top of the overhead guard and projects a
high-power blue dot of light (LED technology)
onto the ground. It is not affected by jolts and
vibrations. The system allows pedestrians to
notice an approaching industrial truck early.

NOTE
"BlueSpot" can be installed for forwards and
reverse travel.

WARNING
Damage to eyes
Looking into BlueSpot can damage
eyes. Therefore do not look into
BlueSpot.

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Special equipment

Switching on BlueSpot
Depending on the equipment fitted, there are
three different ways to activate BlueSpot:
Option 1
 Use toggle switch (see arrow).
Setting the toggle switch:
• Level 0:BlueSpot"OFF"
• Level 1:BlueSpot"ON" for reverse travel
• Level 2: BlueSpot for continuous operation
Option 2
 Use the key switch.
BlueSpot is permanently in operation.
Option 3
 Turn the key switch and press the reverse
pedal.
BlueSpot is only operational for reverse travel.

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Special equipment

Windscreen wipers
Front windscreen wiper and rear window
wiper
 Move the multifunction lever (1) on the
steering wheel downwards to activate the
windscreen wipers.
Depending on the position of the toggle switch
(7) and the drive direction, the following modes
of operation are possible:
Drive direction forwards:
Switch
Front wiper Rear wiper
setting
Intermittent
Setting 0 Off
mode
Continuous Intermittent
Setting 1
mode mode
Continuous Continuous
Setting 2
mode mode
Drive direction backwards:
Switch
Front wiper Rear wiper
setting
Intermittent
Setting 0 Off
mode
Intermittent Continuous
Setting 1
mode mode
Continuous Continuous
Setting 2
mode mode

NOTE
Pulling the multifunction lever (1) upwards
activates the selected mode of operation for
as long as the multifunction lever is pulled up.

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Special equipment

Roof panel wiper

The toggle switch (8) switches the roof panel
wiper to the front windscreen wiper and rear
window wiper.
Depending on the position of the toggle switch
(8), the following modes of operation are
available:

Switch setting Roof panel wiper

Setting 0 Off
Setting 1 Intermittent mode
Setting 2 Continuous mode
.

Wash-wipe mode
 Push in multifunction lever (1) as far as it will
go.
Activates wash-wipe mode for the front
windscreen wiper and rear window wiper while
the multifunction lever is pressed in.

Window heater
Switching on the rear window heating
 Press push button (1).
Dummy (2) test.
 Dummy (1) test.
The rear window heating is switched off.
 Dummy (1) test.
The rear window heating is in operation for a
further 15 minutes.

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Special equipment

Heating system

1 Turning knob for temperature control 3 Turning knob for setting vent positions for
2 Rotary switch for blower setting windscreen defrosting

Operating devices
• Turning knob (3) for setting vent positions
for windscreen defrosting
• Turning knob (1) for temperature control
• Rotary switch (2) for blower setting
• Cab air vents (4)

Switching on ventilation
 Turn switch (2) to switch setting "1".
The blower is switched on.
The air flow can be switched to three different
settings.

Windscreen defrosting
For maximum windscreen defrosting:
• Turning knob (1) in far right position (warm)
• Turning knob (3) in far right position (wind-
screen defrosting)
• Rotary switch (2) to far right position (setting
3)
• Close cab air vents (4).

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4 Operation
Special equipment

For normal heating operation:

• Select the temperature using turning knob
(1) (far left → cold / far right → hot)
• Use the blower switch (2) (settings 1 to 3),
air distribution vent (turning knob (3)) and
cab air vents (4) to set the most comfortable
temperature and temperature distribution.

Switching on the seat heater

 Actuate the switch (7).

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Special equipment

Linde Forklift Data Management

(LFM)
Truck data acquisition via the keypad
The input device (1) for truck data acquisition
(FDE) is built into the armrest (3).
The input device has a 12-digit keypad (2).
Each driver is assigned a 5-digit PIN so that
only authorised personnel can operate the
truck.
The truck can only be started once the PIN and
a status code have been entered.

NOTE
The PIN number can be extended from 5 to
8 digits. Before entering the PIN number,
please contact your fleet manager to check
the number of digits in the PIN number and
find out about the truck settings.

Status code

NOTE
The code provides information on the status of
the truck. There is a plug on the LFM housing
for importing and exporting data.
The following codes are available:
0 = truck OK
1 = truck will not start (request service)
2 = request maintenance (truck starts)
3 = problem with driving
4 = problem with lifting
5 = problem with steering
6 = accident damage
7 = user-defined
8 = user-defined
9 = user-defined
The status messages 7 , 8 , 9 can be
defined individually by the user. Please

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4 Operation
Special equipment

contact your fleet manager to find out the

definition of these status messages.

NOTE
If you notice one of these states (such as a
problem with driving) only after you have input
the status code 0 (truck OK), you have to log
off.
 Log in again with the status message 3
(problem with driving).
Logging on and starting the truck:

NOTE
• In the standard setting, the PIN and status
code are required for logging on.
• There is a special setting for logging on only
with a PIN.
 Pull the emergency off switch.
 Turn the knob switch (instead of the key
switch) on the right of the steering column
clockwise as far as the stop.
 Fold open the cover of the armrest (4) to the
right via the opening (5) on the side.

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Special equipment

 Press any button on the keypad to start the

input device.
The green LED (2) flashes.
 Enter your PIN number (factory setting = 0
0 0 0 0 ) and status code.

Therefore, for a properly set-up truck, the PIN

number should be as follows: 0 0 0 0
0 0 .

The status code is not required with the special

setting.
 Confirm the input with the # button (3).
Green LED (2) lights up.

NOTE
The red LED (1) lights up when a code is
entered incorrectly. Press the * button
(4) and re-enter the PIN. If more than three
incorrect entries are made (factory setting),
the red LED (1) lights up and the green LED
(2) flashes. You are blocked from entering a
PIN for 10 minutes. The blocking time can be
interrupted by entering a special PIN. Please
contact your fleet manager.

NOTE
If the truck does not start properly the first time,
the starting procedure can be repeated until
the turning knob (5) is returned to the zero
position and the PIN is discarded after expiry
of the delay time.

NOTE
If the green (2) and red (1) LEDs both light up
as steady lights, the data must be read out.
Please inform your fleet manager at once.
 Close cover of the armrest (4) again.

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4 Operation
Special equipment

 Release parking brake either by pressing

the brake switch (see arrow) or by actuating
the accelerator pedal.
The truck is now ready for use.
Logging out of the truck:
 Press # button.
or
 Leave driver’s seat — this actuates the seat
switch.
After a delay time (factory setting = 10 sec-
onds) the red LED (1) lights up briefly, and the
green (2) and red (1) LEDs then flash for ap-
prox. 3 seconds.
During this period, the truck can be started at
any time. Afterwards, the LEDs go out. The
PIN is discarded and the truck is automatically
turned off.

NOTE
The delay time can be set to between 10 se-
conds and 10 minutes using the diagnostic
program. Please contact your authorised dea-
ler.
Switching off the truck:
 Turn knob switch anticlockwise to the zero
position.
The truck is turned off immediately without a
delay time.

Truck data acquisition via RFID chip or

magnetic strip card
The truck data acquisition (FDE) input device
is integrated in the armrest console.
The input device has a corresponding field
(3) on which the RFID chip or a magnetic strip
card must be placed so that the truck data can
be read in and the truck can be started.
Logging on and starting the truck:
 Pull the emergency off switch.
 Turn the knob switch (instead of the key
switch) on the right of the steering column
clockwise as far as the stop.

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 Fold open the cover of the armrest to the

right via the opening on the side.
The green LED (2) flashes.
 Place the RFID chip or magnetic strip card
on the truck data acquisition unit (3).
The truck data is read in.
Green LED (2) lights up.
 Close the armrest cover again.
 Release parking brake either by pressing
the brake switch or by actuating the accel-
erator pedal.
The truck is now ready for use.

NOTE
The red LED (1) lights up when a code is
entered incorrectly.
Possible causes of errors:
• Read errors
• Incorrect or defective RFID chip or magnetic
strip card.

NOTE
If the green (2) and red (1) LEDs both light up
as steady lights, the data must be read out.
Please inform your fleet manager at once.
Logging out of the truck:
 Press # button.
or
 Leave driver’s seat — this actuates the seat
switch.
After a delay time (factory setting = 10 sec-
onds) the red LED (1) lights up briefly, and the
green (2) and red (1) LEDs then flash for ap-
prox. 3 seconds.
During this period, the truck can be started at
any time. Afterwards, the LEDs go out. The
PIN is discarded and the truck is automatically
turned off.

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4 Operation
Special equipment

NOTE
The delay time can be set to between 10 se-
conds and 10 minutes using the diagnostic
program. Please contact your authorised dea-
ler.
Switching off the truck:
 Turn knob switch anticlockwise to the zero
position.
The truck is turned off immediately without a
delay time.

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Special equipment

Integrated charger
Battery charger LPS-80/75

NOTE
With a new battery, the battery charger must
be set accordingly prior to its first commissi-
oning using the diagnostic program (charging
characteristic curve setting). This does not
need to be carried out if the battery is supplied
by the factory. Please contact your authorised
dealer.
The integrated battery charger (1) (Linde
Power Source) is attached to the counter-
weight within the battery compartment and is
responsible for charging the truck battery.
The battery charger is available in the follow-
ing design:
LPS-80/75 (80 V / 75 A)

NOTE
The battery charger LPS-80/75 (80 V/75 A) is
a class A device in accordance with EN 55011.
It may be operated in all areas that are directly
connected to the low voltage power supply and
that supply domestic buildings, apart from in
the living areas. However, only after approval
by the electricity supply authorities may class
A devices also be operated in the living areas
or in areas that are directly connected to a
public low voltage power supply. Contact your
authorised dealer.
To protect the battery charger, there is an
output fuse for the battery charging current
under the cover (2).

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Special equipment

The battery charger always has a 400 V / 16 A

CEE plug (1).

NOTE
A helix cable with a CEE 400 V/16 A socket
and a CEE plug (400 V/16 A) can be supplied
for the battery charger. It is located at the back
in the counterweight.
The battery charger directly activates the
charging indicator lights in the display unit.
A further component of the integrated charger
system is a temperature sensor in the battery
tray.
The charging process can be interrupted by
pressing a push button (3), located on the
right of the battery male connector (CEE
400 V / 16 A plug).
The mains plug can then be disconnected
from the socket.
The push button (3) functions as a start button
for the charging process when batteries are
deeply discharged.
During the charging process, the battery hood
can remain closed.
The charge gases produced are extracted
outwards from the battery compartment via
the fan (2).

NOTE
The fan (2) starts to operate as soon as the
emergency off switch is pressed. If the truck is
not used for a longer period of time, the battery
male connector must be removed in order to
prevent an unnecessary battery discharge.

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Special equipment

The truck control unit has a sensor (3) on the

hinge (2) of the rear cover (1), to determine
whether or not the cover is fitted to the truck. If
the sensor is deactivated during the charging
process (rear cover removed or folded up),
all drive functions and hydraulic functions are
interrupted.

The battery charger is also able to control an

external air pump (1) for electrolyte circulation
(EC).

NOTE
A filter is integrated into the air pump for the
electrolyte circulation; this must be cleaned or
replaced in accordance with the maintenance
intervals.
All parameters (charging procedure, battery
type etc.) can be set using the diagnostic
program.
Contact your authorised dealer.

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Charging / mains supply for the battery

charger
The integrated charger is connected via a
mains line (helix cable) to a mains socket
(CEE socket 16 A / 400 V) for power supply
and to start the charging process.
Insert the mains line (helix cable) connection
to the mains socket.
DANGER
Improper protection of the mains socket means that
the mains cable is at risk of overheating.
The mains socket must be protected in accordance
with regulations. This applies especially to the use
of extension cords. Observe the notes for correct
protection of mains sockets. Contact an authorised
technician.

DANGER
There is a risk of fatal electric shock from a dama-
ged mains cable.
Only use mains cables in good condition that have
been tested by an authorised technician.

NOTE
With a new battery, the battery charger must
be set accordingly prior to its first commissi-
oning using the diagnostic program (charging
characteristic curve setting). Contact your au-
thorised dealer.

NOTE
During charging, ensure sufficient ventilation
for the charge gases to escape. It is not
necessary to open the battery hood or the
battery door, because a fan is installed to
extract the charge gases. Only charge the
battery in well ventilated areas. The sealing
plugs on the cells must remain closed.
The following procedure must be complied
with, otherwise in some circumstances error
codes may be registered in the display unit.
 Switch off the key switch.
 Push the emergency off switch.

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Special equipment

NOTE
The fan (2) for extracting the charge gases is
operational.
 Open the rear cover.
 Insert the mains line CEE coupling into the
battery charger socket (1).
 Insert the mains line CEE plug into the
mains socket.

NOTE
If the rear cover is removed, the sensor
is deactivated. This causes the traction
and hydraulic functions of the truck to be
disabled. After charging, the rear cover must
be correctly refitted, so that the sensor is
reactivated and the traction and hydraulic
functions are restored.

Start of charging
The yellow "plug symbol" indicator light
lights up and the charging process begins
automatically.

NOTE
The charging process only begins automati-
cally if the battery terminals are correctly con-
nected to the integrated charger, the system
voltage is present and the battery voltage is
at least 1.6 V/cell. It may take up to one mi-
nute for charging to start. To start charging
deeply discharged batteries with a cell vol-
tage between 1.0 V/cell and 1.6 V/cell (red
"lightning symbol" indicator light flashes), the
push button (3) (deep discharge start/char-
ging interruption) must be pressed for at least
3 seconds.

Operating Instructions – 387 801 1501 EN – 12/2012 111

4 Operation
Special equipment

End of charging
The charging process is automatically ended
when the charging program comes to an end,
i.e. when the battery has been charged.
When the battery has been charged to its full
capacity, the green indicator light "battery
symbol" in the display unit lights up.

NOTE
Once the charging process is complete, the
rear flap must be closed again correctly.
Otherwise the truck is not ready for operation
(rear sensor not actuated).

Charging interruption
The battery charger should not be interrupted
during the charging process.
However, external factors may make an inter-
ruption of the charging process necessary.

NOTE
The charging process is systematically inter-
rupted if, for example, the fan is blocked or if
the minimum number of revolutions for the fan
is not achieved as a result of contamination
being too heavy.
DANGER
People or property may be seriously injured or da-
maged if the mains plug or battery male connector
is disconnected while charging underway. The
sparks which are generated can ignite the gases
which are formed during the charging process.
To end the charging process, always press push
button (3) (deep discharge start / charging interrup-
tion) first and then remove the mains plug.

Charging will restart as soon as the mains

plug is re-inserted into the mains socket (wait
at least 20 seconds) and the emergency off
switch is switched off.

NOTE
During normal operation, the charging pro-
cess should not be terminated before it is

112 Operating Instructions – 387 801 1501 EN – 12/2012

 Operation 4
Special equipment

automatically switched off. Early switch-off

during charging results in an insufficiently
charged battery. This diminishes the battery’s
capacity.

Equalising and maintenance charges

If the mains plug remains in the socket, the
battery automatically undergoes equalising
charging when charging has been completed.
The yellow indicator light "plug symbol" in the
display unit flashes to signal an equalising
charge.

Charge indicators
The status of the integrated charger is shown
by three indicator lights in the display unit.
The indicator lights are activated even if the
truck has been switched off.
Depending on the operating status of the
battery charger, the following states may be
displayed.

State Description
1
Charging
Yellow
2
Charging start, equalising charge and recharging phase
Flashing yellow
3
Charging ended
Green
4
Maintenance charging
Flashing green
5 Battery is totally discharged; the battery charger can be started manually by
Flashing red pressing the charge start/charging interruption push button
.

Operating Instructions – 387 801 1501 EN – 12/2012 113

4 Operation
Special equipment

Error messages

During charging procedure

State +
Error Description Troubleshooting solutions
code
1 Battery charger’s output module has Replace the battery charger. Contact
C150 failed your authorised dealer.
1 Replace the battery charger. Contact
Wrong battery charger installed in truck.
C153 your authorised dealer.
Check allocation of battery voltage to the
battery charger.
When the battery voltage is between
1 Battery voltage less than 1.0 V/cell
1.0 V/cell and 1.6 V/cell, start the deep
C100 or greater than 3.0 V/cell
discharge.
Battery faulty. Contact your authorised
dealer.
Allow the battery to cool down; the charg-
2 Battery temperature too high (higher than
ing process will resume automatically
C110 55°C)
when the temperature falls below 45°C.

114 Operating Instructions – 387 801 1501 EN – 12/2012

 Operation 4
Special equipment

During charging procedure

State +
Error Description Troubleshooting solutions
code
Battery was disconnected during the Before disconnecting the battery, unplug
1
charging process without first unplugging the mains plug.
C101
the mains plug. Check charging connector contacts.
3 Pressure drop in the EC air system Check the hoses for leak tightness.
C102 Switch to charging program without EC Check the pump for correct function.
1 Pressure drop in the EC air system Check the hoses for leak tightness.
C103 Shut-off Check the pump for correct function.
The maximum permissible charging
Battery capacity too large for the battery
1 time or the safety charging factor was
charger.
C104 exceeded.
Battery faulty
Safety shutdown
3 Forced switching to recharging
C105 No shut-off
3 Safety characteristic curve active Set correct charging characteristic curve.
C106 No shut-off Contact your authorised dealer.
4 Charging process complete (with acti- Set correct charging characteristic curve.
C106 vated safety characteristic curve) Contact your authorised dealer.
Charging process complete (with Check the hoses for leak tightness.
4
switched charging program after pres- Check the pump for correct function.
C102
sure drop in the EC system) Contact your authorised dealer.
Check the mains fuse or replace the
1 System voltage too low or has dropped
mains cable. Contact your authorised
C109 out <207 VAC or <360 VAC
dealer.
Disconnect the battery charger from the
mains and allow it to cool down.
1 Overtemperature at the battery charger
If necessary, clean the cooling fins and
C108 power module
cooling air vents; alternatively the fan
may be faulty.
Disconnect the battery charger from the
mains and allow it to cool down.
3 Overloading at the battery charger power
If necessary, clean the cooling fins and
C107 module
cooling air vents; alternatively the fan
may be faulty.
C 112 Manual charging start performed.

During discharging
State +
Error Description Troubleshooting solutions
code
5 The battery charger output module has Battery charger faulty. Contact your
C150 failed. authorised dealer.
5
Fault on the CAN bus. Contact your authorised dealer.
C152

Operating Instructions – 387 801 1501 EN – 12/2012 115

4 Operation
Working under load

During discharging
State +
Error Description Troubleshooting solutions
code
5 Replace the battery charger. Contact
Wrong battery charger installed in truck.
C153 your authorised dealer.
5T553 The battery charger has system voltage Disconnect the mains plug before
D170 and the truck is switched on. switching on the truck.
.

Working under load

Before load pick up
Before picking up a load, check the load
capacity diagram (see arrow). It is attached to
the top left-hand side of the overhead guard.

DANGER
The residual load capacity of a truck is determined
by the mast type (standard, duplex, triplex), the
lift height of the installed mast, the tyres on the
front axle, the use of attachments or additional
equipment and the backwards tilt restriction. If one
of these parameters is changed, this can have a
considerable effect on the residual load capacity.
If the event of conversions, the new residual load
capacity of the truck must be determined and
the load capacity diagram must be changed as
necessary. Please contact your authorised dealer.

The maximum permissible load is determined

by the centre of gravity distance between the
load and the back of the fork arms, and the lift
height.

DANGER
The values specified in the load capacity diagram
apply to compact homogeneous loads and must not
be exceeded, as this will impair the stability of the
truck and the rigidity of the fork arms and lift mast.
When using attachments, observe the capacity
rating plate for each attachment.

NOTE
Observe the load restriction and consult your
authorised dealer.
• Before transporting off-centre or swinging 1 Maximum weight of permissible loads in kg
loads 2 Lift height in mm

116 Operating Instructions – 387 801 1501 EN – 12/2012

 Operation 4
Working under load

3 Series designation with truck model and lift

• Before transporting loads with the lift mast mast series
tilted forward or the load not close to the 4 Distance between load centre of gravity and
ground fork back in mm
• Loads involving a large centre of gravity
distance
• Before transporting loads in a wind force of
6 and upwards.
Example
Load centre of gravity distance: 600 mm
Load height to be lifted: 6000 mm
 Trace a vertical line from a load distance of
600 mm to its point of intersection with the
line for a lift height of 6000 mm.
 Read off the maximum permissible load to
the left of the point of intersection with the
horizontal line.
The maximum load in this example is 600 kg
Use the same procedure for other lift heights
and centre of gravity distances. The deter-
mined values refer to both fork arms and
evenly distributed loads.

Adjust fork arm distance

NOTE
The centre of gravity of the load should be
positioned between the fork arms in the
middle.

Operating Instructions – 387 801 1501 EN – 12/2012 117

4 Operation
Working under load

 Lift the stopping lever (1).

 Adjust the fork arms inwards or outwards
according to the load to be lifted .
Ensure a uniform distance to the centre of the
forklift truck.
 Allow the stopping lever to snap into place
in a groove on the fork carriage.

d3921429

118 Operating Instructions – 387 801 1501 EN – 12/2012


Load pick up
DANGER
Risk of falling and crushing.
Never allow people to be lifted on
either the forks, or on a pallet placed
on the forks.
If the truck is to be used for lifting
people then it must be fitted with
a purposely designed working
platform. Ensure that the platform,
platform securing method and
platform interlocks have been
approved for the truck.
Please contact your local distributor.
DANGER
Danger of a falling load. Standing or
walking in the vicinity of an elevated
mast is extremely dangerous.
During stacking and de-stacking
operations do not allow people to
stand or walk in the working area of
the truck.
Trucks should only be driven with the
load lowered and tilted back. Look
out for people.
DANGER
Danger of falling load when load is picked up
incorrectly
Loads must be arranged so that they do not pro-
trude beyond the truck loading area and cannot
slip, topple over or fall off. If necessary, use a load
backrest (special equipment).
Driving under load
NOTE
When transporting cargo, the dispatcher must
ensure that the goods are safely loaded for
transportation and secured as necessary.
Please therefore make sure that goods are
properly stacked and there is no damage
to packaging, pallets etc. The carrier must
ensure safe loading.
Operating Instructions – 387 801 1501 EN – 12/2012
Operation 4
Working under load
DANGER
Danger of overloading
Adhere to the permitted load weight based on the
load capacity diagram.
DANGER
When a load is raised, it is not permitted for anyone
to stand beneath the suspended cargo.
Always drive the industrial truck with the load
lowered and the lift mast tilted to the rear.
 Approach the load to be taken up carefully
and as accurately as possible.
 Set the lift mast to vertical.
 Lift or lower the fork carriage to the neces-
sary height.
 Carefully steer the truck forks beneath the
centre of the load to be taken up, where
possible so the load touches the fork back,
taking account of adjacent loads.
 Lift fork carriage until the load is no longer in
contact with the supporting surface.
 Reverse the industrial truck to release the
load.
 Tilt the lift mast backwards.
 Do not transport loads if they have slipped
to the side ( e. g. with sideshift).
 Transport loads close to the floor.
 On ascents/descents, always transport
loads facing uphill; never travel across the
slope or turn around.
 If visibility is poor, instructions should be
provided by a second person.
119
4 Operation
Working under load

 If the load to be transported is stacked so direction, the industrial truck must only be
high as to obstruct visibility in the drive driven in reverse.

120 Operating Instructions – 387 801 1501 EN – 12/2012

 Operation 4
Working under load

Setting down loads

DANGER  Position the lift mast vertically (load hori-

zontal).
Danger caused by a falling load
Carefully lower the fork carriage until the fork arms  Carefully move the load over the load
touch the ground. storage area.
Never park the truck and leave it with a raised load.
 Carefully lower the load until the fork arms
are clear.
 Carefully drive the industrial truck up to the
load storage area.  Back up the truck.
 Lift the fork carriage to the necessary height.

Operating Instructions – 387 801 1501 EN – 12/2012 121

4 Operation
Working under load

Towing device

NOTE
The towing device is only used to tow light
trolleys on the factory premises. (The appli-
cable VDI directives (VDI 3973) and "Regular
testing" regulations must be observed).
 Turn the towing pin (1) through 90° and lift.
 Insert the towing jaws into the clutch release
sleeve.
 Push down the towing pin against the spring
pressure, turn through 90° and allow to snap
into place in the catch.

122 Operating Instructions – 387 801 1501 EN – 12/2012

 Operation 4
Before exiting the truck

Before exiting the truck

 Select a location that is secure and as clean The fork arms must touch the ground.
as possible.
 Remove foot from accelerator pedal.
 Set down the load and lower the fork
 Apply the parking brake manually.
carriage completely.
 Turn the key switch anticlockwise to the
 Tilt mast forwards slightly.
zero position and remove the switch key.

Parking the truck securely

The manually actuated parking brake holds
the industrial truck on gradients of up to 15%.
On gradients greater than 10%, the truck must
also be secured with chocks, for example.
DANGER
Risk to life
It is dangerous and therefore forbidden to park
or leave the industrial truck on ramps without the
parking brake actuated, or on gradients greater
than 10%, or with the load raised, or with the lifting
accessory raised.

Loading / Transporting
Removing the lift mast
This work should only be performed by
specialist staff working for your authorised
dealer.

Operating Instructions – 387 801 1501 EN – 12/2012 123

4 Operation
Loading / Transporting

Driving without the lift mast

NOTE
Driving the truck without a lift mast is permis-
sible only for transfer purposes and the speed
must be adjusted as appropriate.
 Switch off the truck
 Push the emergency off button.
 Remove the lift mast.
CAUTION
When driving without a lift mast, the speed of the
industrial truck must be also reduced for safety
reasons.
For this reason, before the lift mast is removed,
two additional stop screws must be fitted under the
forwards and backwards accelerator pedals (dual
pedal operation) or a stop screw must be fitted
under the forwards accelerator pedal (single pedal
operation) in order to reduce the speed.

 Screw a hexagon head screw M10 x 12 (3)

half way into a long hexagon nut M10 (2).
 Screw the hexagon nut (2) onto the existing
hexagon head screw M10 (1) until one
hexagon head screw (3) hits the other
hexagon head screw (1).
 Lock the hexagon nut (2). 3

NOTE 2
The required long hexagon nuts will be
provided.
 Refit the lift mast.
1
After fitting the lift mast:
d3921520
 Remove the stop screws for speed reduc-
tion.
This work should only be performed by
authorised specialist staff.
Contact your authorised dealer.

124 Operating Instructions – 387 801 1501 EN – 12/2012

 Operation 4
Loading / Transporting

Crane loading

DANGER
There is a risk of accident and risk
to life when loading with a crane if
persons are in the working area of
the crane.
When using a crane to load the truck,
be particularly careful to ensure
that no-one is in the working area
of the crane! Observe loading weight
according to nameplate. Do not walk
under suspended loads! Only use
round slings and a loading crane with
a sufficient load capacity.

WARNING
Crane loading may cause damage to the tilt cylin-
ders and the cover sheet on the counterweight.
Retract the lift mast, retract the tilt cylinders as far
as the stop and lift the truck in such a way that it
hangs at an angle towards the front.

 Attach round slings to the lifting points.

The lifting positions on the truck are not
marked.
 Place the round sling (2) (min. load ca-
pacity: 3500 kg) around the bottom of the
counterweight.
 Use edge protectors as a safeguard from
sharp edges on the bridge piece.
 Place the round sling (3) (min. load capac-
ity: 3500 kg) around the bridge piece on the
outer mast of the lift mast.
 Insert all ends into the crane hook (1).
 Make sure that the safety lock (4) is closed.

NOTE
During lifting, the lifting gear should not touch
the overhead guard, the cover sheet on the
counterweight and any additional equipment
attached.

Operating Instructions – 387 801 1501 EN – 12/2012 125

4 Operation
Loading / Transporting

Crane loading with lifting eyes

CAUTION
If crane loading is carried out at an angle, the lifting
eyes may break off.
Crane loading with lifting eyes should only be
carried out with the appropriate lifting gear (3),
whereby the chains (2, 6) lead up vertically from the
lifting eyes (1). Make sure that the safety lock (5) is
closed.

 Attach chains (6) (min. load capac-

ity: 3500 kg) to the lifting eyes (1) on the
counterweight.
 Attach chains (2) (min. load capac-
ity: 3500 kg) to the lifting eyes (1) on the
lift mast.

NOTE
During lifting, the lifting gear should not touch
the overhead guard, the cover sheet on the
counterweight and any additional equipment
attached.

Transportation by lorry or low loading trucks

 Lower the lift mast completely.
 Tilt lift mast forwards.
The fork arms must be resting on the ground.
 Apply the parking brake.
 Place wedges underneath.
 Lash the truck securely to the outer profiles
on the left and right of the lift mast and to the
towing jaws of the counterweight.

126 Operating Instructions – 387 801 1501 EN – 12/2012

 5

Maintenance
5 Maintenance
General remarks
General remarks
Your industrial truck will only remain in a state
ready for use at all times if you perform a small
number of maintenance and inspection tasks
according to the information in the registration
document for the industrial truck and the data
or instructions in the operating instructions at
regular intervals.
Servicing should be carried out only by
qualified staff authorised by Linde.
You can agree to have this work performed on
the basis of a maintenance contract concluded
with your authorised Linde dealer.
If you wish to perform this work yourself, we
recommend at least having the first 3 customer
service checks carried out by the dealer’s
service technician in the presence of your
workshop representative, so that your own
workshop staff can be instructed accordingly.
Whenever performing maintenance work,
the industrial truck should be parked on a level
surface and secured so that it cannot roll away.
The industrial truck must be switched off com-
pletely and the switch key must be removed.
 Disconnect the battery male connector.
When working with the fork carriage and/or
lift mast raised, make sure they are secured
against unintentionally dropping.
Whenever work is carried out at the front of the
industrial truck, the lift mast must be secured
to prevent it from tilting backwards.
No modifications, in particular attachments or
conversions, should be made to your industrial
truck without the manufacturer’s approval.
128
All servicing work should be followed by a
function check and a test run performed on the
industrial truck.
WARNING
Any side doors fitted could fall shut during mainten-
ance work and trap staff.
For this reason, both doors should be opened and
secured in place during servicing.
CAUTION
The industrial truck must always be properly label-
led.
Missing or damaged identification plates and/or ad-
hesive labels must be replaced. For the warehouse
or order number, please consult the spare parts
catalogue.
ENVIRONMENT NOTE
Observe information about working with
consumables.
NOTE
When using industrial trucks under extreme
conditions (e.g. extreme heat or cold, high
levels of dust etc.), the time periods given in
the maintenance overview should be reduced
accordingly.
Maintenance intervals
The inspection and maintenance intervals
depend on the operating and application
conditions of the industrial truck.
For more difficult conditions we recommend
shorter intervals.
Please contact your authorised dealer.
Operating Instructions – 387 801 1501 EN – 12/2012
 Maintenance 5
Inspection and maintenance data

Inspection and maintenance data

No. Unit Devices/consumables Filling quantity/set values
Distilled water As required
1 Battery
Acid-free grease As required
Electric motors:
2 Traction motor Electric cleaner
Hydraulic motor
Electrical system: - -
Right- and left-hand traction motor Fuse (1F1) 1 x 355 A
Pump motor Fuse (2F1) 1 x 355 A
Discharge indicator Fuse (F3) 1 x 10 A
3 Fan 9M1, 9M4, 9M5 Fuse (1F8) 1x5A
Fan 9M2, 9M3 Fuse (2F6) 1x5A
Control current Fuse (F2) 1 x 15 A
Horn Fuse (4F1) 1 x 10 A
Voltage transformer (secondary) Fuse (F4) 1x5A
4 Hydraulic system Filter insert for suction filter Efficiency =15 µm
Filter insert for pressure Efficiency = 6 µm
filter
Hydraulic system Hydraulic oil Maximum 25 litres
Standard, duplex — all lift heights -
Triplex — lift height up to 5161 mm 18 litres
Triplex — lift height up to 7955 mm 24 litres
Drive wheel Torque value 425 Nm
5 Wheels
Rear wheel Torque value 210 Nm
6 Wheel gear Gearbox oil Oil change 0.55 litres
7 Steering axle Grease As required
8 Lift mast and chain guide Linde chain spray As required
.

Operating Instructions – 387 801 1501 EN – 12/2012 129

5 Maintenance
Recommendations for consumables
Recommendations for consumables
Hydraulic oil
CAUTION
Damage to the hydraulic system due to unapproved
hydraulic oil.
Use only approved hydraulic oils. Only the oils
listed below have the manufacturer’s approval. Do
not mix hydraulic oils. If in doubt, please contact
your authorised dealer. Recommendations made
by representatives from the mineral oil industry
should also be agreed with your authorised dealer.
Standard (mean oil continuous temperature
40 °C - 60 °C)
ISO-L-HM 46 as per ISO 6743-4
or ISO VG46-HLP as per DIN 51524-2
Heavy duty (mean oil continuous temperature
over 60 °C)
ISO-L-HM 68 as per ISO 6743-4
or ISO VG68-HLP as per DIN 51524-2
Light duty (mean oil continuous temperature
below 40 °C)
ISO-L-HM 32 as per ISO 6743-4
or ISO VG32-HLP as per DIN 51524-2
Widely varying conditions of usage
NOTE
All the above applications can be covered
by a hydraulic oil with a high viscosity index
(multigrade oils).
ISO-L-HV 46 as per ISO 6743-4
or ISO VG46-HVLP as per DIN 51524-3
Bio-hydraulic oil
Castrol Carelube HFS 46 highly biodegrad-
able hydraulic fluid
CAUTION
Damage to the hydraulic system due to mixing
bio-hydraulic oil with mineral oil.
Only use approved, pure bio-hydraulic oil.
130
Gearbox oil
Preferably SAE 80W-90 API GL4
also suitable: SAE 80W-90 API GL5
Recommendation:
ARAL EP Plus SAE80W-90 API
Castrol Syntrax Universal 80W-90
BP Energear HT 80W-90
ENVIRONMENT NOTE
Used oil must be kept away from children until
disposed of according to the regulations. Un-
der no circumstances should oil be allowed to
penetrate the mains drainage or the ground.
Due to disposal problems and the specialist
knowledge required, the gearbox oil change
should ideally be carried out by your authori-
sed dealer.
Grease
Linde lithium-saponified lubricating grease
KPF2K as per DIN 51825
Linde spare part no., see spare parts
catalogue
Linde heavy-duty grease, lithium-saponi-
fied with EP agents and MOS2
KPF2N-20 as per DIN 51825
Linde spare part no., see spare parts
catalogue
NOTE
Mixing with soap-based lubricating grease
types other than lithium-saponified is not
permitted.
Battery grease
Acid-free lubricating grease (battery
grease)
Chain spray for leaf chains
Linde standard chain spray
Linde spare part no., see spare parts
catalogue
Operating Instructions – 387 801 1501 EN – 12/2012
 Maintenance 5
Recommendations for consumables

Electric cleaner
Contact your authorised dealer.

Operating Instructions – 387 801 1501 EN – 12/2012 131

5 Maintenance
Inspection and maintenance overview

Inspection and maintenance overview

One-off service plan after 1000 hours
At operating hours Carried
out
1000  
Note about service plan
Refer also to the recommendation for consumables.
Preparations
Clean the truck (as required).
Check and adjust the date and time of the display unit.
Gearbox
Drive axle and planetary transmission: Check the mounting.
Check the planetary transmission for leaks.
Change the oil for the planetary transmission.
Check leak tightness between planetary transmission and traction motor (checking
screw axle)
Chassis, bodywork and fittings
Check the condition and mounting of the metal–rubber bearings on the drive axle.
Check the mountings of the steering axle, planetary transmission, counterweight
and overhead guard.
Check and lubricate other bearings and joints (if necessary).
Check the axle bearing mounting; tighten as required.
Chassis frame
Check the towing mechanism: Release the multi-disc brake by pressing the brake
lever on the brake valve several times.
Check the brake system (service brake, parking brake) is working correctly.
Check the mounting of the wheels and tighten if necessary (at least every 100
hours).
Check the condition of the antistatic belt when using non-antistatic tyres (light-
coloured tyres).
Clean the steering axle and lubricate (as required).
Operating devices
Align the accelerator potentiometer.
Check the bellows on the joystick.
Check that the horn is functioning correctly.
Adjust joysticks

132 Operating Instructions – 387 801 1501 EN – 12/2012

 Maintenance 5
Inspection and maintenance overview

Carried
At operating hours
out
1000  
Check the pedal group for ease of movement and oil joints as required.
Electrics
Check the condition and secure positioning of the electric cables, plug connectors
and cable connections.
Check that the electrical connections on the power modules are securely attached.
Check the electrical components on the contactor carrier for contamination and
clean as required.
Check the power modules for contamination and clean as required.
Check the fan for correct function and contamination and clean as required.
Check the truck battery in accordance with the manufacturer’s specifications.
Integrated charger: Clean the heat sink and fan.
Check the active charging ventilation unit for correct operation and check fan.
Test rear cover sensor for correct function.
Check the filters on the electrolyte circulation pump, cleaning as required.
Check the filter on the heating system/blower.
Hydraulics
Check the hydraulic system for leaks.
Hydraulic system: Check the oil level.
Check the oil cooler with fan for contamination (series 388 only)
Load lift system
Check the condition of the lift mast, lift mast chain, lift cylinders and end stops and
check for secure attachment and correct operation.
Check the lift mast mounting at the axle and tighten as required.
Adjust the length of the lift mast chain, clean and apply chain spray.
Check the tilt cylinder mountings on the tilt cylinder supports and lift mast.
Check fork arms and arm safety devices.
Check and lubricate the mast fixation at the drive axle.
Check the pre-load of the double hoses for the auxiliary hydraulics.
Clean and lubricate the sideshift and attachments and carry out function checking
(refer to the manufacturer’s operating instructions).
Subsequent tasks
Read out the error memory and delete.

Operating Instructions – 387 801 1501 EN – 12/2012 133

5 Maintenance
Inspection and maintenance overview

Carried
At operating hours
out
1000  
Enter the next maintenance interval.
Carry out a functional test and test drive.
Affix maintenance sticker.

134 Operating Instructions – 387 801 1501 EN – 12/2012

 Maintenance 5
Inspection and maintenance overview

Service plan for every 1000 hours

At operating hours

2000 4000 5000 7000 8000

Carried
10000 11000 13000 14000 16000 out
17000 19000 20000  
Note about service plan
However, depending on the consumables used, driving style and application con-
ditions, at least every year of operating time. Refer also to the recommendation for
consumables.
Preparations
Clean the truck (as required).
Check and adjust the date and time of the display unit.
Gearbox
Drive axle and planetary transmission: Check the mounting.
Check the planetary transmission for leaks.
Check leak tightness between planetary transmission and traction motor (checking
screw axle)
Chassis, bodywork and fittings
Check and lubricate other bearings and joints (if necessary).
Check the axle bearings for wear; replace as required.
Check the axle bearing mounting; tighten as required.
Chassis frame
Check the towing mechanism: Release the multi-disc brake by pressing the brake
lever on the brake valve several times.
Check the brake system (service brake, parking brake) is working correctly.
Check the mounting of the wheels and tighten if necessary (at least every 100
hours).
Check the condition of the antistatic belt when using non-antistatic tyres (light-
coloured tyres).
Clean the steering axle and lubricate (as required).
Operating devices
Align the accelerator potentiometer.
Check that the horn is functioning correctly.
Align the joysticks.
Check the pedal group for ease of movement and oil joints as required.
Electrics

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5 Maintenance
Inspection and maintenance overview

At operating hours
2000 4000 5000 7000 8000
Carried
10000 11000 13000 14000 16000 out
17000 19000 20000  
Check the electrical components on the contactor carrier for contamination and
clean as required.
Check the power modules for contamination and clean as required.
Check the fan for correct function and contamination and clean as required.
Check the truck battery in accordance with the manufacturer’s specifications.
Integrated charger: Clean the heat sink and fan.
Check the active charging ventilation unit for correct operation and check fan.
Check the rear cover sensor for correct function.
Check the filters on the electrolyte circulation pump, cleaning as required.
Check the filter on the heating system/blower.
Hydraulics
Hydraulic system: Check the oil level.
Check the oil cooler with fan for contamination (series 388 only)
Load lift system
Check the lift mast mounting at the axle and tighten as required.
Adjust the length of the lift mast chain, clean and apply chain spray.
Check the tilt cylinder mountings on the tilt cylinder supports and lift mast.
Check and lubricate the mast fixation at the drive axle.
Check the pre-load of the double hoses for the auxiliary hydraulics.
Clean and lubricate the sideshift and attachments and carry out function checking
(refer to the manufacturer’s operating instructions).
Subsequent tasks
Read out the error memory and delete.
Enter the next maintenance interval.
Carry out a functional test and test drive.
Affix maintenance sticker.

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 Maintenance 5
Inspection and maintenance overview

Service plan for every 3000 hours

At operating hours Carried
out
3000 9000 15000  
Note about service plan
However, depending on the consumables used, driving style and application condi-
tions, at least every two years of operating time. Refer also to the recommendation
for consumables.
Preparations
Clean the truck (as required).
Check and adjust the date and time of the display unit.
Gearbox
Drive axle and planetary transmission: Check the mounting.
Check the planetary transmission for leaks.
Planetary transmission: change the oil.
Check the oil level in the planetary transmission.
Check leak tightness between planetary transmission and traction motor (checking
screw axle)
Chassis, bodywork and fittings
Check the condition and mounting of the metal–rubber bearings on the drive axle.
Check the mountings of the steering axle, planetary transmission, counterweight
and overhead guard.
Check and lubricate other bearings and joints (if necessary).
Check the mounting of the battery hood locking bolt.
Check the axle bearing mounting on the drive axle and tighten as required.
Chassis frame
Check the towing mechanism: Release the multi-disc brake by pressing the brake
lever on the brake valve several times.
Check the brake system (service brake, parking brake) is working correctly.
Check the mounting of the wheels and tighten if necessary (at least every 100
hours).
Check the condition of the antistatic belt when using non-antistatic tyres (light-
coloured tyres).
Clean the steering axle and lubricate (as required).
Operating devices
Align the accelerator potentiometer.
Check the bellows on the joystick.

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5 Maintenance
Inspection and maintenance overview

Carried
At operating hours
out
3000 9000 15000  
Check that the horn is functioning correctly.
Adjust joysticks
Check the pedal group for ease of movement and oil joints as required.
Electrics
Check the condition and secure positioning of the electric cables, plug connectors
and cable connections.
Check that the electrical connections on the power modules are securely attached.
Check the electrical components on the contactor carrier for contamination and
clean as required.
Check the power modules for contamination and clean as required.
Check the fan for correct function and contamination and clean as required.
Check the truck battery in accordance with the manufacturer’s specifications.
Integrated charger: Clean the heat sink and fan.
Check the active charging ventilation unit for correct operation and check fan.
Check the rear cover sensor for correct function.
Check the filters on the electrolyte circulation pump, cleaning as required.
Check the filter on the heating system/blower.
Hydraulics
Hydraulic system: Change the breather filter, pressure filter and suction filter.
Check the hydraulic system for leaks.
Hydraulic system: Check the oil level.
Check the oil cooler with fan for contamination (series 388 only)
Load lift system
Check the condition of the lift mast, lift mast chain, lift cylinders and end stops and
check for secure attachment and correct operation.
Check the lift mast mounting at the axle and tighten as required.
Adjust the length of the lift mast chain, clean and apply chain spray.
Check the tilt cylinder mountings on the tilt cylinder supports and lift mast.
Check the tilt cylinder bearing (visual inspection) for wear and replace if necessary.
Check fork arms and arm safety devices.
Check and lubricate the mast fixation.
Check the pre-load of the double hoses for the auxiliary hydraulics.

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 Maintenance 5
Inspection and maintenance overview

Carried
At operating hours
out
3000 9000 15000  
Clean and lubricate the sideshift and attachments and carry out function checking
(refer to the manufacturer’s operating instructions).
Check slide guides on sideshift for wear.
Subsequent tasks
Read out the error memory and delete.
Enter the next maintenance interval.
Carry out a functional test and test drive.
Affix maintenance sticker.

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5 Maintenance
Inspection and maintenance overview

Service plan for every 6000 hours

At operating hours Carried
out
6000 12000 18000  
Note about service plan
However, depending on the consumables used, driving style and application condi-
tions, at least every three years of operating time. Refer also to the recommendation
for consumables.
Preparations
Clean the truck (as required).
Check and adjust the date and time of the display unit.
Gearbox
Drive axle and planetary transmission: Check the mounting.
Visually check the planetary transmission for leaks.
Planetary transmission: change the oil.
Check the oil level in the planetary transmission.
Check leak tightness between planetary transmission and traction motor (checking
screw axle)
Chassis, bodywork and fittings
Check the condition and mounting of the metal–rubber bearings on the drive axle.
Check the mountings of the steering axle, planetary transmission, counterweight
and overhead guard.
Check and lubricate other bearings and joints (if necessary).
Check the mounting of the battery hood locking bolt.
Check the axle bearing mounting on the drive axle and tighten as required.
Chassis frame
Check the towing mechanism: Release the multi-disc brake by pressing the brake
lever on the brake valve several times.
Check the brake system (service brake, parking brake) is working correctly.
Check the mounting of the wheels and tighten if necessary (at least every 100
hours).
Check the condition of the antistatic belt when using non-antistatic tyres (light-
coloured tyres).
Clean the steering axle and lubricate (as required).
Operating devices
Align the accelerator potentiometer.
Check the bellows on the joystick.

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 Maintenance 5
Inspection and maintenance overview

Carried
At operating hours
out
6000 12000 18000  
Check that the horn is functioning correctly.
Adjust joysticks
Check the pedal group for ease of movement and oil joints as required.
Electrics
Check the condition and secure positioning of the electric cables, plug connectors
and cable connections.
Check that the electrical connections on the power modules are securely attached.
Check the electrical components on the contactor carrier for contamination and
clean as required.
Check the power modules for contamination and clean as required.
Check the fan for correct function and contamination and clean as required.
Check the truck battery in accordance with the manufacturer’s specifications.
Integrated charger: Clean the heat sink and fan.
Check the active charging ventilation unit for correct operation and check fan.
Check the rear cover sensor for correct function.
Check the filters on the electrolyte circulation pump, cleaning as required.
Check the filter on the heating system/blower.
Hydraulics
Hydraulic system: Change the breather filter, pressure filter and suction filter.
Check the hydraulic system for leaks.
Hydraulic system: Check the oil level.
Change the hydraulic oil.
Check the oil cooler with fan for contamination (series 388 only)
Load lift system
Check the condition of the lift mast, lift mast chain, lift cylinders and end stops and
check for secure attachment and correct operation.
Check the lift mast mounting at the axle and tighten as required.
Adjust the length of the lift mast chain, clean and apply chain spray.
Check the tilt cylinder mountings on the tilt cylinder supports and lift mast.
Check the tilt cylinder bearing (visual inspection) for wear and replace if necessary.
Check fork arms and arm safety devices.
Check and lubricate the mast fixation.

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5 Maintenance
Inspection and maintenance overview

Carried
At operating hours
out
6000 12000 18000  
Check the pre-load of the double hoses for the auxiliary hydraulics.
Clean and lubricate the sideshift and attachments and carry out function checking
(refer to the manufacturer’s operating instructions).
Check slide guides on sideshift for wear.
Subsequent tasks
Read out the error memory and delete.
Enter the next maintenance interval.
Carry out a functional test and test drive.
Affix maintenance sticker.

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 Maintenance 5
Gearbox

Gearbox
Checking the planetary transmission
oil level
 Park the truck so that checking screw (1) is
between the 5 and 6 o’clock positions.
 Switch off the truck.

 Unscrew the screw (3).

 Set the depth gauge (2) tightly to 113 mm
and insert into the filling opening (4).
 Remove the depth gauge.
At the minimum oil level, oil must be visible at
the depth gauge measuring tip.
• Minimum oil level: (113 mm setting dimen-
sion at the depth gauge)
• Maximum oil level: (111 mm setting dimen-
sion at the depth gauge)
 Top up with oil as required.

NOTE
Drain off excess oil via the checking screw (1)
into a collection container.
 Unscrew checking screw(1) (tightening
torque 20 Nm).

ENVIRONMENT NOTE
Observe information regarding working with
consumables. See the recommendations for
consumables.
 Check the oil level again.

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5 Maintenance
Gearbox

 Screw in the filler plug (3) and tighten

(tightening torque 70 Nm).

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 Maintenance 5
Gearbox

Checking the planetary transmission

for leaks.
 Raise the truck using jacks at the front left
and right of the truck.
 Place square timbers underneath.
 Depending on the version, check the left
and right-hand sides of the planetary
transmission for leaks at the filler plug,
checking screw, drain plug, the housing
flange and the points shown by the arrows.
Check for leaks between the planetary trans-
mission and the motor:
 Unscrew the checking screw (torx screw),
underneath the drive axle (see the black
arrow) between the planetary transmission
and the motor, and check for leaks.
 Screw the checking screw back in again
(tightening torque 10 Nm).

NOTE
If leaks occur at the planetary transmission,
please contact your authorised dealer.

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5 Maintenance
Gearbox

Changing the oil in the planetary

transmission

ENVIRONMENT NOTE
Observe information regarding working with
consumables. See recommendations for
consumables

NOTE
Change the oild after the first 50 operating
hours, with further oil changes every 3000
hours thereafter.
The oil may also be changed when the drive
wheels are attached.

NOTE
When carrying out an oil change, it should be
ensured that the drive axle is horizontal.
 Warm up the planetary transmission.
 Park the truck so that checking screw (1) is
between the 5 and 6 o’clock positions.
 Switch off the truck.
 Raise the truck using jacks on the left and
the right and secure.
 Carefully lower the jacks until the drive axle
is horizontal.

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 Maintenance 5
Gearbox

 Clean the area around the filler plug (1) and

drain plug (3).
 Unscrew the filler plug (1) (tightening
torque 70 Nm).
 Place a collection container under the drain
plug (3).

NOTE
The drain plug is not located on the planetary
transmission, but on the bottom of the axle
housing.
 Unscrew the drain plug with the magnetic
plug and allow all of the gearbox oil to drain
off.

ENVIRONMENT NOTE
Dispose of used gearbox oil in an environmen-
tally friendly manner.
 Clean, screw in and tighten the drain
plug with magnetic plug (tightening
torque 20 Nm).
 Pour 0.55 litres of gearbox oil into the filling
opening (4) of each planetary transmission.
 Set the depth gauge (2) tightly to 113 mm
and insert into the filling opening (4).
 Remove the depth gauge.
 Check oil level.
At the minimum oil level, oil must be visible at
the depth gauge measuring tip.
• Minimum oil level: (113 mm setting dimen-
sion at the depth gauge)
• Maximum oil level: (111 mm setting dimen-
sion at the depth gauge)
 Top up with oil as required.

NOTE
Drain off excess oil via the checking screw (4)
(tightening torque 20 Nm).
 Check the oil level again.

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5 Maintenance
Gearbox

 Screw in the checking screw (4) and tighten

(tightening torque 20 Nm).
 Lower the truck.

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 Maintenance 5
Chassis, bodywork and fittings

Chassis, bodywork and fittings

Checking the mountings
 Check that the counterweight, chas-
sis, overhead guard, drive axle, steering
axle, tilt cylinders and tilt cylinder supports
are securely seated and check for wear.
 Tighten loose screw connections.

NOTE
Note the corresponding tightening torques.
 Change damaged parts.
 Touch up paintwork if necessary.

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5 Maintenance
Chassis, bodywork and fittings
Cleaning the industrial truck
Cleaning requirements depend on the use of
the industrial truck.
For operations with highly abrasive materials,
e.g. salt water, fertiliser, chemicals, cement
etc., thorough cleaning should be carried out
after the task is complete.
Hot steam or cleaning materials with a pow-
erful degreasing effect should only be used
with great caution as they will affect the grease
filling of bearings with lifetime lubrication,
causing it to escape.
As relubrication is not possible, the bearings
will be irreparably damaged.
When cleaning with compressed air, remove
stubborn contamination with a cleaner sol-
vent.
150
Pay particular attention to cleaning the oil
filling openings, their surroundings and the
lubricating nipples before lubricating.
CAUTION
Never wash the truck when it is switched on.
Switch off the truck entirely.
CAUTION
When cleaning with a water jet (high-pressure or
steam cleaner etc.), it should not be applied directly
to the area of the front axle, electric and electronic
components, plug connectors or insulating mate-
rial. Water should not be used for cleaning in the
area of the central electrical system and switch con-
sole.
If this cannot be avoided, the affected parts must
be covered in advance or only cleaned using a dry
cloth or clean compressed air
Operating Instructions – 387 801 1501 EN – 12/2012
 Maintenance 5
Chassis, bodywork and fittings

Opening and closing the battery

hood
Open the battery hood
• To maintain the battery
• To replace the battery
• To open the hinged battery door

WARNING
Risk of crushing fingers and hands.
Before opening the battery hood, always slide the
driver’s seat and armrest all the way back. Other-
wise, the battery hood may shut unintentionally.

 Open the rear window bolts (special equip-

ment) and swing the window backwards
and upwards to the stop.
 Move the steering column forwards and the
driver’s seat and armrest backwards.
 Fold in the driver’s seat backrest.

NOTE
Before doing this, be sure to remove any loose
items from the battery hood or from under the
driver’s seat.
 Operate the locking lever (1).
 Slowly swivel the battery hood with the
driver’s seat to the rear.

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5 Maintenance
Chassis, bodywork and fittings

Closing the battery hood

 Swing the battery hood down against
the pressure of the gas spring and push
it closed until locking lever (1) audibly
engages in fastener (2).

Battery hood fastener (2)

NOTE
When closing the battery hood, check also
that the side battery door is correctly locked.

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 Maintenance 5
Chassis, bodywork and fittings

Checking the condition and correct

function of the seat belt

DANGER
Risk of accident or danger to life if the restraining
belt is defective
Do not use industrial trucks if the restraining belt is
defective.
After an accident, restraining belts must be chan-
ged.
In the case of restraining belts mounted on the
driver’s seat, the driver’s seat and the driver’s seat
mounting must also be checked by a technician
following an accident.
Screw connections should be checked regularly to
make sure they are secure.
If the seat wobbles, this may indicate loose screw
connections or other defects.
Any failure to do so creates a risk to your health and
an increased risk of accidents.
If you notice any irregularities in the functioning of
the seat (e.g. seat suspension) or the restraining
belt, you should immediately contact your authori-
sed dealer to eliminate the cause.

NOTE
For safety reasons, the condition and correct
function of the restraint system should be
checked regularly (once a month). When
used under extreme conditions, this should be
carried out on a daily basis before starting up
the truck.

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5 Maintenance
Chassis, bodywork and fittings

 Pull belt (3) right out and check for fraying

and torn stitching.
 Check that the buckle (4) functions correctly
and that the belt retracts properly.
 Check the covers and attachment points for
damage.
Test automatic blocking mechanism.
 Park truck in a horizontal position.
 Remove the belt (3) with a jerk.
The automatic mechanism should block
extension of the belt from the belt retractor
(1).
 Push the driver’s seat all the way forwards.
 Fold the seat backrest completely forwards.

NOTE
When opening the battery hood, remember
that the rear window may be attached.
 Release the battery hood and open approx.
30° with the driver’s seat.
The automatic mechanism should block
extension of the belt from the belt retractor
(1).

Check the tilt cylinder bearings for

wear

NOTE
The tilt cylinders are attached on both sides in
spring elements.

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 Maintenance 5
Chassis, bodywork and fittings

 Undo screw (1) and remove it together with

washer (2).
 Visually check the spring elements for
cracks.
The rubber must not exhibit any cracks.
 Check the spring elements for each tilt
cylinder at the front and rear.
If the rubber bearings are worn or damaged,
renew them. Please advise your authorised
dealer.
 Refit the screw and washer.
 Tighten the screw to 275 Nm.

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5 Maintenance
Chassis, bodywork and fittings

Check and oil other bearings and

joints

ENVIRONMENT NOTE
Observe information regarding working with
consumables.
 Check and oil the following bearings and
mountings:
• Driver’s seat guide
• Windscreen wiper bearings (special equip-
ment)
• Door locks and hinges of weather protection
cab (special equipment)

Other cleaning and greasing

When used indoors in clean dry conditions, it
is generally sufficient to perform maintenance
every 1000 operating hours. If used both
indoors and outdoors, cleaning / greasing
is recommended between 500 and 1000
operating hours, however not later than 12
months.

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 Maintenance 5
Chassis, bodywork and fittings

Filling up the washer system / water

tank
The water tank (1) for the washer system is
fitted on the counterweight in the left-hand part
of the rear area.
 Open the rear flap (4) and move it upwards.
 Remove the filler cap (2) from the filler neck
of the water tank (1).
 Fill up with water until it is visible in the filling
opening.
 Fit the filler cap (2) back onto the filler neck
and close it properly.
 Close the rear flap (4) again securely.

NOTE
The rear flap (4) is monitored by a sensor (3).
If the rear flap is not closed properly, the truck
is not ready for operation. Therefore, make
sure that the rear flap is closed properly.

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5 Maintenance
Chassis frame

Chassis frame
Checking the tyres

Checking tyres for damage

and foreign objects
Secure the industrial truck against rolling
away.
 Apply the parking brake.
 Place a wheel chock under a wheel that will
not be lifted.
 Lift the industrial truck with a hydraulic jack
until the wheels are off the ground.
 Place hard square timbers underneath the
truck.
 Check for free movement of the wheels and
remove anything hindering their movement.
 In the case of pneumatic tyres, check the air
pressure (see Chapter 6 "Tyre variants").
 Change worn or damaged tyres.
The upper edge of the 60 Joule indicator (1)
is the maximum limit for wear and regrooving.
The decision about whether to regroove the
tyres should be based on the application
conditions.
A minimum tread depth is not required with
solid rubber tyres.
It must be ensured that the degree of wear on
the tyres on one axle is the same.

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 Maintenance 5
Chassis frame

Anti-static tyres

NOTE
Under certain circumstances, the truck may
become electrostatically charged. The charge
level depends on a number of factors such as
the type of tyre, air humidity, floor covering etc.
• Excessive electrostatic charge is noticed
when the electrostatic charge is discharged
to the ground via the body of a person who
touches the truck (electric shock) or when
a spark passes from the truck to an earthed
part (e.g. a metal shelf).
• With standard types of tyre (black pneuma-
tic or solid rubber tyres), the high graphite
content means that electrostatic charging
is relatively rare. However, if non-marking
tyres (light-coloured tyres) are used and the
truck is driven into an area with a sealed
floor, this electrostatic charge effect will oc-
cur very often.
• Non-marking tyres are identified by the
safety information on the tyre wall (see
arrow).
DANGER
Risk of fire and explosion possible with electrostatic
discharging.
Safety warning: Tyres are not electrically conduc-
tive.
The truck must always be earthed with an antistatic
belt.
The antistatic belt must be in permanent contact
with the ground.

Electrostatic charging is prevented by means

of an antistatic belt, which is attached to the
chassis under trucks with light-coloured tyres
(non-marking tyres), and its free end trails
along the ground.
Antistatic belts are made of a synthetic con-
ductive material.

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5 Maintenance
Chassis frame
Checking the condition of the antistatic belt
NOTE
Under certain circumstances the truck may
become electrostatically charged.
• The charging level depends on a number
of factors such as type of tyre, air humidity,
floor covering etc.
• Excessive electrostatic charging is noticed
when the electrostatic charge is discharged
to the ground via the body of a person who
touches the truck (electric shock) or when
a spark passes from the truck to an earthed
part (e.g. a metal shelf).
• With standard types of tyre (black pneuma-
tic or solid rubber tyres), the high graphite
content means that electrostatic charging is
relatively rare.
• However, if non-scrubbing tyres (light-
coloured tyres) are used and the truck is
160
driven into an area with a sealed floor, the
electrostatic charging effect occurs very
often.
• Non-scrubbing tyres are identified by the
safety information on the tyre wall.
For this case, an antistatic belt is fitted to the
underside of the truck and is connected to the
truck chassis.
 Check that the antistatic belt is securely
seated on the frame floor and check for
wear.
 Change the antistatic belt if it is damaged.
NOTE
The antistatic belt must always be in contact
with the ground.
Operating Instructions – 387 801 1501 EN – 12/2012
 Maintenance 5
Chassis frame

Wheel change

WARNING
Note the weight of the industrial truck.
Only use hydraulic jacks with a load capacity of at
least 3600 kg.

CAUTION
When using wheels that are not antistatic, consider
the antistatic belt.
When changing wheels that are not antistatic, the
truck must be equipped with an antistatic belt as
these wheels are not electroconductive.
The antistatic belt must always be in contact with
the ground.
Please contact your authorised dealer.

Front wheel change

 Extend lift mast to first level and secure.
 Loosen all wheel fastenings (1) of the wheel
in question.
 Position the hydraulic jack under the
right-hand lift mast profile and lift the truck
until the right-hand wheel moves freely.
 Support the chassis securely from below
using square timber supports.
 Position the hydraulic jack (2) under the
left-hand lift mast profile and lift the truck
until the left-hand wheel moves freely.
 Support the chassis securely from below
using square timber supports.
 Unscrew wheel fastenings and change
wheel.
WARNING
Ensure correct positioning of the hydraulic jack.
The industrial truck should only be lifted at the lifting
points at the front.

 Position wheel fastenings and hand-tighten.

 Lower the industrial truck.
 Tighten the wheel fastenings crosswise
with a torque of 425 Nm.

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5 Maintenance
Chassis frame

Rear wheel change

 Loosen all wheel fastenings of the wheel in
question.
 Position the hydraulic jack (1) only at
the lifting point in the centre under the
counterweight (2) and lift the truck until
the wheel is free.
WARNING
Ensure correct positioning of the hydraulic jack.
The industrial truck should only be raised at these
lifting points at the rear.

 Support the chassis securely from below

using square timber supports.
 Unscrew wheel fastenings and change
wheel.
 Position wheel fastenings and hand-tighten.
 Lower the industrial truck.
 Tighten the wheel fastenings crosswise
with a torque of 210 Nm.

Tightening the wheel fastenings

The wheel fastenings should be tightened
before initial commissioning and whenever
wheels are changed or repairs are made.
After this tightening should be performed after
100 operating hours at the latest.
The wheel fastenings should be tightened
crosswise with a torque of:

Front 425 Nm
Rear 210 Nm

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 Maintenance 5
Chassis frame

Cleaning and lubricating the com-

bined axle
When used indoors in clean, dry conditions, it
is generally sufficient to perform maintenance
every 1000 operating hours.
If used both indoors and outdoors, cleaning /
lubricating is recommended between 500 and
1000 operating hours, however not later than
12 months.

Cleaning the combined axle

 Fully lower the fork carriage.
 Push the emergency off switch.
 Clean the combined axle with water or
cleaner solvent.

NOTE
After cleaning with a steam jet, lubrication is
always recommended.

ENVIRONMENT NOTE
Observe information regarding working with
consumables.

Lubricating the combined axle

NOTE
Lubricating grease should be used for lubri-
cation (see "Recommendations for consuma-
bles").
 Apply lubricating grease to lubricating
nipples (arrowed) on the left and right tie
rods.
 Lubricate with a grease gun until fresh
lubricating grease escapes at the bearings.

NOTE
It is better to apply a little grease to the
bearings frequently than a lot of grease
infrequently.

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5 Maintenance
Chassis frame

Checking the drive axle heat sinks for

contamination, cleaning if necessary
 Extend the lift mast
 Connect the chain over the cross beam of
the outer mast (1) and under the cross beam 1
of the inner mast (2).
 Lower the inner mast to the end of the chain.
 Switch off the key switch.
 Push the emergency off switch.

2
d3921482

 Lift up the panelling and check heat sink

(see arrows) for contamination.
 If necessary, clean heat sink with com-
pressed air and/or cleaner solvent.

NOTE
If the contamination is very heavy, remove the
covering in the engine compartment. Please
contact your authorised dealer.

ENVIRONMENT NOTE
Observe information regarding working with
consumables.
e3861315

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 Maintenance 5
Operating devices

Operating devices
Checking the brake system
Checking the hydraulic service brake
DANGER
A defective brake system not only entails a risk of
injury but also possible fatality to the driver and any
people in his immediate environment.
Check that the truck’s braking function is in perfect
condition prior to each commissioning. In the case
of defects in the brake system, the truck must be
taken out of operation at once. The truck may only
be restarted once the brake system is in perfect
condition again. Please contact your authorised
dealer immediately.

DANGER
The braking characteristics of the truck are influen-
ced by the viscosity of the oil, among other things.
Using an oil other than the one prescribed by the
manufacturer will increase the stopping distance
accordingly and there is an increased risk of acci-
dents.
Therefore, only use the oil prescribed by the manu-
facturer (see Recommendations for consumables).
Please contact your authorised dealer.

 Press stop pedal (3) with your foot.

The truck should immediately come to a
standstill when the stop pedal is pressed.

NOTE
To ensure maximum braking force when the
stop pedal is fully actuated, there must be a
distance of at least 3 mm between the lower
edge of the stop pedal and the rubber mat
on the bottom plate. Otherwise the pedal
travel will have to be readjusted accordingly
to ensure maximum braking performance.
Please contact your authorised dealer.

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5 Maintenance
Operating devices

Checking the electric regenerative brake

 Release the accelerator pedal (2) or (4)
while in motion.
The accelerator pedal automatically returns
to the zero position and the LBC brakes the
truck.

NOTE
If required, this function can be adjusted via a
diagnostic program so that the effect is greater
or less. Contact your authorised dealer.

Checking the automatic brake

In the quiescent state, the truck is braked using
the automatic brake. To check this, the brake
symbol (see arrow) appears in the display unit.

NOTE
When the truck is standing on a clean floor
covering, the brake will hold the truck in
position on gradients of up to 10%.
 Press the accelerator pedal (2).
The parking brake is released and the brake
symbol in the display unit goes out.
The truck is now ready for operation.
 Trucks with the maximum permissible lift
load should not be driven on gradients
above 10%.
 Remove foot from accelerator pedal (2).
If the truck is braked to a standstill, the auto-
matic brake will become active after a short
time.
The brake symbol (see arrow) appears in the
display unit.

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 Maintenance 5
Operating devices

Checking the parking brake

 Actuate brake switch (1) by pressing the "P"
symbol.
The red LED in the brake switch must light up.
 Release the parking brake by pressing the
red LED symbol.
The red LED goes out.

The brake symbol (see arrow) in the display

unit goes out.

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5 Maintenance
Operating devices

Check bellows on joystick

 Check bellows for proper positioning and
damage, replacing if necessary.

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 Maintenance 5
Operating devices

Checking and oiling the pedal group

and linkage
 Remove the rubber mat from the bottom
plate.
 Remove the bottom plate.
 Check bolt and joint fastenings for secure
positioning.
 Lightly oil rod bearings and fork clevises as
necessary.
 Test tension springs for function.
 Apply Molykote-G paste to the contact
surface of the pedal (oil if necessary, but
do not grease under any circumstances).

Operating Instructions – 387 801 1501 EN – 12/2012 169

5 Maintenance
Electrics / Electronics

Electrics / Electronics
Checking the battery charge status
General
The battery’s discharge status is shown by an
LED bar display (2) in the display unit (1).
The 7 green LEDs go out one after another as
the battery discharges
When the battery is 75 % discharged, the red
LED (3) with the battery symbol lights up.
At a discharge level of 80 % (20 % residual
capacity), the lifting speed of the truck will be
reduced.
As the battery discharges further (residual
battery capacity < 20 %), the red LED (3)
flashes and the buzzer sounds.
CAUTION
Repeated deep discharging of the battery can
cause irreparable damage.
When the red LED flashes, the battery must be
charged immediately.

 Pull out the emergency off switch (5).

 Insert switch key (4) into the switch lock and
turn clockwise to the stop.
 Check the battery’s charge status at the
discharge indicator (2) in the display unit
(1).

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 Maintenance 5
Electrics / Electronics

Charging the battery

DANGER
Possible risk of explosion when charging the bat-
tery in unventilated areas due to flammable gases.
The battery must only be charged at the charging
stations and locations provided for this purpose and
in accordance with regulations.
They must fulfil certain criteria, such as ensuring
sufficient ventilation during the charging process.

NOTE
The "safety information for the battery and
battery charger" in section "2 Safety" should
be followed without fail. The following instruc-
tions must be observed for the operation and
maintenance of batteries.

NOTE
Charging, maintenance and servicing of the
battery should only ever be carried out accor-
ding to the battery maintenance instructions of
the battery manufacturer. Should the battery
maintenance instructions be missing, please
request them from the dealer. The operating
instructions for any battery charger supplied
must also be observed. If a battery charger is
already available, only the instructions belon-
ging to the battery charger are applicable.

CAUTION
Repeated deep discharges of the battery may not
only shorten the service life but also damage the
battery irreparably.
Batteries can be discharged to an acid density of
1.13 kg/l.
The battery must then be recharged.

CAUTION
Storage of discharged batteries over lengthy peri-
ods will result in lasting damage.
Discharged batteries should be recharged at once.

NOTE
It is recommended to recharge the battery
when all green LEDs of the discharge indicator

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5 Maintenance
Electrics / Electronics

(2) are extinguished on the display unit (1) and

the red LED (3) lights up (battery discharged
by 80 %). If the red LED is flashing (residual
battery capacity <20%), the battery has to be
recharged immediately.
Display unit in the truck
Display unit (1)
Discharge indicator (2)
Red LED (3)

NOTE
You can also charge the battery using an
integrated charger. Please contact your
authorised dealer.

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 Maintenance 5
Electrics / Electronics

Charging the battery using an

external battery charger
The battery can be charged using an external
battery charger in the following ways:
• Usually via a battery male connector (1) in
the battery compartment
• Via a battery female connector in the rear
area (special equipment)

Charging process when using a battery

male connector in the battery compart-
ment
CAUTION
Battery chargers with a charging current over 250 A
are not permitted and cause damage to the battery
male connector.
The battery charger used to recharge the battery
must not exceed a charging current of 250 A.
If the charger available exceeds this charging
current, contact your authorised dealer.

 Fully lower the fork carriage.

The fork arms must touch the ground.
 Push the emergency off switch.

WARNING
Risk of crushing fingers and hands.
Before opening the battery hood, always slide the
driver’s seat and armrest all the way back. Other-
wise, the battery hood may shut unintentionally.

 Open the battery hood and fold it back.

 Pull out the battery male connector (1) by
the handle (2) of the connecting socket.
 Connect the battery charger connector plug
to the battery male connector (1).
 Switch on the charger.

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5 Maintenance
Electrics / Electronics

Charging process when using a battery

female connector in the rear area
CAUTION
Battery chargers with a charging current higher
than 180 A are not permissible and can damage the
battery female connector (1).
The battery charger used to recharge the battery
must not exceed a charging current of 180 A.
If the charger available exceeds this charging
current, contact your authorised dealer.

 Fully lower the fork carriage.

The fork arms must touch the ground.
 Push the emergency off switch.

NOTE
The fan (2) is activated when the emergency
off switch is pressed.
 Open the rear flap and fold it upwards.
 Connect the battery charger connector plug
to the battery female connector (1).
 Switch on the charger.

NOTE
If the truck will not be used for a prolonged
period of time, either press the emergency off
switch or unplug the battery male connector
from the truck battery after the charging
process has ended, in order to prevent
unnecessary battery discharge.

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 Maintenance 5
Electrics / Electronics

Active charging ventilation unit

The active charging ventilation unit ensures
that the gases produced when the battery
is being charged can escape out of the
truck. It is not necessary for the battery
hood to be open during charging. The gases
produced are blown out by means of a fan at
the counterweight.

DANGER
The escaping gases are flammable.
The battery must only be charged in sufficiently
ventilated areas.

The active charging ventilation unit is part

of the "integrated battery charger" special
equipment.
Trucks without an integrated battery charger
may also be equipped with the "active charg-
ing ventilation unit" special equipment.
The fan in the counterweight is activated via a
contactor and a relay. A voltage transformer
that is fitted in the counterweight serves as the
power supply for the fan.

Active charging ventilation with an

integrated battery charger
The contactor is supplied with battery voltage
when the emergency off switch is pressed.
As soon as the integrated battery charger
produces voltage, the fan is supplied with
the voltage via a voltage transformer and is
activated.

NOTE
The fan (2) runs until the emergency off switch
is deactivated.

NOTE
After the charging process, the emergency off
switch must not be pressed and held down,
as the battery is discharged during prolonged
downtimes.

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5 Maintenance
Electrics / Electronics

Active charging ventilation unit without

an integrated battery charger
In trucks without an integrated battery charger,
a battery male connector for an external
battery charger is located under the rear cover.

NOTE
The plug on the battery side of the external
battery charger must be equipped with au-
xiliary contacts (pilot contacts) and a jumper
between the two auxiliary contacts. Contact
your authorised dealer.
The contactor is supplied with battery voltage
when the emergency off switch is pressed.
As soon as the integrated battery charger
produces voltage, the voltage transformer is
supplied with voltage via the jumper on the
auxiliary contact and the fan is activated.
The monitoring logic of the fan emits a neg-
ative signal while the fan is running. This
causes the contactor to be activated via a re-
lay. A contactor is used to supply the battery
with charging current and the active charging
ventilation unit with voltage. This allows the
active charging ventilation unit to run until the
emergency off switch is deactivated or the ex-
ternal battery charger plug is disconnected.

NOTE
After the charging process, the emergency off
switch must not be pressed and held down,
as the battery is discharged during prolonged
downtimes.

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 Maintenance 5
Electrics / Electronics

Battery replacement

WARNING
The truck is at risk of tipping if the battery is replaced
while the truck is carrying a load.
Battery replacement is prohibited whilst the truck is
carrying a load.
The load must be put down and the fork arms must
be resting fully on the ground.
For safety reasons, the battery must only be repla-
ced on a level, smooth and clean surface.

 Park the truck safely.

 Lower the fork carriage fully.
 Tilt lift mast forwards.
The fork arms must touch the ground.
 Apply the parking brake.
 Switch off the key switch.
 Push the emergency off switch.
 Bring the steering wheel into uppermost
position (towards the truck console).
 Move the armrest into the neutral position.

WARNING
Risk of crushing fingers and hands.
Before opening the battery hood, always slide the
driver’s seat and armrest all the way back. Other-
wise, the battery hood may shut unintentionally.

 Move the driver’s seat and armrest back-

wards.

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5 Maintenance
Electrics / Electronics

 Release the battery hood using lever (1)

and swing all the way backwards along with
the driver’s seat.
 For safety reasons, take appropriate
measures to ensure that the battery hood
does not lower from the uppermost position.

NOTE
If the driver’s cab with rear window special
equipment is fitted, the driver’s seat backrest
must also be folded in and the driver’s seat
moved backwards. Fold the rear window out-
wards and upwards by opening the interlocks
at the bottom right and left.

 Pull out the battery male connector (1)

by the handle (2) of the battery female
connector.
 Remove the air hose from the battery (if not
routed through the battery male connector).
 Unlock the side battery door (4) by pushing
the red knob (3).
 Open the side battery door (4) to the stop
and secure it to prevent it from swinging
back.
 Check the battery for leaking acid, cracked
housing or raised plates.
 Check that the battery male connector and
battery cable are in good condition and
place them securely on the battery.

CAUTION
If the battery slips, this can result in damage to the
battery and battery tray.
The new battery must correspond to the standard
model in terms of size and weight. Any variation in
weight must be offset using ballast weights.
Contact your authorised dealer.

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 Maintenance 5
Electrics / Electronics

Replacing the battery using a crane and

C hooks
WARNING
Risk of accident
Only use C hooks approved by the manufacturer,
and always with the appropriate lifting gear.
The crane, C hooks and lifting gear must have
sufficient load-bearing capacity.
Contact your authorised dealer.

NOTE
When picking up the C hook (3), ensure that
the fastener (4) on the crane hook (5) is closed
correctly.
 Carefully drive the crane, C hooks and lifting
gear over the battery.
 Insert the four hooks into the appropriate
openings (2) in the battery tray.
 Carefully lift the battery (1), slowly remove
from the battery compartment and put down
in a suitable place.

Replacing the battery with the truck and a

battery removal tool (special equipment)
WARNING
Risk of accident
Only trucks and battery removal tools with sufficient
load capacity may be used.

 Pick up the battery removal tool (3) fully with

the fork arms of the truck.
 Drive the truck and battery removal tool
(3) slowly and carefully into the battery
compartment over the battery.
 Insert the four hooks into the openings (2)
provided for this purpose in the battery tray.
Carefully lift the battery (1), slowly remove
from the battery compartment and put down in
a suitable place.

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5 Maintenance
Electrics / Electronics

Replacing the battery with the truck and a

battery support (special equipment)
The battery support also remains in the truck
underneath the battery tray.
Four covers are fitted (see red arrows) to
protect the floor area when replacing the
battery.

CAUTION
The truck floor may be damaged if the fork arms are
not correctly positioned on the covers provided.
Adjust the fork arm distance correspondingly.

The underside of the battery support has four

feet (see arrows), on which the battery carrier
with the battery can be placed securely in a
suitable position.

CAUTION
The truck floor in the battery compartment may
be damaged if the battery has not been lifted high
enough.
Raise the battery support to a sufficient height for it
to be safely removed from the battery compartment.

 Drive the truck slowly until the fork arms are

positioned underneath the battery support
(1).
 Raise the battery until the battery support
feet are off the floor.
 Slowly lift the battery out of the battery
compartment and put down in a suitable
place.

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 Maintenance 5
Electrics / Electronics

Replacing the battery using a lateral

hydraulic battery carrier
(special equipment)
An additionally installed hydraulic power unit
fitted to the counterweight in the rear area
extends the battery over halfway out (60%)
when a push button is actuated.

NOTE
When the push button is actuated, the locking
cylinder initially extends, which blocks the
steering axle. The battery then extends.

Extending the battery

WARNING
Risk of crushing and risk of accident when exten-
ding and retracting the battery.
When extending and retracting the battery, ensure
that no one is in the area surrounding the battery
compartment (observe decal information (3) on the
battery support).

 Move the steering axle to the straight-ahead

position.
The hydraulic power unit is actuated using a
push button (1).
 Press the left-hand side (left arrow) of push
button (1), which is located on the right-hand
side of the truck console.
The locking cylinder extends and blocks the
steering axle. The battery then slowly extends
(by approx. 60%).
 Disconnect the battery male connector from
the battery female connector.
 Insert suitable lifting gear into the openings
provided in the battery tray.
 Carefully lift the battery and put down safely
in a suitable place.

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5 Maintenance
Electrics / Electronics

Retracting the battery

 Carefully insert the new battery into battery
support (2), ensuring that it is positioned
correctly.
 Remove the lifting gear.
 Plug the battery male connector into the
battery female connector.
 Press the right-hand side (right arrow) of
push button (1).
Battery retracts slowly. After the battery
retracts, the locking cylinder releases the
steering axle.
Once the locking cylinder has been released,
the green LED in the symbol lights up. This
means that the steering axle is enabled for
drive mode again.
 Release the right-hand side of the push
button. The green LED goes out.
 Close the side battery door, ensuring that it
is fastened correctly.
 Close the battery hood.

Checking the oil level of the hydraulic

power unit

ENVIRONMENT NOTE
Observe information regarding working with
consumables

NOTE
Only check the oil level when the battery is
retracted.
WARNING
Risk of crushing fingers and hands.
Before opening the battery hood, always slide the
driver’s seat and armrest all the way back. Other-
wise, the battery hood may shut unintentionally.

 Open the battery hood.

 Check the oil level at the hydraulic tank (see
arrow). Note the oil level markings.

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 Maintenance 5
Electrics / Electronics

 Unscrew the cap screw and top up with hy-

draulic oil (standard oil, see Recommenda-
tions for consumables) to the corresponding
oil level marking, as required.
 Screw the cap screw back onto the tank.
 Close the battery hood.

Hydraulic power unit technical data

• Pump motor power rating 1.2 kW
• Hydraulic tank: filling quantity 1.5 litres
standard oil (see Recommendations for
consumables)
• Main current fuse 100 A for pump motor
• Hydraulic power unit: set maximum pres-
sure 180 bar

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5 Maintenance
Electrics / Electronics

Battery replacement — truck with

elevated driver’s compartment

NOTE
In truck versions with elevated driver’s seat
(e.g. series 387, E30HL-600), left-hand side
door (1) must also be opened (depending on
the battery size) so that the lifting gear hooks
can be attached to the corresponding eyelets
on the battery tray.

Unlock battery door (1) via opening (2).

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 Maintenance 5
Electrics / Electronics

Open battery door (1) towards the left and to

the stop.

NOTE
There is a microswitch (2) in the area around
the battery door lock. This microswitch
deactivates the driving and lifting functions
if the battery door is open.
 Disconnect the battery male connector.

Battery replacement using a battery

support (special equipment)
In truck versions fitted with a battery support
(1), the battery can also be replaced when the
battery hood is closed.
 Drive the truck slowly and carefully until the
fork arms are positioned underneath the
battery support .
 Raise the battery (by about 10 cm) until the
battery support feet are off the floor.
 Slowly lift the battery out of the battery
compartment and put down in a suitable
place.
 Correctly lock both battery doors again after
replacing the battery.

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5 Maintenance
Electrics / Electronics

Checking the main contactor

The main contactor is located along with the
main current fuses underneath the right-hand
truck console on the contactor carrier. In order
to access the main contactor and to be able to
check for possible burns, the following steps
are required:

WARNING
Risk of crushing fingers and hands.
Before opening the battery hood, always slide the
driver’s seat and armrest all the way back. Other-
wise, the battery hood may shut unintentionally.

 Open the battery hood and fold it back.

 Pull the battery male connector (see arrow).
 Loosen and unscrew the screw (1).

 Remove the panelling (2) and place it to the

side.

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 Maintenance 5
Electrics / Electronics

Fan (1) for heat extraction from the control

compartment

NOTE
As a precaution, pull out the plug connector
(see arrow) for the fan (1).

 Check the main contactor (3) for burns and

replace if necessary.
 Check that the main current fuses (4) are
securely positioned.
Contact your authorised dealer.

Operating Instructions – 387 801 1501 EN – 12/2012 187

5 Maintenance
Electrics / Electronics

Adjusting the accelerator

CAUTION
Note the accelerator adjustment.
Adjustment/readjustment of the accelerator may
only be carried out by a trained technician!
Please contact your authorised dealer.

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 Maintenance 5
Electrics / Electronics

Checking the fans for function and

contamination, and cleaning if
necessary
The truck has 4 or 5 fans, depending on
the design. There are 4 fans in the control
compartment.
An additional fan (special equipment —
"charging the battery using an external
charger" or "integrated battery charger") is
fitted to the counterweight under the rear flap.
At the drive axle under the cover (1), there are
two fans for cooling the power module for the
traction motors.

In the left-hand area of the control compart-

ment, directly behind the hydraulic tank, there
is another fan located under a cover (2) for
cooling the power module for the pump motor.

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5 Maintenance
Electrics / Electronics

On the front right side of the truck behind the

cover (2), there is a fan (1) which conveys
hot air from the control compartment to the
outside.
All fans must be cleaned and checked for
correct function in the course of the inspection
and maintenance work to prevent the power
modules from overheating.

Cleaning the fan for the traction motor

power module
The best medium for cleaning the fans is
oil–free compressed air and/or cleaner sol-
vent.
Particular care should be taken to clean the
spaces between the fan blades to ensure
efficient cooling of the power modules.
 Park the truck safely.
 Fully lower the load forks.
 Switch off the truck entirely.
 Remove the rubber mat from the bottom
plate.
 Unscrew the mounting screws from the
bottom plate.
 Pull the plug out of the accelerator and put
the bottom plate to one side.
 Remove the fan panelling (1).
 Clean fans with compressed air and/or
cleaner solvent.

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 Maintenance 5
Electrics / Electronics

Cleaning the fan for the pump motor

power module
 Remove the fan panelling (2).
 Clean fans with compressed air and/or
cleaner solvent.

Cleaning the side fan for the control

compartment

NOTE
To clean the fan (1) located on the right side
of the truck, the panelling (2) must first be
removed.
 Remove the side panelling (2), pull out the
fan plug (see arrow) and place the panelling
to one side.

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5 Maintenance
Electrics / Electronics

 Disassemble the fan (1) from the panelling

(2).
 Clean fans with compressed air and/or
cleaner solvent.

ENVIRONMENT NOTE
Observe information regarding working with
consumables.

NOTE
If there is too much contamination, remove or
replace the fans in the control compartment.
Please contact your authorised dealer.

Cleaning the fan for the battery-charging

function
In the "charging the battery using an external
charger" or "charging the battery using an
integrated battery charger" special equipment,
a fan (see arrow) is fitted to the counterweight
underneath the rear flap.
 Clean fans with compressed air and/or
cleaner solvent.

Check fans for correct function

All fans must be checked for correct function
during inspection and maintenance work.

NOTE
The fans may only be tested using an appro-
priate diagnostic program (Pathfinder).

NOTE
Defective fans or those exhibiting faults must
be changed immediately. Please contact your
authorised dealer.

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 Maintenance 5
Electrics / Electronics

Checking the condition and secure

positioning of electric cables, cable
connectors and connections

NOTE
Oxidised connections and brittle cables cause
voltage drops, so causing malfunctions.
 Unscrew the mounting screws from the
bottom plate (pedals).
 Before removing the bottom plate, pull the
plug connector out from the accelerator.
 Remove the fan covers and check the
connections.
 Check all electric cables and connections
on contactor carrier.
 Electric motors connections: check con-
nection assemblies for secure positioning
and oxidation residues.
 Check that the battery cable is securely
attached.
 Check electric wiring for abrasion and
secure positioning.
 Remove oxidation residues and replace
brittle cables.

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5 Maintenance
Hydraulics

Hydraulics
Checking oil level for hydraulic
system

ENVIRONMENT NOTE
Observe information regarding working with
consumables.
CAUTION
Observe the oil level, oil volume, specifications.
When checking the hydraulic oil level, always have
the lift mast vertical and the fork carriage lowered.
Observe the recommendations for consumables.

 Fully lower the fork carriage.

 Switch off the key switch.
 Fold up a section of the rubber mat on the
bottom plate or remove the rubber mat
entirely.
 Undo the breather filter (3) with oil dipstick
in an anti-clockwise direction.
 Wipe the oil dipstick with a clean cloth,
reinsert it and screw it in.
 Loosen the breather filter with oil dipstick
again, pull it out and check the oil level on
the dipstick.
The oil dipstick has two markings (1, 2) for the
different lift heights.

Marking Filling quantity Lift height

1 Approx. 18 l Up to 5161 mm
2 Approx. 24 l Up to 7955 mm

NOTE
The maximum permissible oil filling quantity is
25 litres.
 Top up hydraulic oil to the appropriate oil
level marking (1) or (2) as required.
 Reinsert the oil dipstick and screw in in a
clockwise direction.
 Place the rubber mat back on the bottom
plate.

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 Maintenance 5
Hydraulics

Checking the hydraulic system for

leaks
 Remove the rubber mat from the bottom
plate.
 Unscrew the 4 bottom plate fixing screws.
 Remove the accelerator plug connector.
 Remove the bottom plate and place safely
to one side.
 Check the hydraulic pump of the working
and steering hydraulics, valves, hoses and
lines for leaks.
 Change porous hoses.
 Check lines for abrasion spots and replace
if necessary.

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5 Maintenance
Hydraulics

Changing the hydraulic oil

WARNING
Adding hydraulic oil with the wrong viscosity may
result in brake malfunctions. This may also present
a risk of accidents to the driver.
Only hydraulic oil with suitable viscosity should be
used. See the recommendation for consumables.

ENVIRONMENT NOTE
Observe information regarding working with
consumables. See the recommendation for
consumables.

NOTE
Hydraulic oil can only be extracted with a hand
pump.
 Fully lower the fork carriage.
 Push the emergency off button and pull the
key switch out of the switch lock.
 Remove the rubber mat from the bottom
plate.
 Remove the bottom plate.
 Undo the breather filter (3) with oil dipstick
(4).
 Turn filler cap (5) in an anti-clockwise
direction and remove.
 Slowly pull out the filter cartridge / suction
filter (6) so oil can run back into the hydraulic
tank.
 Remove filter cartridge entirely.
 Extract hydraulic oil from the tank (7) with a
suitable hand pump.

ENVIRONMENT NOTE
Dispose of used oil in an environmentally
friendly manner.
 Add new hydraulic oil to hydraulic oil tank.

NOTE
The filling quantity depends on the lift height.

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 Maintenance 5
Hydraulics

The oil dipstick (4) has two markings for the

different mast types.

Marking Filling quantity Lift height

1 Approx. 18 l Up to 5161 mm
2 Approx. 24 l Up to 7955 mm

NOTE
The maximum permissible oil filling quantity is
25 litres.
 Clean the sealing ring of the filter cover, wet
with oil and reassemble.
 Carefully insert a new filter cartridge (6) into
the hydraulic oil tank (7).
 Insert the breather filter (3) with oil dipstick
(4) into the hydraulic tank and check the
hydraulic oil level using the dipstick; top
up with hydraulic oil to markings (1) or (2)
on the oil dipstick (depending on lift mast
height) as necessary.
 Top up hydraulic oil to appropriate oil level
marking as required.

NOTE
The oil level marking (2) must not be exceeded
under any circumstances.
 Clean the filler cap seal and coat with oil.
 Refit filler cap (5) and turn it in a clockwise
direction.
 Tighten the filler cap to 25 Nm.
 Screw breather filter (3) back on.
 Check the filler cap for leaks during a test
run.

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5 Maintenance
Hydraulics

Checking the breather filter for leaks

The breather filter (3) is equipped with a
bleeder valve that permits an over pressure
of 0.35 bar in the tank.
 Switch on the key switch.
 Extend the lift mast to the stop and lower it
again.
 Switch off the key switch.
 Loosen the breather filter (3) by turning
it slowly ½ a turn in an anti-clockwise
direction.
Air must be heard escaping from the tank. If
air cannot be heard escaping, insert a new
breather filter.

ENVIRONMENT NOTE
Dispose of the old breather filter in an environ-
mentally friendly manner.

Changing the breather filter

NOTE
If there is heavy dust accumulation, it may be
necessary to change the filter earlier.
 Remove the rubber mat from the bottom
plate.
 Unscrew the breather filter (3) with oil
dipstick (4) from the tank cap in an anti-
clockwise direction.
 Pull the breather filter (3) off the oil dipstick
(4).
 Connect the new breather filter to the oil
dipstick.
 Screw the breather filter (3) together with oil
dipstick (4) onto the tank cap in a clockwise
direction.
 Place the rubber mat back on the bottom
plate.

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 Maintenance 5
Hydraulics

Checking the control unit for correct function

Specialist knowledge and special tools are
required to check the lowering stop valve and
the exhaust valve in the control unit.
Please contact your authorised dealer.

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5 Maintenance
Hydraulics

Replacing the high-pressure filter

The high-pressure filter is located next to
the control valve and is secured to the truck
chassis with a support.
It consists of the filter housing (1), a filter insert
(3) and a dirt trap (2).
The high-pressure filter has the task of pro-
tecting the control valve from contaminants in
the hydraulic oil.
The dirt trap (2) prevents dirt from the filter
element surface from falling back into the filter
housing when removing the filter element (3).
This is important as any impurities in the
hydraulic oil will damage the proportional
valves in the control valve or cause operational
faults.
When replacing the filter insert (3), ensure that
it is completely clean so that no dirt particles
can enter the hydraulic system.

ENVIRONMENT NOTE
Observe information regarding working with
consumables. Hydraulic oil will escape so
place a collection container underneath
beforehand.
 Fully lower the fork carriage.
 Remove the key switch.
 Remove the rubber mat from the bottom
plate.
 Remove the bottom plate.
 Clean both the outside of the high-pressure
filter housing (1) and the upper cover.

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 Maintenance 5
Hydraulics

 Unscrew the cover (4) of the filter housing

(1) using a socket wrench or box-end
wrench.
 Slowly remove the filter insert (3) with dirt
trap (2) from the filter housing (1).
 Remove and clean the dirt trap (2) from the
filter insert (3).
 Collect oil drips in a container.

ENVIRONMENT NOTE
Dispose of old filter insert and oil in an environ-
mentally friendly manner.
 Fit dirt trap (2) to new filter insert (3).
 Insert the new filter insert (3) into the
pressure filter housing (1).
 Replace the filter cover O-ring and back-up
ring.
 Screw the cover (4) back onto the filter
housing.
Tightening torque: 10+5 Nm.
 Check the filter cover for leaks during the
test run.
 The hydraulic system is bled automatically
once the pump motor starts.

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5 Maintenance
Hydraulics

Changing the suction filter

ENVIRONMENT NOTE
Observe information regarding working with
consumables.
 Fully lower the fork carriage.
 Push the emergency off button and pull the
key switch out of the switch lock.
 Remove the rubber mat from the bottom
plate.
 Remove the bottom plate.
 Unscrew the breather filter (1) in an anti-
clockwise direction.
CAUTION
As long as the tank container is under internal
pressure, the head of the suction filter is generally
full with hydraulic oil. Due to the diagonally installed
suction filter housing, a quantity of approx. 0.3 litres
hydraulic oil can flow out into the truck when the fuel
tank cap is opened and the suction filter is taken
out.
To avoid this, make sure that the breather filter (1) is
unscrewed before opening the suction filter cover.
This allows the air to escape so that the oil will not
overflow when the filter cartridge is taken out.

 Turn the fuel tank cap (2) in an anti-clock-

wise direction and unscrew it.
 Pull out the filter cartridge (3) slowly by the
handle (4).
This will allow the oil to flow back slowly into
the container.
 Remove the filter cartridge (3) entirely.

ENVIRONMENT NOTE
Dispose of old filter insert and oil in an environ-
mentally friendly manner.
 Clean the seal (5) of the filter cover and wet
with oil.
 Carefully insert new filter cartridge in
hydraulic tank.
Ensure that it is correctly centred in the base
of the tank.

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 Maintenance 5
Hydraulics

 Clean the seal of the fuel tank cap and wet

with oil.
 Refit the fuel tank cap (2) and turn it in a
clockwise direction.
 Tighten the filter cover to 25 Nm.
 Screw the breather filter back on.
 Check the tightness of the fuel tank cap
during the test run.

Check the tension of double hoses

The tension of the double hoses should be
5-10 mm per metre, depending upon the
original length.
 Adjust the tension of the hoses to the
specified dimension by sliding them in the
clamps.

d3921519

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5 Maintenance
Load lift system

Load lift system

Lift mast/protection

DANGER
When working in the area of the lift mast, there
is a risk of becoming trapped and the lift mast
accidentally lowering.
If the lift mast or fork carriage is raised, no work
must be performed on the lift mast or at the front
of the forklift truck without observing the following
protection measures!
These safety precautions are only sufficient for
general maintenance on the truck (inspection and
greasing).
For repairs (such as changing chains, dismantling
lift cylinders), additional safety precautions must be
taken.
Relevant specialist knowledge is required in these
cases, and possibly also special tools.
Contact your authorised dealer.

Secure lift mast against tilting backwards

The lift mast must be secured against uninten-
tionally tilting backwards (see arrow).
 Tilt the lift mast all the way back.
 Push the emergency off switch.
 Pull the key out of the key switch.
 Disconnect the battery male connector.
The truck must be switched off completely.
 Apply the parking brake.

Standard lift mast

Function:: When raising the inner mast, the
chain rollers are moved upwards with the
chains so that the fork carriage is lifted with
a transmission ratio of 2:1 due to the chain
deflection.

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 Maintenance 5
Load lift system

Securing the
raised standard lift mast 1
DANGER
Check chain load!
Select the safety chain with sufficient load-bearing
capacity for the respective lift mast. Take the
maximum lift height into account.

 Extend the lift mast

 Connect the chain over the cross beam of
the outer mast (1) and under the cross beam
of the inner mast (2).
 Watch out for the hose lines on the cross 2
beam of the outer mast.
d3921482
 Lower the inner mast to the end of the chain.

Duplex mast

NOTE
The benefit of this equipment version is that
full advantage is taken of the special free
lift height, even in very low rooms (cellars,
wagons, ships).
Function:: The fork carriage is raised to the
special free lift height via the chain guide pulley
of the centre cylinder.
Here it moves twice as fast as the centre
cylinder.
The inner mast is then lifted by the two outer
cylinders, taking the fork carriage with it.
The centre cylinder is positioned on the
extendable inner mast.

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5 Maintenance
Load lift system

Securing the
raised duplex lift mast 1
DANGER
Check chain load!
Select a safety chain with sufficient load bearing
capacity for the lift mast. Take the maximum lift
height into account.

 Extend the lift mast

 Connect the chain over the cross beam of
the outer mast (1) and under the cross beam
of the inner mast (2).
 Watch out for the hose lines on the cross
beam of the outer mast. 2 d3921483
 Lower the lift mast until the end of the chain.
 Lower fork carriage as far as it will go.

Triplex mast
Function:: The fork carriage is raised to the
special free lift height via the chain guide pulley
of the centre cylinder.
Two lift cylinders then raise the inner mast.
Once the inner mast is fully extended, two
additional lift cylinders lift the middle mast,
which is lifted together with the inner mast and
the fork carriage.
The centre cylinder is positioned on the
extendable inner mast.

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 Maintenance 5
Load lift system

Securing the raised triplex lift mast

1
DANGER
Check chain load!
Select a safety chain with sufficient load bearing
capacity for the lift mast. Take the maximum lift
height into account.

 Extend the lift mast

 Connect the chain over the cross beam of
the outer mast (1) and under the cross beam
of the centre mast (2).
 Watch out for the hose lines on the cross
beam of the outer mast.
2
 Lower the lift mast until the end of the chain. d3921484

 Lower fork carriage as far as it will go.

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5 Maintenance
Load lift system

Tightening the lift mast/

mountings
To access the lift mast mounting screws, the
lift mast be tilted forwards to the mechanical
stop.

NOTE
The relevant specialist knowledge, a special
tool and a corresponding diagnostic program
are required to carry out these tasks.
Contact your authorised dealer.

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 Maintenance 5
Load lift system

Lift mast — cleaning the chain and

applying chain spray

DANGER
Lift mast chains are safety elements. Using the
incorrect cleaning materials may damage the
chains.
Do not use cleaner solvent, chemical cleaners or
fluids that are corrosive or contain acid or chlorine.

If the lift mast chain is so dusty that penetration

of the lubricating oil cannot be guaranteed, the
chain must be cleaned.
 Place a collection container under the lift
mast.
 Clean the lift mast chain with paraffin
derivatives, such as benzine.
Take note of the manufacturer’s safety infor-
mation.
When cleaning with a steam jet, do not use
additives.
 After cleaning, immediately use com-
pressed air to remove any water remaining
on the surface of the chain and in the chain
joints.
The chain should be moved several times
during this process.
 Immediately apply Linde chain spray to
chain, moving chain while doing so.

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5 Maintenance
Load lift system

Lift mast — adjusting the chain

Securing the standard lift mast

NOTE
The lift mast chain stretches during operation
and therefore has to be readjusted on the right
and left sides.
 Fully lower the lift mast
 Release counter nut (2).
 Adjust chain at adjusting nut (1) of chain
anchor.
The lower guide roller on the fork carriage
must only protrude max. 25 mm from the inner
lift mast guide rail.
 Tighten counter nut (2) securely.
 Also adjust second chain.

CAUTION
When extending the lift mast, it must not touch the
end stops.
Fully extend the lift mast and check clearance to
end stops.

Apply chain spray.

NOTE
In the case of industrial trucks that are used in
the food production industry, chain spray must
not be used. Instead, use a low-viscosity oil
approved for use in the food industry.
 Apply Linde chain spray to guide surfaces
and chain.

Duplex lift mast or triplex lift mast

NOTE
The lift mast chain stretches during operation
and therefore has to be readjusted.
 Lower the lift mast and fork carriage com-
pletely.

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 Maintenance 5
Load lift system

 Loosen lock nut (4). Adjust chain at the

adjustment nut (3) of chain anchor.
The lower guide roller on the fork carriage
must only protrude max. 25 mm from the inner
lift mast guide rail.
 Tighten counter nut (4) securely.

CAUTION
When extending the lift mast, it must not touch the
end stops.
Fully extend the lift mast and check clearance to
end stops.
3
Apply chain spray.
4 d3921486
NOTE
In the case of industrial trucks that are used in
the food production industry, chain spray must
not be used. Instead, use a low-viscosity oil
approved for use in the food industry.
 Apply Linde chain spray to guide surfaces
and chain.

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5 Maintenance
Load lift system

Lift mast, chains, lift cylinder and end

stops:
Checking the mountings, condition
and function
 Clean the lift mast guides and chain.
 Check the chain for condition and wear,
especially around the guide pulleys.
 Check the mounting of the chain to chain
anchor.
 Replace damaged chains. Contact your
authorised dealer.

NOTE
Individual plastic links that are damaged or
missing do not impair function or service life.
 Check the condition and mounting of the lift
mast, guide surfaces and rollers.
 Check the condition, mounting and correct
function of the end stops.
 Check the mounting of the lift cylinders.
 Check that the locking ring of the piston rod
mounting at the top of the lift mast is seated
correctly.

Check fork arms and arm safety

devices
 Check fork arms for visible deformation, 1
wear and damage .
 Check the screws of the arm safety de-
vices (2, 3) and arrests of the arms (1) for
secure positioning and signs of damage.
 Replace defective parts. 2

3
E336/085

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 Maintenance 5
Load lift system

Cleaning and lubricating the sideshift

(special equipment), checking the
fastening

ENVIRONMENT NOTE
Observe information regarding working with
consumables.

NOTE
The sideshift should be greased whenever
the truck is washed. Use lubricating grease
complying with the recommendations for
working materials.
 Clean sideshift with steam jet.
 Check hydraulic lines for scuffing and
replace if necessary.
 Check hydraulic connections and fastening
elements for secure positioning and wear
and tighten/replace if necessary.
 Check cylinders for leaks.
 Check piston rods for damage.
 Move fork arms so that the 4 lubricating
nipples (1) are accessible.
 Let down sideshift until fork arms touch the
ground.
 Apply lubricating grease to the lubricating
nipples (1) of the support rollers on the fork
carriage until grease escapes at the side.
 Apply lubricating grease to the lubricating
nipples (2) of the slide guides on the fork
carriage until grease escapes at the side.

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5 Maintenance
Load lift system

Checking the sideshift (special

equipment) for wear

CAUTION
A special tool and specialist knowledge is required
for this work.
Contact your authorised dealer.

Checking the slide guides on the

sideshift (special equipment) for
wear
 Dismantle sideshift.
 Clean sideshift.
 Remove the slide guides from the upper
guide (1).
 Measure the wall thickness of the slide
guide (3).
If wall thickness is less than 2.5 mm, change
the slide guides.
 Lubricate slide guides.
 Reassemble sideshift.
 Tilt the lift mast forwards and lower the fork
arms until they touch the ground, so that
sideshift frame is relieved of the weight of
forks.
 Lubricate the sideshift at lubricating nipples
(2) and (4).

Cleaning and lubricating the fork

prong positioner (special equip-
ment), checking the mounting
 Clean the fork prong positioner using a
steam jet.
 Check condition of fork prong positioner
and check for leaks.
 Check hydraulic lines for chafing and
replace if necessary.

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 Maintenance 5
Load lift system

 Check hydraulic connections for tightness,

replace if necessary.
 Check cylinders for leaks.
 Check piston rods for damage.
 Tighten mounting screws (1) to 106 Nm.
 Screw in the screws (2) to the fork arm stop,
tighten lock nut to 50 Nm.
 Tighten mounting screws (3) to 120 Nm.

 Tighten mounting screws (7) to 145 Nm.

 Lubricate slide guides (4) with lubricating
grease.
 Apply lubricating grease to lubricating
nipples (5) of the sliding shoes until grease
escapes at the side.
 Apply lubricating grease to lubricating
nipples (6) of the slide rollers until grease
escapes at the side.

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5 Maintenance
Load lift system

Checking the fork prong positioner

(special equipment) for wear

CAUTION
A special tool and specialist knowledge is required
for this work.
Contact your authorised dealer.

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 Maintenance 5
Self-help

Self-help
Malfunctions during operation

CAUTION
If one of the following indicator lights illuminates
in the display unit and the buzzer sounds during
operation, a malfunction has occurred.
The truck must be switched off immediately and the
malfunction dealt with.

Each error is indicated by a numerical code

or symbols in the text field (5). Please contact
your authorised dealer.

Warning light (1) is illuminated: "Motor temperature at upper limit"

Possible cause Remedy
Traction motors and/or pump motor are too hot. Allow motors to cool down.

Warning light (2) is illuminated: "Error in electrical controllers or battery charger operation"
Possible cause Remedy
Error in electrical controllers or battery charger
Please contact your authorised dealer.
operation

Warning light (3) is illuminated: "Error in the lift height switching"

Possible cause Remedy
Error in the lift height switching Please contact your authorised dealer.

Warning light (4) in the display unit is illuminated:

Possible cause Remedy
Consult operating instructions for further If the fault cannot be remedied, contact your
information. authorised dealer.

Warning light (6) is illuminated: "Prewarning: Motor temperature at upper limit"

Possible cause Remedy
Traction motors and/or pump motors have
Allow motors to cool down as soon as possible.
almost reached the temperature limit
.

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5 Maintenance
Self-help

Fuses -
Basic equipment
The fuses for the basic equipment are located
on the contactor carrier beneath the right-hand
truck console. In order to access the fuses,
the side panelling in the front right wheel area
must be removed.
 Remove panelling (2) and place down
safely to one side.
 Remove clear cover (9) from the fuse
holder.

Checking the fuses

1 10 A fuse 4F1 for alarm horn
2 15 A control current fuse F2

3 10 A fuse for discharge indicator F3

Fuse F4
4
5 A voltage transformer (13 V)
5 A fuse for active charging ventilation
5
unit (9F100) — (special equipment)
6 5 A fuse 2F6 for fan (9M2, 9M3)
7 Not assigned
8 5 A fuse 1F8 for fan (9M1, 9M4, 9M5)
9 Clear cover for fuse block strip
Main current fuse 2F1
10
355 A pump motor
Main current fuse 1F1
11
355 A traction motor

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 Maintenance 5
Self-help

CAUTION
Risk of fire if automotive fuses are used.
Only use genuine Linde spare fuses with a high
voltage rating.
Automotive fuses must not be used under any
circumstances.
The control current fuses are equipped with a
special quartz sand filling and are designed for a
higher voltage range.
Please contact your authorised dealer.

 Change the defective fuse.

Checking the main current fuses

The 2 main current fuses (safety fuses) for
both traction motors and the pump motor are
located on the main contactor.
355 A main current fuse 2F1 for pump
10
motor
355 A main current fuse 1F1 for traction
11
motor

NOTE
The fuse elements must be correctly fitted.
The assembly sequence of the individual
components must be observed. Please
contact your authorised dealer.
 Change the defective fuse.

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5 Maintenance
Self-help

Fuses -
Special equipment

NOTE
The fuses and the relays for the special
equipment are located in a plastic housing
fitted to the counterweight in the rear area.

Checking the fuses

 Open the rear flap (1) and fold it upwards.

NOTE
When the rear flap is open, the sensor (4)
is deactivated and all traction functions and
hydraulic functions are switched off.

 Turn the star handle (2) in an anti-clockwise

direction to loosen it and undo it.
 Remove the cover (3) from the plastic
housing.
 Check the fuses.
 Change the defective fuses.

NOTE
Use only genuine Linde spare fuses with a
high voltage rating (32V). Please contact your
authorised dealer.

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 Maintenance 5
Self-help

Fuses/configuration of the slots

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5 Maintenance
Self-help

Fuse Slot Value Function

5F40 1.1 15 A/32 V Working spotlight pos. 1 + 2
5F41 1.2 15 A/32 V Working spotlight pos. 3 + 4
5F42 1.3 * Working spotlight pos. 5 + 6 or cross beam

5F43 1.4 * Working spotlight pos. 7 + 8

9F80 2.1 2 A/32 V Windscreen wiper (general)

9F81 2.2 10 A/32 V Wash pumps

9F82 2.3 10 A/32 V Front windscreen wiper

9F83 2.4 10 A/32 V Rear window and roof panel wipers
9F98 3.1 7.5 A/32 V Battery carrier

3.2 Not assigned

9F73 3.3 15 A/32 V Seat heater

9F93 3.4 15 A/32 V 12 V socket
9F94 8.1 1 A/32 V 70 A relay coil for relay 9K90
9F99 8.2 10 A/32 V 80/24 V voltage transformer
8.3 Not assigned

8.4 Not assigned

5F20 9.1 15 A/32 V Lighting

5F21 9.2 10 A/32 V Hazard warning system

Hazard warning system for reverse travel with stop light
5F27 9.2 5 A/32 V
and without lighting
5F26 9.3 5 A/32 V Brake light lighting
5F22 9.4 7.5 A/32 V Left dipped beam
5F23 10.1 7.5 A/32 V Right dipped beam
5F24 10.2 5 A/32 V Left-hand sidelights
5F25 10.3 5 A/32 V Right-hand sidelights
5F28 10.4 2 A/32 V Interior lighting/terminal board light
6F60 15.1 2 A/32 V Linde Forklift Data Management
15.2 Not assigned

15.3 Not assigned

15.4 Not assigned

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 Maintenance 5
Self-help

Fuse Slot Value Function

16.1 Not assigned
16.2 Not assigned
16.3 Not assigned
16.4 Not assigned
4F50 17.1 7.5 A/32 V Rotating flashing beacon via switch lock
Switchable reversing signal (warning sound/rotating
4F51 17.2 7.5 A/32 V
flashing beacon)
9F95 17.3 10 A/32 V Radio U+ switched
9F96 17.4 5 A/32 V Radio U+
70 A relay coil for relay 9K91 (U+ switched/voltage
9F91 18.1 1 A/32 V
transformer, position 3)
18.2 Not assigned
9F72 18.3 15 A/32 V Rear window heating
9F71 18.4 20 A/32 V Heater blower
* 7.5 A/32 V fuse where there is 1 working spotlight - 15 A fuse where there are 2 working spot-
lights

9 fuse holders, each with 4 slots, are provided

for the fuses of the special electrical equip-
ment.
The slot code consists of the fuse holder
number and the sequential fuse number, e.g.
17.3.
Additional or fewer fuse holders may be
assigned depending on the version of the
truck.

Fuse colour coding

Fuse Colour
1 A/32 V Black
2 A/32 V Grey
5 A/32 V Light brown

5 A/80 V Light brown

7.5 A/32 V Brown

10 A/32 V Red
10 A/80 V Red

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5 Maintenance
Self-help

Fuse Colour
15 A/32 V Blue
15 A/80 V Blue
20 A/32 V Yellow
30 A/32 V Green
.

MAXI fuses
To protect the special equipment, up to four
maxi fuses can be found at the contactor
carrier.
30 A 9F92 voltage transformer fuse,
1
pos. 1/2
30 A 9F90 voltage transformer fuse,
2
pos. 3
3 40 A 9F70 heating system fuse
4 50 A 9F97 battery carrier fuse
.

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 Maintenance 5
Self-help

Diagnostic connector
The diagnostic connector (2) is located behind
the driver’s seat beneath the rear window.
 Unscrew lid (1) in an anti-clockwise direc-
tion.
 Connect the laptop.
The diagnostic connector (2) can be used to
input and read out truck data with a laptop and
the diagnostic program, as well as to reset
maintenance intervals.

NOTE
After completing the diagnostics, the lid (1)
must be screwed back onto the diagnostic
connector (2) to prevent moisture from ente-
ring.
Please contact your authorised dealer.

Operating Instructions – 387 801 1501 EN – 12/2012 225

5 Maintenance
Self-help

Towing
Towing
If the truck needs to be towed away in an
emergency, only a tow bar should be used for
safety reasons.

WARNING
Braking no longer takes place.
Do not exceed the towing speed.

NOTE
Power-assisted steering does not function
once the emergency off button has been
pressed.
 Lower the load, but not so far that the
fork arms scrape along the ground during
towing.
 Remove the load.

226 Operating Instructions – 387 801 1501 EN – 12/2012

 Maintenance 5
Self-help

 Attach the towing vehicle to the towing pin

(1) using a tow bar.

Releasing the parking brake

 Unscrew and remove bottom plate.
 Tighten screw (1) clockwise to the stop.

Operating Instructions – 387 801 1501 EN – 12/2012 227

5 Maintenance
Self-help

 Disassemble the flat iron (see arrow) from

the bottom plate.

Insert the flat iron in the opening provided and

place on the tappet rod.
 Use the flat iron as a lever.
Repeatedly using the flat iron as a lever
(approx. 20 times) creates a corresponding
pressure that releases the multi-disc brake.

NOTE
To release the multi-disc brake in the wheel
gears, an accumulator is also used for supply
of the brake valve.
DANGER
Acute risk of injury when working on accumulator.
Improper handling may lead to serious accidents.
Before starting repair work on the accumulator
or on any pressurised hydraulic pipework, the
accumulator must be depressurised.
Appropriate specialist knowledge is required to do
this. Contact your authorised dealer.

 A driver must steer the truck while it is being

towed.
 Do not exceed the permissible operating
speed when towing away the truck.

228 Operating Instructions – 387 801 1501 EN – 12/2012

 Maintenance 5
Self-help

DANGER
Risk of accident or danger to life! No braking effect
if the screw (1) is tightened to the stop
Directly after the towing procedure, the screw
(1) must be removed again in an anti-clockwise
direction.

Operating Instructions – 387 801 1501 EN – 12/2012 229

5 Maintenance
Self-help
Shutting down the industrial truck
Measures to be implemented before
shutdown
If the truck is to be shut down for a period
longer than 2 months, e.g. for operational
reasons, it must only be stored in a well-
ventilated, clean and dry room that is free
of frost. The following measures must be
implemented:
 Thoroughly clean the industrial truck.
 Raise the fork carriage several times to the
end stop.
 Tilt the lift mast forwards and backwards
repeatedly and actuate the attachment
repeatedly.
 Lower the fork carriage to a supporting
surface until the chains are relieved of load.
 Check the hydraulic oil level and top up if
necessary.
 Coat all unpainted mechanical components
with a thin film of oil or grease.
 Grease vehicle.
 Disconnect the battery male connector.
 Check battery condition and density of acid.
 Lubricate battery terminals with acid-free
grease. (Follow the battery manufacturer’s
instructions.)
230
 Jack up the truck so that all wheels are off
the ground.
This will prevent permanent deformation of the
tyres.
NOTE
Do not cover with plastic film, as this will
encourage water condensation to form and
collect.
NOTE
If the truck is to be shut down for more than
six months, further measures must be agreed
with your authorised dealer.
Recommissioning after shutdown
 Thoroughly clean the industrial truck.
 Grease vehicle.
 Clean the battery and lubricate battery
terminals with acid-free grease
 Check battery condition and acid density;
recharge if necessary.
 Check hydraulic oil for condensed water
and change if necessary.
 Perform maintenance as before initial
commissioning.
 Put the industrial truck into operation.
Operating Instructions – 387 801 1501 EN – 12/2012

Disposal of old trucks
The disposal of old trucks is regulated in
directive 2000/53/EC from the European
Parliament and Council.
We therefore recommend having this work
carried out in an approved recycling plant. If
you would like to carry out this work yourself,
you must obtain approval from the relevant
authorities as per articles 9, 10 and 11 of
directive 75/442/EEC.
The following minimum requirements must
also be observed:
• The locations in which old trucks are stored
before treatment must be areas suited to
this task with impervious surfaces. These
areas are also to be equipped with collection
devices and separators for leaking fluids
and degreasing cleaning materials
• The locations for treatment must be areas
suited to this task with impervious surfaces.
These areas are also to be equipped with
collection devices and separators for
leaking fluids and degreasing cleaning
materials. Suitable storage areas must be
Operating Instructions – 387 801 1501 EN – 12/2012
Maintenance 5
Self-help
available for disassembled and partially
oil-smeared parts, as well as for tyres
including fire protection measures. Suitable
storage tanks for fluids such as fuel, engine
oil, hydraulic oil, coolant and fluids from
air conditioning systems must also be
provided.
• In order to dispose of harmful substances
from the old trucks, the batteries and LPG
container must be removed. The following
must also be removed, collected and
stored separately: fuel, engine oil, coolant,
hydraulic oil and fluids from air conditioning
systems
• The following parts are to be collected sep-
arately and recycled: catalytic converters,
metal components containing copper and
aluminium, tyres, large plastic components
(consoles, fluid containers) and glass
NOTE
The operating company is responsible for ad-
herence to the directives as well as additional
country-specific regulations.
231
5 Maintenance
Self-help

232 Operating Instructions – 387 801 1501 EN – 12/2012

 6

Technical data
6 Technical data
Type sheet E 20/500, as at 01/2012

Type sheet E 20/500, as at 01/2012

1 Identification
1.1 Manufacturer (code designation) Linde
1.2 Manufacturer’s type designation E 20/500
1.3 Drive Electric
1.4 Operation Seated
1.5 Load capacity/load Q [kg] 2000
1.6 Load centre of gravity c [mm] 500
1.8 Load distance x [mm] 445
1.9 Wheelbase y [mm] 1622

2 Weights
2.1 Net weight kg 42101
2.2 Axle load with front/rear load kg 5615/595

2.3 Axle load without front/rear load kg 2450/17602

3 Wheels, chassis frame

Tyres: solid rubber, superelastic, pneumatic,
3.1 SE
polyurethane
3.2 Tyre size, front 23x9—10
3.3 Tyre size, rear 18x7-8
3.5 Number of wheels, front/rear (x = driven) 2x/2
3.6 Front track width b10 [mm] 942
3.7 Rear track width b11 [mm] 900

4 Basic dimensions
4.1 Lift mast/fork carriage tilt, forwards/backwards α/β (°) 5.0/8.0
4.2 Height with lift mast retracted h1 [mm] 2146
4.3 Free lift h2 [mm] 150
4.4 Lift h3 [mm] 2950
4.5 Height with lift mast extended h4 [mm] 3498

1 Including battery, line 6.4/6.5

2 Including battery, line 6.4/6.5

234 Operating Instructions – 387 801 1501 EN – 12/2012

 Technical data 6
Type sheet E 20/500, as at 01/2012

4 Basic dimensions
4.7 Height above overhead guard (cab) h6 [mm] 20803
4.8 Seat height/standing height h7 [mm] 1002
4.12 Coupling height h10 [mm] 621
4.19 Total length l1 [mm] 3318
4.20 Length including fork back l2 [mm] 2318
4.21 Total width b1/b2 [mm] 1150/1148
4.22 Fork arm dimensions s/e/l [mm] 45 x 100 x 1000
4.23 ISO 2328 fork carriage, class/model A, B 2A
4.24 Fork carriage width b3 [mm] 1080
4.31 Ground clearance with load under lift mast m1 [mm] 130
4.32 Ground clearance at centre of wheelbase m2 [mm] 120
4.33 Aisle width for pallet 1000 x 1200 crosswise Ast [mm] 36384
4.34 Aisle width for pallet 800 x 1200 longitudinal Ast [mm] 37665
4.35 Turning radius Wa [mm] 1873
4.36 Smallest pivot point distance b13 [mm] 0

5 Performance data
5.1 Driving speed with/without load km/h 20/20
5.2 Lifting speed with/without load m/s 0.45/0.56
5.3 Lowering speed with/without load m/s 0.54/0.54
5.5 Pulling force with/without load N 4600/4600
5.6 Maximum pulling force with/without load N 15,000/15,000
5.7 Climbing capability with/without load % 8.2/12.2
5.8 Maximum climbing capability with/without load % 25.4/39.0
5.9 Acceleration time with/without load s 4.0/4.0
Hydraulic/me-
5.10 Service brake
chanical

6 Drive/motor
6.1 Traction motor, power rating S2 60 min kW 9
6.2 Lift motor, power rating at S3 15% kW 22

3 Standard lift mast

4 Triplex lift mast
5 Triplex lift mast

Operating Instructions – 387 801 1501 EN – 12/2012 235

6 Technical data
Type sheet E 20/500, as at 01/2012

6 Drive/motor
Battery in accordance with DIN 43531/35/36 A, B, C,
6.3 43536/A
no
6.4 Battery voltage, nominal capacity K5 V/Ah 80 V / 440
6.5 Battery weight (±5%) kg 1210
Energy consumption in accordance with standardised
6.6 kWh/h 6.4
VDI cycle

8 Miscellaneous
Digital con-
8.1 Traction controller type troller/continu-
ously variable
8.2 Working pressure for attachments bar 170+10
8.3 Oil volume for attachments l/MIN38 38+10
8.4 Noise level at the driver’s ear (dB(A)) <65.0
.

236 Operating Instructions – 387 801 1501 EN – 12/2012

 Technical data 6
Type sheet E 20/600H, as at 01/2012

Type sheet E 20/600H, as at 01/2012

1 Identification
1.1 Manufacturer (code designation) Linde
1.2 Manufacturer’s type designation E 20/600H
1.3 Drive Electric
1.4 Operation Seated
1.5 Load capacity/load Q [kg] 2000
1.6 Load centre of gravity c [mm] 600
1.8 Load distance x [mm] 445
1.9 Wheelbase y [mm] 1651

2 Weights
2.1 Net weight kg 48256
2.2 Axle load with front/rear load kg 5885/940
2.3 Axle load without front/rear load kg 2620/22057

3 Wheels, chassis frame

Tyres: solid rubber, superelastic, pneumatic,
3.1 SE
polyurethane
3.2 Tyre size, front 23x9—10
3.3 Tyre size, rear 18x7-8
3.5 Number of wheels, front/rear (x = driven) 2 x/2
3.6 Front track width b10 [mm] 942
3.7 Rear track width b11 [mm] 900

4 Basic dimensions
4.1 Lift mast/fork carriage tilt, forwards/backwards α/β (°) 5.0/8.0
4.2 Height with lift mast retracted h1 [mm] 2295
4.3 Free lift h2 [mm] 150
4.4 Lift h3 [mm] 3250
4.5 Height with lift mast extended h4 [mm] 3911

6 Including battery, line 6.4/6.5

7 Including battery, line 6.4/6.5

Operating Instructions – 387 801 1501 EN – 12/2012 237

6 Technical data
Type sheet E 20/600H, as at 01/2012

4 Basic dimensions
4.7 Height above overhead guard (cab) h6 [mm] 22378
4.8 Seat height/standing height h7 [mm] 1160
4.12 Coupling height h10 [mm] 656
4.19 Total length l1 [mm] 3352
4.20 Length including fork back l2 [mm] 2352
4.21 Total width b1/b2 [mm] 1150/1146
4.22 Fork arm dimensions s/e/l [mm] 45 x 100 x 1000
4.23 ISO 2328 fork carriage, class/model A, B 2A
4.24 Fork carriage width b3 [mm] 1080
4.31 Ground clearance with load under lift mast m1 [mm] 130
4.32 Ground clearance at centre of wheelbase m2 [mm] 120
4.33 Aisle width for pallet 1000 x 1200 crosswise Ast [mm] 36729
4.34 Aisle width for pallet 800 x 1200 longitudinal Ast [mm] 380010
4.35 Turning radius Wa [mm] 1907
4.36 Smallest pivot point distance b13 [mm] 0

5 Performance data
5.1 Driving speed with/without load km/h 20/20
5.2 Lifting speed with/without load m/s 0.45/0.56
5.3 Lowering speed with/without load m/s 0.54/0.54
5.5 Pulling force with/without load N 4600/4600
5.6 Maximum pulling force with/without load N 15,000/15,000
5.7 Climbing capability with/without load % 7.5/10.6
5.8 Maximum climbing capability with/without load % 23.0/33.4
5.9 Acceleration time with/without load s 4.0/4.0
Hydraulic/me-
5.10 Service brake
chanical

6 Drive/motor
6.1 Traction motor, power rating S2 60 min kW 9
6.2 Lift motor, power rating at S3 15% kW 22

8 Standard lift mast

9 Triplex lift mast
10 Triplex lift mast

238 Operating Instructions – 387 801 1501 EN – 12/2012

 Technical data 6
Type sheet E 20/600H, as at 01/2012

6 Drive/motor
Battery in accordance with DIN 43531/35/36 A, B, C,
6.3 43536 A
no
6.4 Battery voltage, nominal capacity K5 V/Ah 80 V / 560
6.5 Battery weight (+/- 5%) kg 1 558
Energy consumption in accordance with standardised
6.6 kWh/h 7.0
VDI cycle

8 Miscellaneous
Digital con-
8.1 Traction controller type troller/continu-
ously variable
8.2 Working pressure for attachments bar 170+10
8.3 Oil volume for attachments l/min 50
8.4 Noise level at the driver’s ear (dB(A)) <65.0
.

Operating Instructions – 387 801 1501 EN – 12/2012 239

6 Technical data
Type sheet E 25/500, as at 01/2012

Type sheet E 25/500, as at 01/2012

1 Identification
1.1 Manufacturer (code designation) Linde
1.2 Manufacturer’s type designation E 25/500
1.3 Drive Electric
1.4 Operation Seated
1.5 Load capacity/load Q [kg] 2500
1.6 Load centre of gravity c [mm] 500
1.8 Load distance x [mm] 445
1.9 Wheelbase y [mm] 1622

2 Weights
2.1 Net weight kg 465411
2.2 Axle load with front/rear load kg 6401/754
2.3 Axle load without front/rear load kg 2444/221012

3 Wheels, chassis frame

Tyres: solid rubber, superelastic, pneumatic,
3.1 SE
polyurethane
3.2 Front tyre size 23x9-10
3.3 Rear tyre size 180x60-10
3.5 Number of wheels, front/rear (x = driven) 2x/2
3.6 Front track width b10 [mm] 942
3.7 Rear track width b11 [mm] 900

4 Basic dimensions
4.1 Lift mast/fork carriage tilt, forwards/backwards α/β (°) 5.0/8.0
4.2 Height with lift mast retracted h1 [mm] 2146
4.3 Free lift h2 [mm] 150
4.4 Lift h3 [mm] 2950
4.5 Height with lift mast extended h4 [mm] 3611

11 Including battery, line 6.4/6.5

12 Including battery, line 6.4/6.5

240 Operating Instructions – 387 801 1501 EN – 12/2012

 Technical data 6
Type sheet E 25/500, as at 01/2012

4 Basic dimensions
4.7 Height above overhead guard (cab) h6 [mm] 208013
4.8 Seat height/standing height h7 [mm] 1002
4.12 Coupling height h10 [mm] 621
4.19 Total length l1 [mm] 3318
4.20 Length including fork back l2 [mm] 2318
4.21 Total width b1/b2 [mm] 1150/1148
4.22 Fork arm dimensions s/e/l [mm] 45 x 100 x 1000
4.23 ISO 2328 fork carriage, class/model A, B 2A
4.24 Fork carriage width b3 [mm] 1080
4.31 Ground clearance with load under lift mast m1 [mm] 129
4.32 Ground clearance at centre of wheelbase m2 [mm] 120
4.33 Aisle width for pallet 1000 x 1200 crosswise Ast [mm] 363814
4.34 Aisle width for pallet 800 x 1200 longitudinal Ast [mm] 376615
4.35 Turning radius Wa [mm] 1873
4.36 Smallest pivot point distance b13 [mm] 0

5 Performance data
5.1 Driving speed with/without load km/h 20/20
5.2 Lifting speed with/without load m/s 0.45/0.56
5.3 Lowering speed with/without load m/s 0.54/0.54
5.5 Pulling force with/without load N 4600/4600
5.6 Maximum pulling force with/without load N 15,000/15,000
5.7 Climbing capability with/without load % 7.1/10.8
5.8 Maximum climbing capability with/without load % 21.6/34.1
5.9 Acceleration time with/without load s 4.0/4.0
Hydraulic/me-
5.10 Service brake
chanical

6 Drive/motor
6.1 Traction motor, power rating S2 60 min kW 9
6.2 Lift motor, power rating at S3 15% kW 22

13 Standard lift mast

14 Triplex lift mast
15 Triplex lift mast

Operating Instructions – 387 801 1501 EN – 12/2012 241

6 Technical data
Type sheet E 25/500, as at 01/2012

6 Drive/motor
Battery in accordance with DIN 43531/35/36 A, B, C,
6.3 43536 A
no
6.4 Battery voltage, nominal capacity K5 V/Ah 80 V / 440
6.5 Battery weight (±5%) kg 1210
Energy consumption in accordance with standardised
6.6 kWh/h 7.5
VDI cycle

8 Miscellaneous
Digital con-
8.1 Traction controller type troller/continu-
ously variable
8.2 Working pressure for attachments bar 170+10
8.3 Oil volume for attachments l/min 50
8.4 Noise level at the driver’s ear (dB(A)) <65.0
.

242 Operating Instructions – 387 801 1501 EN – 12/2012

 Technical data 6
Type sheet E 25/600 H, as at 01/2012

Type sheet E 25/600 H, as at 01/2012

1 Identification
1.1 Manufacturer (code designation) Linde
1.2 Manufacturer’s type designation E 25/600 H
1.3 Drive Electric
1.4 Operation Seated
1.5 Load capacity/load Q [kg] 2500
1.6 Load centre of gravity c [mm] 600
1.8 Load distance x [mm] 468
1.9 Wheelbase y [mm] 1651

2 Weights
2.1 Net weight kg 543016
2.2 Axle load with front/rear load kg 7080/850
2.3 Axle load without front/rear load kg 2965/246517

3 Wheels, chassis frame

Tyres: solid rubber, superelastic, pneumatic,
3.1 SE
polyurethane
3.2 Front tyre size 23x9-10
3.3 Rear tyre size 180x60-10
3.5 Number of wheels, front/rear (x = driven) 2x/2
3.6 Front track width b10 [mm] 942
3.7 Rear track width b11 [mm] 900

4 Basic dimensions
4.1 Lift mast/fork carriage tilt, forwards/backwards α/β (°) 5.0/8.0
4.2 Height with lift mast retracted h1 [mm] 229618
4.3 Free lift h2 [mm] 150
4.4 Lift h3 [mm] 320019

16 Including battery, line 6.4/6.5

17 Including battery, line 6.4/6.5
18 Standard lift mast
19 Standard lift mast

Operating Instructions – 387 801 1501 EN – 12/2012 243

6 Technical data
Type sheet E 25/600 H, as at 01/2012

4 Basic dimensions
4.5 Height with lift mast extended h4 [mm] 397420
4.7 Height above overhead guard (cab) h6 [mm] 223721
4.8 Seat height/standing height h7 [mm] 1160
4.12 Coupling height h10 [mm] 658
4.19 Total length l1 [mm] 3375
4.20 Length including fork back l2 [mm] 2375
4.21 Total width b1/b2 [mm] 1150/1146
4.22 Fork arm dimensions s/e/l [mm] 45 x 100 x 1000
4.23 ISO 2328 fork carriage, class/model A, B 2A
4.24 Fork carriage width b3 [mm] 1150
4.31 Ground clearance with load under lift mast m1 [mm] 127
4.32 Ground clearance at centre of wheelbase m2 [mm] 120
4.33 Aisle width for pallet 1000 x 1200 crosswise Ast [mm] 369322
4.34 Aisle width for pallet 800 x 1200 longitudinal Ast [mm] 382223
4.35 Turning radius Wa [mm] 1907
4.36 Smallest pivot point distance b13 [mm] 0

5 Performance data
5.1 Driving speed with/without load km/h 20/20
5.2 Lifting speed with/without load m/s 0.44/0.53
5.3 Lowering speed with/without load m/s 0.56/0.56
5.5 Pulling force with/without load N 4600/4600
5.6 Maximum pulling force with/without load N 15,000/15,000
5.7 Climbing capability with/without load % 6.4/9.4
5.8 Maximum climbing capability with/without load % 19.7/29.3
5.9 Acceleration time with/without load s 4.1/4.0
Hydraulic/me-
5.10 Service brake
chanical

20 Standard lift mast

21 Triplex lift mast
22 Standard lift mast
23 Standard lift mast

244 Operating Instructions – 387 801 1501 EN – 12/2012

 Technical data 6
Type sheet E 25/600 H, as at 01/2012

6 Drive/motor
6.1 Traction motor, power rating S2 60 min kW 9
6.2 Lift motor, power rating at S3 15% kW 22
Battery in accordance with DIN 43531/35/36 A, B, C,
6.3 43536 A
no
6.4 Battery voltage, nominal capacity K5 V/Ah 80 V / 560
6.5 Battery weight (±5%) kg 1 558
Energy consumption in accordance with standardised
6.6 kWh/h 8.2
VDI cycle

8 Miscellaneous
Digital con-
8.1 Traction controller type troller/continu-
ously variable
8.2 Working pressure for attachments bar 170+10
8.3 Oil volume for attachments l/min 50
8.4 Noise level at the driver’s ear (dB(A)) <65.0
.

Operating Instructions – 387 801 1501 EN – 12/2012 245

6 Technical data
Type sheet E 25/500 L, as at 01/2012

Type sheet E 25/500 L, as at 01/2012

1 Identification
1.1 Manufacturer (code designation) Linde
1.2 Manufacturer’s type designation E 25/500 L
1.3 Drive Electric
1.4 Operation Seated
1.5 Load capacity/load Q [kg] 2500
1.6 Load centre of gravity c [mm] 500
1.8 Load distance x [mm] 445
1.9 Wheelbase y [mm] 1767

2 Weights
2.1 Net weight kg 458524
2.2 Axle load with front/rear load kg 6410/675
2.3 Axle load without front/rear load kg 2575/201025

3 Wheels, chassis frame

Tyres: solid rubber, superelastic, pneumatic,
3.1 SE
polyurethane
3.2 Front tyre size 23x9-10
3.3 Rear tyre size 180x60-10
3.5 Number of wheels, front/rear (x = driven) 2x/2
3.6 Front track width b10 [mm] 942
3.7 Rear track width b11 [mm] 900

4 Basic dimensions
4.1 Lift mast/fork carriage tilt, forwards/backwards α/β (°) 5.0/8.0
4.2 Height with lift mast retracted h1 [mm] 2145
4.3 Free lift h2 [mm] 150
4.4 Lift h3 [mm] 2950
4.5 Height with lift mast extended h4 [mm] 3611

24 Including battery, line 6.4/6.5

25 Including battery, line 6.4/6.5

246 Operating Instructions – 387 801 1501 EN – 12/2012

 Technical data 6
Type sheet E 25/500 L, as at 01/2012

4 Basic dimensions
4.7 Height above overhead guard (cab) h6 [mm] 208026
4.8 Seat height/standing height h7 [mm] 1002
4.12 Coupling height h10 [mm] 624
4.19 Total length l1 [mm] 3463
4.20 Length including fork back l2 [mm] 2463
4.21 Total width b1/b2 [mm] 1150/1148
4.22 Fork arm dimensions s/e/l [mm] 45 x 100 x 1000
4.23 ISO 2328 fork carriage, class/model A, B 2A
4.24 Fork carriage width b3 [mm] 1080
4.31 Ground clearance with load under lift mast m1 [mm] 130
4.32 Ground clearance at centre of wheelbase m2 [mm] 120
4.33 Aisle width for pallet 1000 x 1200 crosswise Ast [mm] 378327
4.34 Aisle width for pallet 800 x 1200 longitudinal Ast [mm] 391128
4.35 Turning radius Wa [mm] 2018
4.36 Smallest pivot point distance b13 [mm] 0

5 Performance data
5.1 Driving speed with/without load km/h 20/20
5.2 Lifting speed with/without load m/s 0.45/0.56
5.3 Lowering speed with/without load m/s 0.54/0.54
5.5 Pulling force with/without load N 4600/4600
5.6 Maximum pulling force with/without load N 15,000/15,000
5.7 Climbing capability with/without load % 7.2/11.2
5.8 Maximum climbing capability with/without load % 22.1/35.4
5.9 Acceleration time with/without load s 4.1/4.0
Hydraulic/me-
5.10 Service brake
chanical

6 Drive/motor
6.1 Traction motor, power rating S2 60 min kW 9
6.2 Lift motor, power rating at S3 15% kW 22

26 Standard lift mast

27 Triplex lift mast
28 Triplex lift mast

Operating Instructions – 387 801 1501 EN – 12/2012 247

6 Technical data
Type sheet E 25/500 L, as at 01/2012

6 Drive/motor
Battery in accordance with DIN 43531/35/36 A, B, C,
6.3 43536 A
no
6.4 Battery voltage, nominal capacity K5 V/Ah 80 V / 550
6.5 Battery weight (±5%) kg 1458
Energy consumption in accordance with standardised
6.6 kWh/h 7.3
VDI cycle

8 Miscellaneous
Digital con-
8.1 Traction controller type troller/continu-
ously variable
8.2 Working pressure for attachments bar 170+10
8.3 Oil volume for attachments l/min 50
8.4 Noise level at the driver’s ear (dB(A)) <65.0
.

248 Operating Instructions – 387 801 1501 EN – 12/2012

 Technical data 6
Type sheet E 25/600 HL, as at 01/2012

Type sheet E 25/600 HL, as at 01/2012

1 Identification
1.1 Manufacturer (code designation) Linde
1.2 Manufacturer’s type designation E 25/600 HL
1.3 Drive Electric
1.4 Operation Seated
1.5 Load capacity/load Q [kg] 2500
1.6 Load centre of gravity c [mm] 600
1.8 Load distance x [mm] 468
1.9 Wheelbase y [mm] 1796

2 Weights
2.1 Net weight kg 544529
2.2 Axle load with front/rear load kg 7055/890
2.3 Axle load without front/rear load kg 3070/237530

3 Wheels, chassis frame

Tyres: solid rubber, superelastic, pneumatic,
3.1 SE
polyurethane
3.2 Front tyre size 23x9-10
3.3 Rear tyre size 180x60-10
3.5 Number of wheels, front/rear (x = driven) 2x/2
3.6 Front track width b10 [mm] 942
3.7 Rear track width b11 [mm] 900

4 Basic dimensions
4.1 Lift mast/fork carriage tilt, forwards/backwards α/β (°) 5.0/8.0
4.2 Height with lift mast retracted h1 [mm] 229431
4.3 Free lift h2 [mm] 150
4.4 Lift h3 [mm] 320032

29 Including battery, line 6.4/6.5

30 Including battery, line 6.4/6.5
31 Standard lift mast
32 Standard lift mast

Operating Instructions – 387 801 1501 EN – 12/2012 249

6 Technical data
Type sheet E 25/600 HL, as at 01/2012

4 Basic dimensions
4.5 Height with lift mast extended h4 [mm] 397233
4.7 Height above overhead guard (cab) h6 [mm] 223734
4.8 Seat height/standing height h7 [mm] 1160
4.12 Coupling height h10 [mm] 659
4.19 Total length l1 [mm] 3520
4.20 Length including fork back l2 [mm] 2520
4.21 Total width b1/b2 [mm] 1150/1146
4.22 Fork arm dimensions s/e/l [mm] 45 x 100 x 1000
4.23 ISO 2328 fork carriage, class/model A, B 2A
4.24 Fork carriage width b3 [mm] 1150
4.31 Ground clearance with load under lift mast m1 [mm] 127
4.32 Ground clearance at centre of wheelbase m2 [mm] 120
4.33 Aisle width for pallet 1000 x 1200 crosswise Ast [mm] 383835
4.34 Aisle width for pallet 800 x 1200 longitudinal Ast [mm] 396736
4.35 Turning radius Wa [mm] 2052
4.36 Smallest pivot point distance b13 [mm] 0

5 Performance data
5.1 Driving speed with/without load km/h 20/20
5.2 Lifting speed with/without load m/s 0.44/0.53
5.3 Lowering speed with/without load m/s 0.56/0.56
5.5 Pulling force with/without load N 4600/4600
5.6 Maximum pulling force with/without load N 15,000/15,000
5.7 Climbing capability with/without load % 6.4/9.4
5.8 Maximum climbing capability with/without load % 19.6/29.3
5.9 Acceleration time with/without load s 4.1/4.0
Hydraulic/me-
5.10 Service brake
chanical

33 Standard lift mast

34 Triplex lift mast
35 Comfort version H1/H3/H4 = 2375/3350/4125 mm
36 Comfort version H1/H3/H4 = 2375/3350/4125 mm

250 Operating Instructions – 387 801 1501 EN – 12/2012

 Technical data 6
Type sheet E 25/600 HL, as at 01/2012

6 Drive/motor
6.1 Traction motor, power rating S2 60 min kW 9
6.2 Lift motor, power rating at S3 15% kW 22
Battery in accordance with DIN 43531/35/36 A, B, C,
6.3 43536 A
no
6.4 Battery voltage, nominal capacity K5 V/Ah 80 V / 700
6.5 Battery weight (±5%) kg 1863
Energy consumption in accordance with standardised
6.6 kWh/h 8.2
VDI cycle

8 Miscellaneous
Digital con-
8.1 Traction controller type troller/continu-
ously variable
8.2 Working pressure for attachments bar 170+10
8.3 Oil volume for attachments l/min 50
8.4 Noise level at the driver’s ear (dB(A)) <65.0
.

Operating Instructions – 387 801 1501 EN – 12/2012 251

6 Technical data
Type sheet E 30/500, as at 01/2012

Type sheet E 30/500, as at 01/2012

1 Identification
1.1 Manufacturer (code designation) Linde
1.2 Manufacturer’s type designation E 30/500
1.3 Drive Electric
1.4 Operation Seated
1.5 Load capacity/load Q [kg] 3000
1.6 Load centre of gravity c [mm] 500
1.8 Load distance x [mm] 471
1.9 Wheelbase y [mm] 1665

2 Weights
2.1 Net weight kg 532537
2.2 Axle load with front/rear load kg 7580/765
2.3 Axle load without front/rear load kg 2810/251538

3 Wheels, chassis frame

Tyres: solid rubber, superelastic, pneumatic,
3.1 SE
polyurethane
3.2 Front tyre size 23x9-10
3.3 Rear tyre size 200/50-10
3.5 Number of wheels, front/rear (x = driven) 2x/2

3.6 Front track width b10 [mm] 942

3.7 Rear track width b11 [mm] 886

4 Basic dimensions
4.1 Lift mast/fork carriage tilt, forwards/backwards α/β (°) 5.0/8.0
4.2 Height with lift mast retracted h1 [mm] 2146
4.3 Free lift h2 [mm] 150
4.4 Lift h3 [mm] 2900
4.5 Height with lift mast extended h4 [mm] 3674

37 Including battery, line 6.4/6.5

38 Including battery, line 6.4/6.5

252 Operating Instructions – 387 801 1501 EN – 12/2012

 Technical data 6
Type sheet E 30/500, as at 01/2012

4 Basic dimensions
4.7 Height above overhead guard (cab) h6 [mm] 208039
4.8 Seat height/standing height h7 [mm] 1002
4.12 Coupling height h10 [mm] 623
4.19 Total length l1 [mm] 3444
4.20 Length including fork back l2 [mm] 2444
4.21 Total width b1/b2 [mm] 1150/1178
4.22 Fork arm dimensions s/e/l [mm] 45 x 100 x 1000
4.23 ISO 2328 fork carriage, class/model A, B 3A
4.24 Fork carriage width b3 [mm] 1150
4.31 Ground clearance with load under lift mast m1 [mm] 136
4.32 Ground clearance at centre of wheelbase m2 [mm] 120
4.33 Aisle width for pallet 1000 x 1200 crosswise Ast [mm] 376240
4.34 Aisle width for pallet 800 x 1200 longitudinal Ast [mm] 389141
4.35 Turning radius Wa [mm] 1973
4.36 Smallest pivot point distance b13 [mm] 0

5 Performance data
5.1 Driving speed with/without load km/h 20/20
5.2 Lifting speed with/without load m/s 0.42/0.51
5.3 Lowering speed with/without load m/s 0.56/0.56
5.5 Pulling force with/without load N 4600/4600
5.6 Maximum pulling force with/without load N 15,000/15,000
5.7 Climbing capability with/without load % 6.1/9.6
5.8 Maximum climbing capability with/without load % 18.7/30.0
5.9 Acceleration time with/without load s 4.0/4.1
Hydraulic/me-
5.10 Service brake
chanical

6 Drive/motor
6.1 Traction motor, power rating S2 60 min kW 9
6.2 Lift motor, power rating at S3 15% kW 22

39 Standard lift mast

40 Triplex lift mast
41 Triplex lift mast

Operating Instructions – 387 801 1501 EN – 12/2012 253

6 Technical data
Type sheet E 30/500, as at 01/2012

6 Drive/motor
Battery in accordance with DIN 43531/35/36 A, B, C,
6.3 43536 A
no
6.4 Battery voltage, nominal capacity K5 V/Ah 80 V / 440
6.5 Battery weight (+/- 5%) kg 1210
Energy consumption in accordance with standardised
6.6 kWh/h 8.6
VDI cycle

8 Miscellaneous
Digital con-
8.1 Traction controller type troller/continu-
ously variable
8.2 Working pressure for attachments bar 170+10
8.3 Oil volume for attachments l/min 50
8.4 Noise level at the driver’s ear (dB(A)) <65.0
.

254 Operating Instructions – 387 801 1501 EN – 12/2012

 Technical data 6
Type sheet E 30/500 L, as at 01/2012

Type sheet E 30/500 L, as at 01/2012

1 Identification
1.1 Manufacturer (code designation) Linde
1.2 Manufacturer’s type designation E 30/500 L
1.3 Drive Electric
1.4 Operation Seated
1.5 Load capacity/load Q [kg] 3000
1.6 Load centre of gravity c [mm] 500
1.8 Load distance x [mm] 471
1.9 Wheelbase y [mm] 1767

2 Weights
2.1 Net weight kg 536542
2.2 Axle load with front/rear load kg 7585/800
2.3 Axle load without front/rear load kg 2915/245043

3 Wheels, chassis frame

Tyres: solid rubber, superelastic, pneumatic,
3.1 SE
polyurethane
3.2 Tyre size, front 23x9-10
3.3 Tyre size, rear 200/50-10
3.5 Number of wheels, front/rear (x = driven) 2x/2
3.6 Front track width b10 [mm] 942
3.7 Rear track width b11 [mm] 886

4 Basic dimensions
4.1 Lift mast/fork carriage tilt, forwards/backwards α/β (°) 5.0/8.0
4.2 Height with lift mast retracted h1 [mm] 2146
4.3 Free lift h2 [mm] 150
4.4 Lift h3 [mm] 2900
4.5 Height with lift mast extended h4 [mm] 3674

42 Including battery, line 6.4/6.5

43 Including battery, line 6.4/6.5

Operating Instructions – 387 801 1501 EN – 12/2012 255

6 Technical data
Type sheet E 30/500 L, as at 01/2012

4 Basic dimensions
4.7 Height above overhead guard (cab) h6 [mm] 208044
4.8 Seat height/standing height h7 [mm] 1002
4.12 Coupling height h10 [mm] 622
4.19 Total length l1 [mm] 3539
4.20 Length including fork back l2 [mm] 2539
4.21 Total width b1/b2 [mm] 1150/1148
4.22 Fork arm dimensions s/e/l [mm] 45 x 100 x 1000
4.23 ISO 2328 fork carriage, class/model A, B 3A
4.24 Fork carriage width b3 [mm] 1150
4.31 Ground clearance with load under lift mast m1 [mm] 136
4.32 Ground clearance at centre of wheelbase m2 [mm] 120
4.33 Aisle width for pallet 1000x1200 crosswise Ast [mm] 385745
4.34 Aisle width for pallet 800x1200 longitudinal Ast [mm] 398646
4.35 Turning radius Wa [mm] 2068
4.36 Smallest pivot point distance b13 [mm] 0

5 Performance data
5.1 Driving speed with/without load km/h 20/20
5.2 Lifting speed with/without load m/s 0.42/0.51
5.3 Lowering speed with/without load m/s 0.56/0.56
5.5 Pulling force with/without load N 4600/4600
5.6 Maximum pulling force with/without load N 15,000/15,000
5.7 Climbing capability with/without load % 6.1/9.5
5.8 Maximum climbing capability with/without load % 18.6/29.7
5.9 Acceleration time with/without load s 4.2/4.0
Hydraulic/me-
5.10 Service brake
chanical

6 Drive/motor
6.1 Traction motor, power rating S2 60 min kW 9
6.2 Lift motor, power rating at S3 15% kW 22

44 Standard lift mast

45 Triplex lift mast
46 Triplex lift mast

256 Operating Instructions – 387 801 1501 EN – 12/2012

 Technical data 6
Type sheet E 30/500 L, as at 01/2012

6 Drive/motor
Battery in accordance with DIN 43531/35/36 A, B, C,
6.3 43536 A
no
6.4 Battery voltage, nominal capacity K5 V/Ah 80 V / 550
6.5 Battery weight (±5%) kg 1458
Energy consumption in accordance with standardised
6.6 kWh/h 8.6
VDI cycle

8 Miscellaneous
Digital con-
8.1 Traction controller type troller/continu-
ously variable
8.2 Working pressure for attachments bar 170+10
8.3 Oil volume for attachments l/min 50
8.4 Noise level at the driver’s ear (dB(A)) <65.0
.

Operating Instructions – 387 801 1501 EN – 12/2012 257

6 Technical data
Type sheet E 30/600 H, as at 01/2012

Type sheet E 30/600 H, as at 01/2012

1 Identification
1.1 Manufacturer (code designation) Linde
1.2 Manufacturer’s type designation E 30/600 H
1.3 Drive Electric
1.4 Operation Seated

1.5 Load capacity/load Q [kg] 3000

1.6 Load centre of gravity c [mm] 600

1.8 Load distance x [mm] 476
1.9 Wheelbase y [mm] 1651

2 Weights
2.1 Net weight kg 587047
2.2 Axle load with front/rear load kg 8000/870
2.3 Axle load without front/rear load kg 3045/282548

3 Wheels, chassis frame

Tyres: solid rubber, superelastic, pneumatic,
3.1 SE
polyurethane
3.2 Tyre size, front 23x10-12
3.3 Tyre size, rear 200/50-10
3.5 Number of wheels, front/rear (x = driven) 2 x/2
3.6 Front track width b10 [mm] 980
3.7 Rear track width b11 [mm] 886

4 Basic dimensions
4.1 Mast/fork carriage tilt, forward/backward α/β (°) 5.0/8.0
4.2 Height with lift mast retracted h1 [mm] 230149
4.3 Free lift h2 [mm] 150
4.4 Lift h3 [mm] 320050

47 Including battery, line 6.4/6.5

48 Including battery, line 6.4/6.5
49 Standard lift mast
50 Standard lift mast

258 Operating Instructions – 387 801 1501 EN – 12/2012

 Technical data 6
Type sheet E 30/600 H, as at 01/2012

4 Basic dimensions
4.5 Height with lift mast extended h4 [mm] 397951
4.7 Height above overhead guard (cab) h6 [mm] 223752
4.8 Seat height/standing height h7 [mm] 1160
4.12 Coupling height h10 [mm] 656
4.19 Total length l1 [mm] 3383
4.20 Length including fork back l2 [mm] 2383
4.21 Total width b1/b2 [mm] 1228/1146
4.22 Fork arm dimensions s/e/l [mm] 50 x 120 x 1000
4.23 ISO 2328 fork carriage, class/model A, B 3A
4.24 Fork carriage width b3 [mm] 1150
4.31 Ground clearance with load under lift mast m1 [mm] 136
4.32 Ground clearance at centre of wheelbase m2 [mm] 120
4.33 Aisle width for pallet 1000 x 1200 crosswise Ast [mm] 370053
4.34 Aisle width for pallet 800 x 1200 longitudinal Ast [mm] 383054
4.35 Turning radius Wa [mm] 1907
4.36 Smallest pivot point distance b13 [mm] 0

5 Performance data
5.1 Driving speed with/without load km/h 20/20
5.2 Lifting speed with/without load m/s 0.42/0.51
5.3 Lowering speed with/without load m/s 0.56/0.56
5.5 Pulling force with/without load N 4600/4600
5.6 Maximum pulling force with/without load N 15,000/15,000
5.7 Climbing capability with/without load % 5.8/8.7
5.8 Maximum climbing capability with/without load % 17.5/27.0
5.9 Acceleration time with/without load s 4.2/4.0
Hydraulic/me-
5.10 Service brake
chanical

51 Standard lift mast

52 Triplex lift mast
53 Comfort version H1/H3/H4 = 2375/3350/4125 mm
54 Comfort version H1/H3/H4 = 2375/3350/4125 mm

Operating Instructions – 387 801 1501 EN – 12/2012 259

6 Technical data
Type sheet E 30/600 H, as at 01/2012

6 Drive/motor
6.1 Traction motor, power rating S2 60 min kW 9
6.2 Lift motor, power rating at S3 15% kW 22
Battery in accordance with DIN 43531/35/36 A, B, C,
6.3 43536 A
no
6.4 Battery voltage, nominal capacity K5 V/Ah 80 V / 560
6.5 Battery weight (±5%) kg 1 558
Energy consumption in accordance with standardised
6.6 kWh/h 9.1
VDI cycle

8 Miscellaneous
Digital con-
8.1 Traction controller type troller/continu-
ously variable
8.2 Working pressure for attachments bar 170+10
8.3 Oil volume for attachments l/min 50
8.4 Noise level at the driver’s ear (dB(A)) <65.0
.

260 Operating Instructions – 387 801 1501 EN – 12/2012

 Technical data 6
Type sheet E 30/600 HL, as at 01/2012

Type sheet E 30/600 HL, as at 01/2012

1 Identification
1.1 Manufacturer (code designation) Linde
1.2 Manufacturer’s type designation E 30/600 HL
1.3 Drive Electric
1.4 Operation Seated
1.5 Load capacity/load Q [kg] 3000
1.6 Load centre of gravity c [mm] 600
1.8 Load distance x [mm] 476
1.9 Wheelbase y [mm] 1796

2 Weights
2.1 Net weight kg 583055
2.2 Axle load with front/rear load kg 7935/895
2.3 Axle load without front/rear load kg 3140/269056

3 Wheels, chassis frame

Tyres: solid rubber, superelastic, pneumatic,
3.1 SE
polyurethane
3.2 Tyre size, front 23x10-12
3.3 Tyre size, rear 200/50-10
3.5 Number of wheels, front/rear (x = driven) 2 x/2
3.6 Front track width b10 [mm] 980
3.7 Rear track width b11 [mm] 886

4 Basic dimensions
4.1 Lift mast/fork carriage tilt, forwards/backwards α/β (°) 5.0/8.0
4.2 Height with lift mast retracted h1 [mm] 229957
4.3 Free lift h2 [mm] 150
4.4 Lift h3 [mm] 320058

55 Including battery, line 6.4/6.5

56 Including battery, line 6.4/6.5
57 Standard lift mast
58 Standard lift mast

Operating Instructions – 387 801 1501 EN – 12/2012 261

6 Technical data
Type sheet E 30/600 HL, as at 01/2012

4 Basic dimensions
4.5 Height with lift mast extended h4 [mm] 397759
4.7 Height above overhead guard (cab) h6 [mm] 223760
4.8 Seat height/standing height h7 [mm] 1160
4.12 Coupling height h10 [mm] 661
4.19 Total length l1 [mm] 3528
4.20 Length including fork back l2 [mm] 2528
4.21 Total width b1/b2 [mm] 1228/1146
4.22 Fork arm dimensions s/e/l [mm] 50 x 120 x 1000
4.23 ISO 2328 fork carriage, class/model A, B 3A
4.24 Fork carriage width b3 [mm] 1150
4.31 Ground clearance with load under lift mast m1 [mm] 136
4.32 Ground clearance at centre of wheelbase m2 [mm] 120
4.33 Aisle width for pallet 1000x1200 crosswise Ast [mm] 384561
4.34 Aisle width for pallet 800x1200 longitudinal Ast [mm] 397562
4.35 Turning radius Wa [mm] 2052
4.36 Smallest pivot point distance b13 [mm] 0

5 Performance data
5.1 Driving speed with/without load km/h 20/20
5.2 Lifting speed with/without load m/s 0.42/0.51
5.3 Lowering speed with/without load m/s 0.56/0.56
5.5 Pulling force with/without load N 4600/4600
5.6 Maximum pulling force with/without load N 15,000/15,000
5.7 Climbing capability with/without load % 5.8/8.8
5.8 Maximum climbing capability with/without load % 17.6/27.2
5.9 Acceleration time with/without load s 4.2/4.0
Hydraulic/me-
5.10 Service brake
chanical

59 Standard lift mast

60 Triplex lift mast
61 Comfort version H1/H3/H4 = 2375/3350/4125 mm
62 Comfort version H1/H3/H4 = 2375/3350/4125 mm

262 Operating Instructions – 387 801 1501 EN – 12/2012

 Technical data 6
Type sheet E 30/600 HL, as at 01/2012

6 Drive/motor
6.1 Traction motor, power rating S2 60 min kW 9
6.2 Lift motor, power rating at S3 15% kW 22
Battery in accordance with DIN 43531/35/36 A, B, C,
6.3 43536 A
no
6.4 Battery voltage, nominal capacity K5 V/Ah 80 V / 700
6.5 Battery weight (+/- 5%) kg 1863
Energy consumption in accordance with standardised
6.6 kWh / h 9.1
VDI cycle

8 Miscellaneous
Digital con-
8.1 Traction controller type troller/continu-
ously variable
8.2 Working pressure for attachments bar 170+10
8.3 Oil volume for attachments l/min 50
8.4 Noise level at the driver’s ear (dB(A)) <65.0
.

Operating Instructions – 387 801 1501 EN – 12/2012 263

6 Technical data
Type sheet E 35/500 L, as at 01/2012

Type sheet E 35/500 L, as at 01/2012

1 Identification
1.1 Manufacturer (code designation) Linde
1.2 Manufacturer’s type designation E 35/500 L
1.3 Drive Electric
1.4 Operation Seated
1.5 Load capacity/load Q [kg] 3500
1.6 Load centre of gravity c [mm] 500
1.8 Load distance x [mm] 476
1.9 Wheelbase y [mm] 1810

2 Weights
2.1 Net weight kg 570563
2.2 Axle load with front/rear load kg 8420/785
2.3 Axle load without front/rear load kg 3035/267064

3 Wheels, chassis frame

Tyres: solid rubber, superelastic, pneumatic,
3.1 SE
polyurethane
3.2 Tyre size, front 315/45-12
3.3 Tyre size, rear 200/50-10
3.5 Number of wheels, front/rear (x = driven) 2 x/2
3.6 Front track width b10 [mm] 1028
3.7 Rear track width b11 [mm] 886

4 Basic dimensions
4.1 Lift mast/fork carriage tilt, forwards/backwards α/β (°) 5.0/8.0
4.2 Height with lift mast retracted h1 [mm] 2145
4.3 Free lift h2 [mm] 150
4.4 Lift h3 [mm] 2900
4.5 Height with lift mast extended h4 [mm] 3673

63 Including battery, line 6.4/6.5

64 Including battery, line 6.4/6.5

264 Operating Instructions – 387 801 1501 EN – 12/2012

 Technical data 6
Type sheet E 35/500 L, as at 01/2012

4 Basic dimensions
4.7 Height above overhead guard (cab) h6 [mm] 208065
4.8 Seat height/standing height h7 [mm] 1002
4.12 Coupling height h10 [mm] 626
4.19 Total length l1 [mm] 3594
4.20 Length including fork back l2 [mm] 2594
4.21 Total width b1/b2 [mm] 1322/1178
4.22 Fork arm dimensions s/e/l [mm] 50 x 120 x 1000
4.23 ISO 2328 fork carriage, class/model A, B 3A
4.24 Fork carriage width b3 [mm] 1150
4.31 Ground clearance with load under lift mast m1 [mm] 129
4.32 Ground clearance at centre of wheelbase m2 [mm] 120
4.33 Aisle width for pallet 1000 x 1200 crosswise Ast [mm] 391166
4.34 Aisle width for pallet 800 x 1200 longitudinal Ast [mm] 404167
4.35 Turning radius Wa [mm] 2118
4.36 Smallest pivot point distance b13 [mm] 0

5 Performance data
5.1 Driving speed with/without load km/h 20/20
5.2 Lifting speed with/without load m/s 0.39/0.51
5.3 Lowering speed with/without load m/s 0.56/0.56
5.5 Pulling force with/without load N 4600/4600
5.6 Maximum pulling force with/without load N 15,000/15,000
5.7 Climbing capability with/without load % 5.5/9.0
5.8 Maximum climbing capability with/without load % 16.8/27.8
5.9 Acceleration time with/without load s 4.2/4.0
Hydraulic/me-
5.10 Service brake
chanical

6 Drive/motor
6.1 Traction motor, power rating S2 60 min kW 9
6.2 Lift motor, power rating at S3 15% kW 22

65 Standard lift mast

66 Triplex lift mast
67 Triplex lift mast

Operating Instructions – 387 801 1501 EN – 12/2012 265

6 Technical data
Type sheet E 35/500 L, as at 01/2012

6 Drive/motor
Battery in accordance with DIN 43531/35/36 A, B, C,
6.3 43536 A
no
6.4 Battery voltage, nominal capacity K5 V/Ah 80 V / 550
6.5 Battery weight (+/- 5%) kg 1458
Energy consumption in accordance with standardised
6.6 kWh/h 9.5
VDI cycle

8 Miscellaneous
Digital con-
8.1 Traction controller type troller/continu-
ously variable
8.2 Working pressure for attachments bar 170+10
8.3 Oil volume for attachments l/min 50
8.4 Noise level at the driver’s ear (dB(A)) <65.0
.

266 Operating Instructions – 387 801 1501 EN – 12/2012

 Technical data 6
Type sheet E 35/500 HL, as at 01/2012

Type sheet E 35/500 HL, as at 01/2012

1 Identification
1.1 Manufacturer (code designation) Linde
1.2 Manufacturer’s type designation E 35/500 HL
1.3 Drive Electric
1.4 Operation Seated
1.5 Load capacity/load Q [kg] 3500
1.6 Load centre of gravity c [mm] 500
1.8 Load distance x [mm] 476
1.9 Wheelbase y [mm] 1796

2 Weights
2.1 Net weight kg 598568
2.2 Axle load with front/rear load kg 8545/940
2.3 Axle load without front/rear load kg 3145/284069

3 Wheels, chassis frame

Tyres: solid rubber, superelastic, pneumatic,
3.1 SE
polyurethane
3.2 Tyre size, front 315/45-12
3.3 Tyre size, rear 200/50-10
3.5 Number of wheels, front/rear (x = driven) 2 x/2
3.6 Front track width b10 [mm] 1028
3.7 Rear track width b11 [mm] 886

4 Basic dimensions
4.1 Lift mast/fork carriage tilt, forwards/backwards α/β (°) 5.0/8.0
4.2 Height with lift mast retracted h1 [mm] 229570
4.3 Free lift h2 [mm] 150
4.4 Lift h3 [mm] 320071

68 Including battery, line 6.4/6.5

69 Including battery, line 6.4/6.5
70 Standard lift mast
71 Standard lift mast

Operating Instructions – 387 801 1501 EN – 12/2012 267

6 Technical data
Type sheet E 35/500 HL, as at 01/2012

4 Basic dimensions
4.5 Height with lift mast extended h4 [mm] 397372
4.7 Height above overhead guard (cab) h6 [mm] 223773
4.8 Seat height/standing height h7 [mm] 1160
4.12 Coupling height h10 [mm] 659
4.19 Total length l1 [mm] 3528
4.20 Length including fork back l2 [mm] 2528
4.21 Total width b1/b2 [mm] 1322/1146
4.22 Fork arm dimensions s/e/l [mm] 50 x 120 x 1000
4.23 ISO 2328 fork carriage, class/model A, B 3A
4.24 Fork carriage width b3 [mm] 1150
4.31 Ground clearance with load under lift mast m1 [mm] 129
4.32 Ground clearance at centre of wheelbase m2 [mm] 120
4.33 Aisle width for pallet 1000 x 1200 crosswise Ast [mm] 384574
4.34 Aisle width for pallet 800 x 1200 longitudinal Ast [mm] 397575
4.35 Turning radius Wa [mm] 2052
4.36 Smallest pivot point distance b13 [mm] 0

5 Performance data
5.1 Driving speed with/without load km/h 20/20
5.2 Lifting speed with/without load m/s 0.39/0.51
5.3 Lowering speed with/without load m/s 0.56/0.56
5.5 Pulling force with/without load N 4600/4600
5.6 Maximum pulling force with/without load N 15,000/15,000
5.7 Climbing capability with/without load % 5.4/8.5
5.8 Maximum climbing capability with/without load % 16.3/26.4
5.9 Acceleration time with/without load s on request
Hydraulic/me-
5.10 Service brake
chanical

72 Standard lift mast

73 Triplex lift mast
74 Comfort version H1/H3/H4 = 2375/3350/4125 mm
75 Comfort version H1/H3/H4 = 2375/3350/4125 mm

268 Operating Instructions – 387 801 1501 EN – 12/2012

 Technical data 6
Type sheet E 35/500 HL, as at 01/2012

6 Drive/motor
6.1 Traction motor, power rating S2 60 min kW 9
6.2 Lift motor, power rating at S3 15% kW 22
Battery in accordance with DIN 43531/35/36 A, B, C,
6.3 43536 A
no
6.4 Battery voltage, nominal capacity K5 V/Ah 80 V / 700
6.5 Battery weight (±5%) kg 1863
Energy consumption in accordance with standardised
6.6 kWh / h 9.8
VDI cycle

8 Miscellaneous
Digital con-
8.1 Traction controller type troller/continu-
ously variable
8.2 Working pressure for attachments bar 170+10
8.3 Oil volume for attachments l/min 50
8.4 Noise level at the driver’s ear (dB(A)) <65.0
.

Operating Instructions – 387 801 1501 EN – 12/2012 269

6 Technical data
Type sheet E 30/600 HL, elevated driver’s compartment, as at 12/2012

Type sheet E 30/600 HL, elevated driver’s compartment, as at

12/2012

1 Characteristics
1.1 Manufacturer (code designation) Linde
1.2 Manufacturer’s type designation E 30/600 HL
1.3 Drive Electric
1.4 Operation Seat
1.5 Load capacity/load Q [kg] 3000
1.6 Load centre of gravity c [mm] 600
1.8 Load distance x [mm] 476
1.9 Wheelbase y [mm] 1796

2 Weights
2.1 Net weight kg 601176
2.2 Axle load with front/rear load kg 8023/988
2.3 Axle load without front/rear load kg 3226/278577

3 Wheels, chassis frame

Tyres: solid rubber, superelastic, pneumatic,
3.1 Super elastic
polyurethane
3.2 Front tyre size 315/45-12
3.3 Rear tyre size 200/50-10
3.5 Number of wheels, front/rear (x = driven) 2 x/2
3.6 Track width, front b10 [mm] 1028
3.7 Track width, rear b11 [mm] 886

4 Basic dimensions
4.1 Lift mast/fork carriage tilt, forwards/backwards α/β (°) 5/778 // 5/579
4.2 Height with lift mast retracted h1 [mm] 272480
4.3 Free lift h2 [mm] 150

76 Including battery, line 6.4/6.5

77 Including battery, line 6.4/6.5
78 Standard lift mast
79 Triplex lift mast
80 Comfort version H1/H3/H4 = 2375/3350/4125 mm

270 Operating Instructions – 387 801 1501 EN – 12/2012

 Technical data 6
Type sheet E 30/600 HL, elevated driver’s compartment, as at 12/2012

4 Basic dimensions
4.4 Lift h3 [mm] 405081
4.5 Height with lift mast extended h4 [mm] 482782
4.7 Height above overhead guard (cab) h6 [mm] 266783
4.8 Seat height/standing height h7 [mm] 1510
4.12 Coupling height h10 [mm] 659
4.19 Total length l1 [mm] 3535
4.20 Length including fork back l2 [mm] 2535
4.21 Total width b1/b2 [mm] 1322/1178
4.22 Fork arm dimensions s/e/l [mm] 50x120x1000
4.23 ISO 2328 fork carriage, class/model A, B 3A
4.24 Fork carriage width b3 [mm] 1150
4.31 Ground clearance with load under lift mast m1 [mm] 136
4.32 Ground clearance at centre of wheelbase m2 [mm] 120
4.33 Aisle width for pallets 1000x1200 crosswise Ast [mm] 386084
4.34 Aisle width for pallets 800x1200 lengthwise Ast [mm] 399085
4.35 Turning radius Wa [mm] 2067
4.36 Smallest pivot point distance b13 [mm] 0

5 Performance data
5.1 Driving speed with/without load km/h 20/20
5.2 Lifting speed with/without load m/s 0.42/0.51
5.3 Lowering speed with/without load m/s 0.56/0.56
5.5 Tractive force with/without load N 4600/4600
5.6 Maximum pulling force with/without load N 15,000/15,000
5.7 Climbing capability with/without load % 5.7/8.5
5.8 Maximum climbing capability with/without load % 17.2/26.3
5.9 Acceleration time with/without load s 4.2/4.0
Hydraulic/me-
5.10 Service brake
chanical

81 Comfort version H1/H3/H4 = 2375/3350/4125 mm

82 Comfort version H1/H3/H4 = 2375/3350/4125 mm
83 Comfort version H6 = 2317 mm
84 Including a = 200 mm safety distance
85 Including a = 200 mm safety distance

Operating Instructions – 387 801 1501 EN – 12/2012 271

6 Technical data
Type sheet E 30/600 HL, elevated driver’s compartment, as at 12/2012

6 Drive/motor
6.1 Traction motor, power rating (S2 60 min) kW 9
6.2 Lift motor, power rating at S3 15% kW 22
Battery in accordance with DIN 43531/35/36 A, B, C,
6.3 43536 A
no
6.4 Battery voltage, nominal capacity K5 V/Ah 80 V / 700
6.5 Battery weight (+5%) kg 1863
6.6 Energy consumption according to VDI cycle kWh/h 8.8

8 Miscellaneous
Digital con-
8.1 Traction controller type troller/continu-
ously variable
8.2 Working pressure for attachments bar 170+10
8.3 Oil volume for attachments l/min 50
8.4 Noise level at the driver’s ear (dB(A)) <65.0
.

272 Operating Instructions – 387 801 1501 EN – 12/2012

 Technical data 6
Truck configuration

Truck configuration
"Truck configuration" sign

NOTE
If attachments and conversions are required,
please contact your authorised dealer. A new
"truck configuration" sign must then be created
and attached to the truck by the authorised
dealer.

1 Chassis serial number

2 Identification plate designation for lift mast with:
Lift mast series – lift mast version – lift height in cm or
Identification: "ohne / CO"*
Lift mast version — variants:
"S" means standard lift mast
"D" means duplex lift mast
"T" means triplex lift mast
3 Number of capacity rating plate
4 Maximum permissible forwards/backwards tilt angle
5 Drive axle tyres:
"SE" means solid rubber tyres
"Luft" means pneumatic tyres
"ZW" means twin tyres
"Band" means bandage tyres
6 Attachment:
"GTR" means fork carriage
"ISS" means integrated sideshift
"IZVG" means integrated fork prong positioner
"ohne / CO" means customer-specific option
7 Placeholder for "data matrix code"
"ohne / CO"* means customer-specific option (without lift mast or with released non-original lift
mast)
.

Operating Instructions – 387 801 1501 EN – 12/2012 273

6 Technical data
Tyre variants andrim sizes

Tyre variants and

rim sizes
Pneumatic tyres

Drive axle tyres

Pneumatic tyres

E20/500
E20/600
E25/500
E25/500 L
E25/600 H
23x9-10 10 bar
E25/600 HL
E30/500
E30/500 L
E30/600
E30/600 HL

Drive axle tyres

Pneumatic tyres

E35/500 L
315/45-12 10 bar
E35/500 HL

Steering axle tyres

Pneumatic tyres

E20/500
18x78 10 bar
E20/600

Steering axle tyres

Pneumatic tyres

E25/500
E25/500 L
180/60-10 10 bar
E25/600 H
E25/600 HL

274 Operating Instructions – 387 801 1501 EN – 12/2012

 Technical data 6
Tyre variants andrim sizes

Steering axle tyres

Pneumatic tyres

E30/500
E30/500 L
E30/600 H
200/50-10 10 bar
E30/600 HL
E35/500 L
E35/500 HL
.

Tyres made of solid material

Drive axle tyres

Full rubber tyres SE (Superelastic)

E20/500
E20/600
E25/500
E25/500 L
E25/600 H
23x9-10 Super elastic
E25/600 HL
E30/500
E30/500 L
E30/600
E30/600 HL

Drive axle tyres

Full rubber tyres SE (Superelastic)

E35/500 L
315/45-12 Super elastic
E35/500 HL

Steering axle tyres

Full rubber tyres SE (Superelastic)

E20/500
18x78 Super elastic
E20/600

Operating Instructions – 387 801 1501 EN – 12/2012 275

6 Technical data
Tyre variants andrim sizes

Steering axle tyres

Full rubber tyres SE (Superelastic)

E25/500
E25/500 L
180/60-10 Super elastic
E25/600 H
E25/600 HL

Steering axle tyres

Full rubber tyres SE (Superelastic)

E30/500
E30/500 L
E30/600 H
200/50-10 Super elastic
E30/600 HL
E35/500 L
E35/500 HL
.

Rim sizes

Rim size Tyre size

4.33R-8 18x7-8
6.50F-10 23x9-10
8.00G-12 23x10-12
6.50F-10 200/50-10
10.00G–12 315/45–12

NOTE
Only rims that have been approved by the
manufacturer may be used. Contact your
authorised dealer.

276 Operating Instructions – 387 801 1501 EN – 12/2012

 Technical data 6
Load capacity diagrams

Load capacity diagrams

Operating Instructions – 387 801 1501 EN – 12/2012 277

6 Technical data
Lift mast data

Lift mast data

278 Operating Instructions – 387 801 1501 EN – 12/2012

 Technical data 6
Lift mast data

E20 E25-600H/E25-600HL
E20 E30
Standard E20-600H E30/E30L
E25 E30L
lift mast (in mm) E25 E30-600H/E30-600HL
E25L E35L
E25L E35L/E35HL
h
Lift 3150 3450 3750 4050 4550 3050 3200 3650 4050 4450 4950
3
Lift mast h
2247 2397 2547 2697 2947 2225 2300 2524 2724 2924 3174
retracted 1
Lift mast h
3813 4113 4413 4713 5213 3828 3978 4428 4828 5228 5728
extended 4
Free lift h
150 150 150 150 150 150 150 150 150 150 150
2

E20 E25-600H/E25-600HL
Duplex E20 E30
E20-600H E30/E30L
lift mast (in mm) E25 E30L
E25 E30-600H/E30-600HL
E25L E35L
E25L E35L/E35HL
h
Lift 3170 3770 2925 3215 3765 4065
3
Lift mast h
2174 2474 2081 2226 2501 2651
retracted 1
Lift mast h
3832 4432 3652 3942 4442 4742
extended 4
Free lift h
1511 1811 1274 1424 1674 1824
2

E20 E25-600H/E25-600HL
Triplex E20 E30
E20-600H E30/E30L
lift mast (in mm) E25 E30L
E25 E30-600H/E30-600HL
E25L E35L
E25L E35L/E35HL
Lift h 3 4715 4865 5165 5515 5965 6465 4350 4780 5355 5955 6455
Lift mast
h 1 2174 2224 2324 2474 2624 2824 2074 2224 2449 2649 2849
retracted
Lift mast h4
5378 5528 5828 6178 6628 7128 5125 5555 6130 6730 7230
extended
Free lift h 2 1511 1561 1661 1811 1961 2161 1299 1449 1674 1874 2074
.

Operating Instructions – 387 801 1501 EN – 12/2012 279

6 Technical data
Lift mast data 387 series elevated driver’s compartment

Lift mast data 387 series elevated driver’s compartment

Standard
E30/600HL
Lift mast (in mm)
Lift h3 4050 4450 4950 5450

Lift mast retracted h1 2651 2851 3101 3351

Lift mast extended h4 4827 5227 5727 6227
Free lift h2 150 150 150 150

Duplex
E30/600HL
Lift mast (in mm)
Lift h3 4065 4565

Lift mast retracted h1 2651 2901

Lift mast extended h4 4842 5342
Free lift h2 1874 2124

Triplex
E30/600HL
Lift mast (in mm)
Lift h3 5955 6605

Lift mast retracted h1 2651 2901

Lift mast extended h4 6732 7382
Free lift h2 1874 2124
.

280 Operating Instructions – 387 801 1501 EN – 12/2012

 Technical data 6
Additional capacity rating plate for attachments

Additional capacity rating plate

for attachments
DANGER
The entries in the following capacity rating plates
are examples. The information will vary depending
on the truck series, lift mast series, truck equipment
and attachment. If an attachment is fitted, an
additional capacity rating plate must be attached
to your truck within the driver’s field of vision.
If the label is missing or if the information about
the truck equipment, attachments, load data etc.
is not accurate, please contact your authorised
dealer, who will calculate the data using a program
authorised by Linde.

Additional capacity rating plate for attachments with loads that are not clamped

1 Truck series (year of manufacture, from - to) 7 Reference number and note about person
2 Lift mast type (series) calculating the load capacity
3 Lift heights 8 Front tyres
4 Attachments 9 Maximum permissible centre offset of load
5 Load capacities 10 Maximum permissible load height
6 Load centres of gravity 11 Maximum permissible lift mast backwards
tilt

NOTE
Example for reading the load capacity:
• a = 3930 kg at load centre of gravity b =
900 mm to lift height c = 7200 mm.

Operating Instructions – 387 801 1501 EN – 12/2012 281

6 Technical data
Additional capacity rating plate for attachments
Additional capacity rating plate for attachments with loads that are fixed or clamped
1 Truck series (year of manufacture, from - to)
2 Lift mast type (series)
3 Lift heights
4 Attachments
5 Load capacities
6 Reduced load capacities
7 Load centres of gravity
8 Reference number and note about person
calculating the load capacity
9 Front tyres
10 Note — If there is sufficient visibility for
forwards travel when transporting loads,
we recommend that the calculated residual
load capacity based on the roller height /
load height (value = maximum permissible
load height (13)) is limited to the following in
order to achieve a more dynamic driving
NOTE
Example for reading the load capacity:
• a = 4340 kg at load centre of gravity b =
650 mm to lift height c = 6800 mm.
282
behaviour: at a load centre of gravity
650 mm = 4,560 kg.
11 Specifies in mm how much the load centre
of gravity is offset vertically upwards to the
centre of the attachment (e.g. roller / bale
taken off).
Also applicable for attachments with a rotate
function: The actual centre of gravity of the
load during rotation must not lie outside the
pivot point by more than 100 mm (truck rated
capacity ≤ 6300 kg) or 150 mm (truck rated
capacity > 6300 kg and ≤ 10,000 kg)!
12 Maximum permissible centre offset of load
13 Maximum permissible load height
14 Maximum permissible lift mast backwards
tilt
Operating Instructions – 387 801 1501 EN – 12/2012
 Technical data 6
Vibration characteristics for bodily vibrations

Vibration characteristics for bodily vibrations

The values were determined according
NOTE
to EN 13059 using trucks with standard
equipment according to the type sheet (driving The vibration characteristic for bodily vibrati-
over test course with humps). ons cannot be used to determine the actual
vibration load during operation. This depends
Specified vibration characteristic according
on the application conditions (state of road-
to EN 13059
way, method of operation etc.) and should
Measured
therefore be determined on site where appro-
vibration aW,ZS = < 0.5 m/s2
priate. It is mandatory to specify the hand-arm
characteristic
vibrations even where the values do not indi-
Specified vibration characteristic for hand- cate any hazard, as in this case.
arm vibrations
Vibration characteristic 2.1 m/s2

Noise emission values

Calculated in the test cycle in accordance
NOTE
with EN 12053 from the weighted values for
the TRACTION, LIFT and IDLING operating Lower or higher noise emission values may
states. occur when using industrial trucks, e.g. due
to the method of operation, factors in the
Acoustic pressure level on the driver’s
surrounding area and other sources of noise.
compartment
E 20 - E 35 LPAZ = 66 dB (A)
Insecurity KPA = 4 dB (A)

Operating Instructions – 387 801 1501 EN – 12/2012 283

6 Technical data
Noise emission values

284 Operating Instructions – 387 801 1501 EN – 12/2012


A Battery replacement in truck with
Active charging ventilation unit
with an integrated battery charger . . 175
without an integrated battery
charger . . . . . . . . . . . . . . . . . . . 176
Actuating the fork arm positioner
Single lever operation . . . . . . . . . . . . 87
Additional capacity rating plate for
attachments . . . . . . . . . . . . . 19, 281
with loads that are fixed or clamped . 282
with loads that are not clamped . . . . 281
Adjust fork arm distance . . . . . . . . . . . . 117
Adjust the seat angle . . . . . . . . . . . . . . . 75
Adjust the seat back . . . . . . . . . . . . . . . . 76
Adjust the seat height . . . . . . . . . . . . . . . 75
Adjusting the backrest extension . . . . . . 76
Adjusting the driver’s seat . . . . . . . . . . . . 39
Adjusting the driver’s seat equipped
with air suspension . . . . . . . . . . . . 74
Adjusting the driver’s seat with rotating
device . . . . . . . . . . . . . . . . . . . . . 77
Adjusting the lift mast chain
Duplex lift mast or triplex lift mast . . . 210
Securing the standard lift mast . . . . . 210
Adjusting the lumbar support . . . . . . 41, 76
Adjusting the seat backrest . . . . . . . . . . . 40
Adjusting the steering column . . . . . . . . . 42
Applying the parking brake manually . . . . 57
Attachments
Fitting . . . . . . . . . . . . . . . . . . . . . . . . 17
Hydraulic connection . . . . . . . . . . . . . 17
Mechanical connection . . . . . . . . . . . 17
Automatic brake
Checking . . . . . . . . . . . . . . . . . . . . 166
B connectors and connections . . . . 193
Battery charger
Charge indicators . . . . . . . . . .
Mains supply . . . . . . . . . . . . . .
Battery charger LPS-80/75 . . . . . .
Battery grease . . . . . . . . . . . . . . .
Battery replacement . . . . . . . . . . .
Operating Instructions – 387 801 1501 EN – 12/2012
Index
g
elevated driver’s compartment . . 184
Battery replacement using a battery
support (special equipment) . . . . 185
Before exiting the truck . . . . . . . . . . . . . 123
Before load pick up . . . . . . . . . . . . . . . . 117
BlueSpot . . . . . . . . . . . . . . . . . . . . . . . . 95
Brake system . . . . . . . . . . . . . . . . . . . . . 55
Checking . . . . . . . . . . . . . . . . . . . . 165
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . .. 6
C
Changing the breather filter . . . . . . . . . 198
Changing the drive direction . . . . . . . 50, 53
Changing the hydraulic oil . . . . . . . . . . 196
Changing the oil in the planetary
transmission . . . . . . . . . . . . . . . 146
Changing the suction filter . . . . . . . . . . 202
Charging interruption . . . . . . . . . . . . . . 112
Charging the battery . . . . . . . . . . . . . . . 171
Charging the battery using an external
battery charger . . . . . . . . . . . . . . 173
Check and oil other bearings and joints . 156
Check bellows on joystick . . . . . . . . . . . 168
Check fork arm safety devices . . . . . . . 212
Check fork arms . . . . . . . . . . . . . . . . . . 212
Check slide guides on the sideshift for
wear . . . . . . . . . . . . . . . . . . . . . 214
Check the tension of double hoses . . . . 203
Check the tilt cylinder bearings for wear . 154
Checking and oiling the pedal group
and linkage . . . . . . . . . . . . . . . . 169
Checking the battery charge status . . . . 170
Checking the breather filter for leaks . . . 198
Checking the condition and secure po-
sitioning of electric cables, cable
Checking the condition of the antistatic
. . . . 113 belt . . . . . . . . . . . . . . . . . . . . . . 160
. . . . 110 Checking the control unit for correct
function . . . . . . . . . . . . . . . . . . . 199
. . . . 107
Checking the drive axle heat sinks
. . . . 130
for contamination, cleaning if
. . . . 177 necessary . . . . . . . . . . . . . . . . . 164
285
Index
g

Checking the fans for function and Driving

contamination, and cleaning if Dual-pedal operation . . . . . . . . . . . . . 48
necessary . . . . . . . . . . . . . . . . . 189
Single-pedal operation . . . . . . . . . . . 51
Checking the hydraulic system for
under load . . . . . . . . . . . . . . . . . . . 119
leaks . . . . . . . . . . . . . . . . . . . . . 195
without the lift mast . . . . . . . . . . . . . 124
Checking the main contactor . . . . . . . . 186
Duplex mast . . . . . . . . . . . . . . . . . . . . . 205
Checking the mountings . . . . . . . . . . . . 149
Securing the raised lift mast . . . . . . . 206
Checking the oil level of the hydraulic
power unit . . . . . . . . . . . . . . . . . 182 E
Checking the planetary transmission
for leaks. . . . . . . . . . . . . . . . . . . 145 EC declaration of conformity . . . . . . . .... 9
Checking the planetary transmission Electric regenerative brake . . . . . . . . . . . 56
oil level . . . . . . . . . . . . . . . . . . . 143 Electrical system . . . . . . . . . . . . . . . .... 7
Checking the tyres . . . . . . . . . . . . . . . . 158 Emergency exit with attached rear
Checks, window . . . . . . . . . . . . . . . . . . . . 15
pre-shift . . . . . . . . . . . . . . . . . . . . . . 37 Emergency off switch . . . . . . . . . . . . . . . 74
Cleaning . . . . . . . . . . . . . . . . . . . . . . . 163 End of charging . . . . . . . . . . . . . . . . . . 112
Fork prong positioner . . . . . . . . . . . 214 Entering the truck . . . . . . . . . . . . . . . . . . 38
Sideshift . . . . . . . . . . . . . . . . . . . . . 213 Equalising and maintenance charges . . 113
Cleaning and lubricating the combined Error messages . . . . . . . . . . . . . . . . . . 114
axle . . . . . . . . . . . . . . . . . . . . . . 163 Exiting the truck . . . . . . . . . . . . . . . . . . . 38
Cleaning and lubricating the sideshift Extending the battery . . . . . . . . . . . . . . 181
Checking the fastening . . . . . . . . . . 213
Cleaning the fan for the battery- F
charging function . . . . . . . . . . . . 192 Fire extinguisher . . . . . . . . . . . . . . . . . . 13
Cleaning the industrial truck . . . . . . . . . 150 Fork carriage emergency lowering . . . . . 20
Climatic conditions . . . . . . . . . . . . . . . . .. 5 Fork carriage emergency lowering for
Combined axle . . . . . . . . . . . . . . . . . . . 163 trucks with an elevated driver’s
Competent person . . . . . . . . . . . . . . . . . 16 compartment . . . . . . . . . . . . . . . . 21
Consumables . . . . . . . . . . . . . . . . . . . . 15 Fork prong positioner
Crane loading with lifting eyes . . . . . . . . 126 Checking for wear . . . . . . . . . . . . . . 216
Cleaning and lubricating, checking
D the mounting . . . . . . . . . . . . . . . 214
Depressurisation . . . . . . . . . . . . . . . . . . 89 Forklift Data Management . . . . . . . . . . 101
Description of use . . . . . . . . . . . . . . . . .. 5 Forward travel . . . . . . . . . . . . . . . . . 50, 53
Diagnostic connector . . . . . . . . . . . . . . 225 Front wheel change . . . . . . . . . . . . . . . 161
Display unit . . . . . . . . . . . . . . . . . . . . . . 28 Fuses
Disposal of old trucks . . . . . . . . . . . . . . 231 Basic equipment . . . . . . . . . . . . . . . 218
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6 Main current fuses . . . . . . . . . . . . . . 219
Special equipment . . . . . . . . . . . . . 220

G
General . . . . . . . . . . . . . . . . . . . . . . . . 170
General remarks . . . . . . . . . . . . . . . . . 128

286 Operating Instructions – 387 801 1501 EN – 12/2012

 Index
g

H Lifting the fork carriage

Central-lever operation . . . . . . . . . . . 62
Handling consumables . . . . . . . . . . . . . . 15
Single lever operation . . . . . . . . . . . . 82
Heating system . . . . . . . . . . . . . . . . . . . 99
Single-lever operation . . . . . . . . . . . . 68
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . 91
Hydraulic power unit technical data . . . . 183
Load capacity diagrams . . . . . . . . . . . . 277
Hydraulic system . . . . . . . . . . . . . . . . . .. 6
Load pick up . . . . . . . . . . . . . . . . . . . . 119
Check the oil level . . . . . . . . . . . . . . 194
Lowering the fork carriage
I Central-lever operation . . . . . . . . . . . 62
Identification plate . . . . . . . . . . . . . . . . . 24 Single lever operation . . . . . . . . . . . . 82
Impermissible use . . . . . . . . . . . . . . . . .. 4 Single-lever operation . . . . . . . . . . . . 68
Inspection data . . . . . . . . . . . . . . . . . . 129 Lubricating . . . . . . . . . . . . . . . . . . . . . . 163
Instructions for running-in . . . . . . . . . . . . 36 M
Integrated charger . . . . . . . . . . . . . . . . 107
Maintenance data . . . . . . . . . . . . . . . . 129
Intended use . . . . . . . . . . . . . . . . . . . . .. 3
Maintenance intervals . . . . . . . . . . . . . 128
J Malfunctions during operation . . . . . . . . 217
Joystick Mast positioning . . . . . . . . . . . . . . . . . . . 78
Central-lever operation . . . . . . . . . . . 61 MAXI fuses . . . . . . . . . . . . . . . . . . . . . 224
Single-lever operation . . . . . . . . . . . . 67 Measures to be implemented before
shutdown . . . . . . . . . . . . . . . . . . 230
L
N
Legal requirements for placing on the
market . . . . . . . . . . . . . . . . . . . . .. 9 Noise emission values . . . . . . . . . . . . . 283
Lift height restriction . . . . . . . . . . . . . . . . 80 O
Lift mast
Opening and closing the battery hood . . 151
Cleaning the chain and applying
chain spray . . . . . . . . . . . . . . . . 209 Operating attachments
Protection . . . . . . . . . . . . . . . . . . . . 204 Single lever operation . . . . . . . . . . . . 84
Secure against tilting backwards . . . 204 Operating devices . . . . . . . . . . . . . . . . . 27
Lift mast data . . . . . . . . . . . . . . . . . . . . 278 Operating the attachments
Lift mast data 387 series Central-lever operation . . . . . . . . . . . 62
Elevated driver’s compartment . . . . 280 Single-lever operation . . . . . . . . . . . . 69
Lift mast, chains, lift cylinder and end Operating the clamp
stops: Checking the mountings, Central-lever operation . . . . . . . . . . . 64
condition and function . . . . . . . . 212 Single lever operation . . . . . . . . . . . . 88
Lifting system and attachments Single-lever operation . . . . . . . . . . . . 70
Single lever operation with 3rd aux- Operating the fork prong positioner
iliary hydraulics . . . . . . . . . . . . . . 81
Central-lever operation . . . . . . . . . . . 64
Single-lever operation . . . . . . . . . . . . 70
Operating the lift and tilt attachments
Single-lever operation . . . . . . . . . . . . 61

Operating Instructions – 387 801 1501 EN – 12/2012 287

Index
g

Operating the sideshift Rim sizes . . . . . . . . . . . . . . . . . . . . . . . 276

Central-lever operation . . . . . . . . . . . 63
Single lever operation . . . . . . . . . . . . 86
S
Single-lever operation . . . . . . . . . . . . 70 Safety guidelines . . . . . . . . . . . . . . . . . . 12
Operation . . . . . . . . . . . . . . . . . . . . . . . . 6 Safety information . . . . . . . . . . . . . . . . . 12
Other cleaning and greasing . . . . . . . . . 156 active medical equipment . . . . . . . . . 13
Driver’s field of vision . . . . . . . . . . . . . 13
P Gas springs . . . . . . . . . . . . . . . . . . . 13
Parking brake Speed reduction . . . . . . . . . . . . . . . . 13
Checking . . . . . . . . . . . . . . . . . . . . 167 Welding operations . . . . . . . . . . . . . . 12
Parking the truck securely . . . . . . . . . . 123 Seat belt
Periodic safety inspection . . . . . . . . . . . . 16 Checking the condition and correct
Pneumatic tyres . . . . . . . . . . . . . . . . . . 274 function . . . . . . . . . . . . . . . . . . . 153
Fastening . . . . . . . . . . . . . . . . . . . . . 44
R Open . . . . . . . . . . . . . . . . . . . . . . . . 45
Rear lights . . . . . . . . . . . . . . . . . . . . . . . 94 Seat heater . . . . . . . . . . . . . . . . . . . . . . 75
Rear wheel change . . . . . . . . . . . . . . . 162 Securing the standard lift mast
Receiving the industrial truck . . . . . . . . . . 8 when raised . . . . . . . . . . . . . . . . . . 205
Recommendations for consumables Service brake
Chain spray . . . . . . . . . . . . . . . . . . 130 Checking . . . . . . . . . . . . . . . . . . . . 165
Electric cleaner . . . . . . . . . . . . . . . . 131 Service brake via the stop pedal . . . . . . . 55
Gearbox oil . . . . . . . . . . . . . . . . . . . 130 Service plan
Grease . . . . . . . . . . . . . . . . . . . . . . 130 before initial commissioning . . . . . . . . 10
Hydraulic oil . . . . . . . . . . . . . . . . . . 130 Every 1000 hours . . . . . . . . . . . . . . 135
Recommissioning after shutdown . . . . . 230 Every 3000 hours . . . . . . . . . . . . . . 137
Regenerative brake Every 6000 hours or every 3 years . . 140
Checking . . . . . . . . . . . . . . . . . . . . 166 Once after 1000 hours . . . . . . . . . . . 132
Regulations . . . . . . . . . . . . . . . . . . . . . . 16 Service plan,
Removing the lift mast . . . . . . . . . . . . . 123 pre-shift . . . . . . . . . . . . . . . . . . . . . . 37
Replacing a battery using a truck and a Setting down loads . . . . . . . . . . . . . . . . 121
battery removal tool . . . . . . . . . . 179 Setting the driver’s weight . . . . . . . . . 40, 74
Replacing the battery using a crane Shutting down the industrial truck . . . . . 230
and C hooks . . . . . . . . . . . . . . . . 179 Sideshift
Replacing the battery using a lateral Checking for wear . . . . . . . . . . . . . . 214
hydraulic battery carrier (special
Stability . . . . . . . . . . . . . . . . . . . . . . . . . 14
equipment) . . . . . . . . . . . . . . . . 181
Standard lift mast . . . . . . . . . . . . . . . . . 204
Replacing the battery with the truck
and a battery support (special Start of charging . . . . . . . . . . . . . . . . . . 111
equipment) . . . . . . . . . . . . . . . . 180 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Replacing the high-pressure filter . . . . . 200 Steering angle display . . . . . . . . . . . . . . 80
Residual risks . . . . . . . . . . . . . . . . . . . . 13 Steering system . . . . . . . . . . . . . . . . . . . 54
Retracting the battery . . . . . . . . . . . . . . 182 Switch on BlueSpot . . . . . . . . . . . . . . . . 96
Reverse travel . . . . . . . . . . . . . . . . . 50, 53 Switch panel . . . . . . . . . . . . . . . . . . . . . 34

288 Operating Instructions – 387 801 1501 EN – 12/2012


Switching on the clipboard light . . . . . . . . 91
Switching on the direction indicators . . . . 93
Switching on the front working spotlights . 91
Switching on the hazard warning system . 92
Switching on the interior lighting . . . . . . . 91
Switching on the rear window heating . . . 98
Switching on the rear working spotlights . 92
Switching on the rotating beacon /
flashing beacon . . . . . . . . . . . . . . 92
Switching on the seat heater . . . . . . 41, 100
Switching on the side lights, dipped
beams and licence plate lamp . . . . 91
Switching on the working spotlights for
reverse travel . . . . . . . . . . . . . . . . 92
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . 5
T Type sheet E 25/500, as at 01/2012 . . . 240
Technical description . . . . . . . . . . . .
Tightening the lift mast/
mountings . . . . . . . . . . . . . . . . . .
Tightening the wheel fastenings . . . .
Tilt the lift mast forward.
Single lever operation . . . . . . . . .
Tilting the lift mast back
Central-lever operation . . . . . . . .
Single-lever operation . . . . . . . . .
Tilting the lift mast backwards
Single lever operation . . . . . . . . .
Tilting the lift mast forwards
Central-lever operation . . . . . . . .
Single-lever operation . . . . . . . . .
Time
Setting . . . . . . . . . . . . . . . . . . . .
Tip-over of the truck . . . . . . . . . . . . .
Towing . . . . . . . . . . . . . . . . . . . . . .
Towing device . . . . . . . . . . . . . . . . .
Transportation by lorry or low loading
trucks . . . . . . . . . . . . . . . . . .
Triplex mast . . . . . . . . . . . . . . . . . . .
Securing the raised lift mast . . . . .
Truck
Switching off . . . . . . . . . . . . . . . .
Switching on . . . . . . . . . . . . . . . .
Operating Instructions – 387 801 1501 EN – 12/2012
Index
g
Truck configuration sign . . . . . . . . . . . . 273
Truck data acquisition
Logging off . . . . . . . . . . . . . . . 104 – 105
Logging on and starting . . . . . . 102, 104
PIN . . . . . . . . . . . . . . . . . . . . . . . . . 101
Status code . . . . . . . . . . . . . . . . . . . 101
Switching off . . . . . . . . . . . . . . 104, 106
via RFID chip or magnetic strip card . 104
Via the keypad . . . . . . . . . . . . . . . . 101
Truck overview . . . . . . . . . . . . . . . . . . . 26
Truck with elevated driver’s compart-
ment . . . . . . . . . . . . . . . . . . . . . . 38
Type sheet E 20/500, as at 01/2012 . . . 234
Type sheet E 20/600H, as at 01/2012 . . 237
Type sheet E 25/500 L, as at 01/2012 . . 246
Type sheet E 25/600 H, as at 01/2012 . . 243
.... 6
Type sheet E 25/600 HL, as at 01/2012 . 249
Type sheet E 30/500 L, as at 01/2012 . . 255
. . 208
Type sheet E 30/500, as at 01/2012 . . . 252
. . 162
Type sheet E 30/600 H, as at 01/2012 . . 258
Type sheet E 30/600 HL, as at 01/2012 . 261
. . . 83
Type sheet E 30/600 HL, elevated
driver’s compartment, as at
. . . 62 12/2012 . . . . . . . . . . . . . . . . . . . 270
. . . 68 Type sheet E 35/500 HL, as at 01/2012 . 267
Type sheet E 35/500 L, as at 01/2012 . . 264
. . . 83 Tyre variants and rim sizes . . . . . . . . . . 274
Tyres made of solid material . . . . . . . . . 275
. . . 62
. . . 68 V
Ventilation
. . . 43 Switching on . . . . . . . . . . . . . . . . . . . 99
. . . 14 Vibration characteristics . . . . . . . . . . . . 283
. . 226
. . 122
W
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . 126 Washer system (special equipment)
. . 206 Filling up the water tank . . . . . . . . . . 157
. . 207 Wheel change . . . . . . . . . . . . . . . . . . . 161
. . . 47
. . . 46
289
Linde Material Handling GmbH

387 801 1501 EN – 12/2012