SAFETY TIPS

LINDE MATERIAL HANDLING

NORTH AMERICA CORPORATION

IC Sit-Down Rider Trucks

SAFETY TIPS
and a guide to the
Information Plates,
Operation and Warning Decals
found on your truck
161970 Rev D May 2007

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SAFETY TIPS

The following warning is provided pursuant to

California Health & Safety Code Sections 25249.5 et. seq.

WARNING
California Proposition 65
This product contains and emits
chemicals known to the state of
California to cause cancer, birth defects,
and other reproductive harm.

WARNING
California Proposition 65
Diesel engine exhaust and some of its
constituents are known to the state of
California to cause cancer, birth defects,
and other reproductive harm.

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 SAFETY TIPS

FOREWORD
The operator’s manual is not a training manual. It is a guide to help operators
safely operate their equipment by pointing out the correct methods and procedures.
The operator's manual cannot cover every possible hazard or potential accident
situation. It is up to you, the operator, to avoid or correct these potential dangers.
It is important that you know and understand the information in this manual as
well as the equipment you will be operating. Do not operate a damaged or
malfunctioning truck. Practice safe operation every time you use your lift truck so
that we can join together to set high standards for safety.

The lift truck is designed for lifting and transporting of pallets or loads of material.
The truck is designed for operation on smooth and dry surfaces. The truck has
the ability to climb or descend smooth and dry ramps with or without a load.
Ensure you use the truck only for the job it was intended to do.

NOTICE:

The descriptions and specifications included in this manual were in effect at the
time of printing. Linde Material Handling reserves the right to make improve-
ments and changes in specifications or design without notice and without
incurring obligation. Please check with your authorized Linde dealer for infor-
mation on possible updates or revisions.

Regular care and maintenance of your truck is not only important for full and efficient
truck life, it is essential for equipment and operator safety. The importance of
maintaining the truck in a safe operating condition with regular planned servicing and
prompt repairs when necessary cannot be emphasized too strongly. Experience has
shown that powered industrial trucks can cause injury if improperly used or maintained.
To assist in keeping your truck in service and in good operating condition, a
maintenance section is included in the operator’s manual. The maintenance
section outlines maintenance and inspection procedures to be completed at
regular intervals. These procedures are considered essential to the life and safe
performance of your truck.

Certain data and information are presented in the operator’s manual to ensure
safe operating and maintenance procedures.

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SAFETY TIPS

NOTICE:
Indicates information or points of particular interest for more efficient and
convenient operation.

This manual contains operating and periodic maintenance instructions as well

as specifications for the lift truck. The manual is designed to assist in the proper
care and maintenance of your truck while providing maximum safety and efficient
operation. Consider this manual a special tool which, if properly applied, can
help ensure years of safe and efficient material handling. Your local dealer or the
factory can arrange for operator training and/or maintenance instructions for your
truck should you need them.

Parts and Service

See your Linde dealer for genuine Linde parts (the only factory-authorized
replacements), factory-trained service personnel and manuals for your equipment.

General Safety Rules

Safety signs and messages are placed in this manual and on the truck to provide
instructions and identify specific areas where potential hazards exist and special
precautions should be taken. Know and understand the meaning of these
instructions, signs, and messages. Damage to the truck, death or serious injury
to you or others may result if these messages are not followed.
CAUTION

INDICATES A POTENTIALLY HAZARDOUS SITUATION, WHICH IF NOT AVOIDED,

MAY RESULT IN MINOR OR MODERATE INJURY.
WARNING

INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH IF NOT AVOIDED

COULD RESULT IN DEATH OR SERIOUS INJURY.
DANGER
DANGER

INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH IF NOT AVOIDED

WILL RESULT IN DEATH OR SERIOUS INJURY.

You, as the operator, are ultimately responsible for your own safety and the safety
of those around you. Read and study this manual. Be sure to understand all the
operating procedures and safety precautions before operating the truck.

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 SAFETY TIPS

A Word to the Linde Forklift Owner / Employer

On December 1st, 1998 the Occupational Safety and Health Administration
(O.S.H.A.) adopted a new and stringent Powered Industrial Truck Operator Training
rule 29 CFR 1910.178(1). Based on the American Society of Mechanical Engineers
(ASME) B56 2000 standard, operator training is now spelled out in detail. The
employer shall ensure that operators of powered industrial trucks are competent
and trained in safe and proper operation of powered industrial trucks. This training
will include formal training, practical demonstration and on-site evaluation.
O.S.H.A. also requires a proper pre-shift inspection and any repair required shall
be done by a person trained and authorized to repair industrial trucks.
As the employer you should be familiar with the rules of 29 CFR 1910.178(1) as
well as ASME B56 for the user. You should also be aware of any state OSHA rules
that may differ from the federal rule.
Linde trucks meet all applicable requirements of ASME B56 at time of manufacture.
Linde Material Handling will not assume, and expressly disclaims any liability for
injuries or damages arising from or caused by the removal, disconnection or
disengagement of any part from any of its trucks. Linde Material Handling
recommends that all replacement parts be of OEM (Original Equipment
Manufacturer) origin.
Any modifications and/or additions which affect capacity or safe operation of
industrial trucks manufactured by Linde may not be performed without prior
written approval. A user should consult the Local Authorized Dealer if the
user’s intended application is outside the designated performance
characteristics of the vehicle.

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SAFETY TIPS

Before Operation
Before using the truck, inspect your work area. Check that it is neat, well lit,
adequately ventilated, and free from hazardous material. Aisles and roadways
should be unobstructed and well marked.
Fire extinguishers and other emergency equipment should be visible and easy to
reach. Wear safety equipment when required. Don’t smoke in “No Smoking” areas,
when refueling. Don’t mix drugs or alcohol with your job.
The truck is designed for safety. Unauthorized additions or modifications without
Linde’s prior approval are prohibited. Do not remove or alter nameplates.
If you have any questions or concerns about lift truck safety, talk to your
supervisor. If an accident should occur, report it immediately.

WARNING
Start the engine only when securely seated in the operator’s compartment.

WARNING
Do not remove any safety guards or other safety devices. These include the
overhead guard, load backrest extension, and if equipped by the owner, alarm,
lights and mirrors.

The overhead guard is intended to provide protection to the operator from falling
objects, but cannot protect from every possible impact.

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 SAFETY TIPS

OPERATOR’S DAILY CHECKLIST

At the beginning of each shift, inspect your truck by using the Linde Operator’s Daily
Checklist. Check for damage and maintenance problems. Have repairs made
before you operate the truck.

Checklist for IC Sit-down Trucks

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SAFETY TIPS

Periodic maintenance is vital to safe operation of the truck. Adhere to a strict

inspection, lubrication, and maintenance schedule.

WARNING
Do not operate a damaged or defective lift.

WARNING
If warning decals are damaged or missing, they must be replaced.

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 SAFETY TIPS

PEDESTRIANS
Watch out for pedestrians. Always yield the right-of-way to pedestrians. Do not drive
the truck up to anyone standing in front of a rack or other fixed object.

Do not pass another truck traveling in the same direction at an intersection, blind
spot or other dangerous location. Sound horn at intersections and other locations
where vision is obstructed. Always look in the direction of travel.

If your vision is restricted by the load, then operate the truck in reverse.

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SAFETY TIPS

Do not engage in stunt driving or horseplay. Use lights in dark and dim areas.
Always ensure that there are no pedestrians in the trucks rear swing area before
turning. Watch for pedestrians beside the truck.

DANGER
Watch for people in your work area because they may not watch for you, even
if you have lights or alarms.

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 SAFETY TIPS

OPERATING POSITION
Face the truck when mounting and dismounting. Maintain a three-point contact,
one foot and two hands with the truck when mounting or dismounting. Never exit
a moving truck. Never jump on or off the truck.

WARNING
Operate the truck only when you are in the normal operating position. Keep
hands and feet inside the operator’s compartment.

WARNING
Always keep hands, feet and legs out of the mast uprights.

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SAFETY TIPS

WARNING
Do not walk under raised forks at any time.

WARNING
Wear your seat belt at all times when operating the truck.

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 SAFETY TIPS

WARNING
Do not place yourself between the mast and the body of the truck. Do not
use the upright as a ladder.

WARNING
Do not transport personnel at any time. Do not lift personnel using the forks
of the truck, or with a work platform. The truck is not designed to lift
personnel.

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SAFETY TIPS

TRAVEL

The truck is designed for operation on smooth, and dry surfaces such as
warehouse and factory floors, loading docks or paved surfaces. Under all travel
conditions, operate the truck at a speed that will permit it to be brought to a stop
in a safe manner.

WARNING
Do not travel at excessive speeds; keep your truck under control at all times.

Travel with the load near the floor, tilted back to cradle the load whenever possible.
Never lift or lower the load when the truck is in motion. When handling bulky loads
that restrict your vision operate your truck in reverse to improve visibility. Unstable
loads are a hazard to you and to your fellow workers. Always make certain that the
load is well stacked, secured and evenly positioned across both forks. Never
attempt to lift a load with only one fork. Do not travel on an uneven surface. Watch
for overhead obstructions such as lights, wiring, pipes, sprinkler systems,
doorways, etc. Do not move railroad cars, semi or tractor trailers with this truck, or
use to operate or close railroad car doors.

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 SAFETY TIPS

LIFTING AND LOWERING LOADS

Know your truck’s capacity. Read and understand the truck data plate. Never
attempt to lift or transport a load exceeding the truck’s rated capacity.

WARNING
Never attempt to lift or transport a load exceeding the truck’s rated
capacity.

WARNING
Watch for slack chain condition. Slack chains mean rail or carriage hang-up.
Raise the forks before you move. Do not attempt to make repairs yourself,
always get a trained mechanic.

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SAFETY TIPS

INCLINES, RAMPS, DOCKS, ELEVATORS

If you must travel on an incline, do so with caution. Do not operate truck on a wet
incline. Keep the load upgrade to maintain control when traveling up or down an
incline with a loaded truck.
Be aware that when descending an incline your stopping distance will be greater
than when on a level surface. Reduce your speed, and ensure that there is
adequate clear space at the bottom of the ramp to stop and turn.
To avoid hazards associated with a dock, you should personally check that the
trailer brakes have been applied, wheel chocks are in place, and that any trailer-
to-dock locking systems are being utilized. The impact of moving in and out of a
trailer may cause the trailer to creep or move. Confirm that the driver will not move
the trailer until you are done.

Do not drive the truck onto an elevator without specific authorization. Verify that the
capacity of the elevator exceeds the weight of your truck and the weight of the
load.

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 SAFETY TIPS

Keep the counterweight upgrade when traveling up or down an incline with an

empty truck.

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SAFETY TIPS

DANGER
Never turn on an incline or ramp either loaded or unloaded. Travel straight up
or straight down.

Be especially cautious when driving the truck on ramps or bridge plates. Be sure
to maintain a safe distance from each edge. Before driving the truck over a ramp
or bridge plate, verify that their position is secured to prevent movement of the
plates.

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 SAFETY TIPS

TIP-OVER
Lateral tip over can occur with a combination of speed and sharpness of turn.
This condition of instability is even more likely with an unloaded truck. With the
load raised, lateral tipover can occur while turning and/or braking when traveling
in reverse or accelerating and turning while traveling forward. Lateral tip over can
occur loaded or unloaded by turning on a ramp. Longitudinal tip over can occur
with a combination of overloading and load elevated. This condition is even more
likely with excessive forward tilt, braking in forward travel or accelerating rearward.

DANGER
Lift truck tip over can cause serious injury or death if the operator is trapped
between the truck and the ground.

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WARNING
If your truck starts to tip over DO NOT JUMP! Make sure your seat belt is
securely fastened, stay in the seat, grip the wheel, lean away from impact and
brace your feet.

SUSPENDED LOADS

Traveling with suspended loads on a

cable or chain can induce swinging.
Avoid suspended loads if possible. If
necessary to carry suspended loads,
keep them low.

WARNING
• Swinging of loads can cause truck
tip over.
• Use a partner with a rope or tether
to prevent swinging.
• Operate the truck slowly.

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 SAFETY TIPS

REFUELING
Confirm the engine type before filling the tank with the recommended fuel.

WARNING
Lift trucks should be refueled only at designated safe locations. Safe outdoor
locations are preferable to those indoors. Never fill the tank near open flame
or when the engine is running. Explosive fumes may be present during refueling.
DO NOT smoke in refueling areas. Before fueling an internal combustion truck,
turn the engine off and leave the operator’s compartment. When filling, keep
the funnel or fuel hose nozzle in contact with the tank’s metal. This avoids the
possibility of an electric spark igniting the fuel.
After refueling, close the cap tight and wipe up any spilled fuel carefully and
completely. Verify that fuel tank cap has been replaced securely before restarting
engine.

NOTICE:
Do not allow diesel or gasoline powered lift trucks to become low on fuel or
completely run out of fuel. Sediment or other impurities in the fuel tank could be
drawn into the fuel system. This could result in difficult starting or damage to
components.
DO NOT fill the tank to the top. Fuel expands when it gets warm and may overflow.

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SAFETY TIPS

HANDLING LP GAS
WARNING
Only trained, authorized personnel should fill or exchange LP-gas tanks.
Protective clothing such as a face shield, long sleeves, and long gloves
(covering the wrist) should be worn.
Do not refill DOT cylinders while mounted on the truck.
Do not refuel or store LP-gas powered lift trucks near underground entrances,
elevator shafts, or other places where LP-gas could collect in a pocket and cause
potential danger for an explosion.
Do not leave the lift truck, for even a short time, near equipment that generates
high temperatures. Oven and furnaces are examples. The heat may raise the
pressure of the fuel tank in place.
Close the service valve on the tank when LP-gas fueled lift trucks are parked
overnight or stored for long periods indoors with the fuel tank in place. Close
valves on empty tanks.

WARNING
Never use an open flame to check the liquid level in the fuel tank,or the
condition of LP gas lines/connectors.
Examine LP-gas tanks before filling and before reuse. Look for damage to the
valve, liquid gauge, fittings and hand wheels. Check for dents, scrapes or other
damage to the pressure vessel and for dirt or debris in the openings.
Inspect LP-gas fuel lines and fittings with a soap solution after replacing the tank
or when looking for leaks. All defective or damaged LP-Gas tanks must be removed
from service.

CHANGING LP GAS TANKS

WARNING
Serious accidents can occur if LP-Gas tanks are not properly handled. To
reduce the risk of injury or tank damage, use extreme care when transporting
them.

WARNING
LP gas is highly flammable. Do not smoke or use open flame for any purpose
while changing LP gas tanks. Gas ignition can cause serious injury or death.

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 SAFETY TIPS

Before changing LP gas tanks, close the hand wheel valve on the gas tank and
allow the truck to idle until it shuts down. This will burn the fuel present in the fuel
system and reduce the chance of pressurized LP gas remaining in the fuel lines.
On trucks with two gas tanks, close the hand wheel valves on both tanks even if
only one tank is being changed.

WARNING
Pressurized LP gas remaining in fuel lines can cause frost burns. To reduce
the risk of injury, use extreme care when disconnecting and reconnecting fuel
lines, or opening tank valves.
When disconnecting fuel line fittings, loosen them slowly to allow any pressurized
gas to bleed off safely. On trucks with two gas tanks, do not alter the diverter valve
position after fuel lines are disconnected.
Always verify the presence and condition of the O-ring and seal in the fitting of the
new tank before installing the tank onto the truck. Make sure the tank engages the
locating pin on the tank mounting plate. On trucks with two gas tanks, there is a
locating pin for each tank. Fasten the tank straps securely before connecting the
fuel line.

Locating Pin

After a tank is installed and connected, always open the hand wheel valve on the
tank slowly to check for leaks. If leaking is heard or otherwise detected, close the
hand wheel valve immediately and do not open it again until the problem is
corrected.

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SAFETY TIPS

REFILLING LPG CYLINDERS

The weight scale method to fill the cylinder is highly recommended to protect the
environment and to reduce fire hazards. This method will reduce overfilling and
discharge of LP-Gas into the environment.

WARNING

• Only trained, authorized personnel should fill or exchange LP-gas tanks.

Protective clothing such as a face shield, long sleeves, and long gloves
(covering the wrist) should be worn.

• Do not refill DOT cylinders while mounted on the truck.

• Make sure you know and understand the proper procedure for filling an LPG
cylinder.

• Know all fire codes in your area.

• If you have any questions regarding refuelling LPG cylinders, please ask
your supervisor.

• If problems with filling occur, call the LPG supplier.

• Store full and empty cylinders according to local fire codes.

• When filling LPG cylinder with LPG, always observe the law or regulations in
your country, state or province.

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SAFETY DURING MAINTENANCE

WARNING
Do not leave the engine running where there is poor ventilation. The engine
exhaust gas contains carbon monoxide. There is danger that this will cause
gas poisoning which may result in serious injury or death.

WARNING
Immediately after using the lift truck, the engine coolant is at high temperature
and high pressure. Do not remove the radiator cap under these conditions.
Hot water may spurt out and cause burns.
When checking the coolant level, stop the engine and wait for the engine and
radiator to cool down before checking. When removing the radiator cap, turn it
slowly to release the internal pressure.
For lift trucks equipped with a subtank or reservoir, check the level in the subtank.
When adding water on lift trucks equipped with a subtank, add the water to the
subtank.

WARNING
Batteries can produce explosive gases. Never smoke or use an open flame
around the battery. Never use an open flame to check battery electrolyte level.

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SAFETY TIPS

WARNING
It is extremely dangerous if you or any tool touches or gets caught in the fan or
fan belt when the fan is rotating. Never touch the fan when it is rotating. Always
stop the engine before inspecting rotating parts.
When inspecting the areas around rotating parts, do not allow anything to
come close which may get caught.

WHEELS AND TIRES

WARNING
If the tire inflation pressure is low, it will affect truck stability. However, do not
inflate the tires immediately. The inflation pressure may have gone down
because of damage to the rim. If the rim is damaged or cracked and the tires
are inflated, there is danger that the rim will break when the tire is under high
pressure, and this may cause personal injury or death.
For safety, when checking tire pressure, place your body in front of the tread
face of the tire. Do not check from the side face of the tire.

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 SAFETY TIPS

Suitable qualifications are needed for tire inflation work. Always have the work
carried out by properly qualified personnel.

WARNING

• OSHA safety procedures must always be followed. Refer to OSHA 1910.177.

• Always use correct procedures when servicing or replacing pneumatic

tires on multi-piece rim sets.

• Failure to use proper procedures can cause explosive separation of tire

and rim set, and death or serious injury could result.

• When inflating or deflating tires, a suitable safety cage or barrier shall be

used.

• Only properly trained personnel should replace pneumatic tires on multi-

piece rim sets.

• Do not mix different sizes or tire types, this could affect stability.

• Incorrect tire pressure can affect the trucks stability, potentially resulting
in a tip over, it also can cause bursting or premature wear or explosive
separation of multi-piece rim sets.

• When checking tire pressure, do not face the tire side to avoid a danger
because the tire pressure is very high.

• If the procedures listed above are not followed the result could be death or
serious injury.
The tire inflation pressure on a forklift truck is several times higher than the
pressure on an automobile. The use of an inflation cage, or some other safety
device, helps prevent serious injury. When the tires are being inflated, there is
danger that dirt or dust may be thrown up by the compressed air and enter
your eyes, so always wear safety glasses.

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SAFETY TIPS

PARKING
When you are finished with the truck, observe proper shutdown procedures.

WARNING

• Never park on a grade

• Always come to a complete stop before leaving truck
• Place travel controls in neutral.
• Lower forks fully to the floor and tilt forward
• Set parking brake
• Turn key to OFF position.
• If operator is more than 25ft. away from the truck or out of sight of the
truck, the key should be removed.

WARNING
Do not park on a grade or incline. Do not park in areas which block emergency
equipment or routes, access to fire aisles or fire equipment, or stairways.

WARNING
Failure to properly shutdown the truck may allow the truck to move causing
injury to pedestrians and damage to property.

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DATA PLATE
1 2
3 4

7
6
11 5

9 8 12 10

1. Model designation of the truck

2. Truck serial number
3. Truck sales order number - the sales and serial numbers are assigned to
each specific truck and should be used when requesting any information on
the truck. Also, these numbers should be referenced when ordering service
parts from your authorized Linde dealer.
4. Truck weight - without battery.
5. Truck type - the code letters in this block signify the type of construction with
safeguards against fire, shock hazards and explosion in classified and
nonclassified areas. Check with the proper authority before entering areas
containing flammable or explosive materials.
6. Back Tilt (degrees)
7. System voltage of the truck
8. Load Center - (500, 600, 700 mm)
9. Attachments (Forks, Sideshifter, Clamp, etc.)
10. Truck capacity, load center and lifting height - these show the maximum
load capacity of the truck with mast vertical in releation to load centers and lift
heights. Operators of this truck need to be aware of these capacities. Personal
injury or damage to the truck can occur if these capacities are exceeded.

WARNING
Never attempt to lift a load greater than the maximum capacity listed on this
plate

11. Drive Tires- Size and type can affect the capacity of your truck. Ensure truck is
equipped with tires specified.
12. Lift Height (mm)

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SIT-DOWN RIDER TRUCK OPERATOR WARNINGS
1. CHECK YOUR TRUCK - The truck should be checked daily before being
placed in service. If found to be in need of repair, defective, or in any way unsafe it
should be reported immediately to the proper authority and removed from service
until restored to a safe operating condition.
2. KNOW YOUR TRUCK - Do not operate this truck unless you have been
trained and authorized to do so. Read all warnings and instructions in the
Operator's manual on this truck; or obtain them from plant Safety Director or the
local Linde representative.
3. KEEP INSIDE - Operate truck only from designated operating position.
Operate the truck only when you are in the normal operating position and seated
in the Operator's seat. Never place any part of your body into the mast structure,
between the mast and the truck, or outside the truck. Do not carry passengers.
4. PROTECT YOURSELF - Do not operate truck without overhead guard.
5. SEAT BELT - MAKE SURE YOUR SEAT BELT IS FASTENED BEFORE
OPERATING THE TRUCK.
6. LATERAL TIPOVER - Can occur loaded or unloaded by a combination of
speed and sharpness of turn. SLOW DOWN BEFORE TURNING. With the mast
raised, lateral tipover also can occur by turning and/or braking when moving
rearward, turning and/or accelerating forward or turning on an incline or ramp.
TRAVEL WITH THE MAST LOWERED. The potential for lateral tipover will be
further increased by overloading, excessive rearward tilt or off-center positioning
of the load. Don't risk injury or death. Drive smart.
7. LONGITUDINAL TIPOVER - Can occur by driving with the load down slope
on an incline or ramp, overloading, excessive forward tilt or aggressive braking
when moving forward or accelerating rearward with the mast elevated. TRAVEL
WITH THE MAST LOWERED. Don't risk injury or death. Drive smart.
8. LATERAL OR LONGINTUDINAL TIPOVER - Can occur if the truck is driven
over objects on the floor or ground, off the edge of improved surfaces, or into
potholes, or by impacting overhead obstacles or collision with other objects.
Don't risk injury or death. Drive smart.
9. DON'T JUMP OFF - If your truck begins to tip over, DON'T JUMP. Hold the
steering wheel tightly, brace feet, and lean away from tip. Stay in the seat to avoid
being trapped between the truck and the ground.
10. HIGH LOADS - Do not handle loads which are higher than the load backrest
or load backrest extension unless load is secured so that no part of it could fall
backward.
11. STABILIZE YOUR LOAD - Do not handle unstable or loosely stacked loads.
Use special care when handling long, high, or wide loads to avoid losing the load,
striking bystanders, or tipping truck.
Failure to comply with these warnings will create an unreasonable risk of injury to yourself and others.
12. CENTER YOUR LOAD - When using forks, space forks as far apart as load
will permit. Before lifting, be sure load is centered and forks are completely under
load.
13. NEVER OVERLOAD - Do not overload truck. Check capacity plate for load
weight and load center information.
14. AVOID SUDDEN MOVEMENTS - Start, stop, travel, steer, and brake
smoothly. Sudden movements can endanger yourself and others.
SAFETY TIPS
15. LOOK OVERHEAD - Elevate forks or other lifting mechanism only to pick up
or stack a load. Lift and lower with mast vertical or slightly back - NEVER
FORWARD. Watch out for obstructions, especially overhead.
16. MINIMUM TILT - Operate tilting mechanism slowly and smoothly. Do not tilt
forward when elevated except to pick up or deposit a load. When stacking use
only enough backward tilt to stabilize load.
Operator Warnings Decal
17. EYES AHEAD - Travel with load or lifting mechanism as low as possible and
tilted back. Always look in direction of travel. Keep a clear view, and when load
interferes with visibility, travel with lifting mechanism trailing (except when
climbing ramps).
18. CARE ON RAMPS - Use special care when operating on ramps, travel
slowly, and do not angle or turn. When truck is loaded, travel with load uphill.
When truck is empty, travel with lifting mechanism downhill.
19. SLOW DOWN - Observe applicable traffic regulations. Yield right-of-way to
pedestrians. Slow down & sound horn at cross aisles and whenever vision is
obstructed.
20. WATCH PEOPLE - Do not allow anyone to stand or pass under lifting
mechanism, directly behind truck or within rear swing area when turning.
21. WORK PLATFORMS - DO NOT LIFT OR CARRY PERSONNEL
USING THE FORKS OF THE TRUCK, not even with a work platform. The truck is
OPERATOR WARNING AND SAFETY DECALS
designed for transporting, warehousing and stacking of material, not personnel.
22. SHUT DOWN COMPLETELY - Before getting off truck, neutralize travel
Read and understand the following before operating the truck:
control, fully lower lifting mechanism and set the parking brake. Also shut off
power when leaving truck unattended. Block wheels if truck is parked on an
incline.
23. THE ENGINE EXHAUST contains CO. There is a danger of causing severe
injury or death.
139950 11/06
 SAFETY TIPS

Trained Operator Warning Decal

This decal reinforces the requirement that only trained and authorized personnel
are to operate the truck.

Hood Latch Warning Decal

This decal indicates that the operator should verify that the hood latch is securely
fastened before operating the truck.

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SAFETY TIPS

Don’t Walk Under or Stand On Forks Warning Decal

This decal is located on both sides of the mast uprights and warns both the
operator and any pedestrians not to stand on or walk under raised forks at any
time.

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 SAFETY TIPS

Brake Warning Decal

This decal indicates that the operator should engage the parking brake lever
whenever necessary, as it is not automatically applied.

Personnel Warning Decal

This decal indicates that the operator should never use the forks to lift personnel
for any reason.

WARNING
DO NOT LIFT PERSONNEL USING THE
FORKS OF THE TRUCK. TRUCK IS
DESIGNED FOR TRANSPORTING,
WAREHOUSING AND STACKING OF
MATERIAL, NOT PERSONNEL.
142526

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SAFETY TIPS

Seat Belt / Tip-Over Warning Decal

This decal indicates that the operator should read
the operator’s manual and engage the seat belt
before operating the truck. It also instructs the
operator on what to do in the event of a tip-over of the
truck.

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 SAFETY TIPS

Keep Hands Clear Warning Decal

This decal warns personnel to keep hands clear of certain components at all
times.

No Step Warning Decal

This decal warns personnel not to step or stand within a certain location.

WARNING
DO NOT STEP OR STAND HERE.
149579
SERIOUS INJURY COULD RESULT.

35
LINDE MATERIAL HANDLING
NORTH AMERICA CORPORATION

©2007 Linde Material Handling

2450 West 5th North Street
Summerville, S.C. 29484
PHONE (843) 875-8000 FAX (843) 875-8329
Operating Instructions
Diesel forklift truck

H40D, H45D, H50-500D

EN – 03/2007

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.
Your local Linde partner can offer you a
complete package from a single source;
Operating Instructions – EN – 03/2007
Preface
g
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
Schweinheimerstraße 34
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
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1 Introduction
Your forklift truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Technical specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Truck operation with a bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Takeover of forklift truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Initial commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2 Safety
Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
In the case of tip-over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Handling fluids and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Experts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Operation of industrial trucks in plant area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Determination and assessment of hazards from use of industrial trucks . . . . . . . . . . . . 11
Instructions before fitting attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3 Overview
Type plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
General view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Indicator unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4 Operation
Running-in instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Checks before starting work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Standard equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Adjusting the driver’s seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Adjust the steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Setting the clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Lap seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Traction engine (two-pedal operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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Driving (double-pedal operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Traction engine (single-pedal operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Driving (single-pedal operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Steering system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Lifting system and attachments (central lever operation) . . . . . . . . . . . . . . . . . . . . . . . 46
Lifting system and attachments (single-lever operation) . . . . . . . . . . . . . . . . . . . . . . . . 49
Special equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Lifting system and attachments (single lever operation with 3rd additional hy-
draulics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Adjusting the swivel seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Adjusting the driver’s seat with air cushioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Mast positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Windscreen wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Heating, air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Truck Data Management (LFM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Working under load . . . . . . . . ............... ............... ............ 71
Before taking up a load . . . . . . ............... ............... ............ 71
Adjusting the fork spread . . . . ............... ............... ............ 72
Picking up a load . . . . . . . . . . ............... ............... ............ 73
Transporting a load . . . . . . . . ............... ............... ............ 74
Setting down loads . . . . . . . . . ............... ............... ............ 75
Tow coupling . . . . . . . . . . . . . ............... ............... ............ 76
Loading/transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Securing the hose reel against rewinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Dismantling of lift mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Driving without a mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Transport with lorry or low-bed trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Before leaving the truck unattended . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

5 Maintenance
Inspection and maintenance overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Work on the mast and front part of the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Initial commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Checks before starting work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Maintenance after the first 50 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

IV Operating Instructions – EN – 03/2007

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Inspection and maintenance as required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Inspection and maintenance work every 500 to 1000 operating hours* or every
year . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Inspection and maintenance every 3,000 operating hours or every 2 years . . . . . . . . . . 89
Inspection and maintenance work every 6000 operating hours or every 3 years . . . . . . 90
Inspection and maintenance work every 9000 operating hours or every 4 years . . . . . . 90
Inspection and maintenance data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Consumables recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Checks before starting work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Motor hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Check the third auxiliary hydraulic function and safety system (option) . . . . . . . . . . . . . 102
Inspection and maintenance as required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Floorplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Wheel change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Tighten the wheel nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Clean the lift truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Clean the vent hose to the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Clean and lubricate the lift chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Change the air filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Change the air filter safety element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Check the dust discharge valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Cleaning the prefilter (special equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Clean and check the radiator and hydraulic oil cooler for leaks . . . . . . . . . . . . . . . . . . . 110
Regenerating the particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Change the oil in the oil bath air cleaner (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Topping up washer system water tank (special equipment) . . . . . . . . . . . . . . . . . . . . . 115
Drain the fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Lubricate the steering axle bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Check the tyres for damage and foreign objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Check the lap seat belt for condition and proper operation . . . . . . . . . . . . . . . . . . . . . . 117
Maintaining the air conditioning (special equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Inspection and maintenance every 500 to 1000 operating hours or once a year . . . . . . 120
Change motor oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Clean the radiator and hydraulic oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Clean wet type air cleaner (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Check coolant concentration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Hydraulic system: Check the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

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Check correct operation of breather valve on the hydraulic oil tank . . . . . . . . . . . . . . . . 126
Battery: Check condition, level and density of acid . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Change fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Change motor oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Replace breather of boost pressure control system . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Check condition of the ribbed vee belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Check toothed belt condition and tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Check the soot filter system (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Check electrical cables, cable connectors and cable terminals for condition and secure
attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Check the pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Check and oil other pivots and joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Check the control unit for proper operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Change the air filter element, check the vacuum switch . . . . . . . . . . . . . . . . . . . . . . . . 136
Clean and grease the steering axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Clean sideshift (special equipment) and grease, check fastening . . . . . . . . . . . . . . . . . 137
Clean and lubricate fork arm adjustment device (special equipment), check fastenings
Clean and lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Mast, lift chains, lift cylinders and end stops: Check for security, condition and proper
operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Adjust the lift chain length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Check the tension of double hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Check the forks and fork quick-releases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Check the engine mounting for condition and security . . . . . . . . . . . . . . . . . . . . . . . . . 143
Check fastening for frame, tilt cylinders and steering axle . . . . . . . . . . . . . . . . . . . . . . . 144
Check security of axle clamp and wheel motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Check the steering cylinder and king pin for security . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Check, adjust the lateral drive axle stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Check the air intake and exhaust pipes for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Check the hydraulic system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Check the operation of the parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Inspection and maintenance every 3000 operating hours or every 2 years . . . . . . . . . . 149
Hydraulic system: Renew the filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Change the air filter safety element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Replacing ribbed V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Renew the toothed belt and idler pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Check the drive axle mounting for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Check tilt cylinder bearings for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Check hydraulic pump attachment to the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Check slide guides on sideshift (special equipment) for wear . . . . . . . . . . . . . . . . . . . . 154
Check fork arm adjustment device (special equipment) for wear and tear . . . . . . . . . . . 155

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Inspection and maintenance every 6000 operating hours or every 3 years . . . . . . . . . . 156
Change hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Inspection and maintenance every 9000 operating hours or every 4 years . . . . . . . . . . 158
Replace the water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Change coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Opening the electrical system cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Fuses for basic and special equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Main fuses in the engine compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Diagnostic connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Jump start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Emergency lowering of fork carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Emergency exit for trucks with rear screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Towing regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Placing the forklift truck into storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Disposal of old vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Malfunctions during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Malfunctions, Causes and Remedy (diesel engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Malfunctions, causes, remedies (hydraulic equipment) . . . . . . . . . . . . . . . . . . . . . . . . 176

6 Technical data
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Type sheet E 40, Issue 11/2006 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Type sheet H 45, Issue 11/2006 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Type sheet H 50-500, Issue 11/2006 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Load diagrams and lift mast data Issue 11/2006 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Noise emission values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Vibration characteristic values for bodily vibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

Annex

7 Circuit diagrams
Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Basic equipment for diesel sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Basic equipment diesel sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Basic equipment for diesel sheet 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Special equipment sheet 1 − Work lights, lighting, direction indicator system, brake
light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

Operating Instructions – EN – 03/2007 VII

Table of contents
g

Special equipment page 2 − Windscreen wipers, seat heater, seat with air suspen-
sion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Special equipment page 3 − Heater, air conditioning, rotating beacon, reversing signal,
interior light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Special equipment sheet 4 − hazard warning system for reversing, vehicle deactiva-
tion, lift mast positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Special equipment sheet 5 − particulate filter, radio . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Special equipment sheet 6 − Higher lighting, 12 V socket, water trap diesel filter warn-
ing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Special equipment page 7 − Linde Forklift Data Management, display of LPG volume,
motor oil level monitoring, work light items 5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Special equipment sheet 8 − Display of LPG volume for volumetric filling with shut-off
valve, replaceable particulate filter, rear window heater, camera system . . . . . . . . . . . . 226
Special equipment page 9 − Battery main switch with voltage supply indicator unit . . . . 228
Hydraulic circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Traction, operating and steering hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

VIII Operating Instructions – EN – 03/2007

 1

Introduction
1 Introduction
Symbols used
Your forklift truck
offers optimum efficiency, safety, reliability
and comfort. It is now up to you to maintain
these characteristics for as long as possible
and to take advantage of the resulting benefits.
During manufacture:
• all safety requirements of the 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.
This operating manual contains everything
you need to know about commissioning,
driving and maintenance.
A number of special equipment items have
their own operating manuals, which are sup-
plied along with this equipment. Please ob-
serve the information for operation depending
Intended use
The lift truck is designed for transporting and
stacking the loads stated in the load capacity
diagram. In particular
• we refer to the VDMA "Guidelines for the
normal and proper use of industrial trucks"
(or BITA for UK market),
• the safety rules of your trade association,
• the special measures required for driving on
public roads in accordance with the C.U.R.,
• other local regulations.
Symbols used
The precautions WARNING, CAUTION, AT-
TENTION, NOTE and ENVIRONMENTAL
NOTE in this manual are provided to indicate
2 Operating Instructions – EN – 03/2007
on the version of your forklift truck and carry
out the specified work regularly, at the due
times and using the working materials envis-
aged for this purpose according to the inspec-
tion and maintenance overview programme.
Please make sure you record the work per-
formed in the registration document for the
industrial truck; only in this manner will you
retain your warranty claims.
The designations used in the text: front - back
- left - right - always refer to the installation
position of the parts described with forwards
as the direction of travel (fork arms forwards)
for the forklift truck.
In the case of servicing work not described
here, specialist knowledge, measuring instru-
ments and frequently also special tools are
required. Please ask your authorised dealer
to carry out this work.
Servicing should only be carried out by quali-
fied staff authorised by Linde (specialists).
The rules for the intended and approved use
of industrial must be followed under all circum-
stances by the responsible persons, espe-
cially by the operator and service personnel.
The user, and not Linde, is responsible for
any danger arising from applications not
authorised by the manufacturer.
If you desire to use the truck for applications
not mentioned in the manual and convert or
supplement it for this purpose, please first
contact your authorised dealer.
No changes, particularly no modifications and
additions, may be made to the truck without
the approval of the manufacturer.
special hazards or unusual information requir-
ing special identification:

DANGER
indicates hazards that may result in personal injury
or death and/or substantial damage to the product.
WARNING
indicates hazards that may result in personal injury
and/or substantial damage to the product.
CAUTION
indicates hazards that may result in damage to or
destruction of the product.
NOTE
Identifies technical information requiring
special attention because the connection may
not even be obvious to skilled personnel.
Technical specification
The forklift trucks in the 394 series allow
loading and palletising to be performed for
loads up to4 t with H 40, up to 4.5 t with H 45
and up to 5 t with H 50-500with a load distance
of 500 mm.
Details on the exact lift height-specific maxi-
mum loads are available in the load diagram.
The trucks are eco-friendly and their quiet
operational noise and low emission levels
benefit both the driver and the environment.
They are characterised by their compact
design and small turning radius. For this
reason, the forklift trucks are particularly
well-suited for narrow alleys and operational
areas where space is at a premium.
Switching off
A 4-cylinder four-stroke diesel engine with a
turbocharger and intercooler is installed as
the drive engine. It drives the forklift truck’s
hydraulic pumps at a speed to match the load.
The engine is cooled by means of a closed
coolant circuit with expansion reservoir.
Forced circulation lubrication with an oil pump
in the oil sump is used to lubricate the engine.
Operating Instructions – EN – 03/2007
Introduction 1
Technical specification
ENVIRONMENT NOTE
The information contained herein must be
observed, otherwise environmental damage
may occur.
CAUTION
This label is affixed on the truck at
the places needing your special
attention.
Read the related material in this
manual.
For your safety other symbols are also used.
Please note the different symbols.
The combustion air is cleaned by means of a
dry air filter with a paper insert. Diesel engines
with state-of-the-art technology are used for:
• high torque
• low fuel consumption
• low exhaust emissions
• low particulate emissions
• low noise levels
Hydraulic system
The traction drive consists of a variable dis-
placement hydraulic pump, two hydraulic con-
stant wheel motors (assembled as a drive axle
unit), as well as a hydraulic pump (fixed dis-
placement pump) for the operating and steer-
ing hydraulics. Travel direction and speed are
regulated by means of two accelerator pedals
via the variable displacement hydraulic pump.
The hydraulic constant wheel motors in
the drive axle are supplied by the variable-
displacement hydraulic pump and are used
to power the driving wheels via two side
gearboxes.
3
1 Introduction
Technical specification
Operation
One accelerator pedal each for forward and
reverse travel (two-pedal operation) is used
to simultaneously regulate the hydraulic
variable displacement pump and the engine
speed. The hydrostatic drive enables driving
speed to be continuously varied in both
directions, ranging from standstill to maximum
speed. The dual-pedal control means that
operation of the forklift truck is simple, safe,
non-fatiguing and efficient.
The driver always has both hands free for
steering and controlling operational move-
ments. Fast reversing and efficient stacking is
the result.
An optional version is also available whereby
the speed is regulated by an accelerator pedal
(single-pedal operation) and the direction of
travel controlled by means of a travel direction
switch.
To control the operational movements of
lifting, lowering and tilting, there is only one
actuating lever (joystick). Another joystick
is fitted to operate additional attachments.
Working movements can also be controlled
using two joysticks (single-lever operation
version).
Linde Load Control
The truck’s Linde Load Control (LLC) system
enables:
• Millimetre-perfect and secure mast han-
dling
• Effortless control of all lift mast functions
using finger tips
• Drive and lifting functions are entirely
separate.
Linde Truck Control
The Linde Truck Control system (LTC) of the
truck features:
• reliable electronics,
• a high level of safety thanks to multiple
monitoring systems,
4 Operating Instructions – EN – 03/2007
• automatic, load-dependent control of
engine speed,
• protection from dust and dirt though use of
a fully enclosed housing.
Brakes
The hydrostatic drive is used as the operating
brake. This means that the operating brake
is maintenance-free. Two multi-disc brakes
incorporated in the wheel motors are used
as the parking brake. When the engine is
switched off, the multi-disc brakes engage,
meaning that the forklift truck has an automatic
braking function. To operate the parking brake
when switching off the forklift truck the parking
brake handle must always be engaged.
Steering
The steering is a hydrostatic steering system,
under which the steering wheel acts on the
steering cylinder to actuate the rear wheels.
If the power applied to the steering wheel is
increased, the steering system can also be
operated when the engine has been switched
off.
Lift mast
The free-view lift mast enables:
• Ideal visibility through slim mast profiles
• Full lifting capacity up to maximum lift
heights
• Huge residual lifting capacity
• Maintenance-free bearings for lift mast and
tilt cylinders via rubber-cushioned linkage
points
• Electric tilt angle limitation.
Electrical system
The electrical system is powered by the
alternator with 12V DC voltage. A 12 V battery
with 88 Ah has been installed for starting the
engine. It is located under the driver seat in
the engine compartment.

Truck operation with a bucket
If the truck is operated with a bucket, the
anti-stall device can be activated by your
authorised dealer.
In this case the working hydraulics will op-
erate with a slight delay due to the drop in
engine speed when the engine experiences
extremely heavy loads.
Takeover of forklift truck
Before the truck leaves our factory, it is
subjected to a careful inspection to ensure
that it is in perfect condition and is received
by you complete with all equipment according
to your order. Your authorised dealer is also
obliged to perform another inspection and
proper handover.
To avoid subsequent complaints please be
so kind as to carefully check the condition
of the truck and the completeness of the
equipment yourself and to confirm proper
handover/takeover vis-à-vis your dealer.
Linde is constantly engaged in the further
development of its products. We ask for
your understanding that figures/diagrams
and technical data are subject to technical
modification in terms of form, equipment and
know-how in the interest of progress.
For this reason, no claims can be asserted
on the basis of the following data, figures/di-
agrams and descriptions in this operating
manual.
Please address all queries and orders for
spare parts relating to your forklift truck only
to your authorised dealer, stating your mailing
address.
In the event of repairs only use genuine Linde
spare parts. This is the only way to guarantee
that your forklift truck remains in the same
technical condition as at the time of takeover.
This operating manual must not be repro-
duced, translated or made accessible to third
parties - including as excerpts - except with the
express written approval of the manufacturer.
Operating Instructions – EN – 03/2007
Introduction 1
Takeover of forklift truck
NOTE
With a longer sustained load on the engine,
the joystick must be put to the neutral position
to release the working hydraulics again.
With orders for parts please specify the
following along with the parts numbers:
Forklift truck type:
Production number /
Year of manufacture
Transfer date:
to be given. For parts from the units engine, lift
mast, hydraulic variable pump and drive axle,
the production number of these units should
also be specified.
Engine number:
Lift mast number:
Lift mast stroke:
Hydro variable pump
number:
Drive axle number:
When taking over the forklift truck, this data
should be copied from the rating plates of the
units into this operating manual.
NOTE
For forklift trucks which leave our works
without a lift mast, an additional stop screw
for speed restriction can be found under
the forwards/reversing accelerator pedal
(two-pedal operation) or accelerator pedal
(one-pedal operation. This screw must be
removed after attaching the mast by loosening
the screw and removing it with the aid of a
hexagonal nut (see also Driving without lift
mast).
5
1 Introduction
Initial commissioning

Each forklift truck includes the following • Safety rules for the use of industrial trucks
technical documentation: (VDMA)
• operating manual for forklift truck • Registration document for the industrial
truck, provided on handover by your autho-
• EC Declaration of Conformity (manufac-
rised dealer.
turer confirms that industrial truck complies
with requirements of EC Machinery Direc-
tive).

Initial commissioning
¾ Check engine oil level ¾ Hydraulic system: Check oil level
¾ Check the coolant level in the header tank ¾ Check the braking system
¾ Add more fuel ¾ Check steering system
¾ Battery: check condition, acid level and acid ¾ Check lifting system and attachments
density
¾ Regenerate soot filter (special equipment)
¾ Check tyre pressure
¾ Check function and safety system of 3rd
¾ Tighten the wheel bolts auxiliary hydraulic

6 Operating Instructions – EN – 03/2007

 2

Safety
2 Safety
Safety regulations
Safety regulations
The "Rules for the correct use of industrial
trucks" supplied with these operating instruc-
tions must be brought to the attention of the
persons responsible, in particular to those
persons concerned with operating and main-
taining the trucks, before working with or on
the trucks.
The operating company must ensure that the
driver understands all the safety information.
Please observe the regulations and guide-
lines, e.g.
• Operation of industrial trucks,
• Driving licence,
• Rules for driveways and the area of opera-
tion,
• Rights, duties and rules of behaviour for the
driver,
• Special operating areas,
• Information regarding setting off, driving
and braking,
• Information for maintenance and repair,
• Periodic checks,
• UVV accident prevention inspections,
• Disposal of greases, oils and battery,
• Other hazards.
As the operating company or responsible
person, ensure that all regulations and safety
guidelines that are applicable to your industrial
trucks are complied with.
When training a forklift truck driver who has
already been trained to BGV D27 standard,
• the special features of the Linde forklift truck
(dual-pedal control, central joystick, stop
pedal),
• and any special attachments,
• operational and working area special
features
must be practised sufficiently by training,
driving, switching and steering, so that they
are fully mastered.
8 Operating Instructions – EN – 03/2007
Only then should training on forklift access to
the racking commence.
Safety instructions
DANGER
Safety devices (e.g. the seat switch) are there for
your safety.
Safety devices—of whatever kind—must never be
disabled.
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.
Trucks may be retrofitted with a 3rd auxiliary hy-
draulic system only with the approval of the truck
manufacturer.
DANGER
It is prohibited to connect any safety critical func-
tions such as a bale clamp or swivel of a fluid con-
tainer to any 3rd auxiliary hydraulic system.
To prevent the clamp or swivel opening inadver-
tently, the additional function should be connected
to the first auxiliary hydraulic system.
DANGER
Any additional drilled holes or welding to the over-
head guard will compromise its strength.
It is therefore strictly prohibited to drill holes in the
overhead guard or to weld to it.
CAUTION
Welding operations on other parts of the vehicle
can cause damage to the electronics.
Therefore, before performing any welding, always
disconnect the battery and all connections to the
electronic control units.

CAUTION
For ease of operation, various functions on your
Linde fork-lift truck are gas spring assisted. Gas
springs are complex components which contain
high internal pressures (up to 300 bar).
They may under no circumstance be opened unless
so directed, and may be removed only when not
under compression. Any sort of damage, lateral
forces, bucklings, temperatures in excess of 80°
C and heavy soiling must be avoided under all
circumstances. Damaged or defective gas springs
must be exchanged immediately. Please contact
your authorised dealer. He will, if necessary,
depressurise the gas spring in accordance with
regulations before dismantling it. Gas springs must
be depressurised before recycling.
WARNING
The following issues must be observed when an
accumulator is fitted. Improper handling of the
accumulator can lead to serious injuries.
Before starting work on the accumulator it must
be depressurised. Please contact your authorised
dealer.
In the case of tip-over
• Stay buckled up
• Don’t jump
• Hold on tight
• Brace feet
• Lean away
Handling fluids and lubricants
ENVIRONMENT NOTE
Always handle fluids and lubricants as re-
quired and as specified by the manufacturer.
Operating Instructions – EN – 03/2007
Safety 2
Handling fluids and lubricants
WARNING
Depending on the duration of
operation and use, components
carrying exhaust gases and exhaust
air may become hot.
Therefore wear protective clothing.
WARNING
The forklift truck working area must be adequately
lit.
If it is insufficiently lit, work lights must be installed
to ensure that the driver can see properly
CAUTION
The functioning of medical equipment, e g: pace
makers or hearing aids, may be impaired when
driving.
Check with a doctor or the medical equipment
manufacturer whether the equipment is sufficiently
protected against electromagnetic interference.
The stability of your truck is ensured if used
properly and as intended. Should the truck
tip over during an unapproved application or
due to incorrect operation, always follow the
instructions depicted below.
• Only store fluids and lubricants in approved
containers at specified storage places.
• As they could be inflammable, do not allow
contact with hot objects or a naked flame.
9
2 Safety
Regulations
• Only use clean containers when replenish-
ing fluids and lubricants.
• Follow the manufacturer’s safety and
disposal instructions.
• Do not spill fluids.
• Remove any spillage immediately with a
suitable binding agent and dispose of as
specified.
• Also dispose of used or contaminated fuels
and lubricants as specified.
• Follow laws and regulations.
• Clean the area surrounding the part in
question before lubrication, filter renewal
or repairs in the hydraulic system.
• Discard replaced parts in a way friendly to
the environment.
Experts
Experts are persons with a special training and
experience in servicing and testing industrial
trucks and familiar with the applicable worker’s
protection rules, safety regulations, directives
and generally recognised rules of the art
Operation of industrial trucks in plant area
Many plant areas are so-called limited public
traffic areas. In this sense, we would like to
advise you to check your company liability
insurance coverage, to ensure that possible
Regulations
Safety inspection
The accident prevention rules in some coun-
tries require that the fork lift truck must be
checked periodically for proper operation by
trained personnel. Please contact your autho-
rised dealer for this inspection.
10
WARNING
Do not allow hydraulic oil under pressure, for
example at a leak, to penetrate the skin. Medical
aid is required if such an injury occurs.
Wear protective gear.
WARNING
Improper handling of coolants and coolant additives
puts your health and the environment at risk.
Observe manufacturer´s directions.
(DIN and VDE standards, technical rules of
members of the EU or EEA agreements) so
that they can give a qualified assessment
of the safe operating condition of industrial
trucks.
claims for damages caused by your truck
in limited public traffic areas in relation to
third parties are included in the insurance
coverage.
Diesel engine emissions
In Germany, fork trucks equipped with diesel
engines must conform to TRGS 554. Ac-
cording to this regulation, diesel engine emis-
sions are hazardous materials causing can-
cer. They should not get into the air at the
workplace, if possible. If trucks equipped with
diesel engines are used in totally or partially
enclosed spaces, the labour protection au-
thority must first be notified. Appropriate no-
tices must be posted in the work areas (refer
to TRGS 554 for an example).
Operating Instructions – EN – 03/2007

Determination and assessment of hazards from use of industrial trucks
Soot filter inspection
The responsible authorities specify that soot
filters must be inspected and serviced every
six months by an expert. The results of the
Determination and assessment of hazards from use of industrial
trucks
Hazard
Industrial truck
equipment does not
comply with local
provisions
Lack of skills and
qualification of driver
Lack of skills and
qualification of driver
Usage by unauthorised
persons
Industrial truck not in a
safe condition
Impaired visibility
through load
Contamination of
respiratory air
Contamination of
respiratory air
Impermissible usage
(improper usage)
Impermissible usage
(improper usage)
Impermissible usage
(improper usage)
When filling up with a)
diesel
Operating Instructions – EN – 03/2007
Safety 2
inspection must be recorded in a "Diesel
Engine Emissions Inspection Certificate" and
attached to the log book (eg truck’s safety
inspection logbook).
Check note
X = actioned
Action Notes
- = not
concerned
If in doubt, consult
competent factory
Check inspectorate or
employers’ liability
insurance association
Driver training (sit-on UVV-BGV D 27 - § 7,
and stand-on industrial BGG 925 driver permit
trucks) VDI 3313
Instruction for pedestrian-
controlled trucks
Access with key only for
appointed staff
Recurrent testing and UVV-BGV D 27 - §§ 9,
rectification of defects 37, BGG 918
Deployment planning UVV-BGV D 27 - § 12
Assessment of diesel
TRGS 554
exhaust gases
Assessment of fuel gas MAK list (maximum work-
exhaust gases place concentrations list)
Issue of operating
UVV-BGV D 27 - § 5
instructions
Written notice of
UVV-BGV D 27 - §7
instruction to driver
UVV-BGV D 27, observe
operating manual and
VDMA leaflet
UVV-BGV D 27, observe
operating manual and
VDMA leaflet
11
2 Safety
Instructions before fitting attachments

Check note
X = actioned
Hazard Action Notes
- = not
concerned
UVV-BGV D 27, observe
When filling up with b)
operating manual and
fuel gas
VDMA leaflet
UVV-BGV D 27, observe VDE 0510: In particular
When charging traction
operating manual, VDMA a) ventilation b) insulation
batteries
leaflet and VDE 0510 value

In the Federal Republic of Germany the Ger-
man Law on Health and Safety at Work (Arb-
SchG) states that it is up to the Employer to
assess which hazards are associated with
the work of employees and which Health and
Safety measures are required (§ 5 ArbSchG).
The result must be documented (§ 6 Arb-
SchG). In the case of industrial truck deploy-
ments involving similar hazard situations it is
permitted to summarise the results . In coun-
tries outside the Federal Republic of Germany
the country-specific regulations must be ob-
served. With the list we are helping you to
comply with these regulations. The construc-
tion and equipment of industrial trucks comply
with the Machinery Directive 98/37/EC and
are identified by the CE mark accordingly.
This means that they do not fall under the
scope involved in the assessment of hazards,
and nor do attachments due to their own CE
marking . The operator must however select
the type and equipment of industrial trucks so
as to comply with the local provisions for de-
ployment.
In order to ensure the safe usage of industrial
trucks we not only supply every industrial
truck with a copy of the operating manual but
also with the leaflet of the VDMA (German
Engineering Federation) specifying the rules
for the proper usage of industrial trucks "Rules
for the Proper Use of Industrial Trucks".
The list specifies key hazards which are most
frequently the cause of accidents in the event
of non-compliance. If other major hazards are
involved at a specific plant , they must be listed
additionally.
In many plants the conditions of use for
industrial trucks are by and large similar so
that the hazards can be summarised in one
list. The pronouncements of the employers’
liability insurance association competent in
each case as regards this topic should also be
taken into account.

Instructions before fitting attachments

To depressurise the oil in the pipes before
fitting an additional hydraulic attachment to
the hydraulic system, an accumulator (special
equipment) can be used. .
For this consult the section "Operate attach-
ments".
WARNING
Improper handling of the accumulator can lead to
serious injuries.
Before starting work on the accumulator it must
be depressurised. Please contact your authorised
dealer.

12 Operating Instructions – EN – 03/2007

 3

Overview
3 Overview
Type plates

Type plates

1 Truck identification plate

9 Lift mast number (affixed)
10 Chassis number (stamped in the back panel
of the overhead guard frame)
11 Drive axle type plate
12 Engine type plate

14 Operating Instructions – EN – 03/2007

 Overview 3
Type plates

NOTE
The CE symbol certifies compliance with the
EC directives for machinery and all the guide-
lines applicable for the truck.

1 Truck identification plate

2 Manufacturer
3 CE symbol
4 Serial No. / year built)
5 Dead weight
6 Battery voltage
7 Rated load capacity
8 Type

Operating Instructions – EN – 03/2007 15

3 Overview
General view

General view

1 Mast 12 Steering axle

2 Lift cylinder 13 Access cover
3 Composite instrument 14 Chassis and overhead guard
4 Tilt cylinders 15 Bonnet
5 Toggle switch for auxiliary functions (op- 16 Step for mounting and dismounting
tional) 17 Fuses (in the engine compartment)
6 Control lever (joystick) 18 Left drive unit
7 Steering wheel/hydrostatic power steering 19 Fork carriage
8 Operator’s seat 20 Fork quick-releases
9 Electrical system cover 21 Forks
10 Fuses (behind the electrical system cover) 22 Fork stops
11 Counterweight 23 Lift chain

16 Operating Instructions – EN – 03/2007

 Overview 3
Controls

Controls
5 6 7 8 9
4

1
10

11

18
12

d3921508

17 16 15 14 13
1 Parking brake handle 10 Symbol label for auxiliary hydraulics (attach-
2 Handwheel for adjusting steering column ments) (option)
3 Combined lever for wiper/washer and 11 Symbol label for working hydraulics
blinker (option) 12 Operator’s seat armrest
4 Steering wheel/hydrostatic power steering 13 Operator’s seat
5 Signal button 14 Forward accelerator
6 Ignition switch with ignition key 15 Brake pedal
7 Cubby hole 16 Reverse accelerator
8 Control lever (joystick) for working hy- 17 Backrest cushion adjuster (option)
draulics 18 Plate "Guaranteed acoustic power level"
9 Control lever (joystick) for auxiliary hy-
draulics (attachments) (option)

Operating Instructions – EN – 03/2007 17

3 Overview
Indicator unit

Indicator unit

1 Indicator unit 14 Display operating hours

2 Hydraulic oil temperature indicator 15 Symbol operating hours
3 Battery charge indicator 16 Display clock
4 Motor oil pressure indicator / motor oil level 17 Symbol service interval exceeded
indicator 18 Function push-button
5 Electrical control system fault 19 Reset button
6 Engine temperature indicator 20 Symbol for Parking brake applied
7 Load / overload indicator (special equip- 21 Symbol "do not start the engine"
ment) 22 Symbol for operating hours until next service
8 Particulate filter alarm (shown for only 4 s on display (14))
9 Fluid-level indicator (special equipment) 23 Symbol Lift mast position detection
10 Hydraulic oil micro-filter indicator (special 24 Text field
equipment) 25 Glow plug indicator
11 Fuel tank level display 26 Air filter induction pressure indicator
12 Display 27 Cooling water level indicator
13 Particulate filter symbol 28 Warning light - gas system

(2) Hydraulic oil temperature indicator (red) • Oil cooler clogged

Lights up when the specified temperature limit
is reached. A buzzer also sounds when the
permissible temperature limit is reached. If the
engine protection* function is activated, the
vehicle only moves in crawling speed (approx.
2 km/h). Error code X205 is displayed in text
field (24).
• Insufficient oil in the hydraulic system
• Incorrect oil used
• Oil filter clogged
• Switch off the buzzer with the reset button
(19).
(3) Charging indicator (red)
Lights up when there are malfunctions in the
electrical system.
• Ribbed V-belt snapped or ribbed V-belt
tension too slack
• Ribbed V-belt tensioner defective
• Cable defective
• Alternator defective
• Charge controller or cut-out relay defective.

18 Operating Instructions – EN – 03/2007


(4) Engine oil pressure indicator / engine oil
level indicator (red)
If the oil pressure of the engine lubricating
system is too low, this indicator lights up and
a buzzer sounds. If in addition the text field
(24) shows the text Oil with a double arrow
pointing downwards, the engine oil level is too
low.
• Insufficient oil in the crankcase
• Engine too hot
• Incorrect oil used
• Internal leakage in the lubricating-oil circuit
• Top up motor oil
• Switch off the buzzer with the reset button
(19).
If the "engine protection"* function is activated
and the oil pressure and/or engine oil level
continues to fall, the vehicle only moves in
crawling speed (approx. 2 km/h) and text field
(24) displays:
• Oil with double downwards arrow and
error code X201 at low oil level,
• error code X202 at low oil pressure.
(5) Electrical control system fault (red)
Lights up when an electrical control system
fault is present, and displays a error code in
text field (24).
(6) Engine temperature indicator (red)
Lights up when the specified temperature limit
is reached. A buzzer also sounds when the
permissible temperature limit is reached. If the
"engine protection"* function is activated, the
vehicle only moves in crawling speed (approx.
2 km/h). Error code X204 is displayed in text
field (24).
• Fan motor defective
• Thermostatic switch defective
• Water cooler clogged
• Leakage in the cooling circuit
• Coolant level too low
• Switch off the buzzer with the reset button
(19).
Operating Instructions – EN – 03/2007
Overview 3
Indicator unit
(7) Load/overload indicator (special equip-
ment)
Symbol lights up yellow when load is normal.
DANGER
Symbol lights up red when overloaded.
Set down load immediately.
• Consult load diagram.
(8) Particulate filter alarm (red)
Lights up with activated particulate filter con-
trol system, if load period of the particulate
filter exceeds 8.5 h, or if an error in the partic-
ulate filter control system occurs simultane-
ously with the display of an error code in the
text field (24). In addition, the buzzer sounds.
The vehicle only moves at crawling speed.
• Regenerate particulate filter as soon as
possible.
• Correct error in particulate filter control
system.
(9) Level display (yellow) (special equipment)
Lights up when the cooling water level is below
the minimum.
• Top up the coolant.
Please contact your authorised dealer.
(10) Hydraulic oil microfilter indicator (yellow)
(special equipment)
Lights up when micro-oil filter requires mainte-
nance.
• Micro-filter clogged, replace it.
(11) Fuel tank level display (colour depending
on level, green or red)
• Shows the current fuel level.
(13) Particulate filter symbol
Lights up if particulate filter control system is
activated.
(14) Operating hours display
Shows the operating hours of the forklift truck.
This indicator is evidence of the fork lift truck’s
19
3 Overview
Indicator unit
operating hours and of the inspection and
maintenance work to be performed.
NOTE
If a defective indicator unit is replaced, the
operating hours up to that point must be
recorded. Affix the data on an embossed
strip near the indicator unit. There is also the
option of updating the new indicator unit at a
later time. Contact your authorised dealer.
(15) Operating hours symbol
Flashes when operating hours are being
counted (only when the ignition is on and the
engine speed exceeds 500 rpm)
(16) Clock display
24-hour clock display.
Adjustable using the (18) and (19) buttons.
Resetting to 12-hour clock display is possible
via diagnostic device. Please contact your
authorised dealer.
(17) Service interval exceeded symbol
If the number of operating hours until the next
service is less than/equal to 0, the symbol
flashes for 10 s every time the vehicle is
started, and then lights up continuously.
Adjustment and reset of the intervals can be
performed only using the diagnostic device
provided for this purpose. Please contact your
authorised dealer.
(18) Function button
Assignment depending on version.
(19) Reset button
To adjust the time, switch off the warning
buzzer and other functions depending on the
version.
(20) Symbol for parking brake
Lights up when the parking brake is applied.
(21) Symbol for "Do not start engine"
Lights up when the engine has stalled.
20
NOTE
Always leave the ignition switched on until the
symbol goes out (between 15 and 50 seconds
depending on the oil temperature). Then try to
restart.
(22) Symbol for Operating hours until the next
service
After the ignition has been switched on,
display field (14) shows the operating hours
until the next service (counting backwards).
Symbol (22) lights up. After 5 s, symbol
(22) goes out and display (14) automatically
switches to the operating hours of the forklift
truck; the operating hours symbol (15) flashes.
(23) Lift mast position sensing symbol (special
equipment)
Lights up when permissible tilt angle is ex-
ceeded.
(24) Text field
Serves as display field. Please contact your
authorised dealer to read out the error codes.
If the particulate filter (additional equipment)
is fitted and the particulate filter controller is
activated − residual capacity display
The text field display includes 11 symbols
• 0 symbols blacked out → no particulate filter
build-up,
• 6 symbols blacked out → approx. 50%
particulate filter build-up,
• 11 symbols blacked out → 100% particulate
filter build-up.
(25) Glow plug indicator (yellow)
Lights up whilst the glow plugs are warming
up, then goes out.
Flashes when a fault exists in the engine or in
the engine control unit. Please contact your
authorised dealer.
(26) Air filter vacuum indicator (yellow)
Lights up when the air filter is excessively
clogged.
• Air filter clogged, replace it.
Operating Instructions – EN – 03/2007
 Overview 3
Indicator unit

(27) Cooling water level indicator (yellow) (28) Warning light - gas system (red)
Lights up when the cooling water level is below Only works in fuel gas vehicles.
the minimum. If the engine protection*
* The "engine protection" function can be
function is activated , the vehicle only moves
disabled using the diagnostic device. Please
in crawling speed (approx. 2 km/h) and text
contact your authorised dealer.
field (24) displays error code X203.
• Top up the coolant.

Operating Instructions – EN – 03/2007 21

3 Overview
Indicator unit

22 Operating Instructions – EN – 03/2007

 4

Operation
4 Operation
Standard equipment

Running-in instructions
The truck can be operated quickly immedi- hours minimum. Tighten opposite wheel fas-
ately. Avoid high sustained loads on the work- teners to a torque of
ing hydraulics and on the travel drive in the
first 50 hours. The wheel fasteners must be Front: 425 Nm
tightened before the commissioning and after Rear: 640 Nm
each wheel change. Then after 100 service

Checks before starting work

¾ Check the fuel level ¾ Check the coolant level
¾ Check the engine oil level ¾ Check the tyre pressures
¾ Check the hydraulic oil level

Standard equipment
Adjusting the driver’s seat

WARNING
An incorrect adjustment of the seat can cause back
injury. Do not operate the seat adjusting devices
while operating the truck.
Before each start-up of the truck and with each
change in driver, set the weight setting to the indivi-
dual weight of the driver and check if all settings are
correctly engaged. Do not place any objects in the
vicinity of the controls.

24 Operating Instructions – EN – 03/2007

 Operation 4
Standard equipment

Horizontal adjustment
¾ Lift lever (2) up and pull it.
¾ Move the driver’s seat on the slide rails
backwards or forwards to give the driver
the best position in relation to the steering
wheel and the accelerator pedals.
¾ Re-engage the lever.

Backrest adjustment
¾ Push up and hold the backrest adjuster (1). 1
¾ Move the backrest forward and back until a
comfortable sitting position for the driver is
found.
¾ Release the backrest adjuster (1).
d3921352 2

Adjusting the lumbar support (option)

¾ Turn knob (3) until a comfortable sitting
3
position is achieved.
Turning the knob anticlockwise makes the
backrest arch outwards.
Turning the knob clockwise returns the back- 6
rest to its original position.

Adjusting for the operator’s weight

¾ Turn the adjusting handwheel (5) to set the
cushioning to the weight of the driver.
The adjustment range from 50 kg to 130 kg is
visible at the weight range indicator (4).
To reduce the weight, turn the handwheel 5
anticlockwise. 4 d3921353

To increase the weight, turn the handwheel

clockwise.

Operating Instructions – EN – 03/2007 25

4 Operation
Standard equipment

Adjusting the seat angle of tilt (option)

¾ Lift the handle (6).
7
The seat is tilted to the desired position by
applying or taking off one’s weight simultane-
ously.
9
Adjusting the seat position (option) 8
¾ Lift the handle (9).
The desired position is reached by simultane-
ously sliding the seat forward or back.

Adjusting the backrest extension (option)

¾ Push the backrest extension (7) up or down
for an individual adjustment.
d3921354

Turning the seat heating on/off (option)

¾ Toggle the switch (8) on or off.

NOTE
Long sitting puts excessive strain on the spi-
nal column. Prevent strain with regular, light
exercising.

Adjusting the armrest on the operator’s

seat

NOTE
The armrest on the operator’s seat is raised
automatically by spring pressure after the
handwheel (1) is loosened.

26 Operating Instructions – EN – 03/2007

 Operation 4
Standard equipment

¾ Sit down on the operator’s seat and loosen 4

the handwheel (1).
3
¾ Push the armrest (3) down against the force
of the spring until a comfortable position for
the arm is reached.
¾ Tighten the handwheel (1). 2
¾ Loosen the handwheel (2) and slide the
armrest (3) back and forth until the control
lever (4) is easily accessible.
¾ Tighten the handwheel (2).
1

d3921416

Adjust the steering column

DANGER
If the clamping screw is loose, safe driving is not
possible.
The steering column may only be adjusted when
the truck is stationary.

Tilt adjustment
¾ Loosen the clamping screw (2) in counter-
clockwise direction. 1
¾ Move the steering wheel (1) to the desired
position.
¾ Tighten the clamping screw (2) in clockwise
direction.

Height adjustment (Optional)

¾ Loosen the clamping screw (2) counter-
clockwise.
¾ Pull the steering wheel (1) upwards, or push
it downwards, to the desired position.
¾ Tighten the clamping screw (2) clockwise.
2 t3921369

Operating Instructions – EN – 03/2007 27

4 Operation
Standard equipment

Setting the clock

NOTE
The time is shown in the 24 hour mode.
Change to 12 hour mode with diagnostic unit.
Please contact your authorised dealer for this
service.
¾ Depress both buttons (2) and (3) simultane-
ously for 3 seconds.
The hour readout in the time display (1)blinks.

NOTE
The setting of the hours or minutes can be
adjusted slowly with button (2) by tipping it or
fast by holding it.
¾ Depress button (2) to set the hours. 1

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

ting.
Now the minute readout blinks.
¾ Depress button (2) to set the minutes 3 2 d3921348

¾ Depress button (3) to confirm the setting of

the minutes.

Lap seat belt

Applying the lap seat belt

DANGER
It is dangerous to leave the truck in
an uncontrolled manner.
Therefore always keep buckled up
when operating the truck! Only one
person may be fastened with the
seat belt.

WARNING
The proper operation of the lap belt must be gua-
ranteed.
Therefore do not let the belt get twisted, caught
or tangled. Protect the lock and retractor against
foreign objects, damage and dirt.

28 Operating Instructions – EN – 03/2007

 Operation 4
Standard equipment

NOTE
Cabins with closed solid doors or guards com-
ply with the safety requirements for driver
restraint systems. The lap seat belt can be ap-
plied optionally. However, it must be applied
when driving with the doors open or removed.
PVC doors are not considered to be an opera-
tor restraint system.
The automatic blocking system locks the belt
when the truck tilts heavily. The belt can then
no longer be pulled out of the retractor. To
loosen the automatic blocking system of the
truck, drive off the slope carefully.
During the operation of the truck (eg driving,
operation of the mast, etc), sit as far back as
possible so that the back contacts the back-
rest. The retractor’s automatic blocking sys-
tem sufficient freedom of movement during
normal truck operation.
¾ Pull the lap seat belt (1) gently from the
retractor on the left.
5 1

¾ Place the belt over the thighs, not over the

abdomen.
¾ Engage the tongue (2) in belt lock (4).
¾ Check seat belt tension.
The belt should be snug on the body. 4

Opening the lap seat belt 2

¾ Press the red button (5) on the lock (4).
¾ Return the tongue (2) to the retractor (3)
with the hand. 3
d3921415
NOTE
If the belt is retracted too fast the automatic
blocking system can be triggered when the
tongue hits the case. The belt can not be
pulled out with the usual force.

Operating Instructions – EN – 03/2007 29

4 Operation
Standard equipment

Traction engine (two-pedal opera-

tion)
Starting the engine

DANGER
Risk of poisoning!
Do not allow engine to run in
unventilated rooms.

NOTE
Where possible, avoid frequently starting and
stopping the engine over short periods of time,
since this prevents the combustion engine
reaching operating temperature. Frequent
cold starts increase wear.

NOTE
Forklift trucks that have special container roofs
have a reduced clearance between the seat
and the overhead guard. For this reason, such
forklift trucks should only be used by persons
whose normal operating posture is such that
there is a minimum of 30 mm clearance bet-
ween their head and the overhead guard.
¾ The actuating lever (joystick) must be in
neutral.
¾ Sit down on the driver’s seat.
¾ Fasten the seat belt.
¾ Place both feet on the (4) accelerator ped-
1 2
als.
¾ Engage parking brake handle (1), (engine
will only start with parking brake handle
engaged). 3
¾ Insert ignition key (2) into the ignition and
starting switch and turn from the zero posi-
tion to position "I".
The electrical system is switched on.

d3921417 4 4

30 Operating Instructions – EN – 03/2007

 Operation 4
Standard equipment

¾ Look at the indicator unit (3).

NOTE
After the electrical system has been switched
on, the indicator unit will perform a self-test.
The displays all light up for approx. 2 seconds
and the operating hours until the next service
are displayed for 5 seconds in the indicator
unit (3) display field (12). During this time the
symbol (13) remains lit. After 5 seconds the
display reverts automatically to the operating
hours. If the buzzer sounds (particulate filter
unit fault), check the lights (see Malfunctions,
Causes and Remedy (diesel engine)). If the
buzzer continues to sound, please contact
your local authorised dealer. If the symbol (9)
flashes or lights up, the set service interval has
been exceeded. The service that is due must
be performed. Please contact your authorised
dealer.
The following controls light up:
• Parking brake applied (10) symbol,
• Engine oil pressure indicator (6),
• Battery charge indicator (5),
• Glow plug indicator (14)
• Soot filter symbol (7) (only if additional soot
filter is fitted and soot filter control system is
activated).
¾ Wait until the glow plug indicator (14) goes
out
¾ Turn ignition key to position "II".
As soon as the engine starts,
¾ release the ignition key.
Symbol (8) will flash on and off.

CAUTION
Only for vehicles with particulate filter units. If the
exhaust is very smoky and remains so,switch off
the engine. Please contact your authorised dealer.
Every time the engine is started, watch the exhaust
pipe outlet for about 5 seconds.

If the engine fails to start,

¾ After the glow plugs have heated up, keep
turning the starter motor until the engine

Operating Instructions – EN – 03/2007 31

4 Operation
Standard equipment

runs at idling speed. Depending on the

vehicle, temperature and altitude, this may
take more than 1 minute.
If the engine stalls, the symbol "Do not start
the engine will appear"(11).
¾ Always leave the ignition switched on until
the symbol goes out (between 15 and 50
seconds depending on the oil temperature).
¾ Then try to restart.
Leave a break of at least 1 minute between
each engine start to protect the battery. If the
engine still does not start at the third attempt,
see: Malfunctions, Causes and Remedy.
The charging and engine oil pressure symbols
must go out as soon as the engine is running
smoothly.
The engine speed is controlled automatically,
depending on the load on the engine.

NOTE
Do not allow the engine to warm up at idling
speed. When under load, drive the truck at a
brisk speed. The engine will warm up quickly.

Switching off the engine

CAUTION
For engines with a turbocharger, the high speed
of the turbocharger shaft (approx. 100 000 rpm at
full load)could cause the shaft bearing to run dry
through lack of lubrication thus damaging it.
Do not switch off engine under full load, but rather
allow to run on for a few minutes at low speed.

32 Operating Instructions – EN – 03/2007

 Operation 4
Standard equipment

¾ Take your feet off the (3) accelerator pedals.

1 2
¾ Turn the ignition key (2) to the 0 position.

NOTE
The brake is applied when the motor is swit-
ched off.
¾ Pull the parking brake handle (1) upwards.
¾ Remove the ignition key (2) when leaving
the truck.

d3921418 3 3

Driving (double-pedal operation)

WARNING
Driving on gradients over 15 % is generally not
allowed due to the specified minimum brake ap-
plications and the stability values. Contact your
authorised dealer before driving on steeper gradi-
ents. The climbing ability values given in the data
sheet have been derived from the drawbar pull and
apply only for crossing obstacles and short diffe-
rences in height.
Always adapt your driving style to the conditions
of the roadway (rough surfaces, etc.), especially
hazardous work zones and the load.

WARNING
If mirrors are used, please note the rear-view mirror
is only provided for observing the traffic area to the
rear.
If you are reversing, therefore, always look over the
shoulder in the direction your are reversing.

CAUTION
Possibly fitted side doors must be protected against
damage.
Therefore always ensure both side doors are closed
and locked before driving.

Operating Instructions – EN – 03/2007 33

4 Operation
Standard equipment

NOTE
The truck can only be driven with the operator
seated.
¾ Start the engine.
¾ Raise the forks slightly and tilt the mast
back.
¾ Push the parking brake handle (1) down.
1

Forward travel
¾ Depress the right accelerator (2) gently.
Truck speed depends on how far the pedal is
depressed.

NOTE
Flooring the accelerator does not increase the
speed as maximum acceleration is controlled
automatically.

Reversing
d3921419 4 3 2
¾ Depress the left accelerator (4) gently.
The truck will reverse slowly or fast, depending
on how far the accelerator is depressed.

Changing the direction of travel

¾ Release the depressed accelerator.
The hydrostatic drive will act as service brake.
¾ Depress the accelerator for the opposite
direction of travel.
The truck will now accelerate in the selected
direction.
¾ Keep both feet on the accelerators to main-
tain easy control over all truck movements.
The accelerators can be operated directly.
The hydrostatic drive will brake the truck to a
full stop and then accelerate it in the opposite
direction of travel.

34 Operating Instructions – EN – 03/2007

 Operation 4
Standard equipment

Starting on gradients
¾ Fully depress the brake pedal (3).
1
¾ Push the parking brake handle (1) down.
¾ Release the brake pedal half way.
¾ Depress accelerator (2) or (4).
¾ Slowly release the brake pedal fully.
The brake is released and the truck will drive
without rolling back.

Stopping
¾ Release the depressed accelerator slowly.
The hydrostatic drive will act as service brake.
¾ When stopping on gradients, keep both feet d3921419 4 3 2
on the accelerators and compensate drive
slippage by lightly depressing the accelera-
tor in the "upslope" direction of travel.
¾ Depress the brake pedal (3) for a long stop.
1
¾ When dismounting form the truck with the
engine running, for example, to briefly per-
form some actions in close vicinity of the
truck (opening a gate, unhitching a trailer,
etc.), always pull the parking brake handle
(1) and release the seat belt. In case of a
longer stop, shut down the engine and pull
the parking brake handle (1).
¾ Remove the ignition key when leaving the
truck unattended.

d3921419 4 3 2

Traction engine (single-pedal opera-

tion)
Starting the engine

DANGER
Risk of poisoning!
Do not allow engine to run in
unventilated rooms.

Operating Instructions – EN – 03/2007 35

4 Operation
Standard equipment

NOTE
Where possible, avoid frequently starting and
stopping the engine over short periods of time,
since this prevents the combustion engine
reaching operating temperature. Frequent
cold starts increase wear.

NOTE
Forklift trucks that have special container roofs
have a reduced clearance between the seat
and the overhead guard. For this reason, such
forklift trucks should only be used by persons
whose normal operating posture is such that
there is a minimum of 30 mm clearance bet-
ween their head and the overhead guard.
¾ Sit down on the driver’s seat.
¾ Fasten the seat belt.
¾ Move the actuating lever (hydraulics and
direction of travel (5)) into neutral.
5

d3921361

36 Operating Instructions – EN – 03/2007

 Operation 4
Standard equipment

¾ Place foot on accelerator pedal (4).

1 2
¾ Engage parking brake handle (1), (engine
will only start with parking brake handle
engaged).
3
¾ Insert ignition key (2) into the ignition and
starting switch and turn from the zero posi-
tion to position "I".
The electrical system is switched on.

d3921420 4

¾ Look at the indicator unit (3).

NOTE
After the electrical system has been switched
on, the indicator unit will perform a self-test.
The displays all light up for approx. 2 seconds
and the operating hours until the next service
are displayed for 5 seconds in the indicator
unit (3) display field (13). During this time the
symbol (14) remains lit. After 5 seconds the
display reverts automatically to the operating
hours. If the buzzer sounds (particulate filter
unit fault), check the lights (see Malfunctions,
Causes and Remedy (diesel engine)). If the
buzzer continues to sound, please contact
your local authorised dealer. If the symbol (10)
flashes or lights up, the set service interval has
been exceeded. The service that is due must
be performed. Please contact your authorised
dealer.
The following controls light up:
• Parking brake applied (11) symbol,
• Engine oil pressure indicator (7),
• Battery charge indicator (6),
• Glow plug indicator (15)
• Soot filter symbol (8) (only if additional soot
filter is fitted and soot filter control system is
activated).
¾ Wait until the glow plug indicator (15) goes
out

Operating Instructions – EN – 03/2007 37

4 Operation
Standard equipment

¾ Turn ignition key to position "II".

As soon as the engine starts,
¾ release the ignition key.
Symbol (9) will flash on and off.

CAUTION
Only for vehicles with particulate filter units. If the
exhaust is very smoky and remains so,switch off
the engine. Please contact your authorised dealer.
Every time the engine is started, watch the exhaust
pipe outlet for about 5 seconds.

If the engine fails to start

¾ After the glow plugs have heated up, keep
turning the starter motor until the engine
runs at idling speed. Depending on the
vehicle, temperature and altitude, this may
take more than 1 minute.
If the engine stalls, the symbol "Do not start
the engine will appear"(12).
¾ Always leave the ignition switched on until
the symbol goes out (between 15 and 50
seconds depending on the oil temperature).
¾ Then try to restart.
Leave a break of at least 1 minute between
each engine start to protect the battery. If the
engine still does not start at the third attempt,
see: Malfunctions, Causes and Remedy.
The charging and engine oil pressure symbols
must go out as soon as the engine is running
smoothly.
The engine speed is controlled automatically,
depending on the load on the engine.

NOTE
Do not allow the engine to warm up at idling
speed. When under load, drive the truck at
a brisk speed. The engine will quickly reach
normal operating temperature.

38 Operating Instructions – EN – 03/2007

 Operation 4
Standard equipment

Switching off the engine

CAUTION
For engines with a turbocharger, the high speed
of the turbocharger shaft (approx. 100 000 rpm at
full load)could cause the shaft bearing to run dry
through lack of lubrication thus damaging it.
Do not switch off the engine under full load, but
rather allow to run on for a few minutes at low speed.

¾ Remove foot from accelerator pedal (3).

1 2

d3921421
3

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

tral position.
¾ Turn the ignition key (2) to the 0 position. 4

NOTE
The brake is applied when the engine is swit-
ched off.
¾ Pull the parking brake handle (1) upwards.
¾ Remove the ignition key (2) when leaving
the truck.

d3921362

Operating Instructions – EN – 03/2007 39

4 Operation
Standard equipment

Driving (single-pedal operation)

WARNING
Driving on long gradients over 15 % is generally
not allowed due to the specified minimum brake
applications and the stability values. Contact your
authorised dealer before driving on steeper gradi-
ents. The climbing ability values given in the data
sheet have been derived from the drawbar pull and
apply only for crossing obstacles and short diffe-
rences in height.
Always adapt your driving style to the conditions
of the roadway (rough surfaces, etc.), especially
hazardous work zones and the load.

WARNING
If mirrors are used, please note the rear-view mirror
is only provided for observing the traffic area to the
rear.
If you are reversing, therefore, always look over the
shoulder in the direction your are reversing.

CAUTION
Possibly fitted side doors must be protected against
damage.
Therefore always ensure both side doors are closed
and locked before driving.

NOTE
The truck can only be driven with the operator
seated.
¾ Start the engine.
¾ Raise the forks slightly and tilt the mast
back.

40 Operating Instructions – EN – 03/2007

 Operation 4
Standard equipment

¾ Push the parking brake handle (1) down.

1
Forward travel
¾ Push the direction lever (4) forward.
¾ Depress the accelerator (3) gently.
Truck speed depends on how far the pedal is
depressed.

NOTE
Flooring the accelerator does not increase the
speed as maximum acceleration is controlled
automatically.
2 3
Reversing
d3921422

¾ Pull the direction lever (4) back.

¾ Depress the accelerator (3) gently.
The truck will reverse slowly or fast, depending
on how far the accelerator is depressed.

Changing the direction of travel

¾ Release the accelerator.
The hydrostatic drive will act as service brake.
¾ Move the direction lever (4) to the opposite
direction of travel.
The truck will now accelerate in the selected 4
direction.
The direction lever can be moved directly to
the opposite direction. The hydrostatic drive
will brake the truck to a full stop and then ac-
celerate it in the opposite direction of travel.

d3921362

Operating Instructions – EN – 03/2007 41

4 Operation
Standard equipment

Starting on gradients
¾ Fully depress the brake pedal (2).
1
¾ Push the parking brake handle (1) down.
¾ Release the brake pedal half way.
¾ Depress the accelerator (3).
¾ Slowly release the brake pedal fully.
The brake is released and the truck will drive
without rolling back.

Stopping
¾ Release the accelerator slowly.
The hydrostatic drive will act as service brake.
¾ When stopping on gradients, keep the foot d3921422 2 3
on the accelerator, move the direction lever
(4) to the "upslope" direction of travel and
compensate drive slippage by depressing
the accelerator slightly.
¾ Depress the brake pedal (2) for a long stop.
¾ When dismounting form the truck with the
engine running, for example, to briefly per-
form some actions in close vicinity of the
truck (opening a gate, unhitching a trailer,
etc.), always pull the parking brake handle
(1) and release the seat belt. In case of a
longer stop, shut down the engine and pull
the parking brake handle (1).
¾ Remove the ignition key when leaving the
truck unattended.

42 Operating Instructions – EN – 03/2007

 Operation 4
Standard equipment

Steering system
Steering
The hydrostatic steering system allows the
level of effort required to turn the steering
wheel to be very low. This is particularly ad-
vantageous when palletising in narrow aisles.
¾ Starting and driving.
¾ Turn the steering wheel to the left and right
as far as it will go.
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.
P
DANGER
d3941323
The forklift truck must not be driven if the steering
system is defective.
If the steering is stiff or has too much play, contact
your local authorised dealer.

Turning radius

H 40 2672 mm
H 45 2708 mm
H 50-500 2745 mm

Operating Instructions – EN – 03/2007 43

4 Operation
Standard equipment

Braking system
Service brake
¾ Allow accelerator pedals (1) to move to the
neutral position.
The hydrostatic drive acts as the service
brake. Slow or quick release of the accel-
erator pedals to the neutral position allows
the braking action to be sensitively controlled,
from gentle to hard braking.

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

Stop pedal
d3921424 1 2 1
NOTE
The stop pedal (2) is not a sensitive service
brake but a sharply applied parking brake. Its
use whilst driving should be avoided, because
this can cause the drive wheels to lock and in
certain circumstances can cause the load to
slip from the fork arms. In unfavourable situa-
tions the engine can also stall. A wait of about
30 seconds must then elapse to allow the va-
riable pump in the traction drive to return to a
neutral setting . It is recommended that dri-
vers familiarise themselves with the function
and action of this brake without any load on
the forklift truck. For this purpose they should
choose a route without any other traffic, and
drive at low speed.

Parking brake
The multi-disc brakes are used as the parking
brake of the fork-lift truck.

44 Operating Instructions – EN – 03/2007

 Operation 4
Standard equipment

Apply the parking brake

¾ Pull the parking brake handle (3) upwards.
3
The symbol on the indicator unit will light up.

Release the parking brake

NOTE
The multi-disc brake will release only if the
engine is running.
¾ Release parking brake handle (3) down-
wards.
The symbol on the indicator unit will go out.

DANGER
The forklift truck must not be driven if the braking
d3921425

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

Horn
Operating the horn
When operating at blind corners and junctions,
a horn serves as warning signal.
¾ Press the horn button ((1)) on the steering
wheel to sound the horn.

Operating Instructions – EN – 03/2007 45

4 Operation
Standard equipment

Lifting system and attachments (cen-

tral lever operation)

WARNING
With the moving lift mast or any
attachment there is a risk of the driver
getting caught in between.
Therefore never reach or step into
the lift mast or the space between
the lift mast and the vehicle. The
lifting system and attachments
should only ever be used for their
proper purpose. Drivers must be
instructed in the handling of the lifting
system and attachments. Bear the
maximum lift height in mind.

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

NOTE
With the central lever version, use of the ope-
rating lever in an intermediate position (ap-
prox. 45°) will activate both functions at the
same time (e.g. lifting and tilting).
¾ Take note of the switching symbols with
arrows.
The operating lever should always be op-
erated carefully, never jerkily. Moving the
operating lever determines the lifting, lower-
ing and tilt speed . After the operating lever is
released, it automatically returns to its initial
position.

NOTE
The lifting system and attachments only func-
tion with the motor running and the driver’s
seat under load.

d3931329

46 Operating Instructions – EN – 03/2007

 Operation 4
Standard equipment

Tilt lift mast forwards

¾ Move operating lever (1) forwards.
1 2
Tilt lift mast backwards
¾ Pull back operating lever (1) .

Lift fork carriage

DANGER
When lifting the lift mast there is an increased risk
of falling and crushing.
For this reason it is not permitted to step onto the
fork arms when lifted without a protective cage .

¾ Move operating lever (1) to the right.

d3921370
Lower fork carriage
¾ Move operating lever (1) to the left.

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

NOTE
Before fitting an attachment, the depressuri-
sation circuit (special equipment) can be used
to depressurise the hydraulic system for the
additional hydraulics so that the union nuts on
the fork carriage can be opened.
¾ Switch off the engine.
¾ Switch on the ignition.
¾ Operate the lever for the respective addi-
tional hydraulics several times.
¾ Unscrew the union nuts on the fork carriage.
¾ Screw on hoses for attachment or connect
plug-in couplings.

Operating Instructions – EN – 03/2007 47

4 Operation
Standard equipment

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

¾ Take note of the switching symbols with

arrows.

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

Operate sideshift

NOTE
In order to prevent damage, do not activate the
d3931328

sideshift when the fork arm is on the ground.

¾ Move operating lever (2) to the left.
1 2
Sideshift moves to the left.
¾ Move operating lever (2) to the right.
Sideshift moves to the right.

Activate the clamp

¾ Move operating lever (2) forwards.
Clamp opens.
¾ Pull back operating lever (2).
Clamp closes.

Activate the fork arm adjustment device d3921370

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

48 Operating Instructions – EN – 03/2007

 Operation 4
Standard equipment

¾ Move operating lever (2) forwards.

Fork arms move outwards.
¾ Pull back operating lever (2).
Fork arms move inwards.

Lifting system and attachments (sin-

gle-lever operation)

WARNING
With the moving lift mast or any
attachment there is a risk of the driver
getting trapped between parts.
Therefore never reach or step into
the lift mast or the space between
the lift mast and the vehicle. The
lifting system and attachments
should only ever be used for their
proper purpose. Drivers must be
instructed in the handling of the lifting
system and attachments. Bear the
maximum lift height in mind.

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

Operating Instructions – EN – 03/2007 49

4 Operation
Standard equipment

¾ Take note of the switching symbols with

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

NOTE
The lifting system and attachments only func-
tion with the engine running and the driver’s
seat occupied.

Lift fork carriage

DANGER
When lifting the lift mast there is an increased risk
of falling and crushing.
For this reason it is not permitted to step onto the
fork arms when lifted without a protective cage.

¾ Pull operating lever (1) backwards.

Lower fork carriage

¾ Push operating lever (1) forwards.

Tilt lift mast forwards.

¾ Push operating lever (2) forwards.

Tilt lift mast backwards.

¾ Pull operating lever (2) backwards.

Operate attachments
Attachments can be fitted to the truck as spe-
cial equipment (e.g. sideshift, clamps, fork
positioner etc.). Refer to the operating pres-
sure and operating manual for the attachment.
One or more additional operating levers are
fitted for operating the attachments.

NOTE
Before fitting an attachment, the depressuri-
sation circuit (special equipment) can be used
to depressurise the hydraulic system for the

50 Operating Instructions – EN – 03/2007

 Operation 4
Standard equipment

additional hydraulics so that the union nuts on

the fork carriage can be opened.
¾ Switch off the engine.
¾ Switch on the ignition.
¾ Operate the lever for the respective addi-
tional hydraulics several times.
¾ Unscrew the union nuts on the fork carriage.
¾ Screw on hoses for attachment or connect
plug-in couplings.

CAUTION
Attachments affect the loading capacity and stabi-
lity of the forklift truck.
Attachments which are not supplied with the forklift
truck should only be used when the authorised dea-
ler has checked that safe operation is ensured by
the arrangement in terms of lifting capacity and sta-
bility.

¾ Take note of the switching symbols with

arrows.

NOTE
For every attachment device, a plate stating
the lifting capacity of the truck with the attach-
ment must be affixed beside the load diagram
in the top left of the overhead guard, and a
symbol label for the relevant attachment must
be affixed behind the operating lever.

Operate sideshift

NOTE
In order to prevent damage, do not activate
the sideshift when the fork arms are on the
ground.

Operating Instructions – EN – 03/2007 51

4 Operation
Standard equipment

¾ Push operating lever (3) forwards.

Sideshift moves to the left.
¾ Pull operating lever (3) backwards.
Sideshift moves to the right.

Operating the clamp

¾ Push operating lever (4) forwards.
Clamp opens.
¾ Pull operating lever (4) backwards.
Clamp closes.

Operating the fork positioner

NOTE
In order to prevent damage, do not activate the
fork positioner with a load, or with the fork arms
on the ground. Do not use the fork positioner
as a clamp.
¾ Push operating lever (4) forwards.
Fork arms move outwards.
¾ Pull operating lever (4) backwards.
Fork arms move inwards.

52 Operating Instructions – EN – 03/2007

 Operation 4
Special equipment

Special equipment
Lifting system and attachments (sin-
gle lever operation with 3rd addi-
tional hydraulics)

WARNING
With the moving lift mast or any
attachment there is a risk of the driver
getting caught in between.
Therefore never reach or step into
the lift mast or the space between
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.

NOTE
When working with a bucket, see "forklift truck
operation using a bucket".
¾ Take note of the switching symbols with
arrows.
The operating lever should always be oper-
ated carefully, never jerkily. The excursion of
the operating lever determines the lifting, low-
ering and tilt speed . After the operating lever
is released, it automatically returns to its initial
position.

NOTE
The lifting system and attachments only func-
tion with the motor running and the driver’s
seat under load.

Lift fork carriage

DANGER
When lifting the lift mast there is an increased risk
of falling and crushing.
For this reason it is not permitted to step onto the
fork arms when lifted without a protective cage.

Operating Instructions – EN – 03/2007 53

4 Operation
Special equipment

¾ Pull back operating lever (1).

Lower fork carriage

¾ Move operating lever (1) forwards.

Tilt lift mast forwards

¾ Move operating lever (2) forwards.

Tilt lift mast backwards

¾ Pull back operating lever (2).

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

NOTE
Before fitting an attachment, a depressurisa-
tion circuit (special equipment) can be used
to depressurise the hydraulic system for the
additional hydraulics, so that the union nuts on
the fork carriage can be opened.
¾ Switch off the engine.
¾ Switch on the ignition.
¾ Operate the lever for the respective addi-
tional hydraulics several times.
¾ Unscrew the union nuts on the fork carriage.
¾ Screw on lines for attachment or connect
plug-in couplings.

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

54 Operating Instructions – EN – 03/2007

 Operation 4
Special equipment

¾ Take note of the switching symbols with

arrows.

NOTE
For every attachment a plate stating the load
capacity of the forklift truck with attachment
must be affixed above the switch console on
the top right in the driver’s protective roof and
a symbol label for the relevant attachment
behind the operating lever and on the left and
right next to the toggle switch (4) .

Operate fork adjustment

¾ Move operating lever (1) forwards.
Fork arms move outwards.
¾ Pull back operating lever (1).
Fork arms move inwards.

Operate rotating unit

¾ Press left side (2) of toggle switch (3).
Green switch illumination lit up.
¾ Move operating lever (5) forwards.
Unit moves anticlockwise.
¾ Pull back operating lever (5).
Unit moves clockwise.

Operating Instructions – EN – 03/2007 55

4 Operation
Special equipment

Operate sideshift
¾ Press right side (4) of toggle switch (3).
Orange switch illumination lit up.
¾ Move operating lever (5) forwards.
Sideshift moves to the left.
¾ Pull back operating lever (5).
Sideshift moves to the right.

Adjusting the swivel seat

CAUTION
The driver’s seat should not turn when the truck is
being operated.
Make sure, therefore, that the swivel is locked.

The swivel seat allows better view to the rear

when reversing for long periods. It is recom-
mended to set the seat to the straight-ahead
position for long periods of travel in the forward
direction. The swivel is maintenance-free.
¾ Pull up the locking lever(1).
This releases the swivel and allows the seat to
be swivelled 17° to the right, lockable in the 0°
and 17° positions.
¾ Engage the locking bolt (1) audibly.

56 Operating Instructions – EN – 03/2007

 Operation 4
Special equipment

Adjusting the driver’s seat with air

cushioning

WARNING
An incorrect seat adjustment can cause back injury.
Do not operate the seat adjusting devices while
operating the truck.
Before each start-up of the truck and with each
change in driver, set the weight setting to the indivi-
dual weight of the driver. The drivers seat may only
be adjusted when the truck is stationary.

Horizontal adjustment
¾ Pull the lever (8) up.
¾ Slide the seat in the guide rails either for-
ward or back until the optimum position in
relation to the steering wheel and accelera-
tors is obtained.
¾ Re-engage the lever.

Seat heater

NOTE
The maximum temperature is specified.
¾ Depress the switch (4) once.
The seat heater is turned on and the switch
lamp is illuminated.
¾ Depress the switch (4) once again.
The seat heater is turned off and the switch
lamp is extinguished.

Adjusting for the operator’s weight

¾ Tap the top part of the switch (5) briefly.
The seat adjusts automatically to the weight of
the driver.

Adjust the lordotic support

The lordotic support allows a optimum adapta-
tion of the body to the contour of the backrest.
¾ Push the button (6) to fill or empty the air
chamber in the lower part (2) of the back-
rest.

Operating Instructions – EN – 03/2007 57

4 Operation
Special equipment

¾ Push the button (7) to fill or empty the air

chamber in the top part (1) of the backrest.

Backrest adjustment
¾ Push the lever (3) up and hold it.
¾ Move the backrest forward or backward to
obtain a comfortable seat position.
¾ Release the lever (3).

Mast positioning
Programming
The tilt angle sensors allow the programming
of a certain mast angle of tilt. When this func-
tion is actuated the indicator symbol (1) illumi-
nates.
¾ Tilt the mast to the desired angle.
1

d3921357

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

rest longer than 2 seconds.
2

The tilt angle is now permanently stored. As

acknowledgement, a twin tone is heard and
the light in the push button (2) blinks often for
short intervals.
The mast angle of tilt in relation to the vehicle
is stored. The tilt of the mast in relation to the
ground depends on various factors such as
tyre wear, tyre inflation pressure, load, un-
evenness and gradient of the ground.

To operate

NOTE t3921358

The mast positioning feature serves to support

the driver and makes work more relaxing. The

58 Operating Instructions – EN – 03/2007

 Operation 4
Special equipment

operator always has the responsibility for and

control of the selection of the desired mast
position.
¾ Depress the push button (2) shortly, front
left in the arm rest. Lamp in push button
2
illuminates and the mast positioning is acti-
vated.
¾ Operate joystick to reach the stored angle
of tilt. (For safety reasons, tilting is only
possible in the direction of the stored angle
of tilt and must be reactivated with each
mast positioning).
After reaching the programmed tilt, the mast
remains stationary and a tone is heard in the
composite instrument.
¾ Release joystick or depress push button
(2) shortly again. The lamp in the button
extinguishes and the mast position sensing t3921358
is deactivated.
¾ The mast can now be operated normally
with the joystick.
¾ Depress pushbutton (2) shortly again. Pro-
grammed tilt is again actuated.

Lighting

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

Operating Instructions – EN – 03/2007 59

4 Operation
Special equipment

Switch on interior lighting

¾ Press toggle switch (1).

Switch on lighting
¾ Move toggle switch (2) to centre position.
Side lights and licence plate light are
switched on.
¾ Switch toggle switch (2) as far as it will go.
Dipped beam, side lights and licence plate
lights are switched on.

Switch on working headlights

¾ Press toggle switch (3) or (4) (depending on 1 2 3 4 5 6 7 8 9
the version) .
d3921516

Switch on hazard warning lights

¾ Press toggle switch (8).

Switch on rotating flashing light

Depending on the equipment there are two
different versions.
Version 1 (single stage switch):
¾ Press toggle switch (9).
The rotating flashing light is always switched
on.
Version 2 (two stage switch):
¾ Move toggle switch (9) to centre position.
The rotating flashing light is switched on only
when reversing.
¾ Switch toggle switch (9) as far as it will go.
The rotating flashing light is always switched
on.

60 Operating Instructions – EN – 03/2007

 Operation 4
Special equipment

Switch on turn indicator lights

¾ Move operating lever (10 ) on steering
wheel forwards.
The flashing lights flash on the right. Indicator
lamp (11) flashes.
¾ Move operating lever (10 ) on steering
wheel backwards.
The flashing lights flash on the left. Indicator
lamp (11) flashes.

Attach additional consumers

DANGER
The driver’s protective roof is a safety part.
It is therefore not permitted to perform drilling or
welding on the driver’s protective roof .

CAUTION
Any additional electrical consumers to be retrofit-
ted (lights, seat heaters etc.) should be installed
using the unoccupied connections of the harness
provided for this purpose . Other connections going
beyond the scope envisaged are only permitted
after consultation with your authorised dealer.
Such work should only be carried out by trained
competent staff using functional and appropriate
materials subject to compliance with the applicable
rules and regulations .

Operating Instructions – EN – 03/2007 61

4 Operation
Special equipment

Windscreen wiper
Switch on the front windscreen wiper
¾ Move operating lever (10) on steering wheel
from centre position upwards.
The front windscreen wiper will run as long as
the lever is in this position.
¾ Move operating lever (10) on steering wheel
from centre position downwards.
The front windscreen wiper will run in intermit-
tent mode.

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

¾ Move operating lever (10) on steering wheel
from centre position downwards.
The front windscreen wiper will run in continu-
ous mode.

Switch on the rear windscreen wiper

¾ Move toggle switch (6) to centre position.
¾ Move operating lever (10) on steering wheel
from centre position upwards.
The rear windscreen wiper will run as long as 1 2 3 4 5 6 7 8 9
the lever is in this position.
¾ Move toggle switch (6) to centre position. d3921516

¾ Move operating lever (10) on steering wheel

from centre position downwards.
The rear windscreen wiper will run in intermit-
tent mode.
¾ Switch toggle switch (6) as far as it will go.
¾ Move operating lever (10) on steering wheel
from centre position downwards.
The rear windscreen wiper will run in continu-
ous mode. The front windscreen wiper will run
in intermittent mode.

62 Operating Instructions – EN – 03/2007

 Operation 4
Special equipment

Switch on the roof windscreen wiper

¾ Move toggle switch (7) to centre position.
¾ Move operating lever (10) on steering wheel
from centre position upwards.
The roof windscreen wiper will run as long as
the lever is in this position.
¾ Move toggle switch (7) to centre position.
¾ Move operating lever (10) on steering wheel
from centre position downwards.
The roof and front windscreen wipers are in
intermittent mode.
¾ Switch toggle switch (7) as far as it will go.
¾ Move operating lever (10) on steering wheel
from centre position downwards.
The roof windscreen wiper is in continuous
mode. The front windscreen wiper is in inter-
mittent mode.

Switch on the wiper/washer system

¾ Switch on relevant windscreen wiper.
¾ In addition, push the operating lever (10) in
as far as it will go.
The pre-selected wiper/washer system will
run as long as the lever is in this position.

Operating Instructions – EN – 03/2007 63

4 Operation
Special equipment

Heating, air conditioning

Switch on heating
¾ Turn switch (3).
The blower is switched on to any of three air 1 2 3 4
flow settings.
Operating elements
• Rotary knob (1) for setting the vent positions
for windscreen defrosting - positions for
windscreen defrosting - footwell ventilation
1 2
0
3

• Rotary knob (2) for temperature control

• Rotary switch (3) for setting blower
• Interior air vents (4)

Windscreen defrosting
¾ For maximum windscreen defrosting set the d3921478

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

right
• Turn rotary knob (1) to the windscreen de-
frosting position (max. position on the left)
• rotary switch (3) to setting level 3
• interior air vents (4) to open, louvres for-
wards.
For standard heating operation the following
rules apply:
• Select the temperature using the rotary
knob (2) (end position on the left → cold /
end position on the right → hot)
• Use the blower switch (3) (setting level 1 to
3), air distribution vent (rotary knob (1)) and
interior air vents (4) to select the tempera-
ture / temperature distribution you require

Switch on air conditioning

CAUTION
The moving parts must be lubricated and the com-
pressor prevented from seizing.
Therefore switch on the air conditioning briefly
every 3 months. In addition the air conditioning
must be serviced once a year by an authorised ser-
vice centre, preferably before the season starts,
and a record must be kept of the servicing. Other-
wise, warranty claims will be voided.

64 Operating Instructions – EN – 03/2007

 Operation 4
Special equipment

NOTE
It is normal that condensate can build up in
the hoses and under the vehicle when the air
conditioning is in use.
¾ Turn switch (8).
The blower is switched on to any of three air 5 6 7 8 9
flow settings.
Operating elements
• Rotary knob (5) for setting the vent positions
for windscreen defrosting - footwell ventila-
tion
1 2
0
3

• Rotary knob (6) for temperature control

• Toggle switch (7) for switching on the air
conditioning
• Rotary switch (8) for setting blower
• Cab air vents (9)

NOTE d3921505

The air conditioning only works when the en-

gine is running and the blower switch is swit-
ched to setting 1, 2 or 3. The fan in the roof
switches on when necessary. It can come to a
standstill from time to time.
¾ Switch on the toggle switch (7).
Raising the temperature in the cab:
¾ Turn the rotary knob (6) clockwise and re-
duce the blower speed using switch (8).
Lowering the temperature in the cab:
¾ Close windows and doors, turn rotary knob
(6) anti-clockwise and increase the blower
speed using switch (8).

NOTE
To achieve maximum cooling in the cab:
• the air conditioner must be switched on,
• the rotary knob (6) must be fully to the left,
• the blower must be set to its highest setting,
• the windows and doors must be closed.

Operating Instructions – EN – 03/2007 65

4 Operation
Special equipment

NOTE
On cool, humid days, the heater and air con-
ditioning can be used to dehumidify the air
in the cab (operate the heater and air condi-
tioning simultaneously). The vehicle heater
counteracts the cooling effect. This ensures a
pleasant temperature inside the cab and pre-
vents the windows misting up.

Truck Data Management (LFM)

Truck data acquisition
The truck data input terminal (1) is located at
the front left overhead guard leg.
The terminal has a keypad (3) with 12 keys.
With the standard setting, a 5-digit PIN num-
ber assigned to the operator ensures that only
authorised personnel can operate the truck.
The truck can only be started after this PIN
number and maybe a condition code (depend-
ing on the setting) has been entered.

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

Condition code

NOTE
The code indicates the state of the truck.
The following code numbers are available:
0 = Truck in working order
1 = Request Service (truck cannot be started)
2 = Request Maintenance (truck can be
started)
3 = Driving problem
4 = Lifting problem
5 = Steering problem

66 Operating Instructions – EN – 03/2007

 Operation 4
Special equipment

6 = Damaged in accident
7 = User defined
8 = User defined
9 = User defined
The condition codes 7 , 8 , 9 can be defined
by the user as he chooses. Please contact
your truck pool manager for the definition of
these condition codes.

NOTE
If you notice one of these conditions (eg dri-
ving problem) only after you have first logged
in with condition code 0 (truck in working or-
der), you must first log out.
¾ Turn the rotary knob (2) anticlockwise as far
as possible.
¾ Log in again with the condition message 3
(driving problem)

Truck data acquisition - default setting

(PIN number and condition code)
Logging in and starting the truck:
¾ Engage the parking brake.

Operating Instructions – EN – 03/2007 67

4 Operation
Special equipment

¾ Press any key to take the terminal into oper-

ation.
The green LED (2) flashes.
¾ Enter your PIN number (factory setting = 0
0 0 0 0 and condition code.

On a truck in proper working order this is there-

fore the following PIN No: 0 0 0 0 0 0 .

NOTE
In case the incorrect PIN number was entered,
it can be corrected after pressing the key * (4)
with the asterisk.
¾ Confirm the entry by pressing the # (3) key.
Green LED (2) is illuminated steadily.

NOTE
If the red LED (1) comes on, an incorrect PIN
number was entered. Press the key * (4) with
the asterisk and enter the correct number. Af-
ter more than three incorrect inputs (factory
setting), the red LED (1)and the green LEDs
(2) flash. A valid PIN input is disabled for 10
minutes. The disable period can be termina-
ted by entering a special PIN number. Please
contact your pool manager.
¾ Turn the rotary knob (7) clockwise as far as
possible and start the truck.

NOTE
If the truck does not start properly at the first
attempt, the starting procedure can be repea-
ted until the rotary knob (5) is returned to zero
and the PIN number is deleted from memory
after the expiration of the delay period.

NOTE
If the green (2) and red (1) LEDs are both illu-
minated steadily, the data must be read out.
Please inform your pool manager at once.
Turning the truck off and logging out:
¾ Turn the rotary knob (5) anticlockwise as far
as possible.
The engine is turned.

68 Operating Instructions – EN – 03/2007

 Operation 4
Special equipment

NOTE
After a delay period (factory setting = 10 se-
conds), the red LED (1) illuminates briefly and
then the green (2) and red (1) LED flash about
3 seconds. During this time the truck can be
started at any time. The LEDs then go out and
the PIN number is deleted from memory. The
delay time can be set between 10 seconds
and 10 minutes with the FDE configuration
software. Please contact your authorised
dealer.
Pressing the # (3) after the engine is turned
off terminates the delay period at once and the
PIN number is deleted from memory.

Truck data acquisition - special setting

(PIN number)
Logging in and starting the truck:
¾ Engage the parking brake.
¾ Press any key to take the terminal into oper-
ation.
The green LED (2) flashes.
¾ Enter your PIN number (factory setting = 0
0 0 0 0 ).

NOTE
In case the incorrect PIN number was entered,
it can be corrected after pressing the key * (4)
with the asterisk.
¾ Confirm the entry by pressing the # (3) key.
Green LEDs (2) is illuminated steadily.

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

Operating Instructions – EN – 03/2007 69

4 Operation
Special equipment

¾ Turn the rotary knob (7) clockwise as far as

possible and start the truck.

NOTE
If the truck does not start properly at the first
attempt, the starting procedure can be repea-
ted until the rotary knob (5) is returned to zero
and the PIN number is deleted from memory
after the expiration of the delay period.

NOTE
If the green (2) and red ((1)) LEDs are both
illuminated steadily, the data must be read
out. Please inform your pool manager at once.
Turning the truck off and logging out:
¾ Turn the rotary knob (5) anticlockwise as far
as possible.
The engine is turned off.

NOTE
After an delay period (factory setting = 10 se-
conds), the red LED (1) comes on briefly and
then the green (2) and red (1) LEDs flash for
about 3 seconds. During this time the truck
can be started any time. The LEDs then go
out and the PIN number is deleted from me-
mory. The delay time can be set between 10
seconds and 10 minutes with the diagnostic
unit. Please contact your authorised dealer.
Pressing the # (3) after the engine is turned
off terminates the delay period at once and the
PIN number is cleared.

70 Operating Instructions – EN – 03/2007

 Operation 4
Working under load

Working under load

Before taking up a load
Before taking up a load, check the lifting ca-
pacity diagram above the switch console on
the top right in the overhead guard.
The max. permissible load is determined by
the distance between the centre of gravity of
the load and the fork back of the fork arms and
the lift height.

DANGER
The values specified in the lifting capacity diagram
or capacity rating plate apply to compact homoge-
neous loads and must not be exceeded as this will
impair the stability of the truck and the strength of
the fork arms and lift mast.
When using attachments, observe the capacity
t3921383

rating plate for each attachment device.

NOTE
Take the load restriction into account and con-
sult your authorised dealer
• before transporting off-centre or swinging
loads
• before transporting loads with the lift mast
tilted forward or the load not close to the
floor
• loads involving a large centre of gravity
distance
• before using attachments and additional
equipment
• before transporting loads in a wind force of
6 and upwards. 1 Max. weight of permissible loads in kg
2 Lift height in mm
Example 3 Series designation of truck by max. lifting
Load centre of gravity distance: 650 mm capacity and lift mast series
4 Distance between centre of gravity of load
Load height to be lifted: 6800 mm and fork back in mm

¾ Trace a vertical line from a load distance of

650 mm to its point of intersection with the
line for a lift height of 6800 mm.
¾ At the point of intersection with the horizon-
tal line read off the max. permissible load to
the left.
The maximum load in this example is 2100 kg.

Operating Instructions – EN – 03/2007 71

4 Operation
Working under load

The same procedure should be followed for

other lift heights und centre of gravity dis-
tances. The values calculated refer to both
fork arms and a uniformly distributed load.

Wheel-slide protection chains

CAUTION
Mounting wheel-slide protection chains alters the
wheel freedom and lifting capacity of the truck
Before wheel-slide protection chains are fitted, the
standard fork carriage must be replaced with a spe-
cial fork carriage, which is 40 mm further forward.
All other lifting capacity data on the basic lifting ca-
pacity diagram and on the additional capacity rating
plate must be reduced by 100 kg. This reduction in
lifting capacity is still necessary even if wheel-slide
protection chains are not fitted.

¾ In addition, attach plate (5) next to basic

lifting capacity diagram.

Adjusting the fork spread

NOTE
The load centre should be in the centre bet-
ween the forks.

72 Operating Instructions – EN – 03/2007

 Operation 4
Working under load

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

¾ Move the forks further apart or closer to-
gether depending to the size of the load to
be lifted.
Make sure that both forks are equally distant
from the truck centre.
¾ Allow the quick-release levers to engage in
a notch on the fork carriage.

d3921429

Picking up a load

DANGER
When stepping on the raised forks, there is a higher
danger of falling off and getting squeezed.
Stepping on the lifted forks without the appropriate
cage protection is therefore prohibited.

DANGER
The loads must be picked up so that they do not
project beyond the truck loading area and can not
slide, fall over or fall off.
If needed, a load backrest (option) must be used.

DANGER
No persons are allowed to stand under the picked
up load when the load is raised.
Only drive with the load lowered and the mast tilted
back.

¾ Approach the load to be picked up carefully

and as exactly as possible.

Operating Instructions – EN – 03/2007 73

4 Operation
Working under load

¾ Set the mast vertical.

¾ Lift or lower the fork carriage to the required
height.
¾ Drive carefully into the centre of the load
to be picked up. Carefully drive the truck
forward under the centre of the load until
the load contacts the fork-face, if possible,
while taking care not to dislodge adjacent
loads.
¾ Lift the fork carriage until the load is clear of
the ground.

d3941327

¾ Observe the load/overload indicator light

(option) (2) in the composite instrument.

DANGER 2
If the load/overload indicator light illuminates red
when lifting the load:
¾ Deposit the load immediately again.
¾ Check the admissible weight of the load using
the load capacity diagram.

¾ Back up the truck until the load is clear.

¾ Tilt the mast back.

d3921509

Transporting a load

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

74 Operating Instructions – EN – 03/2007

 Operation 4
Working under load

¾ Do not drive with a laterally displaced load

(eg with a sideshifter).
¾ Carry the load close to the ground.
¾ On inclines, always travel with the load up-
hill, never drive or maneuvre across a slope.
¾ Work with a guide if visibility is restricted.
¾ If the load to be transported is stacked so
high that no unobstructed view in direction
of travel is ensured, the truck may only be
driven with the load trailing.

d3921431

Setting down loads

DANGER
Never stop and leave the vehicle with the load still
raised.
Let down the fork carriage until the fork arms touch
the ground.

¾ Carefully move the forklift truck to the load /

storage area.
¾ Lift the fork carriage to the necessary height.
¾ Position the lift mast so it is vertical (load
horizontal).
¾ Observe the lift mast position identification
symbol (1) on the indicator unit if your forklift
truck is equipped with automatic lift mast
position identification.
¾ Carefully move the load over the load / stor-
age area.
¾ Carefully lower the load until the fork arms 1
are clear.
¾ Back the forklift truck away.

d3921357

Operating Instructions – EN – 03/2007 75

4 Operation
Loading/transporting

Tow coupling

NOTE
The tow coupling is used only for towing light
trailers inside the plant. (Observe the applica-
ble safety guidelines and VDI.)
¾ Turn the handle ((1)) of the tow pin 90° to
the rear and then lift it up.
¾ Place the drawbar eye into the coupling
sleeve (2).
¾ Press down the tow pin against spring pres-
sure, turn 90° degrees and let engage in the
retainer.
1

2 d3921373

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

WARNING
The hose reels are spring-tensioned
and must always be secured against rewinding:

• Before the hose couplings at the mast union

can be disconnected (eg for removal of the
mast or the hose reel itself).
• Whenever the hose reels in the vehicle are
being serviced.

76 Operating Instructions – EN – 03/2007

 Operation 4
Loading/transporting

WARNING
Do not open the reel locking mechanism on the
removed hose reel.
If so, the spring tension must first be reduced to 0.
Please contact your authorised dealer.

¾ Open the bonnet.

¾ Open the floor plate and secure it.
¾ hex head screw (3) to the Hose reel (1) in
direction of travel right) with key (SW 10)
against the stop in gesicherte position (6)
turn.
The pawl (2) points opposite to the direction of
travel and the pin (8)is visible; the hose reel is
secured against turning. 5 1

4 2

3
d3921468

¾ If two attachments are installed, also turn

the pawl (4) of the second hose reel (5) to 2
the locked position(6).
¾ Disconnect the hoses before removing the
mast.
6 7
CAUTION
If the mast is extended with the pawl in action, the
hose lines can not be damaged (ratchet effect).
When the mast is lowered again, however, the 8
hoses are not reeled in and can therefore suffer
damage.
The reel locking mechanism may only be released
after the mast has been installed (hoses reconnec- 3
ted). For this set the pawl(s) back to the free-whee-
ling position (7) (pawl visible).
d3921481

Dismantling of lift mast

This work should only be performed by spe-
cialist staff working for your authorised dealer.

Operating Instructions – EN – 03/2007 77

4 Operation
Loading/transporting

DANGER
The spring elements on the drive axle are pre-ten-
sioned.
Before dismantling the tilt cylinders, the lift mast
must be tilted back 2 °.

DANGER
The lift mast may fall off during
transportation.
Do not move under overhead loads!

¾ Fasten the lifting gear to the traverse on the

outer mast of the lift mast at the top.
¾ When dismantling the lift mast, place the tilt
cylinders on a suitable piece of timber and
secure with a steel strap.

CAUTION
After dismantling the lift mast or tilt cylinders, the
potentiometer for the tilt angle is misaligned.
The potentiometer for the tilt angle thus has to be re-
adjusted after reinstalling the lift mast. When doing
so, the parking brake should be applied for safety
reasons, and any restriction in tilt angle taken into
account. Please contact your authorised dealer.

d3941331

Driving without a mast

CAUTION
When driving without a mast the speed of the truck
should be reduced for safety reasons.
Before removing the mast, therefore, install an ad-
ditional stop screw under the reverse accelerator
(double-pedal operation) or accelerator (single-pe-
dal operation) to limit the truck speed.

¾ Shut the engine off.

78 Operating Instructions – EN – 03/2007

 Operation 4
Loading/transporting

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

high as the M8 hexagonal nut (2) (DIN 6330,
6331, 6334).
¾ Screw a hexagonal nut (2) on the existing
M8 hex head screw (1) until hex head screw
(3) contacts hex head screw (1).
¾ Lock the hexagonal nut (2). 3
¾ Remove the mast.
2
Remove the additional stop after the mast is
refitted.

1
d3921520

Loading
Crane lifting

DANGER
When using a crane to lift the truck,
it must be specially ensured that
no-one is in the work area of the
crane! Observe loading weight
according to factory nameplate.
Do not move under overhead loads!
Only use round slings and a loading
crane with a sufficient load capacity.

WARNING
Crane lifting may cause damage to the tilt cylinder
and the cover on the counterweight.
Retract the lift mast, retract the tilt cylinder as far as
the stop and lift the truck in such a way that it hangs
to the front.

¾ Attach round slings to the suspension

points.
There is no special marking for the suspension
positions on the truck.

Operating Instructions – EN – 03/2007 79

4 Operation
Loading/transporting

¾ Place the round sling (2) (min. load ca-

pacity: 4000 kg) around the bottom of the
counterweight.
¾ Use edge protectors as a safeguard from
sharp edges on traverse.
¾ Insert round sling (3) (load capacity min.
4000 kg) around traverse on outer mast of
lift mast.
¾ Insert all ends into crane hook (1).
¾ Make sure that safety lock (4) is closed.

NOTE
During lifting, the lifting gear should not touch
the driver’s protective roof, the cover on the
counterweight and any additional equipment
attached.

Crane lifting with crane eyes

CAUTION
If the crane lifts pulling at an angle, the crane eyes
may break off.
Crane lifting with crane eyes should only be carried
out with the appropriate lifting gear (3), where the
chains (2, 6) lead up vertically from the crane eyes
(1, 7).

¾ Insert chains (6) (load capacity

min. 4000 kg) in crane eyes (7) on
counterweight.
¾ Insert chains (2) (load capacity
min. 4000 kg) in crane eyes (1) on lift mast.
¾ Make sure that safety lock (5) is closed.

NOTE
During lifting, the lifting gear should not touch
the driver’s protective roof, the cover on the
counterweight and any additional equipment
attached.

80 Operating Instructions – EN – 03/2007

 Operation 4
Loading/transporting

Transport with lorry or low-bed trailer

¾ Lower the mast.
¾ Engage the parking brake.
¾ Place chocks behind the wheels.
¾ Lash down the truck.

d3941329

Before leaving the truck unattended

¾ Deposit the load or lower the fork carriage.
¾ Tilt the mast slightly forward.
The forks must contact the ground.
¾ Pull the parking brake handle (1) up.
1 2
¾ Shut the engine off.
¾ Remove the ignition key(2).

d3921432

Operating Instructions – EN – 03/2007 81

4 Operation
Loading/transporting

82 Operating Instructions – EN – 03/2007

 5

Maintenance
5 Maintenance
Inspection and maintenance overview
Inspection and maintenance overview
General information
Your truck will remain operational only if the
maintenance and checks are carried out
regularly and according to the information
and instructions in the operating manual.
The maintenance may only be performed
by qualified authorised personnel. This work
can be carried out by your authorised dealer
under a service contract.
If you wish to do the work yourself, we rec-
ommend that the first three customer service
checks be carried out by your distributor’s
mechanic in the presence of the responsible
mechanic in your workshop so that your staff
can receive the appropriate instruction.
When servicing the truck, it must be placed on
a level surface and the wheels secured. Stop
the engine and remove the ignition key.
When working on the truck with the fork
carriage and mast elevated, secure them
against inadvertent lowering.
When working on the front part of the truck,
secure the mast against tilting back.
No changes, particularly no modifications and
additions, may be made to the truck without
the approval of the manufacturer.
Perform a functional check and trial run after
every servicing.
WARNING
Possibly fitted side doors can close during the
servicing, so that personnel can get caught in the
door.
Fort this reason both doors must be opened and
secured against closing.
84
CAUTION
The truck must always be properly labelled.
Missing or damaged type plates and/or self-adhe-
sive labels must be replaced. Refer to the parts
catalogue for their location and part number.
ENVIRONMENT NOTE
Follow the precautions for handling fluids and
lubricants.
NOTE
When operating the truck under extreme
conditions (ie extreme heat or cold, very dusty
environment, etc), the intervals given in the
maintenance schedule should be reduced
accordingly.
Maintenance intervals
Under certain conditions it is possible to
change the intervals of certain services listed
in the maintenance schedule. Please use
the specified engine oil and coolant in this
case. The required qualities are specified
in the recommended lubricants section.
The inspection and maintenance intervals
depend on the operating and duty conditions
of the truck. Under heavy-duty conditions we
recommend shorter intervals. Please contact
your authorised dealer.
Operating Instructions – EN – 03/2007
 Maintenance 5
Inspection and maintenance overview

Work on the mast and front part of

the truck

DANGER
When working on the front part of the truck, there
is a danger of getting squeezed in and of the mast
lowering accidentally.
Before carrying out any work on the raised mast
and fork carriage, be sure that the following safety
precautions are observed. These safety precauti-
ons are only sufficient for the general maintenance
on your truck (inspections and lubrication services).
For repairs (eg replacement of chains or removal
of the lift cylinder) further safety precautions are
required. Please contact your authorised dealer.

Securing against tilting back

The mast must be secured against tilting back
accidentally.
¾ Tilt the mast back completely.
¾ Shut the engine off.
¾ Remove the ignition key.

Standard mast
METHOD OF OPERATION: When the in-
ner upright is lifted, the chain pulleys are also
moved upwards thereby raising the fork car-
riage at a 2:1 ratio.

Securing the raised standard mast

DANGER
Check the chain load capacity. d3941341
Choose a chain with a sufficient load capacity for
the mast in question. Do not exceed the maximum
height of lift.

¾ Extend the mast.

Operating Instructions – EN – 03/2007 85

5 Maintenance
Inspection and maintenance overview

¾ Fasten the chain around the cross member

of the outer upright (1) and the cross mem- 1
ber of the inner upright(2).
¾ Lower the inner upright until it is held by the
chain.

Duplex mast

NOTE
The advantage of this mast version is that
the special free lift height can be used even
in spaces with a low ceiling (cellars, wagons,
ships). 2
METHOD OF OPERATION: The fork carriage
d3921482
is raised to the special free lift height by the
centre cylinder via the chain pulley. It moves
at twice the rate of the centre cylinder. The
inner upright and the fork carriage are then
raised together by the two outer cylinders. The
centre cylinder is mounted on the extendible
inner upright.

Securing the raised duplex mast

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

¾ Extend the mast.

86 Operating Instructions – EN – 03/2007

 Maintenance 5
Inspection and maintenance overview

¾ Fasten the chain around the cross member

of the outer upright (1) and the cross mem-
ber of the inner upright(2). 1

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

¾ Fully lower the fork carriage.

Triplex mast
METHOD OF OPERATION: The fork carriage
is raised to the special free lift height by the
centre cylinder via the chain pulley. Then the
two lift cylinders raise the inner upright. When
the inner upright is fully extended, two further
lift cylinders raise the intermediate upright,
which is raised together with the inner up- 2
right and fork carriage. The centre cylinder is d3921483

mounted on the extendible inner upright.

Securing the raised triplex mast

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

¾ Extend the mast.

¾ Fasten the chain around the cross member
of the outer upright(1) and of the intermedi- 1
ate upright(2).
¾ Lower the mast until it is held by the chain.
¾ Fully lower the fork carriage.

2
d3921484

Operating Instructions – EN – 03/2007 87

5 Maintenance
Inspection and maintenance overview
Initial commissioning
¾ Check engine oil level
¾ Check the coolant level in the header tank
¾ Add more fuel
¾ Battery: check condition, acid level and acid
density
¾ Check tyre pressure
¾ Tighten the wheel bolts
Checks before starting work
¾ Check the fuel level
¾ Check the engine oil level
¾ Check the hydraulic oil level
Maintenance after the first 50 hours
¾ Check the parking brake for proper opera-
tion.
¾ Tighten the wheel fasteners.
¾ Check the hydraulic system, drive axle,
hydraulic pumps and lines for leaks (visual
inspection).
Inspection and maintenance as required
¾ Cleaning the truck
¾ Wheel change
¾ Clean the fuel tank ventilation hose
¾ Clean lift mast chain and apply chain spray
¾ Change the air filter cartridge (after no
longer than 1000 operating hours)
¾ Change the air filter safety cartridge (after
no longer than 3000 operating hours)
¾ Check the dust discharge valve
¾ Clean the prefilter
88
¾ Hydraulic system: Check oil level
¾ Check the braking system
¾ Check steering system
¾ Check lifting system and attachments
¾ Regenerate soot filter (special equipment)
¾ Check function and safety system of 3rd
auxiliary hydraulic
¾ Check the coolant level
¾ Check the tyre pressures
¾ Check the mast, lift chain, lift cylinder and
stops for condition, security and proper
operation.
¾ Clean the lift chain, adjust and lubricate with
chain spray.
¾ Check the electric lines and cable connec-
tions for condition and security.
¾ Drain water from the fuel filter.
¾ Top up the washer system water tank
¾ Drain water out of the fuel filter
¾ Regenerate soot filter
¾ Clean the radiators in the water and hy-
draulic oil coolers, and check them for leaks
¾ Change the oil bath air filter oil
¾ Tighten wheel fastenings (after each
maintenance or repair, after max. 100
operating hours)
¾ Check tyres for damage and foreign bodies
Operating Instructions – EN – 03/2007
 Maintenance 5
Inspection and maintenance overview

¾ Grease the steering axle bearings (after no ¾ Check condition and function of seat belt
longer than 1000 operating hours)
¾ Service air conditioning

Inspection and maintenance work every 500 to 1000 operating hours* or every
year
¾ Change engine oil (at least once a year) ¾ Check other bearings and joints and oil
them
¾ Change engine oil filter (at least once a
year) ¾ Clean and grease steering axle
¾ Checking the coolant concentration ¾ Clean and grease the sideshift, check that it
is securely fastened
¾ Hydraulic system: Check oil level
¾ Clean and grease fork positioner, check
¾ Check correct operation of breather valve
fastening
on the hydraulic oil tank
¾ Check fork arms and arm safety devices
¾ Change fuel filter
¾ Check condition, secure fastening and
¾ Change the breather filter for charging air
function of lift mast, lift mast chain, lift
control
cylinders and end stops
¾ Check that the control unit is working
¾ Adjust lift mast chain, spray with chain spray
properly
¾ Change air filter cartridge, check vacuum
¾ Check fastening of chassis, tilt cylinders
switch
and steering axle
¾ Check the condition of the engine mount
¾ Check fastening of axle clamps and wheel
and engine suspension; check that they are
motors
attached securely
¾ Check and lubricate pedals
¾ Check suction and exhaust leads for leaks
¾ Check condition of ribbed V-belt
¾ Check hydraulic system for leaks
¾ Check condition and tension of toothed belt,
¾ Check the operation of the parking brake
replace if necessary
¾ Check fastening of steering cylinder and
¾ Clean water and hydraulic oil coolers
steering pivot pin
¾ Check particulate filter system
¾ Check the side stops on the drive axle,
¾ Check the condition and secure positioning adjust them
of electric cables, cable connectors and
¾ Check the pre-tension of the double tubes
connections
¾ Clean oil bath air filter
¾ Battery: check condition, acid level and
acid density (also for maintenance-free * Depending on consumables, driving style,
batteries) and conditions of use. Refer also to consum-
ables recommendations.

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

¾ Change feed / pressure / suction filter and ¾ Change ribbed V-belt
breather of hydraulic system
¾ Change safety cartridge of air filter

Operating Instructions – EN – 03/2007 89

5 Maintenance
Inspection and maintenance overview

¾ Check tilt cylinder bearing for wear
¾ Check drive axle bearing for wear
¾ Hydraulic pump on engine: check fastening
¾ Change toothed belt and tension pulley (at
latest after 5 years)
¾ Check slide guides on sideshift for wear
¾ Check fork arm adjustment device for wear
and tear

Inspection and maintenance work every 6000 operating hours or every 3 years
¾ Change hydraulic oil

Inspection and maintenance work every 9000 operating hours or every 4 years
¾ Change the water pump ¾ Change the G12 coolant

Inspection and maintenance data

No. Unit Devices / fuels Fill quantity / Setting values

1 Engine Engine oil approx. 4.5 l
2 Fuel tank Diesel Approx. 70.0 l
3 Cooling system Coolant additive / drinking with heating / air conditioner:
water approx. 10.0 l
without heating / air
conditioner: approx. 8.5 l
4 Hydraulic system Hydraulic oil approx. 27.8 l
5 Battery Distilled water As required
See sticker on inside of
6 Tyres Air
overhead guard
7 Wheel fastenings tighten front: 425 Nm
rear: 640 Nm
8 Load chains / lift mast guides Linde - chain spray As required

9 Air conditioning Refrigerant 1600 grams

Consumables recommendations
Diesel fuel
Only diesel fuels according to EN 590 with a
cetane number (CN) no lower than 51 may
be used. The fuel sulphur content must not
exceed 350 mg/kg.
If the only diesel fuel available has a sulphur
content above the value permissible for

90 Operating Instructions – EN – 03/2007


EN 590, the engine oil change intervals must
be reduced as follows:
• At a sulphur content more than 350 mg/kg
and less than 2000 mg/kg = engine oil
change interval 300 operating hours.
• At a sulphur content more than 2000 mg/kg
= engine oil change interval 150 operating
hours.
NOTE
If the sulphur content of the diesel fuel is
more than 350 mg/kg, an oil according to VW
standard 505 00 / 505 01 / 506 00 / 506 01
must be used in addition to performing engine
oil changes more frequently.
NOTE
As the ambient temperature falls, the fluidity
of the diesel fuel is reduced due to paraffin
segregation. If "summer" diesel fuels are used
at low ambient temperatures, this can lead to
malfunctions. For this reason, cold-resistant
"winter" diesel fuel is available during the
colder part of the year, which can reliably be
used at temperatures down to about -22°C.
In winter, use only winter diesel fuel, so that
the fuel lines do not become blocked by
segregated paraffin. Very low temperatures
may cause paraffin segregation even in winter
diesel fuel. Contact your authorised dealer.
CAUTION
Several important points must be observed for the
use of bio-diesel fuel (RME according to EN 14214).
Please contact your authorised dealer.
Hydraulic oil
NOTE
The working temperature is the critical factor
to be considered in selecting the correct oil for
hydrostatic traction drives. The recommen-
dations for oils given below can only be guide
values.
Hydraulic oil recommendations for normal
use:
Operating Instructions – EN – 03/2007
Maintenance 5
Inspection and maintenance overview
Hydraulic oil ISO - L - HM 68 to ISO 6743 - 4 or
HLP ISO VG 68 to DIN 51524, T.2 (factory
filling) average sustained oil temperature
60°C–80°C.
Hydraulic oil recommendations for heavy-duty
use:
Hydraulic oil ISO - L - HM 100 to ISO 6743 - 4
or HLP ISO VG 100 to DIN 51524, T.2 for
heavy-duty and multi-shift use, operation in
hot climates or at high ambient temperatures,
average sustained oil temperature over 80°C.
Hydraulic oil recommendations for normal and
heavy-duty use:
Hydraulic oil ISO - L - HV 68 to ISO 6743 -
4 or HVLP ISO VG 68 to DIN 51524, T.3
(multigrade oil)
Bio-hydraulic oil
Highly biodegradable hydraulic fluid
Aral Forbex SE 46
CAUTION
Bio-oils must not be mixed with mineral-based oils.
No recommendations for other fluids from other
manufacturers can be made at the present time.
NOTE
If in doubt, we recommend obtaining the ad-
vice of your authorised dealer. Recommen-
dations made by representatives from the
mineral oil industry should also be agreed with
your authorised dealer. Manufacturer’s ap-
proval only exists for the oils specified above.
Mixing or using with other hydraulic fluids may
result in highly expensive damage.
Lubricating grease
Linde heavy-duty grease, lithium-saponified
with EP active ingredients and MoS2. Des-
ignation according to DIN 51825-KPF 2N-20
(order no.: see spare parts catalogue).
Mixing with lubricating grease types with a
soap basis other than lithium is not permitted.
91
5 Maintenance
Inspection and maintenance overview

Coolant This engine oil must be changed every 500 op-

erating hours.
CAUTION
Engine oil for oil change every 300 operating
Refer to the coolant specifications!
hours
Use only coolant G12 A8D to VW specification
TL-VW 774D (factory filling) or G 12 A8F to VW Engine oils of qualities API CD and
specification TL-VW 774F. ACEA B2 / B3, together with high-quality
API-C and ACEA-B classes are also ap-
proved. See table for viscosity.
Coolant Drinking
Temperature
additive water This engine oil must be changed every 300 op-
-25°C 40% 60% erating hours.
¾ When topping up, the various oils may be
-30°C 45% 55%
mixed with each other; however the oil
-35°C 50% 50% change interval is then determined by the
oil of the lowest quality.
-40°C 60% 40%

Refrigerant for air conditioning

R 134a

Battery grease
Acid-free lubricating grease (terminal grease).

Chain spray
Linde chain spray (order no.: see spare parts
catalogue).

Engine oil Since a good engine oil is a pre-requisite for

"Longlife" engine oils to VW standard 506 00
or 506 01. These oils are available exclusively
in viscosity SAE 0W-30
or "Longlife 3" engine oils to VW standard
507 00 in viscosity SAE 5W-30.
Oil change every 1000 operating hours or
every 12 months.
A high-quality engine oil for 1000 operating
hours to VW standard 507 00 is factory-filled.
Engine oil for oil change every 500 operating
hours
problem-free operation and a long service life
for the engine, use only good quality engine
oil even when topping up and also during oil
change. Due to their limited viscosity range,
single-grade oils should generally not be used
all year round. These oils should be used only
in extreme climatic zones.
NOTE
No additional lubricants of any sort should be
mixed in with the lubricating oils.
¾ Refer to the viscosity table.

Engine oils according to VW standard 505 00

and 505 01 are also approved. For viscosity
see table.

92 Operating Instructions – EN – 03/2007


They apply only to oils which must be changed
every 500 or 300 operating hours.
ENVIRONMENT NOTE
Used oil must be kept away from children
until disposed of according to applicable
regulations. Under no circumstances should
oil be allowed to penetrate the mains drainage
or the ground.
Because of the problems of disposal and
the special tools and knowledge required,
engine oil and filter changing should only be
performed by your authorised dealer.
For forklift trucks with particulate filter sys-
tems, use only low-ash oil. The residues of
Operating Instructions – EN – 03/2007
Maintenance 5
Inspection and maintenance overview
combustion of oil additives (ash) cannot be
regenerated.
When the engine is running, not only is some
of the engine oil for piston lubrication burnt
off ("consumed"), but the temperature stress
and the fuel combustion products that enter
the oil lead to "wear", especially affecting
chemical "additives" in the oil. For this reason,
the entire filling of engine oil must be renewed
at specified intervals.
Since this "oil wear" depends on the operating
conditions, the fuel quality and the oil quality
(the performance characteristics of the oil), oil
change intervals vary.
The longest time a filling of lubricating oil
may remain in the engine is 12 months.
Irrespective of the change intervals, the
lubricating oil must be changed at intervals
not exceeding 12 months.
93
5 Maintenance
Checks before starting work

Checks before starting work

Fuel
Check the fuel level
¾ Switch on the ignition.
1
The current fuel level is displayed on the fuel
4
tank level indicator unit (4).
The tank is full when all 6 LEDs (2) and the 2
illuminated field "Fuel pump" (1) light up green.
As the tank has been emptied, the LEDs go
out, one after the other starting from the right.
If it is on reserve, the illuminated field for fuel
pump (1) lights up red and the LED (3) green. 3
There is only approx. 14.5 litres of fuel left in
the tank and more fuel must be added.
If only the illuminated field for fuel pump (1)
lights up red, the tank is empty.

CAUTION d3921351

Air intake can cause operational faults in the injec-

tion system.
Therefore, never empty the fuel tank completely.

Add more fuel

WARNING
Carelessness when adding fuel can cause fires,
explosions or environmental damage.
¾ Do not smoke or use an open flame,
¾ Do not spill any fuel on the ground or on hot parts,
¾ Comply with regulations on handling diesel fuel.

94 Operating Instructions – EN – 03/2007

 Maintenance 5
Checks before starting work

¾ Open the lid (5) on the fuel tank and add

more clean diesel fuel.
Max. fill quantity: 70 l
¾ Put on lid and turn to tighten.

5
d3941310

Motor hood
Open motor hood
WARNING
Always observe the following when opening the
motor hood with the engine running: The hydraulic
drive and a temperature-specific circuit may cause
the fan to suddenly switch on automatically.
Allow engine to cool down.

WARNING
Remember that parts of the engine
and exhaust will be hot.
Wear protective equipment.

¾ Move the steering column to the very front

and clamp it in place.
For luxury driver seat only

Operating Instructions – EN – 03/2007 95

5 Maintenance
Checks before starting work

¾ Pull lever (2) to outside and slide driver seat

all the way forward. 4 1
¾ Release the lever and allow to engage.

3 d3921405

¾ Push the lever (1) upwards, hold it in place,

4
fold the seat back (4) fully forward and re- 5
lease the lever (1). (Only if rear window has
been attached)
¾ Insert starter key into hole (3) and push to
release the motor hood catch; while doing
so, relieve pressure on motor hood catch by
pressing the motor hood in the direction of
the arrow.
¾ Open motor hood (5) as far back as possi-
ble. 7

NOTE
The motor hood can be opened further for
specific maintenance work. Before opening 6 d3941373
the motor hood in this way, the armrest must
be moved all the way down.

96 Operating Instructions – EN – 03/2007

 Maintenance 5
Checks before starting work

¾ Release locking screw (10) for the armrest

(8), then push the armrest all the way down.
8
¾ Tighten locking screw again.
¾ Release bracket (7). Push bracket to rear.
If a rear window is installed, the armrest
fore/aft adjustment must also be moved all the 9
way to the front. To do so release the locking
screw (9), push armrest (8) all the way to the
front. Tighten locking screw again.
¾ Open motor hood all the way.
10
NOTE
The motor hood is held in the open position by
gas-filled telescopic struts. d3921400

Close motor hood

¾ Release bracket (7) by pushing to the rear.
4
¾ Close the motor hood, then press on it until 5
the locking lever (6) engages.

6 d3941373

Engine oil
Check the engine oil level

ENVIRONMENT NOTE
Pay attention when handling fuels.

Operating Instructions – EN – 03/2007 97

5 Maintenance
Checks before starting work

WARNING
When topping up, no oil should drip
onto hot engine parts - Risk of fire!
Perform filling carefully.

CAUTION
Different oil specifications.
Observe the recommendations for fuels.

CAUTION
The oil level should never exceed the upper mar-
king.
Drain engine oil if necessary.

¾ Park truck in a horizontal position.

¾ Open the bonnet.
¾ Remove oil dipstick (2) on the engine.
¾ Wipe oil dipstick with a clean cloth.
¾ Push oil dipstick right back in and remove
again.
Oil level should be between markings.
¾ If necessary, top up engine oil to upper
marking of filling port.
¾ To so this, take off the lid (1) from the filling
port.
Difference in quantity between min. and max.
marking: 1.0 l
¾ Put on lid and turn to tighten.
¾ Close the bonnet.

98 Operating Instructions – EN – 03/2007

 Maintenance 5
Checks before starting work

Coolant
Check the coolant level

ENVIRONMENT NOTE
Follow the precautions for handling fluids and
lubricants.

NOTE
When the coolant level warning light (depen-
ding on the model) (optional) (1) comes on in
the display, the coolant level is too low and
coolant must be replenished.

NOTE
On models without an indicator (1), the coolant
level can be checked at the sight glass (2).
CAUTION
Only use approved coolant.
Please observe the lubricant recommendations.

¾ Open the bonnet.

The coolant should not drop below the mark in
the sight glass (2).

Operating Instructions – EN – 03/2007 99

5 Maintenance
Checks before starting work

¾ Add coolant, if needed, after removing the

filler cap (3) at the counterweight.

WARNING 3
The expansion reservoir is pressurised, danger of
scalding due to hot coolant.
Open the filler cap (3) slowly. Do not open the cap if

1,
2

GE WE
RM ST-
AN
ZU

Y
the expansion reservoir is hot.

¾ Refit the filler cap.

¾ Close the bonnet.

d3941313

Tyres
Check tyre pressure, tyre sizes
CAUTION
If tyre pressures are too low, tyre life will be reduced
and the stability of the truck will be affected.
Therefore regularly check tyre pressures.

¾ Check that the tyres are at the correct pres-

sure.

d3941314

100 Operating Instructions – EN – 03/2007

 Maintenance 5
Checks before starting work

¾ If necessary, adjust the tyre pressures in

accordance with the settings listed on the
sticker (1) on the right-hand side of the truck
next to the driving wheel:
Drive axle

Single fitment
H 40 250-15/18 PR 10.0 bar
250 R15-XZM 10.0 bar
H 45 / 300-15/22 PR 10.0 bar
50-500
300 R15-XZM 10.0 bar 1

Dual fitment
d3941315
H 40 250-15/18 PR 7.5 bar
250 R15-XZM 7.5 bar
H 45 / 8.25-15/18 PR 7.5 bar
50-500
8.25 R15-XZM 7.5 bar

Steering axle

Single fitment
H 40 / 45 / 250-15/18 PR 6.0 bar
50-500
250 R15-XZM 6.0 bar

Example
Tyre pressure sticker (1)

Drive axle 7.5

107 psi
Single fitment 10.0 bar
Dual fitment 7.5 bar

Steering axle
Single fitment 6.0 bar
6 10
85 psi 142 psi

t3941383

Operating Instructions – EN – 03/2007 101

5 Maintenance
Checks before starting work

Check the third auxiliary hydraulic

function and safety system (option)

NOTE
Always perform a functional and safety check
after initial operation and after repairs in the
third auxiliary hydraulic system.

Functional test:
¾ Operate all three auxiliary functions con-
secutively.
The functions performed on the attachment
must match the labels on the control console.

Safety check:
¾ Turn on the ignition.
¾ Disconnect a cable from the solenoid valve
on the fork carriage.
¾ Operate the selector switch (1) from the
second to the third auxiliary function.
The following safety precautions or warning
messages become effective:
• The selectable auxiliary function is dis-
abled.
• The truck is set to creep speed.
• Display of an error code in the text field of
the composite instrument.
• The buzzer sounds.
In case of malfunctions please contact your
authorised dealer.

102 Operating Instructions – EN – 03/2007

 Maintenance 5
Inspection and maintenance as required

Inspection and maintenance as required

Floorplate
Open floorplate
Some maintenance operations require that
the floorplate is lifted.
¾ Open the bonnet.
¾ Remove the rubber covering from the floor-
plate (1).
¾ Unscrew the fastening screws (2) from the
floorplate.
¾ Swing the floorplate up.

¾ Place restraint strap (3) around the knob on

the steering wheel.
1

Close floorplate 3
¾ Lift up the floorplate.
¾ Detach the restraint strap.
¾ Close the floorplate.
¾ Secure the floorplate with the fastening
screws.
¾ Replace the rubber covering on the floor-
plate.
¾ Close the bonnet.
d3941340

Operating Instructions – EN – 03/2007 103

5 Maintenance
Inspection and maintenance as required

Wheel change

WARNING
Observe the weight of the lift truck.
Only use a jack with a minimum lifting capacity of
3600 kg.

¾ Locate the jack only at the front corner of the

frame (2) and under the counterweight (1).
The truck may only be raised at these loca-
tions on the left- and right-hand side.
¾ Loosen the wheel nuts of the wheel to be
changed.
¾ Raise the truck with the jack until the wheels
are clear.
¾ Secure the truck with wood blocks under
the frame or counterweight.
¾ Remove the wheel fasteners.
¾ Change the wheel.
¾ Install the wheel fasteners and tighten them
by hand.
¾ Lower the truck.
¾ Tighten the wheel fasteners.

front 425 Nm
rear 640 Nm

104 Operating Instructions – EN – 03/2007

 Maintenance 5
Inspection and maintenance as required

Tighten the wheel nuts

The wheel fasteners must be tightened be-
fore the commissioning and after each wheel
change and repair.
Then after 100 service hours minimum.
Tighten opposite wheel fasteners to a torque
of:

front 425 Nm
rear 640 Nm

d3941314

Clean the lift truck

How often a truck must be cleaned depends
on its use. When used with aggressive me-
dia such as salt water, fertiliser, chemicals,
cement, etc, clean the truck thoroughly after
every use.
Hot steam or intensive degreasing solutions
should be used with utmost care! The grease
in the lubricated-for-life bearings will dissolve
and leak out. As regreasing is not possible,
the bearings will be damaged.
Do not wash the truck while the engine is run-
ning or hot.
Regularly remove any deposits/collections of d3941341
inflammable materials particularly on or near
parts having a high temperature (re greasing
exhaust pipes).

CAUTION
When cleaning with a water jet (high-pressure or
steam cleaning machine, etc), do not aim the jet
directly on electric and electronic components, ca-
ble connectors, plastic air duct conduits and hose
clamps. Do not use water to clean the central elec-
trical system and switch console.
If this cannot be avoided, cover them first and clean
only with a dry cloth or clean compressed air.

When cleaning with compressed air, remove

stubborn dirt with a cold cleaner.

Operating Instructions – EN – 03/2007 105

5 Maintenance
Inspection and maintenance as required

Clean the oil filler openings along with the

surrounding area and the grease nipples prior
to lubrication.

Clean the vent hose to the fuel tank

When the truck is used in a dusty and dirty
environment, the vent line (1) to the fuel tank
can become clogged. For this reason it should
be cleaned at regular intervals (depending on
duty).
¾ Pull the hose(1) off the neck at the fuel level
sending unit and blow dry compressed air
through it.
¾ Install the hose(1) on the neck as far as
possible.

d3941342

Clean and lubricate the lift chains

DANGER
Lift chains are safety components. The use of in-
correct cleaning material can immediately cause
chain damage.
The use of cold cleaners, chemical cleaning agents
and caustic or acidic and chlorinated fluids can be a
direct cause of damage to the chains.

The lift chains must be cleaned if dust on the

chains prevents penetration of the lubricant.
¾ Position an oil catch tray underneath the
mast.
¾ Clean the chains using paraffin derivatives d3941343
such as washing petrol.

106 Operating Instructions – EN – 03/2007

 Maintenance 5
Inspection and maintenance as required

Observe the manufacturer’s notes on safety.

When using a steam cleaning device, do not
use any additives.
¾ After cleaning, blow the chain dry at once to
remove any water in the chain links and on
the chain surface.
The chain should be flexed several times in
the process.
¾ Spray the chain at once with Linde chain
spray. Also flex the chain when spraying.

Change the air filter element

NOTE
Do not clean the air filter element. When the air
filter restricted warning light (1) in the compo-
site instrument comes on, the air filter element
must be changed.

Operating Instructions – EN – 03/2007 107

5 Maintenance
Inspection and maintenance as required

Change the air filter safety element

¾ Change the safety element (1):
• After 2 years of operation at the latest.
• If, after successfully changing the filter el-
ement, the air filter restricted warning light
illuminates again.
• In the event of a defective filter element.
CAUTION
Do not clean or reuse safety elements. Do not start
the engine with the air filter element removed.
The safety element reduces the possibility of dust
intrusion during replacement of the air filter element
or if a damaged air filter element is inadvertently
installed.
2 1
¾ Shut the engine off. d3941346

¾ Open the bonnet.

¾ Remove the air cleaner cover and the filter
element (2).
¾ Pull out the safety element.
¾ Insert the new safety element.
¾ Install the filter element and mount the air
cleaner cover in place.
¾ Close the bonnet.

Check the dust discharge valve

The dust discharge valve (1) is largely mainte-
nance-free.
¾ Open the bonnet.

108 Operating Instructions – EN – 03/2007

 Maintenance 5
Inspection and maintenance as required

¾ Compress the valve (1) and remove the

remaining dust.
¾ If the value is damaged, replace it.
¾ Close the bonnet.

d3941348

Cleaning the prefilter (special equip-

ment)

NOTE
The dust collecting tank must never be more
than half full with dust. If there is a heavy ac-
cumulation of dust, the tank must be emptied
every day.
¾ Open the dust collecting tank (1) by turning
to the right (clockwise).
¾ Lift out the dust collecting tank and empty.
¾ Replace the dust collecting tank and secure
by turning to the left (anti-clockwise).

Operating Instructions – EN – 03/2007 109

5 Maintenance
Inspection and maintenance as required

Clean and check the radiator and

hydraulic oil cooler for leaks

NOTE
Clean the radiator and hydraulic oil cooler only
when the engine is stationary and cool.
¾ Open the bonnet.
¾ Loosen the 5 screws (2).
1
¾ Remove the panel (1) from the rear of the
truck.

2 2

d3941375

Cleaning with compressed air

¾ Clean the radiator (3) from the engine side
with compressed air. 3
¾ Use a water hose to remove loosened dirt.

Cleaning with a commercial cold cleaner

CAUTION
Do not allow moisture to enter the alternator.
Therefore do not direct the water jet onto the alter-
nator.

¾ Spray the radiator (3) with a commercial

cold cleaner and allow it to soak in for ap-
prox. 10 minutes.
¾ Clean the radiator with a strong water jet d3941351
from the engine side.
¾ Operate motor to warm it up.
Remaining water evaporates thus reducing
rust formation.

110 Operating Instructions – EN – 03/2007

 Maintenance 5
Inspection and maintenance as required

¾ Check the connection screw fittings, radi-

ator hoses, and pipes at the radiator and
hydraulic oil cooler for leaks.
¾ Replace porous hoses and if required
tighten hose clamps.
¾ Mount cover (1).

Regenerating the particulate filter

1
The particulate filter must be regenerated af-
ter max. 8.5 h of engine operation. After 8.0
h of operation, the orange particulate alarm
indicator light (5) in switch panel (1) lights up,
or the load indicator (7) in the text field of the
indicator unit flashes and the buzzer sounds
at intervals, depending on version. The filter
must be regenerated within the next 30 min-
utes.

d3941300

2 3 4

5
d3941303

Operating Instructions – EN – 03/2007 111

5 Maintenance
Inspection and maintenance as required

If this time period is exceeded, the orange indi-

cator light (7) flashes and the buzzer sounds,
or the load indicator (6) continues to flash and
the particulate filter alarm is displayed on the
indicator unit. In addition, the buzzer sounds
continuously and the truck only moves in craw-
ling speed. In this case, switch off the truck
engine as quickly as possible and perform fil-
ter regeneration. Regeneration can also be
triggered before the maximum build-up time.

DANGER
Do not handle fuel while regeneration is in progress.
In particular do not fill up the truck with fuel during
regeneration.

WARNING
During regeneration, high tempera-
tures occur in the particulate filter,
the exhaust system and in their vi-
cinity. For reasons of fire safety,
regeneration exhaust gases must
not be drawn into fume extraction
systems.
Perform regeneration only in the
open air with the engine at operating
temperature and away from combus-
tible materials. Anything touching
the exhaust system may catch fire.

CAUTION
The engine cannot be started during regeneration.
If the truck must be moved from a safety area or re-
generation must be interrupted for safety reasons,
the stop switch must be unlocked and pressed. The
regeneration process will immediately be termina-
ted, and the truck can be started. If regeneration
has been interrupted, the particulate filter will not
have been regenerated!
Regeneration should only be interrupted in an
emergency as this may lead to system damage.

112 Operating Instructions – EN – 03/2007

 Maintenance 5
Inspection and maintenance as required

¾ In the event of an emergency, unlock and

press the stop switch (3) in switch panel (1).

NOTE
Regeneration can be performed only when the
engine is stopped and the glow plug starting
switch is in the zero position (ignition off).
Once started, regeneration runs automat- 2 3 4
ically, i.e. Pre-glow approx. 60 seconds,
burning-off approx. 12 minutes and blow-
ing-through approx. 10 minutes. Once regen-
eration has been completed, the illuminated
switch (operation indicator) is extinguished
and the truck can be operated again.
5
¾ Clean the exhaust air duct thoroughly. d3941303

¾ If more than 30 minutes have elapsed since

the engine was switched off, move the glow
plug starting switch briefly to position 1
and then back to the zero position (ignition
briefly switched on, then off again).
The particulate filter control system will remain
active for a further 30 minutes and regener-
ation can be started at any time within this
period.
¾ Push starting switch (2) downwards and
hold down for approx. 3 seconds until the
built-in yellow illumination in the switch
lights up (operation indicator). Depending
on version, the orange indicator light (5) or
the particulate filter alarm (6) in the indicator
unit goes out.
The operation indicator stays lit up until the
end of the regeneration process (approx. 23 2 3 4
minutes).
If the particulate alarm was activated before
regeneration is restarted, it remains active. In
this case full regeneration must be performed
immediately.
5
d3941303

Operating Instructions – EN – 03/2007 113

5 Maintenance
Inspection and maintenance as required

In the event of an error during the regeneration

procedure, the orange indicator light (5) and
the red indicator light (4) flash alternately, or
the particulate filter alarm (6) lights up and text
field (8) of the indicator unit displays an error
code.
Start regeneration again. If the fault still per-
sists, switch off the truck. Please contact your
authorised dealer.

NOTE
To switch off the buzzer, press the reset button
(9). Should the buzzer not fall silent, contact
your authorised dealer. During driving ope-
ration, the regeneration system glow plug is
cleaned via intermediate glow every 1.75 h.

Change the oil in the oil bath air

cleaner (Optional)

NOTE
An oil change is necessary when the dirt sedi-
ments have reached half of the oil filling, and
at least whenever the filter element is rene-
wed. Do not add oil between the oil change
intervals.

ENVIRONMENT NOTE
Follow the precautions for handling fluids and
lubricants.
¾ Shut the engine off.

114 Operating Instructions – EN – 03/2007

 Maintenance 5
Inspection and maintenance as required

¾ Open the clamps (3) on the oil bowl (2).

¾ Remove the oil bowl downwards, empty
and clean it.
¾ Clean and check ((1)) the seals, renew if
damaged.
¾ Check the filter element ((5)) and clean if
dirty. Fill the oil bowl (2) with engine oil up to
the mark(4).
¾ Place the oil bowl (2) on the filter head (6),
check for correct seating and fasten with the
clamps (3).

Topping up washer system water

tank (special equipment)
¾ Open motor hood.
¾ Remove cap (1) on water tank (2) on right in
engine compartment.
¾ Top up with water until water is visible in the
filling port.
¾ Replace cap (1).
¾ Close motor hood.

Drain the fuel filter

ENVIRONMENT NOTE
Follow the precautions for handling fluids and
lubricants.
¾ Remove the 3 access cover screws on the
right-hand side of the truck.

Operating Instructions – EN – 03/2007 115

5 Maintenance
Inspection and maintenance as required

¾ Take off the access cover.

¾ Loosen the drain plug (1)at the fuel filter and
drain approx. 100 cm3 into a container until
clean fuel flows out.

ENVIRONMENT NOTE
Discard the drained fuel in an environment-
friendly way.
¾ Tighten the drain plug.
¾ Refit the access cover.

d3921374

Lubricate the steering axle bearings

If used in clean and dry areas inside, servic-
ing every 1000 hours is sufficient as a rule.
For mixed duty inside and outside it is rec-
ommended that the lubrication intervals be
halved.
In an environment with a continuous exposure
to dust, dirt, water and possibly de-icing salt or
chemicals, weekly lubrication will extend the
service life of the bearings substantially.

NOTE
Preferably lubricate the bearings with less
grease more often than with a lot of grease
less frequently.
d3921344

116 Operating Instructions – EN – 03/2007

 Maintenance 5
Inspection and maintenance as required

Check the tyres for damage and

foreign objects
¾ Secure the truck against rolling (apply park-
ing brake).
¾ Chock a wheel that is not to be jacked up.
¾ Raise the truck with a jack until the wheels
are clear of the ground.
¾ Secure the truck with wood blocks.
¾ Check the wheels for ease of rotation and
remove anything hindering their free move-
ment.
¾ Replace worn or damaged tyres.

d3941352

Check the lap seat belt for condition

and proper operation

NOTE
For safety reasons the condition and proper
operation of the restraint system should be
inspected regularly (monthly). Under extreme
operating conditions this check is required
daily before taking the truck into operation.

Operating Instructions – EN – 03/2007 117

5 Maintenance
Inspection and maintenance as required

¾ Pull the belt (1) out fully and inspect for fray-
ing. 1

¾ Check the buckle (3) for correct operation

and the retractor for proper return of the belt.
¾ Check the trims for damage.
Check the automatic lock.
¾ Park the truck on level ground. 3
¾ Jerk out the belt.
The automatic lock should prevent the belt
from unrolling from the retractor (2).
¾ Slide the seat fully forward.
2
¾ Tilt the backrest fully forward. d3921441

NOTE
When opening the bonnet, watch out for a
possibly installed rear windscreen.
¾ Unlock the bonnet and open it with the seat
(4) about 30°.
The automatic lock should prevent the belt
from unrolling from the retractor (2).
4
WARNING
Do not operate a truck with a defective seat belt.
The seat belt must be renewed after an accident.
In the case of seat belts attached to the operator’s
seat, the seat and mounting of the seat must also
be inspected by qualified personnel. Nuts and bolts 30˚
should be checked regularly for tightness. A wobb-
ling of the seat can indicate loose bolts or other
faults. In case of non-observance, you will put your
health at risk and increase the risk of accidents.
If malfunctions in the operation of the seat are de-
tected (eg springy seat), contact your authorised d3941353
dealer immediately to eliminate the cause.

Maintaining the air conditioning (spe-

cial equipment)
The following maintenance must be carried
out at the beginning, middle and end of a sea-
son:
¾ Check the compressor belt tension.

118 Operating Instructions – EN – 03/2007

 Maintenance 5
Inspection and maintenance as required

¾ Check the refrigerant level and moisture

content in the system.
The refrigerant must flow through the dryer
when the engine is running. No bubbles
should be visible in the inspection glass on the
dryer. When the engine is switched off, the
liquid level should drop back into the reser-
voir. Otherwise, there is no guarantee that
the system is not overfilled. There is a blue
indicator ball beside the white floating ball in
the inspection glass on the dryer. If the colour
of this indicator ball changes from blue to red,
remove the dryer. Otherwise, acid will form
in the cooling circuit and may damage the air
conditioner. The position of the white floating
ball corresponds to the refrigerant level.
¾ Cleaning the condenser.
When cleaning the condenser fins, do not
press hard, otherwise they will be damaged
and air will no longer flow properly across
them.
When performing maintenance work, please
consult your authorised dealer.

Operating Instructions – EN – 03/2007 119

5 Maintenance
Inspection and maintenance every 500 to 1000 operating hours or once a year

Inspection and maintenance every 500 to 1000 operating hours

or once a year
Change motor oil
(at the latest after 12 months)

CAUTION
Different oil grades result in different maintenance
intervals.
Recommendations for working materials must al-
ways be observed.

Drain motor oil

WARNING
Risk of scalding when draining hot
motor oil!
Protective equipment must be worn.

ENVIRONMENT NOTE
Observe information about working materials.

NOTE
Only change motor oil when the engine is at
operating temperature.
¾ Drive truck over pit.
¾ Switch off the engine.
¾ Place a collection vessel under truck frame.
¾ Open the motor hood.

120 Operating Instructions – EN – 03/2007

 Maintenance 5
Inspection and maintenance every 500 to 1000 operating hours or once a year

¾ Remove cap (1) of filling port.

¾ Remove cover on floor of frame.
¾ Unscrew the motor oil drain plug (3) under-
neath from the sump.
¾ Allow all oil to drain off into collection vessel.

¾ Fit a new washer to the drain plug (3), and

insert the plug.
Tightening torque: 30 Nm
¾ Re-attach cap (1).

Top up motor oil

¾ Switch off ignition.

d3921445

Operating Instructions – EN – 03/2007 121

5 Maintenance
Inspection and maintenance every 500 to 1000 operating hours or once a year

¾ Open cap (1) of filling port.

¾ Top up new motor oil to filling port according
to Recommendations for working materials.
Fill quantity with filter change: max. 4.5 l
¾ Using dipstick (2) check level of motor oil
after adding oil and top up to Max. marking.
¾ Fit cap (1) and turn to fix in place.

¾ Check indicator unit (4).

Display Oil(5) (special equipment) in indica-
tor unit must be extinguished. The oil level will
not be displayed reliably in the indicator unit
until 10 or so minutes after adding oil.

NOTE
After changing the oil and the filter, run the
engine, checking the oil pressure indicator
and the tightness of the oil drain plug and oil
filter. The oil level should now be checked
again, especially after changing the oil filter.
Switch off the motor and leave it to stand for
about a minute before checking the oil level.

Clean the radiator and hydraulic oil

cooler

NOTE
Clean the radiator and hydraulic oil cooler only
when the engine is stationary and cool. The
exact description can be found with the index.

122 Operating Instructions – EN – 03/2007

 Maintenance 5
Inspection and maintenance every 500 to 1000 operating hours or once a year

Clean wet type air cleaner (Optional)

ENVIRONMENT NOTE
Follow the precautions for handling fluids and
lubricants.
¾ Shut the engine off.
¾ Open the clamps (4) at the oil reservoir (3).
¾ Remove the oil reservoir downwards, empty
and clean it.
¾ Clean and check the seals (2), renew if
damaged.
¾ Slacken the clamp of the air hose at the
clean air intake (1) and withdraw the hose.
¾ Remove and clean the dust bowl (8).
¾ Remove the upper part (7) of the filter from
the overhead guard.
¾ Wash the upper part of the filter and the filter
element with diesel fuel.
Filters and filter elements with a steel fabric
can be cleanded with a steam jet.
¾ Dry thoroughly the cleaned filter.
¾ Refit the upper part of the filter and fasten
the air hose.
¾ Refit the dust bowl (8).
¾ Fill the oil reservoir (3) with engine oil up to
the mark (5).
¾ Place the oil reservoir (3) under the filter
head (7), check for correct seal and fasten
with the clamps (4).

Check coolant concentration

The cooling system has to be filled all year
round with a mixture of water and phosphate-
free glycol-based coolant additive with anti-
corrosion additives to prevent the deposit of
lime scale and damage caused by frost and
corrosion, and to raise the boiling tempera-
ture.

Operating Instructions – EN – 03/2007 123

5 Maintenance
Inspection and maintenance every 500 to 1000 operating hours or once a year

WARNING
Never open the lid (2) when the
motor is hot. Risk of scalding!
Wait until the coolant has cooled
down.

ENVIRONMENT NOTE
Pay attention when handling fuels.
¾ Check coolant concentration in filling port
(1).
The frost protection should be sufficient for
temperatures down to -25 °C. The mixing ratio
required here is 40% coolant additive and 60%
drinking water. 1 2
Mixing ratio for lower temperatures:

1,2

GE WES
Coolant Drinking

RM T-
AN
Y
Temperature
ZU

additive water
-30° C 45% 55%
-35° C 50% 50%
-40° C 60% 40%
d3941360
If coolant additive level is too low:
¾ Open the bonnet.
¾ Place a collection vessel under the coolant
hose (3).
4
¾ Loosen the coolant hose on the cylinder
block and allow some coolant to drain off.
¾ Fasten coolant hose again.

ENVIRONMENT NOTE
Dispose of drained coolant in an environmen-
tally friendly manner.
¾ Add coolant additive to filling port (1) until
right mixing ratio is achieved.
¾ Check coolant level at view window (4). 3
¾ Put on lid (2) and turn to tighten. d3941358

¾ Close the bonnet.

124 Operating Instructions – EN – 03/2007

 Maintenance 5
Inspection and maintenance every 500 to 1000 operating hours or once a year

Hydraulic system: Check the oil level

ENVIRONMENT NOTE
Follow the precautions for handling fluids and
lubricants.

NOTE
See oil specifications in the fluids and lubri-
cants recommendations.
¾ Lower fork carriage completely.
¾ Remove the breather filter (1) with dipstick
at the left side of the truck.
1
NOTE
The reservoir is slightly pressurised. Some air
will escape.
¾ Clean the dipstick with a clean cloth.

d3941374

¾ Screw in breather filter with dipstick com-

pletely and then screw out again.
The oil level should be between both marks.
¾ If needed, fill oil up to the top mark.
Difference between max and min marks: ap-
prox. 3 L

Operating Instructions – EN – 03/2007 125

5 Maintenance
Inspection and maintenance every 500 to 1000 operating hours or once a year

Check correct operation of breather

valve on the hydraulic oil tank

NOTE
The breather filter on the hydraulic oil tank is
fitted with a breather valve, which causes the
tank to be at a slight positive pressure.

ENVIRONMENT NOTE
Observe information about working with con-
sumables.
¾ Close the breather filter (1) and check
whether the breather filter is seated cor-
rectly.
¾ Start the engine.
¾ Extend lift mast several times to the stop
and let it return.
¾ Switch off the engine. Open the breather
filter (1) on the hydraulic oil tank.
Air must be heard to escape from the tank. If
no noise of air escaping is audible, replace the
breather filter.

Battery: Check condition, level and

density of acid
When handling starter batteries, the following
should be taken into account:
¾ Wear industrial goggles and a protection
suit.
¾ Before touching the battery, first grasp con-
ductive parts of the frame to discharge any
static charge.
¾ Avoid producing sparks when connect-
ing/disconnecting.
¾ When recharging new batteries, ensure
good degassing (unscrew any plugs
present).

126 Operating Instructions – EN – 03/2007

 Maintenance 5
Inspection and maintenance every 500 to 1000 operating hours or once a year

¾ After charging the battery, leave it standing

for at least 8 hours before reconnecting, if
possible.
¾ When filling up or recharging, remove any
packaging film beforehand to ensure gas
venting.
¾ Do not use plastic adhesive tape, in par-
ticular on the battery lid and the ventilation
openings of the plugs.
¾ Before recharging, first check battery with-
out electric load to make sure that only intact
batteries undergo charging.
¾ During electrical charging, batteries pro-
duce hydrogen and oxygen gas which
under certain conditions may result in an
explosive mixture. Battery should only be
filled and charged in well ventilated rooms.
¾ Avoid rubbing textiles against the battery.
¾ The electrolyte level must always be main-
tained between max. and min. markers (to
avoid large gas volumes).
¾ Due to the possibility of static charges, do
not rub batteries with dry cloths. Use damp
cloths instead.

WARNING
Battery acid is highly corrosive.
Contact with battery acid should
therefore always be avoided. If the
clothing, skin or eyes have come
into contact with battery acid, the
affected areas should be rinsed with
water immediately. In the event of
contact with the eyes, please consult
a doctor at once! Any spilt battery
acid should be neutralised straight
away!
Wear protective equipment.

NOTE
Even in the case of maintenance-free batte-
ries, it is necessary to check the condition and
acid density/level.
¾ Open the bonnet.

Operating Instructions – EN – 03/2007 127

5 Maintenance
Inspection and maintenance every 500 to 1000 operating hours or once a year

¾ Inspect battery (1) for cracked housing,

raised plates and acid leaks. 1
¾ Unscrew sealing plugs (2) and check acid
level.
In the case of batteries with level checking
inserts, the fluid must reach the bottom of the
insert, and for batteries without level checking
inserts, it must lie 10–15 mm above the lead
plates.
¾ Any lack of fluid should only be made up
with distilled water.
¾ Remove any oxidation residues on the
battery terminals and then apply acid-free
grease. 2
d3941363
¾ Retighten battery-terminal clips firmly.
¾ Check acid density with an acid siphon. The
density value must be 1.24-1.28 kg/l.
¾ Screw sealing plugs (2) back in.
¾ Close the bonnet.

Change fuel filter

(at the latest after 12 months)

ENVIRONMENT NOTE
Observe information about working materials.
¾ Unscrew 3 screws from the maintenance
cover (1) on the right side of the forklift truck.
¾ Remove the maintenance cover.

1 d3941359

128 Operating Instructions – EN – 03/2007

 Maintenance 5
Inspection and maintenance every 500 to 1000 operating hours or once a year

¾ Place a collection vessel under the fuel filter

(2).
¾ Clean the outside of the fuel filter.
¾ Unscrew the old filter and dispose of it in an
environmentally friendly manner.
¾ Clean the sealing face of the filter top (4).
¾ Lightly wet a new sealing ring (3) with fuel. 4
¾ Screw the new filter (2) on until the sealing
ring (3) is seated on the filter top (4).
¾ Fully tighten the filter by hand. 3
2
¾ Start the engine and check for leaks.
If necessary, tighten the filter further by hand. d3941379

¾ Refit the maintenance cover.

Change motor oil filter

WARNING
Risk of scalding with hot motor oil!
Wear protective equipment.

ENVIRONMENT NOTE
Observe information about working materials.
¾ Open motor hood.
¾ Release cap (4) of motor oil filter (5) with an
oil filter wrench and unscrew by hand.
¾ Collect oil escaping from oil filter and dis-
pose of it with oil filter in an environmentally
friendly manner.
4
¾ Insert new oil filter insert.
¾ Replace O-ring of cap.
¾ Screw on cap by hand until O-ring is seated.
¾ Tighten to 25 Nm.
¾ Close motor hood.

NOTE
After changing the oil and the filter, check the 5 d3941376
oil pressure indicator and also that the oil drain

Operating Instructions – EN – 03/2007 129

5 Maintenance
Inspection and maintenance every 500 to 1000 operating hours or once a year

plug or the oil filter do not leak during a trial

run of the motor. To make an accurate oil
level check, particularly after changing the
oil filter, it is necessary to switch off the motor
again and inspect the oil level after approx.one
minute.

Replace breather of boost pressure

control system

ENVIRONMENT NOTE
Observe information about working with con-
sumables.
¾ Open the covering of the electrical system
behind the driver’s seat.
The filter is positioned to the right, near to the
holder fuse.
¾ Release the clamps (4).
¾ Remove filter (1) from the grommet (2).
¾ Remove hose (3) from the filter.
¾ Dispose of filter in an environmentally
friendly manner.
¾ Slide hose (3) onto the new filter right as far
as it will go.

NOTE
From the end of the hose to the middle of the
hose bend is approx. 80 mm.
¾ Insert filter into grommet (2) to the stop.
¾ Secure hose with clamps (4).
¾ Check clamps are positioned correctly.

NOTE
The position of the clamps also prevents the
hose from bending.

130 Operating Instructions – EN – 03/2007

 Maintenance 5
Inspection and maintenance every 500 to 1000 operating hours or once a year

Check condition of the ribbed vee

belt

WARNING
Do not touch rotating parts!
Switch off the engine and take the
key out of the ignition switch.

NOTE
A defective or loose ribbed vee belt will cause
the vehicle electrical voltage to be too low.
¾ Open the bonnet.
¾ Remove the maintenance cover on the right
hand side.
¾ Check the ribbed V-belt (1) for signs of ex-
cessive wear, frayed edges, cracks across
the belt and traces of oil.
¾ Exchange the ribbed vee belt if it is dam-
aged.
¾ Fit maintenance panel again.
¾ Close the bonnet.

1 d3921375

Check toothed belt condition and

tension

WARNING
Do not touch rotating parts!
Switch off the engine and take the
key out of the ignition switch.

¾ Remove the maintenance cover on the right

hand side.

Operating Instructions – EN – 03/2007 131

5 Maintenance
Inspection and maintenance every 500 to 1000 operating hours or once a year

¾ Take off the engine cover

¾ Check the toothed belt for excessive wear,
frayed edges, damaged teeth, cracks
across the belt and traces of oil.
¾ If the toothed belt is damaged, get your
authorised dealer to exchange it.

d3921410

¾ Push the toothed belt hard with your thumb.

The notch and raised section (arrowed) must
move.
¾ Release the toothed belt again.
The tensioning roller must return to its initial
position (notch and raised section opposite
each other). If this does not happen, please
contact your authorised dealer.

t3921395

132 Operating Instructions – EN – 03/2007

 Maintenance 5
Inspection and maintenance every 500 to 1000 operating hours or once a year

¾ Check the water pump gear wheel (2) for

wear.
¾ Place a straight edge (1) on a tooth (4)
and use a feeler gauge to determine the
wastage of material (3) over the length of
the tooth.
If the wastage is more than 0.3 mm the coolant
pump together with the crankshaft pinion gear
and the toothed belt must be exchanged.
Please contact your authorised dealer.
¾ Refit the engine cover.
¾ Refit the side maintenance cover.

Check the soot filter system (option)

¾ Check electric contacts for security, corro-
sion and damage.
¾ Check the combustion air hose for damage,
leaks and security.
¾ Check fuel-conducting lines and parts for
damage, leaks and security.
¾ Check the system for correct operation
(soot alarm, buzzer, regeneration).
¾ Check the burner mounting for leaks, secu-
rity and deformation.
¾ Clean the corrugated hose and elbow (fan
to burner.
¾ Inspect the filter mounts for security.
¾ Check the parts conducting exhaust gases
for leaks.
¾ Clean the air intake tube at the burner
(for this loosen the olive fitting and remove any
soot with a round wire brush.
¾ Check the screws on the filter casing and
parts conducting exhaust gases for tight-
ness.
¾ Inspect the heat plug coil for heavy defor-
mation and soot deposits.

Operating Instructions – EN – 03/2007 133

5 Maintenance
Inspection and maintenance every 500 to 1000 operating hours or once a year

Please contact your authorised dealer for

these services.

Check electrical cables, cable con-

nectors and cable terminals for con-
dition and secure attachment

NOTE
Oxidised terminals and perished insulation
lead to voltage drops and thus to difficulties in
starting and operating.
¾ Check cable terminals for secure attach-
ment and oxidation residues.
¾ Check earth wire for secure attachment.
¾ Check electric wiring for scuffing and secure
attachment.
¾ Remove oxidised connections and replace
brittle cables.

d3941362

Check the pedals

ENVIRONMENT NOTE
Follow the precautions for handling fluids and
lubricants.

134 Operating Instructions – EN – 03/2007

 Maintenance 5
Inspection and maintenance every 500 to 1000 operating hours or once a year

¾ Raise and secure the floor plate.

¾ Unscrew the 4 nuts on the pedal console.
¾ Check the pedals for ease of movement.
¾ If necessary, lightly oil the bearings.
¾ Reassemble the pedal console.

d3921378

Check and oil other pivots and joints

ENVIRONMENT NOTE
Follow the precautions for handling fluids and
lubricants.
¾ Inspect and oil the pivots and mountings of:
• Seat guide
• Bonnet pivot pin
• Wiper mounting (option)
• Cab door hinges and locks (option)
• Grease the bonnet latch.

d3921450

Operating Instructions – EN – 03/2007 135

5 Maintenance
Inspection and maintenance every 500 to 1000 operating hours or once a year

Check the control unit for proper

operation

NOTE
Special tools and know-how are required for
checking the lowering stop valve and the re-
lease valve in the control unit. Please contact
your authorised dealer.

t3941381

Change the air filter element, check

the vacuum switch
(at least every 1000 service hours)
¾ Open the bonnet.
¾ Open the clips (2) (3 items) and take off the
air cleaner cover(3).
¾ Withdraw the air filter element.
3
CAUTION 2
Thoroughly clean the inside of the air cleaner hou-
sing. Do not blow out with compressed air. 1
Wipe with a clean cloth.

¾ Reinstall the filter element into the filter cas-

ing.
Make sure that the filter element is not dam-
aged and that the seal on the filter casing fits
properly.
¾ Install the air cleaner cover. d3941344

136 Operating Instructions – EN – 03/2007

 Maintenance 5
Inspection and maintenance every 500 to 1000 operating hours or once a year

¾ With the engine running, slowly close the air

cleaner intake opening (eg with a cardboard
or metal plate) until the air filter restricted
warning light (1)(in the composite instru-
ment lights up.)
To prevent damage, do not close the opening
any further after the warning light illuminates.
If the air filter restricted warning light does not 1,2

illuminate, contact your authorised dealer.

GER
WE MANY

Z
ST-

U
d3941388

Clean and grease the steering axle

ENVIRONMENT NOTE
Follow the precautions for handling fluids and
lubricants.
¾ Clean the steering axle with water or a com-
mercial cold cleaner.

NOTE
Lubricate with grease according to the lubri-
cant recommendations. Grease the stub axle
bearing first at the top and then at the bottom.
¾ Lubricate the track rod link arm and stub
axle at the grease nipples (see arrows) with
grease.
¾ Lubricate with the grease gun at the grease
nipples until fresh grease emerges from the
bearings.

d3921344

Clean sideshift (special equipment)

and grease, check fastening

ENVIRONMENT NOTE
Observe information about working materials.

Operating Instructions – EN – 03/2007 137

5 Maintenance
Inspection and maintenance every 500 to 1000 operating hours or once a year

NOTE
The sideshift should be greased whenever the
truck is washed. Use lubricating grease com-
plying with the recommendations for working
materials.
¾ Clean sideshift with steam jet.
¾ Check hydraulic lines for scuffing and re-
place if necessary.
¾ Check hydraulic connections and fastening
elements for secure positioning and wear
and tighten/replace if necessary.
¾ Check cylinders for leaks.
¾ Check piston rods for damage.
¾ Adjust the fork arms so that the 4 lubricating
nipples (1) are accessible.
¾ Let down sideshift until fork arms touch the
ground.
¾ Apply lubricating grease to lubricating nip-
ples (1) of support rollers on fork carriage
until grease escapes at the side.
¾ Apply lubricating grease to lubricating nip-
ples (2) of wear strips on fork carriage at top
until grease escapes at the side.

Clean and lubricate fork arm adjust-

ment device (special equipment),
check fastenings Clean and lubri-
cate
¾ Clean the fork arm adjustment device with a
steam jet.

138 Operating Instructions – EN – 03/2007

 Maintenance 5
Inspection and maintenance every 500 to 1000 operating hours or once a year

¾ Check the state of the fork arm adjustment

device. Check it for leaks.
¾ Check hydraulic lines for scuffing and re-
place if necessary.
¾ Check hydraulic connections for tightness,
replace if necessary.
¾ Check cylinders for leaks.
¾ Check piston rods for damage.
¾ Re-tighten fastening screws (1) to 85 Nm.
¾ Re-tighten fastening screws (2) to 85 Nm.

¾ Re-tighten fastening screws (3) to 50 Nm.

¾ Re-tighten fastening screws (7) to 235 Nm.
¾ Apply grease to the slide guides (4).
¾ Apply grease to the lubricating nipple (5) on
the guide shoes until grease escapes out
the side.
¾ Apply grease to the lubricating nipple (6) on
the rollers until grease escapes out the side.

Operating Instructions – EN – 03/2007 139

5 Maintenance
Inspection and maintenance every 500 to 1000 operating hours or once a year

Mast, lift chains, lift cylinders and end

stops: Check for security, condition
and proper operation
¾ Clean the mast channels and chains.
¾ Inspect the chains for condition and wear,
especially in the area of the pulleys.
¾ Check that the chain is attached securely to
the chain anchor.
¾ Replace damaged chains.

NOTE
Single damaged and missing plastic links do
not impair the operation and service life of the
chain.
¾ Check mast, channels and rollers for condi-
tion and security.
¾ Check stops for condition, security and
proper operation.
¾ Check the lift cylinders for security.
¾ Check the circlip of the piston rod fastener
on the top of the lift mast for security.

Adjust the lift chain length

Standard mast

NOTE
When the truck is being used, chains are sub-
ject to elongation and consequently have to be
regularly adjusted.
¾ Completely lower the mast.

140 Operating Instructions – EN – 03/2007

 Maintenance 5
Inspection and maintenance every 500 to 1000 operating hours or once a year

¾ Loosen the locknut (1).

¾ Adjust chain length with the adjusting nut
(2) at the chain anchor. 2
The lower guide pulley on the fork carriage
may project a maximum of 30 mm from the 1
inner mast guide rails.
¾ Tighten the locknut (1) firmly.
¾ Adjust the second chain in the same man-
ner.
CAUTION
The mast must not hit the stops when being exten-
ded.
Check mast, channels and rollers for condition and
d3941365
security.

Lubricate with chain spray

NOTE
Trucks in service in the food industry must be
lubricated with a thin oil approved by the food
industry instead of chain spray.
¾ Spray guide rail surfaces and chains with
Linde chain spray.

Duplex or triplex mast

NOTE
As lift chains stretch with use, they must be
adjusted.
¾ Completely lower the mast and fork car-
riage.

Operating Instructions – EN – 03/2007 141

5 Maintenance
Inspection and maintenance every 500 to 1000 operating hours or once a year

¾ Loosen the locknut (4). Adjust chain length

with the adjusting nut (3) at the chain an-
chor.
The lower guide pulley on the fork carriage
may project a maximum of 30 mm from the
inner mast guide rails.
¾ Tighten the locknut (4) firmly.

CAUTION
The mast must not hit the stops when being exten-
ded.
Check mast, channels and rollers for condition and 3
security.

Lubricate with chain spray 4 d3921486

NOTE
Trucks in service in the food industry must be
lubricated with a thin oil approved by the food
industry instead of chain spray.
¾ Spray guide rail surfaces and chains with
Linde chain spray.

Check the tension of double hoses

The tension of the double hoses should be
5-10 mm per metre, depending upon the origi-
nal length.
¾ Adjust the tension of the hoses to the
specified dimension by sliding them in the
clamps.

d3921519

142 Operating Instructions – EN – 03/2007

 Maintenance 5
Inspection and maintenance every 500 to 1000 operating hours or once a year

Check the forks and fork quick-

releases
¾ Check the forks for visible deformations,
wear and damages.
¾ Check the bolts of the fork stops and fork
quick-releases for correct seating and dam-
age.
¾ Replace any defective parts.

d3941364

Check the engine mounting for con-

dition and security
The engine rubber mountings are subject to
great stresses. Depending on the operating
conditions, their service life is limited.
¾ Check the rubber parts for tearing and de-
formation, if needed replace.
Please contact your authorised dealer.
¾ Check the fastening screws and nuts of the
engine support bracket and engine mount
for condition and security.
Torque of the fastening screws and nuts:
Right side of engine:

2 M8 hex head screws (at

23 Nm
the rear)
1 M10 hexagonal nut (at the
46 Nm
rear)
2 M10 hex head screws (at d3941380
46 Nm
the side)
1 M12 hexagonal nut (below) 110 Nm
2 M12 hex head screws
80 Nm
(silentbloc)

Operating Instructions – EN – 03/2007 143

5 Maintenance
Inspection and maintenance every 500 to 1000 operating hours or once a year

Left side of engine:

1 M12 hex head screw

80 Nm
(silentbloc)
1 M12 hexagonal nut (below) 110 Nm

Top centre of engine:

1 spherical collar nut 110 Nm

2 M12 hex head screws
80 Nm
(silentbloc)

Check fastening for frame, tilt

cylinders and steering axle
¾ Check 6 fastening bolts (M 30) (1) of frame
have a tightening torque of 1350 Nm.
2
¾ Check 4 fastening bolts (M16) (2) of tilt cylin-
ders have a tightening torque of 275 Nm. 2
¾ Check the fastening bolts (M16) on the
steering axle have a tightening torque of
195 Nm. 1

1
1
1 1 d3941377

144 Operating Instructions – EN – 03/2007

 Maintenance 5
Inspection and maintenance every 500 to 1000 operating hours or once a year

Check security of axle clamp and

wheel motors
¾ Check the 4 axle clamp fastening bolts
(M20) (1) with a torque of 540 Nm.
¾ Check the wheel motor fastening bolts
(M16) (arrows) with a torque of 275 Nm.
1 1
To do this, first remove the traction wheels.

1 1 d3941378

Check the steering cylinder and king

pin for security
¾ Check the 4 fastening screws (1)( for tight-
ness.) 2
Torque: 295 Nm
¾ Check the nut (2) on the king pin for tight-
ness.
Torque: 310 Nm 1

d3921345

Operating Instructions – EN – 03/2007 145

5 Maintenance
Inspection and maintenance every 500 to 1000 operating hours or once a year

Check, adjust the lateral drive axle

stops
¾ Check the air space (1) between stop (2)
and chassis (3).
The maximum permitted air gap is 1 mm. The 3 3
gap must be checked at the left and right side
of the axle.
If the air gap is larger the lateral stop must be
adjusted.
¾ Loosen the hex nut (4).
¾ Adjust the lateral stop with hex spanner (5)
until the gap is 1 mm.
1
When the air gap can no longer be adjusted, 2
then the spring element of the axle is worn out.
The spring element must be replaced. Please
contact your authorised dealer.
45 d3941381

¾ Tighten the hex nut (4).

Check the air intake and exhaust

pipes for leaks
¾ Inspect the combustion air intake hose of air
filter for condition and leaks.
If necessary, retighten hose clamps and re-
place any porous hoses.
¾ Check the air intake and exhaust manifolds
at the cylinder head for leaks.
If they prove not to be tight, retighten the fas-
tening bolts or replace the gaskets.
¾ Check the exhaust pipe for leaks at the
manifold and tighten the fastening bolts or
renew the gasket if necessary.

d3941368

146 Operating Instructions – EN – 03/2007

 Maintenance 5
Inspection and maintenance every 500 to 1000 operating hours or once a year

¾ Remove the panel at the counterweight.

¾ Check the mounting, connections and air
tightness of the exhaust pipe in the coun-
terweight, tightening the fastening bolts if
necessary.

1,2

GERM -
ANY

WEST
ZU

¾ Close the panel at the counterweight.

d3941366

Check the hydraulic system for leaks

¾ Raise and secure the floor plate.
¾ Check all unions between oil reservoir, drive
motors, pumps and control valves for leaks.
¾ Tighten connections if necessary.
¾ Check the lift, tilt and steering cylinders for
leaks.
¾ Replace any porous hoses.
¾ Inspect the lines for chafing and replace, if
necessary.
¾ Close the floor plate.

d3941369

Check the operation of the parking

brake
¾ Drive the fork lift truck, carrying its maximum
load, up a gradient of 15 %.

Operating Instructions – EN – 03/2007 147

5 Maintenance
Inspection and maintenance every 500 to 1000 operating hours or once a year

¾ Pull the parking brake handle (1) upwards.

The vehicle must remain stationary.
¾ Switch off the engine.
¾ Release the parking brake handle (1).
The vehicle must remain stationary.

NOTE
If the parking brake fails this test, contact your
authorised dealer.

1 d3921457

148 Operating Instructions – EN – 03/2007

 Maintenance 5
Inspection and maintenance every 3000 operating hours or every 2 years

Inspection and maintenance every 3000 operating hours or every

2 years
Hydraulic system: Renew the filters
Feed and pressure filter

ENVIRONMENT NOTE
Follow the precautions for handling fluids and
lubricants.
¾ Remove the access cover on the left hand
side.
¾ Lower the mast. Loosen the lower fastening
screw (2) and upper fastening screw (1) at
the filter support.
¾ Swing out the filter support.
¾ Place a suitable container beneath the filter.
¾ Loosen the pressure filter housing (3) and
feed filter housing (4) with the hex screw. 4
¾ Remove the filter housings by hand and pull
off the cartridges from the base.
1

ENVIRONMENT NOTE 3
Discard the cartridges in an environmental-
friendly way. 2
d3941383
¾ Coat the filter cartridge seals with oil.
¾ Push the filter cartridges on the base at the
filter head.
¾ Screw the filter housings back in place and
hand-tighten.
Torque to 10+5 Nm, subsequently loosen
¼ turn.
¾ Check the tightness of the filter flange in trial
run.

Operating Instructions – EN – 03/2007 149

5 Maintenance
Inspection and maintenance every 3000 operating hours or every 2 years

Suction filter
CAUTION
It must always be ensured that the oil reaches an
optimum degree of purity.
For the 6000 hour inspection it is important to
change the hydraulic oil before changing the
suction filter. Only this sequence can ensure that
the oil achieves the optimum degree of purity.

¾ Open the bonnet.

¾ Loosen the nuts (3).
1
¾ Remove the strap (4). 3
¾ Loosen and unscrew the filter cover (1).
2
¾ Pull the filter cartridge out slowly.
This allows the oil to flow back into the tank.
¾ Then pull out the filter cartridge completely.
¾ Open the oil filler cap (2).
This allows air to escape so that oil does not
4
overflow when the filter cartridge is installed.
¾ Carefully insert a new filter cartridge into the
filter casing.
Ensure that the cartridge is centred properly at d3941382 3
the bottom of the casing.
¾ Clean the filter cover seal and coat it with oil.
¾ Mount the filter cover in place.
¾ Mount the strap (4) in place and secure with
nuts (3) .
The hydraulic system is bled automatically
with the engine running.
¾ Check the filters for leaks during a trial run.
¾ Close the bonnet.

Breather filter

NOTE
In a dusty atmosphere it may be necessary to
replace the filter earlier.
¾ Open the bonnet.

150 Operating Instructions – EN – 03/2007

 Maintenance 5
Inspection and maintenance every 3000 operating hours or every 2 years

¾ Unscrew the cap with integrated breather

filter (2) from the filler neck of the hydraulic
oil reservoir.
¾ Pull the dipstick (1) out of the breather filter
and mount on the new breather filter.
¾ Screw in the filter and tighten.
¾ Mount the access cover on the left hand
side.
¾ Close the bonnet.

Change the air filter safety element

¾ Change the safety element (1):
• After 2 years of operation at the latest.
• If, after successfully changing the filter el-
ement, the air filter restricted warning light
illuminates again.
• In the event of a defective filter element.
CAUTION
Do not clean or reuse safety elements. Do not start
the engine with the air filter element removed.
The safety element reduces the possibility of dust
intrusion during replacement of the air filter element
or if a damaged air filter element is inadvertently
installed.
2 1
¾ Shut the engine off. d3941346

¾ Open the bonnet.

¾ Remove the air cleaner cover and the filter
element (2).
¾ Pull out the safety element.
¾ Insert the new safety element.
¾ Install the filter element and mount the air
cleaner cover in place.
¾ Close the bonnet.

Operating Instructions – EN – 03/2007 151

5 Maintenance
Inspection and maintenance every 3000 operating hours or every 2 years

Replacing ribbed V-belt

WARNING
Do not touch rotating parts.
Switch off the engine and remove
ignition key.

NOTE
On trucks without air conditioning, first discon-
nect the ribbed V-belt from the alternator and
when reassembling, replace it last. On trucks
with air conditioning, first disconnect the rib-
bed V-belt from the guide pulley and when
reassembling, replace it last. Note the running
direction of the ribbed V-belt.
¾ Open the bonnet.
¾ Remove the maintenance cover on the
right-hand side.
¾ Mark the running direction of the ribbed
V-belt (3). 1 2
¾ Swing away (2) the tensioner pulley, (1)
using a flat 16 AF ring spanner at the ten-
sioning lever.


@@@@
;;;;


@@@@
;;;;
NOTE 
;;;;;;;;;
@@@@@@@@@
 

@@@@
;;;;
;;;;;;;;;
@@@@@@@@@

 

@@@@
;;;;
Observe the running direction of the ribbed ;;;;;;;;;
@@@@@@@@@


V-belt (3).
;;;;;;;;;
@@@@@@@@@


¾ Replace the ribbed V-belt.
¾ Refit the side maintenance cover.
¾ Close the bonnet.
3 d3921458

152 Operating Instructions – EN – 03/2007

 Maintenance 5
Inspection and maintenance every 3000 operating hours or every 2 years

Renew the toothed belt and idler

pulley

NOTE
Special know-how and tools are required for
the renewal of the toothed belt and idler pulley.
Please contact your authorised dealer for this
service.

d3921410

Check the drive axle mounting for

wear

NOTE
The drive axle is mounted in the frame in rub-
ber spring elements on each side.
¾ Remove the drive wheels.
¾ Using a lamp, check the condition of the
rubber spring elements (1) between axle,
chassis and plastic bump stops.
The rubber spring elements must be checked
1 1
on the left and right side at the axle. When the
spring element of the axle or the plastic bump
stop are worn, they must be renewed. Please
contact your authorised dealer.
¾ Install the drive wheels.

d3941385

Operating Instructions – EN – 03/2007 153

5 Maintenance
Inspection and maintenance every 3000 operating hours or every 2 years

Check tilt cylinder bearings for wear

NOTE
The tilt cylinders are mounted in rubber bea-
rings at both ends.
¾ Remove the screw (1) at the disc (2).
1 2
¾ Make a visual inspection of the rubber bear-
ings for cracks.
The rubber should not have any cracks.
¾ Check the rubber bearing at the front and
rear of each tilt cylinder.
When a rubber bearing is worn or damaged,
renew it. Please contact your authorised
dealer.

d3921471

Check hydraulic pump attachment to

the engine
¾ Open the bonnet.
¾ Tighten up the 3 hexagonal head bolts to
the specified tightening torque of 110 Nm.
¾ Close the bonnet.

Check slide guides on sideshift (spe-

cial equipment) for wear
¾ Dismantle sideshift.
¾ Clean sideshift.

154 Operating Instructions – EN – 03/2007

 Maintenance 5
Inspection and maintenance every 3000 operating hours or every 2 years

¾ Remove slide guides from upper guide (1).

¾ Measure wall thickness of slide guide (3).
If the wall thickness is less than 2.5 mm, re-
place slide guides.
¾ Lubricate slide guides.
¾ Reassemble sideshift.
¾ Tilt lift mast forwards and lower fork arms
until they touch the ground, so that sideshift
frame is relieved of the weight of forks.
¾ Grease sideshift at lubricating nipples (2)
and (4).

Check fork arm adjustment device

(special equipment) for wear and
tear
The fork arm adjustment device must only be
dismantled by a specialist using special tools.
Please contact your authorised dealer.

Operating Instructions – EN – 03/2007 155

5 Maintenance
Inspection and maintenance every 6000 operating hours or every 3 years

Inspection and maintenance every 6000 operating hours or every

3 years
Change hydraulic oil
Drain hydraulic oil

ENVIRONMENT NOTE
Observe information about working materials.
¾ Drive truck over pit.
¾ Fully lower fork carriage and lift mast.
¾ Place a collection vessel under the left side
of the truck floor.
¾ Open the motor hood. Unscrew breather
with oil dipstick (2).

¾ Unscrew hydraulic oil drain plug (1) on hy-

draulic oil tank.
¾ Allow all oil to drain off.
¾ Clean area around oil drainage location
thoroughly.
¾ Refit drain plug.
Tightening torque: 25 Nm

d3921335

156 Operating Instructions – EN – 03/2007

 Maintenance 5
Inspection and maintenance every 6000 operating hours or every 3 years

Top up hydraulic oil/refill

¾ Add hydraulic oil to filling port.
Total fill quantity: approx. 27.8 l
¾ Check oil level with dipstick (2) and top up
further until upper marking is reached on
dipstick.
¾ Allow motor to idle for 3 minutes in upper
range (parking brake applied and accelera-
tor pedal depressed).
¾ Check oil level again (do not drive).
Only then should the suction filter be changed.
¾ Close the motor hood.

NOTE
The hydraulic system will bleed itself when the
engine is running.

Operating Instructions – EN – 03/2007 157

5 Maintenance
Inspection and maintenance every 9000 operating hours or every 4 years

Inspection and maintenance every 9000 operating hours or every

4 years
Replace the water pump

NOTE
Special knowledge and special tools are re-
quired for the replacement of the water pump.
Please contact your authorised dealer.

d3921410

Change coolant
The cooling system has to be filled all year
round with a mixture of water and phosphate-
free glycol-based coolant additive with anti-
corrosion additives to prevent the deposit of
lime scale and damage caused by frost and
corrosion, and to raise the boiling tempera-
ture.

WARNING
Never open the cap (2) when the
motor is hot. Risk of scalding!
Wait until the coolant has cooled
down.

ENVIRONMENT NOTE
Observe information about working materials.
¾ Open the motor hood.

158 Operating Instructions – EN – 03/2007

 Maintenance 5
Inspection and maintenance every 9000 operating hours or every 4 years

¾ Place a collection vessel under the coolant

hose (3).
¾ Disconnect coolant hose at cylinder.
¾ Drain off all coolant. Dispose of coolant in
an environmentally friendly manner.
¾ Re-connect coolant hose (3).

3
d3941372

¾ Add new coolant to filling port (1).

Coolant level must be between min. and max.
marking on filler neck.

1 2

1,2

GE WES
RM T-
AN
Y
ZU

d3941360

Operating Instructions – EN – 03/2007 159

5 Maintenance
Inspection and maintenance every 9000 operating hours or every 4 years

¾ Read off filling level in filler neck.

• Min. marking is the edge (4) of the lower 4
step.
• Max. marking is the edge (5) of the upper
step.
5
Difference in quantity between min. and max.:
approx. 0.75 l 5
Fill quantity in cooling system
without heating and air conditioning: 8.5 l
with heating and air conditioning: 10.0 l
The frost protection should be sufficient for
temperatures down to -25 °C. The mixing ratio 4
required here is 40% coolant additive and 60% t3921378
drinking water.
Mixing ratio for lower temperatures:

Coolant Drinking
Temperature
additive water
-30°C 45% 55%
-35°C 50% 50%
-40°C 60% 40%

¾ Run motor until cooling system has been

vented.
¾ Check coolant level.
¾ Fit cap (2) and turn to fix in place.
¾ Close the motor hood.

160 Operating Instructions – EN – 03/2007

 Maintenance 5
Troubleshooting

Troubleshooting
Opening the electrical system cover
Up to 40 fuses can be installed for the protec-
tion of the electric system, depending on the
equipment. The fuse box is accessible after
the removal of the electrical system cover.
¾ Unscrew the two knurled nuts (2).
¾ Remove the cover (1).
¾ Remove the fuse box cover.
1

t3921360

Fuses for basic and special equipment

Check / replace fuses

1 12 V socket-outlet (9F10)*, 15 A 3 Seat heater (9F6)*, 20 A

2 Heating/Air conditioning (9F9)*, 20 A

Operating Instructions – EN – 03/2007 161

5 Maintenance
Troubleshooting

4 Warning light and rotating beacon (4F3)*, 22 Soot filter (7F3)*, 30 A

7.5 A 23 Soot filter (7F2)*, 20 A
5 Working headlight item 3,4 (5F2)*, 15 A 24 Soot filter (7F1)*, 5 A
6 Working headlight item 5,6 (5F3)*, 15 A (with 25 Forklift Data Management (6F1)*, 5 A
attachment of one headlight 7.5 A) 26 Reverse motion (4F1)*, 10 A
7 Working headlight item 7,8 (5F4)*, 15 A (with 27 Radio terminal 58 (9F8)*, 10 A
attachment of one headlight 7.5 A) 28 Radio terminal 30 (9F7)*, 5 A
8 not assigned 29 Wash pumps (9F4)*, 10 A
9 Indicator unit (terminal 30) (F5), 2 A 30 Windscreen wiper rear and roof (9F3)*, 7.5 A
10 Indicator unit (terminal 15) (F6), 2 A 31 Windscreen wiper front (9F2)*, 10 A
11 Alarm horn (F7), 15 A 32 Windscreen wiper (9F1)*, 2 A
12 Traction-lift control (terminal 15) (F8), 2 A 33 Interior light (5F12)*, 5 A
13 Engine control unit (F12), 2 A 34 Brake light (5F7)*, 5 A
14 Engine control unit (F11), 15 A 35 Hazard warning light (5F6/5F13)*, 10 A
15 not assigned 36 Lighting / working headlight item 1, 2
16 Traction-lift control (terminal 30) (F9), 15 A (5F5/5F1)*, 15 A
17 Coolant return-flow pump (F16), 5 A 37 Side lights right (5F11)*, 5 A
18 Terminal 15 (F15), 10 A 38 Sidelights left (5F10)*, 5 A
19 Terminal 58 (F14), 2 A 39 Headlight right (5F9)*, 7.5 A
20 Terminal 30 (F13), max. 15 A 40 Headlight left (5F8)*, 7.5 A
21 not assigned

* Special equipment

Main fuses in the engine compart-

ment
Check/replace fuses
¾ Open the bonnet.
¾ Open the cover of the fuse box.
The MTA fuses in the engine compartment 4
protect the following electric circuits: 3
1
• Fuse (F1) (1) for preheating and fuel sys-
tem, 50 A 2
• Main fuse (F2) (2) for complete electrical
installation, 40 A
• Main fuse (F3) (3) full optional, 70 A
• Fuse (F4) (4) for air conditioning, 30 A

CAUTION
The fuses are designed for use for higher voltage
values. Automotive fuses may not be used.
Only use genuine manufacturer’s fuses.
d3921517

162 Operating Instructions – EN – 03/2007

 Maintenance 5
Troubleshooting

Diagnostic connector
The diagnostic connector can be found under
the cladding on the left behind the driver’s
seat.
¾ When troubleshooting, connect the diag-
nostic device to the diagnostic plug, using
the appropriate diagnostic software . In ad-
dition, truck data can be read in and out,
adjustments made and maintenance inter-
vals reset or amended.
Please contact your authorised dealer.

d3921428

Jump start

NOTE
If the truck battery is discharged, a set of jum-
per cables and a second battery can be used
to start the truck. Observe the following for a
correct connection:
• Both batteries must have the same rated
voltage.
• The capacity (Ah) of the booster battery
should not be substantially lower than the
capacity of the discharged battery.
• Use jumper cables with a sufficient gauge
and insulated jaws.
WARNING
A discharged battery can already freeze at tem-
peratures below 0° In this case the battery can
explode.
Before connecting the jumper cables, a frozen bat-
tery must always be thawed.

¾ Switch off all loads (heater, air conditioner,

lights).

Operating Instructions – EN – 03/2007 163

5 Maintenance
Troubleshooting

¾ Open the bonnet.

¾ Attach one end of the positive lead (1) to
the the positive pole (+) of the discharged
battery (2).
¾ Attach the other end of the positive lead(1)
to the the positive pole (+) of the booster
battery (5).
¾ Attach one end of the negative lead(4) to the
the negative pole (-) of the booster battery
(5).
¾ Attach the other end of the negative lead (4)
as far as possible away from the discharged
battery (2) to a massive metal part firmly
connected to the engine block or to the the
engine block itself (3).

NOTE
In case the booster battery is installed in ano-
ther vehicle, start its engine and let it idle.
¾ Start the engine.
If the engine does not start at once, stop the
starting procedure after 10 seconds and re-
peat it after about half a minute.
¾ While the engine is running, first disconnect
the negative lead (4) from the engine block
(3), then from the battery (5) in the booster
vehicle.
¾ First detach the positive lead (1) from the
booster battery (5), then from the dead bat-
tery (2).

Emergency lowering of fork carriage

If there is a malfunction, the fork carriage can
be lowered manually.
¾ Remove floormat.
DANGER
During lowering no-one should remain in the area
of the fork arms .
During lowering, do not remove the socket wrench
from the screw (1) on the valve block (3) to enable
lowering to be interrupted at any time.

164 Operating Instructions – EN – 03/2007

 Maintenance 5
Troubleshooting

¾ Insert the 8 mm WAF socket wrench through

the opening in the floorplate.
¾ Using the socket wrench slowly rotate the
screw (1) approx. 3 turns anticlockwise
until the fork carriage has been completely
lowered.
¾ Open the motor hood.
¾ Open the floorplate and secure.
¾ Rotate the self-locking nut (2) ap-
prox. 2 turns.

¾ Insert the screw (1) in a clockwise direction

again (tightening torque 10 Nm). Other-
wise, it will not be possible to lift the fork
carriage with the joystick.
¾ Tighten the self-locking nut (2) again (tight-
ening torque 9.5 Nm).
¾ Close floorplate and motor hood.
¾ Put floormat back into position. 1

3 2 d3941386

Emergency exit for trucks with rear

screen
If the truck is fitted with a front and rear wind-
screen, it may not be possible to dismount at
the side if the truck breaks down in a narrow
aisle. In the case of a dangerous situation the
operator can exit the vehicle at the rear wind-
screen. For this purpose, the emergency exit
hammer must be used to destroy the wind-
screen.

Operating Instructions – EN – 03/2007 165

5 Maintenance
Troubleshooting

¾ Bend up the cotter pin (1) on the mounting

(2) underneath the rear wiper motor.

WARNING
Danger of personal injury from glass splinters.
Carefully remove the glass splinter.

¾ Remove the emergency exit hammer (3)

from the mounting and carefully break the
windscreen.
¾ Carefully dismount to the rear.
3

2 1
t3921371

Towing regulations
Towing
If the truck needs to be towed away, the follow-
ing can be brought about by the towing unit:
• short-circuiting of hydraulic oil circuit
• release of multi-disc brakes in drive axle via
brake valve and Stop pedal .

WARNING
Braking of the truck is no longer possible. The par-
king brake does not operate either.
To tow the truck a towing vehicle with sufficient
tractive power and braking force for the unbraked
towed load is thus required. It is only permitted to
tow the truck using a fixed connection (towing rod).

Towing process
¾ Lower the load so that the fork arms do not
scrape on the ground while towing .
¾ Remove load.
¾ Attach towing vehicle (ensure sufficient
tractive power and braking force) to towing
bolt of truck using towing rod .

Open shorting plunger of hydraulics

¾ Open the bonnet.

166 Operating Instructions – EN – 03/2007

 Maintenance 5
Troubleshooting

¾ Release sealing collar nut (1) (size

SW 19 mm) on left on the variable pump
with socket on housing.
¾ Unscrew threaded stud (2) (SW 8 mm)
2 turns with socket .
¾ Lock threaded stud with sealing collar nut
(1), tighten to 50 Nm.
2
¾ Close the bonnet.

Release multi-disc brake

1
The brake valve can be found under the floor-
plate on the truck frame on the left.
¾ Remove floor mat.
d3941332

¾ Insert Allen key (SW 5 mm) through hole

in the floorplate and unscrew socket head
screw (3) about 8 turns.
¾ Sit on driver’s seat.
¾ Press down handle of parking brake.
The symbol on the indicator unit will go out.
3
¾ Move Stop pedal several times in easy-
movement range until resistance is felt
(pump max. 10 strokes) until brake is re-
leased .

After towing
¾ Place chocks underneath on side facing
downhill. d3921511

¾ Open the bonnet.

¾ Loosen sealing collar nut (1) on variable
pump.
¾ Screw in threaded stud (2) (SW 8 mm),
tighten to 20+5 Nm.
¾ Lock threaded stud with sealing collar nut
(1).
¾ Tighten nut to 50 Nm.

Restore braking
¾ Insert socket head screw (3) until stop in
valve block.

Operating Instructions – EN – 03/2007 167

5 Maintenance
Troubleshooting

¾ Replace floor mat and close bonnet.

DANGER
The forklift truck must not be driven if the braking
system is defective.
After repairs to the braking system, check opera-
tion. If defects in the braking system occur , contact
your authorised dealer.

Placing the forklift truck into storage

Actions prior to placing the forklift truck
into storage
If the vehicle is to be placed into storage for
more than 2 months e. g. for operational
reasons, it should be stored only in a well
ventilated, clean and dry room free of frost,
and the following measures undertaken
beforehand.
¾ Clean forklift truck thoroughly.
¾ Raise fork carriage several times to the
end stop, move lift mast backwards and
forwards a few times and operate any
attachments several times.
¾ Lower the fork carriage to a supporting
surface until the chains are relieved of load.
¾ Check the hydraulic oil level and top up if
necessary.
¾ Fill up with fuel.
¾ All unpainted mechanical components
should be coated with a thin film of oil or
grease.
¾ Grease vehicle.
¾ Disconnect the battery.
¾ Check battery condition and density of acid.
¾ Lubricate battery terminals with acid-free
grease. (Follow instructions of battery
manufacturer.)
¾ Apply a suitable contact spray to all exposed
electrical contacts.
¾ Jack up the vehicle so all wheels are off the
ground.
This will prevent permanent deformation of the
tyres.
NOTE
Do not cover with plastic foil or this will en-
courage the formation and collection of con-
densed water.
NOTE
If the vehicle is to be shut down for more than
6 months, further measures should be agreed
with your authorised dealer.
Bringing back into service after storage
¾ Clean forklift truck thoroughly.
¾ Lubricate the forklift truck.
¾ Connect the battery.
¾ Clean the battery and lubricate battery
terminals with acid-free grease
¾ Check battery condition and specific gravity
of acid and recharge if necessary.
¾ Check engine oil for condensed water,
change if necessary. Check hydraulic oil for
condensed water, change if necessary.
¾ Perform maintenance as before initial
commissioning.
¾ Put forklift truck into service.

168 Operating Instructions – EN – 03/2007


Disposal of old vehicles
The disposal of old vehicles is regulated
in directive 2000/53/EC of the European
Parliament and Council.
We recommend having this work carried out
by an authorised salvager. If you want to do
this yourself, you must, according to Articles
9, 10 and 11 the directive 75/442/EEC, obtain
a permit from the responsible authorities.
The following minimum requirements must
also be observed:
• The storage locations for old vehicles
before their processing must be suitable
areas with an impermeable surface. They
must be provided with collecting facilities
and separators for fluids running out and
grease-cutting cleaning agents.
• The processing locations must be suitable
areas with an impermeable surface. They
must be provided with collecting facilities
and separators for fluids running out and
grease-cutting cleaning agents. Suitable
storerooms for removed parts and parts
Operating Instructions – EN – 03/2007
Maintenance 5
Troubleshooting
partially smeared with oil 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
conditioners must also be available.
• For the disposal of harmful substances from
the old vehicles, the batteries and LPG bot-
tle/tanks must be removed. The following
must also be removed, collected and stored
separately: fuel, engine oil, coolant, hy-
draulic oil, fluids from air conditioners.
• The following parts can be collected and
recycled separately: catalytic converters,
metal parts containing copper and alu-
minium, tyres, big plastic parts (console,
fluid reservoirs), glass.
NOTE
The owner is responsible for the compliance
with the directives and further national regula-
tions.
169
5 Maintenance
Troubleshooting

Malfunctions during operation

CAUTION
If one of the following indicator lights lights up in
the indicator unit and the buzzer sounds during
operation, a malfunction has occurred.
The engine must be switched off immediately and
the malfunction dealt with. (See: Malfunctions,
Causes and Remedy)

• Hydraulic oil temperature indicator (1) and

buzzer
• (2) Battery charge indicator
• Engine oil pressure indicator (3) and/or
engine oil level indicator and buzzer
• Indicator light: error in electrical control
system (4)
• Engine temperature indicator (5) and
buzzer
• Level display (7) (special equipment)
• Coolant level indicator (12) (special equip-
ment)
• Hydraulic oil microfilter (8) (special equip-
ment)

CAUTION
Only if additional equipment soot filter system is
fitted: If, depending on version, the orange indicator
light (15) flashes and the buzzer sounds, or the load
indicator (9) flashes and the red soot filter alarm (6)
lights up and the buzzer sounds, the filter is loaded.
The soot filter must be regenerated immediately.

NOTE
• Only if additional equipment soot filter is
fitted: If, depending on version, the orange
indicator light (15) lights up or the soot filter
load indicator (9) flashes and the buzzer
sounds at intervals, the soot filter must be
regenerated within the next 30 minutes.
• Only if additional equipment soot filter is
fitted: In the event of an error during the
regeneration procedure, the orange indica-
tor light (15) and the red indicator light (14)
flash alternately, or the soot filter alarm (6)
lights up and text field (10) of the indicator
unit displays an error code, depending on
version. Restart regeneration procedure.

170 Operating Instructions – EN – 03/2007

 Maintenance 5
Troubleshooting

• If the indicator light (4) flashes, there is an

error in the electrical control system. De-
pending on the setting and error, it may only
be possible to drive the forklift truck at low
speed, or not at all. Each error is indicated
by a numerical code or symbols in text field
(10). Please contact your authorised dea-
ler.
• If the indicator light (13) flashes, there is an
error in the engine or the engine control unit.
Switch off the engine. Please contact your
authorised dealer.
• If the air filter vacuum indicator (11) lights
up on the indicator unit, maintenance must
be performed on the air filter.
• Only with attachment of a 3rd auxiliary hy-
draulics: If the switchable additional func-
tion is blocked or the forklift truck only tra-
vels at crawling speed, or the text field (10)
shows error code L247 and the buzzer
sounds, a malfunction has occurred in the
safety system. Please contact your authori-
sed dealer.

Operating Instructions – EN – 03/2007 171

5 Maintenance
Troubleshooting

Malfunctions, Causes and Remedy (diesel engine)

Engine will not start

Possible cause Correction
Fuel tank empty. Fill up the tank.
Fuel filter clogged, caused in winter by paraffin
Renew the filter. Use winter fuel.
wax segregation.
Water in the fuel filter. Clean water out of the fuel filter.
Check with test lamp whether power present; if
Fuel shut-off valve does not open.
not, check the fuse and the valve.
Immobiliser active. Contact your authorised dealer.
Check all fuel line connections for leaks and
Leak in fuel line.
tighten clamping screws.
Tighten connection terminals at the battery,
The indicator unit does not light up.
check wiring connections.
Check the power supply, lines and connections
on the glow plug starting switch. If the fault
Preheating system defective.
cannot be remedied, please contact your
authorised dealer.
Fuel pump defective.
This fault should be checked and remedied
Fuel injectors defective.
only by a trained technician. Please contact
Injection pump defective.
your authorised dealer.
Engine idling speed incorrect.

Warning lamp for "electrical control system fault" lights up.

Possible cause Correction
Defect can be determined using the diagnos-
Defect in electrical control system
tics tester. Contact your authorised dealer.

Engine starting performance is poor

Possible cause
Battery power too low. Battery terminals loose
or oxidised, causing the starter motor to turn
only slowly.
Fuel supply insufficient. Blockages or air locks
in the fuel system, caused during winter by
paraffin wax segregation.
Especially in winter: engine oil used is too
viscous.
Correction
Have the battery checked, clean the connec-
tion terminals, tighten them and smear them
with acid-free grease.
Renew fuel filter, check fuel line connections
for leaks and tighten clamping screws. In cold
climates, use winter fuel.
Use engine oil appropriate to the external
temperature.

172 Operating Instructions – EN – 03/2007


Soot filter system warning light flashes and buzzer sounds when ignition is switched on.
Possible cause
Switch illumination in the start switch and
emergency stop switch for the soot filter
defective.
Fault in soot filter system.
"Soot filter alarm" indicator light lights up and the vehicle only moves in crawling speed.
Possible cause
Load period of the soot filter exceeds 8.5 h.
Engine runs rough and loses power.
Possible cause
Fuel supply insufficient. Blockages or air locks
in the fuel system, caused during winter by
paraffin wax segregation.
Fuel injector pump overflow valves not operat-
ing correctly.
Fuel injectors defective.
Engine oil level too high.
Very smoky exhaust.
Possible cause
Bad sealing by coked or broken piston rings.
Irregular idling.
Possible cause
Fuel supply problems.
Engine speed incorrectly set.
Fuel hose between fuel injector pump and fuel
filter loose.
Operating Instructions – EN – 03/2007
Maintenance 5
Troubleshooting
Correction
Check the light: switch on glow plug starting
switch using ignition key. Both switch illumina-
tions briefly light up 1x, if not, replace indicator
light. (Regeneration can still be performed
even though the lamp is defective; acknowl-
edge by pressing the start switch).
Please contact your authorised dealer.
Correction
Regenerate soot filter immediately.
Correction
Renew fuel filter, check fuel line connections
for leaks and tighten clamping screws. In cold
climates, use winter fuel.
Contact your authorised dealer.
Contact your authorised dealer.
Drain oil until oil level at upper dipstick mark.
Correction
Contact your authorised dealer.
Correction
Drain water from fuel filter, or exchange it.
Check fuel lines or fuel injector lines for leaks.
This setting should only be made by a trained
technician. Contact your authorised dealer.
Check connections for tightness, exchange
hose if necessary.
173
5 Maintenance
Troubleshooting

Engine overheating, red warning lamp in the indicator unit lights up. Switch off engine immedi-
ately.
Possible cause Correction
Check the cooling system for leaks, seal them
Insufficient coolant fluid in the system
as required. Top up the coolant.
Coolant pump defective. Contact your authorised dealer.
Radiator matrix partially clogged by dirt or
Clean water and hydraulic oil coolers.
foreign bodies.
Injection system setting incorrect. Contact your authorised dealer.

Engine oil pressure too low. Switch off engine immediately.

Possible cause Correction
Leaks in the lubrication system. Contact your authorised dealer.
Oil level too low Top up with engine oil

Charging lamp comes on when truck is in operation.

Possible cause Correction
Alternator speed too low. Check V drive belt tension.
Alternator fails to charge the battery, alternator
Contact your authorised dealer.
or control switch defective.

Truck only moves in crawling speed, the buzzer sounds and error code X201 is displayed in the
text field of the indicator unit.
Possible cause Correction
Engine oil level too low. Top up engine oil.

Truck only moves in crawling speed, the buzzer sounds and error code X202 is displayed in the
text field of the indicator unit.
Possible cause Correction
Top up engine oil, if the error persists, contact
Engine oil pressure too low.
your authorised dealer.

Truck only moves in crawling speed, the buzzer sounds and error code X203 is displayed in the
text field of the indicator unit.
Possible cause Correction
Coolant level too low. Top up coolant.

174 Operating Instructions – EN – 03/2007

 Maintenance 5
Troubleshooting

Truck only moves in crawling speed, the buzzer sounds and error code X204 is displayed in the
text field of the indicator unit.
Possible cause Correction
Top up coolant. Water pump defective. Clean
Raised engine temperature.
the radiator. Adjust the fuel injection system.

Operating Instructions – EN – 03/2007 175

5 Maintenance
Troubleshooting

Malfunctions, causes, remedies (hydraulic equipment)

Abnormal noises.
Possible cause Correction
Clogged suction filter. Replace the filter.
Seal the pipe line. Check the hydraulic oil level,
Leaks in the suction pipe line, oil foaming.
top up as necessary.
Hydraulic pump or motor damage, defective Have the hydraulic power unit checked by your
seals, causing air to be drawn in. authorised dealer.
Incorrect oil viscosity, insufficient oil in the tank Change the hydraulic oil; ensure the oil has the
or hydraulic pump. specified viscosity. Top up hydraulic oil.

No pressure or insufficient pressure in the system.

Possible cause
Suction line damaged, noisy.
Defective pump, loss of pressure, pressure
valves fail to close, valve seat damaged.
Pipe line broken or leaking.
Oil too thin, causing excessive leakage losses.
Oil temperature indicator lights up.
Correction
Change the hydraulic oil, top up the hydraulic
oil.
Contact your authorised dealer.
Replace pipe line or seal it.
Change the hydraulic oil; ensure the oil has the
specified viscosity.
Check hydraulic oil level, clean hydraulic oil
cooler.

Oil pressure fluctuations.

Possible cause Correction
Causes as for abnormal noises. See under abnormal noises.
Pressure relief valve or feed pressure valves
Please contact your authorised dealer.
jamming.
Lift and tilt cylinders exhibit chafe points. Please contact your authorised dealer.
Lift mast does not extend fully, or leans back
Top up hydraulic oil. Bleed the cylinders.
somewhat.

No flow or insufficient flow.

Possible cause Correction
Clogged filters (if noises also occur at the same
Clean the filter or replace it.
time).
Defective pump, loss of pressure, pressure
Contact your authorised dealer.
valves fail to close, valve seat damaged.
Pipe line broken or leaking. Replace pipe line or seal it.

176 Operating Instructions – EN – 03/2007


No flow or insufficient flow.
Possible cause
Valves clogged.
Hydraulic system overheats.
Hydraulic oil temperature too high.
Possible cause
Pump damage, valves leaking.
Insufficient oil in the tank or oil cooler clogged.
Truck is still running only at crawling speed, the buzzer sounds and error code X205 is displayed
in the text field of the indicator unit
Possible cause
Hydraulic oil temperature too high.
Malfunction in the third auxiliary hydraulic system (special equipment).
Possible cause
Truck running in crawler mode.
Error code L 247 is displayed in the indicator
unit and the buzzer sounds.
Switchable auxiliary hydraulic functions are
blocked.
Operating Instructions – EN – 03/2007
Maintenance 5
Troubleshooting
Correction
Contact your authorised dealer.
Check the hydraulic oil level, use the specified
hydraulic oil, clean the hydraulic oil cooler.
Correction
Contact your authorised dealer.
Check the hydraulic oil level, top up with
hydraulic oil if necessary. Clean the hydraulic
oil cooler and check for leaks, if defective
contact your authorised dealer.
Correction
Check the hydraulic oil level Clean the hy-
draulic oil cooler.
Correction
Solenoid valve slider jamming.
Wiring damaged.
Short circuit.
Please contact your authorised dealer.
177
5 Maintenance
Troubleshooting

178 Operating Instructions – EN – 03/2007

 6

Technical data
6 Technical data
Technical data

Technical data
Type sheet E 40, Issue 11/2006

1 Identification
1.1 Manufacturer (abbreviation) Linde
1.2 Manufacturer’s model designation H 40 D
1.3 Drive: electric, diesel, petrol, LPG, mains electric Diesel
Operation: manual, accompanied, stand, seated,
1.4 Seat
order picking
1.5 Capacity/load Q [kg] 4000
1.6 Load centre-of-gravity distance c [mm] 500
1.8 Load distance x [mm] 483
1.9 Wheelbase y [mm] 1998

2 Weight
2.1 Tare weight kg 5785
2.2 Axle weight with front/rear load kg 8610 / 1180
2.3 Axle weight without front/rear load kg 2640 / 3145

3 Wheels, tyres
3.1 Solid rubber tyres SE, air, polyurethane SE (L)
3.2 Front tyre size 250-15-SC 15
3.3 Rear tyre size 250-15-SC 15
3.5 Wheels, number front/rear (x = driven) 2x (4x)/21
3.6 Front track width b10 [mm] 1221 (1499)2
3.7 Rear track width b11 [mm] 1122

4 Basic dimensions
4.1 Forward/reverse lift mast/fork carriage tilt α/β (°) 5.0/9.0
2420
4.2 Height lift mast retracted h1 [mm]
(2375/2375)3,4

1 Bracketed value with dual tyres.

2 Bracketed values with SE dual tyres 250-15.
3 With 150 mm free lift on standard lift mast.
4 Bracketed value for duplex and triplex lift mast.

180 Operating Instructions – EN – 03/2007

 Technical data 6
Technical data

4 Basic dimensions
4.3 Free lift h2 [mm] 150 (1611/1614)5
3100
4.4 Lift h3 [mm]
(3130/4675)6,7
3895
4.5 Height with lift mast extended h4 [mm]
(3895/5436)8,9
4.7 Height to top of overhead guard (cab) h6 [mm] 2383
4.8 Sitting height/standing height h7 [mm] 1226
4.12 Coupling height h10 (mm) 703
4.19 Total length l1 (mm) 3984
4.20 Length including fork back l2 (mm) 2984
1446/1423
4.21 Maximum length b1/b2 [mm]
(2003/1423)10
4.22 Fork dimensions s/e/l [mm] 50 x 120 x 1000
4.23 Fork carriage DIN 15173, class/form A, B 3A
4.24 Fork carriage width b3 [mm] 1350 (1750)11
4.31 Ground clearance with load under lift mast m1(mm) 158
4.32 Ground clearance centre of wheelbase m2(mm) 201
4.33 Working width for pallet 1000x1200 transverse Ast (mm) 4355
4.34 Working width for pallet 800x1200 longitudinal Ast (mm) 4555
4.35 Turning radius Wa (mm) 2672
4.36 Smallest pivot point radius b13 (mm) 700

5 Performance data
5.1 Truck speed with/without load km / h 21/21
5.2 Lifting speed with/without load m/s 0.53/0.56
5.3 Lowering speed with/without load m/s 0.52/0.57
5.5 Pulling force with/without load N 28541 / 20570

5 Bracketed value for duplex and triplex lift mast.

6 With 150 mm free lift on standard lift mast.
7 Bracketed value for duplex and triplex lift mast.
8 With 150 mm free lift on standard lift mast.
9 Bracketed value for duplex and triplex lift mast.
10 Bracketed values with SE dual tyres 250-15.
11 Bracketed value with dual tyres.

Operating Instructions – EN – 03/2007 181

6 Technical data
Technical data

5 Performance data
5.7 Climbing capability with/without load %12 29.0 / 34.0
5.9 Acceleration time with/without load S. 5.7 / 4.8
5.10 Service brake Hydrostatic

7 Drive/Engine
7.1 Engine manufacturer / type VW / BJC
7.2 Engine output as per ISO 1585 kW 53
7.3 Rated rpm rpm 2800
3
7.4 Number of cylinders/capacity cm 4 / 1896
7.5 Fuel consumption according to VDI cycle l/h 4.613

8 Miscellaneous
Hydrostat./con-
8.1 Type of traction control
tinuously variable
8.2 Working pressure for equipment bar 170
8.3 Oil volume for add-on devices l/min 48
8.4 Noise level in driver’s ear dB (A) 79 (75)14
8.5 Towing hook, type/DIN model DIN 15170-H

12 On short slopes, driving over obstacles (see section: Driving).

13 Due to a change in the measuring procedure in VDI standard 2198,
the value stated is higher when compared to previous data.
14 Bracketed value with overhead guard 6 (cab).

182 Operating Instructions – EN – 03/2007

 Technical data 6
Technical data

Type sheet H 45, Issue 11/2006

1 Identification
1.1 Manufacturer (abbreviation) Linde
1.2 Manufacturer’s model designation H 45 D
1.3 Drive: electric, diesel, petrol, LPG, mains electric Diesel
Operation: manual, accompanied, stand, seated,
1.4 Seat
order picking
1.5 Capacity/load Q [kg] 4500
1.6 Load centre-of-gravity distance c [mm] 500
1.8 Load distance x [mm] 525
1.9 Wheelbase y [mm] 2038

2 Weight
2.1 Tare weight kg 6295
2.2 Axle weight with front/rear load kg 9555 / 1285
2.3 Axle weight without front/rear load kg 2790 / 3505

3 Wheels, tyres
3.1 Solid rubber tyres SE, air, polyurethane SE (L)
3.2 Front tyre size 300-15-SC 15
3.3 Rear tyre size 250-15-SC 15
3.5 Wheels, number front/rear (x = driven) 2x (4x)/215
3.6 Front track width b10 [mm] 1190 (1499)16
3.7 Rear track width b11 [mm] 1122

4 Basic dimensions
4.1 Forward/reverse lift mast/fork carriage tilt α/β (°) 5.0/9.0
2421
4.2 Height lift mast retracted h1 [mm]
(2376/2376)17,18
4.3 Free lift h2 [mm] 150 (1460/1460)19

15 Bracketed value with dual tyres.

16 Bracketed values with SE dual tyres 8.25-15.
17 With 150 mm free lift on standard lift mast.
18 Bracketed value for duplex and triplex lift mast.
19 Bracketed value for duplex and triplex lift mast.

Operating Instructions – EN – 03/2007 183

6 Technical data
Technical data

4 Basic dimensions
3000
4.4 Lift h3 [mm]
(3030/4525)20,21
3916
4.5 Height with lift mast extended h4 [mm]
(3946/5441)22,23
4.7 Height to top of overhead guard (cabin) h6 [mm] 2416
4.8 Sitting height/standing height h7 [mm] 1264
4.12 Coupling height h10 (mm) 726
4.19 Total length l1 (mm) 4066
4.20 Length including fork back l2 (mm) 3066
1448/1423
4.21 Maximum length b1/b2 [mm]
(1988/1423)24
4.22 Fork dimensions s/e/l [mm] 50 x 120 x 1000
4.23 Fork carriage DIN 15173, class/form A, B 3A
4.24 Fork carriage width b3 [mm] 1350 (1750)25
4.31 Ground clearance with load under lift mast m1(mm) 205
4.32 Ground clearance centre of wheelbase m2(mm) 236
4.33 Working width for pallet 1000x1200 transverse Ast (mm) 4433
4.34 Working width for pallet 800x1200 longitudinal Ast (mm) 4633
4.35 Turning radius Wa (mm) 2708
4.36 Smallest pivot point radius b13 (mm) 700

5 Performance data
5.1 Truck speed with/without load km / h 24/24
5.2 Lifting speed with/without load m/s 0.53/0.56
5.3 Lowering speed with/without load m/s 0.52/0.57
5.5 Pulling force with/without load N 25285 / 21841
5.7 Climbing capability with/without load %26 22.0/32.0

20 With 150 mm free lift on standard lift mast.

21 Bracketed value for duplex and triplex lift mast.
22 With 150 mm free lift on standard lift mast.
23 Bracketed value for duplex and triplex lift mast.
24 Bracketed values with SE dual tyres 8.25-15.
25 Bracketed value with dual tyres.
26 On short slopes, driving over obstacles (see section: Driving).

184 Operating Instructions – EN – 03/2007

 Technical data 6
Technical data

5 Performance data
5.9 Acceleration time with/without load s6.0 6.0 / 5.2
5.10 Service brake Hydrostatic

7 Drive/Engine
7.1 Engine manufacturer / type VW / BJC
7.2 Engine output as per ISO 1585 kW 53
7.3 Rated rpm rpm 2800
3
7.4 Number of cylinders/capacity cm 4 / 1896
7.5 Fuel consumption according to VDI cycle l/h 4.827

8 Miscellaneous
Hydrostat./con-
8.1 Type of traction control
tinuously variable
8.2 Working pressure for equipment bar 170
8.3 Oil volume for attachments l/min 48
8.4 Noise level in driver’s ear dB (A) 79 (75)28
8.5 Towing hook, type/DIN model DIN 15170-H

27 Due to a change in the measuring procedure in VDI standard 2198,

the value stated is higher when compared to previous data.
28 Bracketed value with overhead guard 6 (cab).

Operating Instructions – EN – 03/2007 185

6 Technical data
Technical data

Type sheet H 50-500, Issue 11/2006

1 Identification
1.1 Manufacturer (abbreviation) Linde
1.2 Manufacturer’s model designation H 50 D
1.3 Drive: electric, diesel, petrol, LPG, mains electric Diesel
Operation: manual, accompanied, stand, seated,
1.4 Seat
order picking
1.5 Capacity/load Q [kg] 5000
1.6 Load centre-of-gravity distance c [mm] 500
1.8 Load distance x [mm] 535
1.9 Wheelbase y [mm] 2078

2 Weight
2.1 Tare weight kg 6580
2.2 Axle weight with front/rear load kg 10371 / 1209
2.3 Axle weight without front/rear load kg 2880 / 3700

3 Wheels, tyres
3.1 Solid rubber tyres SE, air, polyurethane SE (L)
3.2 Front tyre size 300-15-SC 15
3.3 Rear tyre size 250-15-SC 15
3.5 Wheels, number front/rear (x = driven) 2x (4x)/229
3.6 Front track width b10 [mm] 1190 (1499)30
3.7 Rear track width b11 [mm] 1122

4 Basic dimensions
4.1 Forward/reverse lift mast/fork carriage tilt α/β (°) 5.0/9.0
2421
4.2 Height lift mast retracted h1 [mm]
(2376/2376)31,32
4.3 Free lift h2 [mm] 150 (1460/1460)33

29 Bracketed value with dual tyres.

30 Bracketed values with SE dual tyres 8.25-15.
31 With 150 mm free lift on standard lift mast.
32 Bracketed value for duplex and triplex lift mast.
33 Bracketed value for duplex and triplex lift mast.

186 Operating Instructions – EN – 03/2007

 Technical data 6
Technical data

4 Basic dimensions
3000
4.4 Lift h3 [mm]
(3030/4525)34,35
3916
4.5 Height with lift mast extended h4 [mm]
(3946/5441)36,37
4.7 Height to top of overhead guard (cabin) h6 [mm] 2416
4.8 Sitting height/standing height h7 [mm] 1264
4.12 Coupling height h10 (mm) 719
4.19 Total length l1 (mm) 4116
4.20 Length including fork back l2 (mm) 3116
1448/1423
4.21 Maximum length b1/b2 [mm]
(1988/1423)38
4.22 Fork dimensions s/e/l [mm] 60 x 130 x 1000
4.23 Fork carriage DIN 15173, class/form A, B 3A
4.24 Fork carriage width b3 [mm] 1350 (1750)39
4.31 Ground clearance with load under lift mast m1(mm) 203
4.32 Ground clearance centre of wheelbase m2(mm) 235
4.33 Working width for pallet 1000x1200 transverse Ast (mm) 4480
4.34 Working width for pallet 800x1200 longitudinal Ast (mm) 4680
4.35 Turning radius Wa (mm) 2745
4.36 Smallest pivot point radius b13 (mm) 700

5 Performance data
5.1 Truck speed with/without load km / h 24/24
5.2 Lifting speed with/without load m/s 0.48/0.50
5.3 Lowering speed with/without load m/s 0.50 / 0.56
5.5 Pulling force with/without load N 25285 / 22375
5.7 Climbing capability with/without load %40 21.0 / 32.0

34 With 150 mm free lift on standard lift mast.

35 Bracketed value for duplex and triplex lift mast.
36 With 150 mm free lift on standard lift mast.
37 Bracketed value for duplex and triplex lift mast.
38 Bracketed values with SE dual tyres 8.25-15.
39 Bracketed value with dual tyres.
40 On short slopes, driving over obstacles (see section: Driving).

Operating Instructions – EN – 03/2007 187

6 Technical data
Technical data

5 Performance data
5.9 Acceleration time with/without load S. 6.2 / 5.5
5.10 Service brake Hydrostatic

7 Drive/Engine
7.1 Engine manufacturer / type VW / BJC
7.2 Engine output as per ISO 1585 kW 53
7.3 Rated rpm rpm 2800
3
7.4 Number of cylinders/capacity cm 4 / 1896
7.5 Fuel consumption according to VDI cycle l/h 5.041

8 Miscellaneous
Hydrostat./con-
8.1 Type of traction control
tinuously variable
8.2 Working pressure for equipment bar 170
8.3 Oil volume for add-on devices l/min 48
8.4 Noise level in driver’s ear dB (A) 79 (75)42
8.5 Towing hook, type/DIN model DIN 15170-H

41 Due to a change in the measuring procedure in VDI standard 2198,

the value stated is higher when compared to previous data.
42 Bracketed value with overhead guard 6 (cab).

188 Operating Instructions – EN – 03/2007

 Technical data 6
Technical data

Load diagrams and lift mast data Issue 11/2006

Operating Instructions – EN – 03/2007 189

6 Technical data
Technical data

Load diagrams apply to trucks with standard

and duplex masts equipped as per type sheet.

Standard lift mast (in mm)

Overall heights h 1 H 40 - 2420 2470 2720 2920 3070 3370 5570
retracted with
specified free H 45/50 2421 2471 2521 2771 2971 3121 3421 3621
lift
Free lift h 2 H 40-50 150 150 150 150 150 150 150 150
Lift h 3 H 40-50 3000 3100 3200 3700 4100 4400 5000 5400
Overall height h 4 H 40 - 3895 3995 4495 4895 5195 5795 6195
extended
H 45/50 3916 4016 4116 4616 5016 5316 5916 6316

190 Operating Instructions – EN – 03/2007

 Technical data 6
Technical data

Duplex lift mast (in mm)

Overall heights retracted with h1 H 40 - 2375 2675 2875
specified free lift
H 45/50 2376 2426 2726 2926
Free lift h2 H 40 - 1611 1911 2111
H 45/50 1460 1510 1810 2010
Lift h3 H 40-50 3030 3130 3730 4130
Overall height extended h4 H 40 - 3894 4494 4894
H 45/50 3946 4046 4646 5046

Triplex lift mast (in mm)

Overall heights retracted h1 H 40 - 2375 2625 2825 2975
with specified free lift
H 45/50 2376 2426 2676 2876 3026
Free lift h2 H 40 - 1614 1864 2064 2214
H 45/50 1460 1510 1760 1960 2110
Lift h3 H 40-50 4525 4675 5365 5865 6315
Overall height extended h4 H 40 - 5436 6426 6626 7076
H 45/50 5441 5591 6281 6781 7231

Noise emission values

Calculated in the test cycle in accordance with Sound power level
EN 12053 from the weighted values for the
in IDLING mode LWb = 85 dB (A)
TRACTION, LIFT and IDLING modes.
in DRIVE mode LWc = 98 dB (A)
Acoustic pressure level in the driver’s
compartment
Uncertainty KWA = 2 dB (A)
H 40, H 45,
LPAZ = 79 dB (A)
H 50-500
in LIFT mode LPa = 82 dB (A) Guaranteed sound power level

in IDLING mode LPb = 70 dB (A) in accordance

with 200/14/EC LWA = 99 dB (A)
in DRIVE mode LPc = 83 dB (A) Directive
Uncertainty KPA = 4 dB (A)
Under the terms of the directive, it is a statutory
requirement to provide this information. The
Sound power level value is calculated from the sound power
H 40, H 45, levels of the "Lift" and "Drive" modes. It
LWAZ = 94 dB (A) can only be used as a comparative value
H 50-500
for different forklift trucks. The value is less
in LIFT mode LWA = 97 dB (A) suitable for determining real environmental

Operating Instructions – EN – 03/2007 191

6 Technical data

impact levels, as it is not representative for operation, factors in the surrounding area and
normal operation, which includes "Idling" other noise sources.
mode.

NOTE
Lower or higher noise values may occur when
using industrial trucks due to the method of

Vibration characteristic values for bodily vibrations

The values were determined according to EN Specified vibration characteristic for hand-
13059 using trucks with standard equipment arm vibrations
according to the data sheet (driving over test Vibration characteristic < 2.5 m/s2
course with humps).

Specified vibration characteristic as per EN NOTE

12096
The vibration characteristic for bodily vibra-
Measured
tions cannot be used to determine the actual
vibration aW.ZS = 0.9 m/s2
load level of vibrations during operation. This
characteristic
depends on the operating conditions (state
Insecurity K = 0.3 m/s2 of pathway, method of operation etc.) and
should therefore be determined on site, where
appropriate. It is mandatory to specify the
hand-arm vibrations even where the values do
not indicate any hazard, as in this case.

192 Operating Instructions – EN – 03/2007


A Battery grease . . . . . . . . . . . . . . . . . .
Actions prior to placing the forklift truck
into storage . . . . . . . . . . . . . . . . 168
Activate the clamp
Central lever operation . . . . . . . . . . . 48
Activate the fork arm adjustment device
Central lever operation . . . . . . . . . . . 48
Add more fuel . . . . . . . . . . . . . . . . . . . . 94
Adjust the lift chain length
Duplex or triplex mast . . . . . . . . . . . 141
Standard mast . . . . . . . . . . . . . . . . 140
Adjust the lordotic support . . . . . . . . . . . 57
Adjust the steering column . . . . . . . . . . . 27
Adjusting for the operator’s
weight . . . . . . . . . . . . . . . . . . 25, 57
Adjusting the armrest on the operator’s
seat . . . . . . . . . . . . . . . . . . . . . . . 26
Adjusting the driver’s seat . . . . . . . . . . . . 24
Adjusting the driver’s seat with air
cushioning . . . . . . . . . . . . . . . . . . 57
Adjusting the fork spread . . . . . . . . . . . . 72
Adjusting the lumber support . . . . . . . . . 25
Adjusting the seat angle of tilt . . . . . . . . . 26
Adjusting the swivel seat . . . . . . . . . . . . 56
After towing . . . . . . . . . . . . . . . . . . . . . 167
air conditioning . . . . . . . . . . . . . . . . . . . 64
Air conditioning
maintenance . . . . . . . . . . . . . . . . . . 118
switch on . . . . . . . . . . . . . . . . . . . . . 64
Air filter
change element . . . . . . . . . . . 107, 136
an accumulator . . . . . . . . . . . . . . . . . . . 12
Apply the
parking brake . . . . . . . . . . . . . . . . . . 45
Attach additional consumers . . . . . . . . . . 61
Attachments
Instructions before fitting . . . . . . . . . . 12
Axle clamp, check security of . . . . . . . . 145
B operation . . . . . . . . . . . . . . . . . . 136
Backrest adjustment . . . . . . . . . . . . 25, 58
Backrest extension adjustment . . . . . . . . 26
Operating Instructions – EN – 03/2007
Index
g
. . 92
Battery: Check condition, level and
density of acid . . . . . . . . . . . . . . 126
Before taking up a load . . . . . . . . . . . . . . 71
Bio-hydraulic oil . . . . . . . . . . . . . . . . . . . 91
Bringing back into service after storage . 168
Bucket operation . . . . . . . . . . . . . . . . ... 5
C
Chain spray . . . . . . . . . . . . . . . . . . . . . . 92
Change
hydraulic oil . . . . . . . . . . . . . . . . . . . 156
Change coolant . . . . . . . . . . . . . . . . . . 158
Change fuel
filter . . . . . . . . . . . . . . . . . . . . . . . . 128
Change motor
oil . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Change the breather filter . . . . . . . . . . . 150
Change the safety element . . . . . . 108, 151
Change the suction filter . . . . . . . . . . . . 150
Changing the direction of travel . . . . . 34, 41
Check
fuses . . . . . . . . . . . . . . . . . . . . . . . 161
Check and oil other pivots and joints . . . 135
Check cable connectors for condition
and secure attachment . . . . . . . . 134
Check cable terminals for condition
and secure attachment . . . . . . . . 134
Check coolant concentration . . . . . . . . 123
Check correct operation of breather
valve on the hydraulic oil tank . . . 126
Check electrical cables for condition
and secure attachment . . . . . . . . 134
Check hydraulic pump attachment to
the engine . . . . . . . . . . . . . . . . . 154
Check slide guides on sideshift (special
equipment) for wear . . . . . . . . . . 154
Check the combustion air intake for
leaks . . . . . . . . . . . . . . . . . . . . . 146
Check the control unit for proper
Check the coolant level . . . . . . . . . . . . . 99
Check the dust discharge valve . . . . . . 108
193
Index
g
Check the engine mounting for
condition and security . . . . . . . . . 143
Check the exhaust pipes for leaks . . . . . 146
Check the fork quick-releases . . . . . . . . 143
Check the forks . . . . . . . . . . . . . . . . . . 143
Check the fuel level . . . . . . . . . . . . . . . . 94
Check the king pin for security . . . . . . . 145
Check the operation
of the parking brake . . . . . . . . . . . . . 147
Check the pedals . . . . . . . . . . . . . . . . . 134
Check the soot filter system . . . . . . . . . 133
Check the steering cylinder for security . 145
Check the tension of double hoses . . . . 142
Check the third auxiliary hydraulic
function and safety system . . . . . 102
Check the tyres for damage and foreign
objects . . . . . . . . . . . . . . . . . . . . 117
Check the vacuum switch . . . . . . . . . . . 136
Check tilt cylinder bearings for wear . . . 154
Check tyre pressure . . . . . . . . . . . . . . . 100
Checks before starting work . . . . . . . 24, 88
Circuit diagram special equipment
Page 2 − Windscreen wipers, seat
heater, seat with air suspension . 214
Page 3 − Heater, air conditioning,
rotating beacon, reversing
signal, interior light . . . . . . . . . . . 216
Page 7 − Linde Forklift Data Man-
agement, display of LPG vol-
ume, motor oil level monitoring,
work light items 5 and 6 . . . . . . . . 224
Page 9 − Battery main switch with
power supply indicator unit . . . . . 228
Particulate filter, radio . . . . . . . . . . . 220
Sheet 1 − Work lights, lighting,
direction indicator system, brake
light . . . . . . . . . . . . . . . . . . . . . . 212
Sheet 4 − hazard warning system
for reversing, vehicle deactiva-
tion, lift mast positioning . . . . . . . 218
Sheet 6 − Higher lighting, 12 V
socket, Water trap diesel filter
warning . . . . . . . . . . . . . . . . . . . 222
Sheet 8 − LPG residual volume
indicator for volumetric filling
194
with shut-off valve, replaceable
particulate filter, rear window
heater, camera system . . . . . . . . 226
Clean and lubricate the lift chains . . . . . 106
Clean sideshift and
grease . . . . . . . . . . . . . . . . . . . . . . 137
Clean the lift truck . . . . . . . . . . . . . . . . . 105
Clean the vent hose to the fuel tank . . . . 106
Cleaning the prefilter . . . . . . . . . . . . . . 109
clock
display . . . . . . . . . . . . . . . . . . . . . . . 20
Clock
setting . . . . . . . . . . . . . . . . . . . . . . . 28
Close
floorplate . . . . . . . . . . . . . . . . . . . . 103
Close motor
hood . . . . . . . . . . . . . . . . . . . . . . . . . 97
Condition code . . . . . . . . . . . . . . . . . . . . 66
Consumables recommendations . . . . . . 90
Controls . . . . . . . . . . . . . . . . . . . . . . . . . 17
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . 92
Crane lifting . . . . . . . . . . . . . . . . . . . . . . 79
Crane lifting with crane eyes . . . . . . . . . . 80
D
Depressurisation . . . . . . . . . . . . . . . . . . 12
Determination and assessment of
hazards from use of industrial
trucks . . . . . . . . . . . . . . . . . . . . . 11
Diagnostic connector . . . . . . . . . . . . . . 163
Diesel engine emissions . . . . . . . . . . . . . 10
Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . 90
Dismantling of lift mast . . . . . . . . . . . . . . 77
Disposal of old vehicles . . . . . . . . . . . . 169
“Do not start engine” symbol . . . . . . . . . . 20
Drain
hydraulic oil . . . . . . . . . . . . . . . . . . . 156
Drain motor
oil . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Drive axle
Adjust the lateral stops . . . . . . . . . . 146
Check the lateral stops . . . . . . . . . . 146
Check the mounting for wear . . . . . . 153
Operating Instructions – EN – 03/2007
 Index
g

Driving Fuses
double-pedal operation . . ......... 33 check . . . . . . . . . . . . . . . . . . . . . . . 162
single-pedal operation . . . ......... 40 Engine compartment . . . . . . . . . . . . 162
without a mast . . . . . . . . . ......... 78 replace . . . . . . . . . . . . . . . . . . . . . . 162
Duplex mast . . . . . . . . . . . . . ......... 86 Fuses for basic and special equipment . 161
securing raised mast . . . . ......... 86
G
E General information . . . . . . . . . . . . . . . . 84
Emergency exit for trucks with rear General view . . . . . . . . . . . . . . . . . . . . . 16
screen . . . . . . . . . . . . . . . . . . . . 165
Emergency lowering . . . . . . . . . . . . . . 164 H
Emergency lowering of fork carriage . . . 164 Handling fluids and lubricants . . . . . . . . . . 9
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . 92 Heating . . . . . . . . . . . . . . . . . . . . . . . . . 64
Check the level . . . . . . . . . . . . . . . . . 97 Hydraulic circuit diagram
Engine temperature indicator . . . . . . . . . 19 Accumulator . . . . . . . . . . . . . . . . . . 232
Experts . . . . . . . . . . . . . . . . . . . . . . . . . 10 Traction, operating and steering
hydraulics . . . . . . . . . . . . . . . . . 230
F Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . 91
Fluids and lubricants . . . . . . .......... 9 Temperature indicator . . . . . . . . . . . . 18
fork arm adjustment device Hydraulic oil cooler
, check fastenings . . . . . . . . . . . . . . 138 check for leaks . . . . . . . . . . . . . . . . 110
Fork arm adjustment device clean . . . . . . . . . . . . . . . . . . . . . . . 122
Check wear and tear . . . . . . . . . . . . 155 cleaning . . . . . . . . . . . . . . . . . . . . . 110
Forward travel . . . . . . . . . . . . . . . . . 34, 41 Hydraulic system
Frame Check fasteningsTilt c . . . . . . . . 144 check for leaks . . . . . . . . . . . . . . . . 147
Fuel filter check the oil level . . . . . . . . . . . . . . 125
drain . . . . . . . . . . . . . . . . . . . . . . . . 115 Renew the filters . . . . . . . . . . . . . . . 149

Operating Instructions – EN – 03/2007 195

Index
g

I L
Indicator unit . . . . . . . . . . . . . . . . . . . . . 18 Lap seat belt
Air filter vacuum indicator . . . . . . . . . . 20 applying . . . . . . . . . . . . . . . . . . . . . . 28
Battery charge indicator . . . . . . . . . . . 18 check for condition and proper
Cooling water level indicator . . . . . . . 21 operation . . . . . . . . . . . . . . . . . . 117
Display clock . . . . . . . . . . . . . . . . . . . 20 opening . . . . . . . . . . . . . . . . . . . . . . 29
Display operating hours . . . . . . . . . . . 19 Leaving the lift truck . . . . . . . . . . . . . . . . 81
“Do not start engine” symbol . . . . . . . 20 Leaving the truck unattended . . . . . . . . . 81
Electrical control system fault Level indicator
indicator light . . . . . . . . . . . . . . . . 19 Engine oil . . . . . . . . . . . . . . . . . . . . . 19
Engine oil level indicator . . . . . . . . . . 19 Lift fork carriage
Engine oil pressure indicator . . . . . . . 19 central lever operation . . . . . . . . . . . . 47
Engine temperature indicator . . . . . . . 19 single lever operation with 3rd
Fuel tank level display . . . . . . . . . . . . 19 additional hydraulics . . . . . . . . . . . 53
Function push-button . . . . . . . . . . . . 20 Single-lever operation . . . . . . . . . . . . 50
Glow plug indicator . . . . . . . . . . . . . . 20 Lift mast data . . . . . . . . . . . . . . . . . . . . 189
Hydraulic oil micro-filter indicator . . . . 19 Lift mast position sensing . . . . . . . . . . . . 20
Hydraulic oil temperature indicator . . . 18 Lifting system and attachments
Level display . . . . . . . . . . . . . . . . . . . 19 central lever operation . . . . . . . . . . . . 46
Load / overload indicator . . . . . . . . . . 19 single lever operation with 3rd
additional hydraulics . . . . . . . . . . . 53
Parking brake symbol . . . . . . . . . . . . 20
Particulate filter alarm . . . . . . . . . . . . 19 Single-lever operation . . . . . . . . . . . . 49
Lighting
Particulate filter symbol . . . . . . . . . . . 19
switch on . . . . . . . . . . . . . . . . . . . . . 60
Reset button . . . . . . . . . . . . . . . . . . . 20
Service interval exceeded symbol . . . 20 Load diagrams . . . . . . . . . . . . . . . . . . . 189
Load display . . . . . . . . . . . . . . . . . . . . . 19
Symbol for lift mast position sensing . . 20
Lower fork carriage
Symbol for operating hours until
next service . . . . . . . . . . . . . . . . . 20 central lever operation . . . . . . . . . . . . 47
Symbol operating hours . . . . . . . . . . . 20 single lever operation with 3rd
additional hydraulics . . . . . . . . . . . 54
Text field . . . . . . . . . . . . . . . . . . . . . . 20
Single-lever operation . . . . . . . . . . . . 50
Initial commissioning . . . . . . . . . . . . . 6, 88
Inspection data . . . . . . . . . . . . . . . . . . . 90 Lubricating grease . . . . . . . . . . . . . . . . . 91
Inspection work M
Every 6000 operating hours or
every 3 years . . . . . . . . . . . . . . . . 90 Main fuses in the engine compartment . 162
Every 9000 operating hours or Maintenance
every 4 years . . . . . . . . . . . . . . . . 90 after the first 50 hours . . . . . . . . . . . . 88
Intended use . . . . . . . . . . . . . . . . . . . . . . 2 Maintenance data . . . . . . . . . . . . . . . . . 90
Maintenance intervals . . . . . . . . . . . . . . 84
J
Jump start . . . . . . . . . . . . . . . . . . . . . . 163

196 Operating Instructions – EN – 03/2007


Maintenance work
Every 6000 operating hours or
every 3 years . . . . . . . . . . . . . . . . 90
Every 9000 operating hours or
every 4 years . . . . . . . . . . . . . . . . 90
Malfunctions during operation . . . . . . . . 170
Malfunctions, Causes and Remedy
Diesel engine . . . . . . . . . . . . . . . . . 172
Malfunctions, causes, remedies
Hydraulic equipment . . . . . . . . . . . . 176
Mast positioning . . . . . . . . . . . . . . . . . . . 58
Mast, lift chains, lift cylinders and
end stops: Check for security,
condition and proper operation . . 140
micro-filter indicator
Hydraulic oil . . . . . . . . . . . . . . . . . . . 19
Motor oil
Change filter . . . . . . . . . . . . . . . . . . 129
N Parking brake
Noise emission values . . . . . . . . . . . . . 191
O Placing the forklift truck into storage
Oil bath air cleaner
Change the oil . . . . . . . . . . . . . . . . . 114
Open
floorplate . . . . . . . . . . . . . . . . . . . . 103
Open motor
hood . . . . . . . . . . . . . . . . . . . . . . . . . 95
Open shorting plunger of hydraulics . . . 166
Opening the electrical system cover . . . 161
Operate attachments
central lever operation . . . . . . . . . . . . 47
single lever operation with 3rd
additional hydraulics . . . . . . . . . . . 54
Single-lever operation . . . . . . . . . . . . 50
Operate fork adjustment
single lever operation with 3rd
additional hydraulics . . . . . . . . . . . 55
Operate rotating unit
single lever operation with 3rd
additional hydraulics . . . . . . . . . . . 55
Operating Instructions – EN – 03/2007
Index
g
Operate sideshift
central lever operation . . . . . . . . . . . . 48
single lever operation with 3rd
additional hydraulics . . . . . . . . . . . 56
Single-lever operation . . . . . . . . . . . . 51
operating hours display . . . . . . . . . . . . . 19
operating hours symbol . . . . . . . . . . . . . 20
Operating the clamp
Single-lever operation . . . . . . . . . . . . 52
Operating the fork positioner
Single-lever operation . . . . . . . . . . . . 52
Operating the horn . . . . . . . . . . . . . . . . . 45
Operation of industrial trucks in plant
area . . . . . . . . . . . . . . . . . . . . . . . 10
Overload display . . . . . . . . . . . . . . . . . . 19
P
parking brake . . . . . . . . . . . . . . . . . . . . . 44
symbol . . . . . . . . . . . . . . . . . . . . . . . 20
Picking up a load . . . . . . . . . . . . . . . . . . 73
. . . 168
Pressure indicator
Engine oil . . . . . . . . . . . . . . . . . . . . . 19
R
Radiator
Check for leaks . . . . . . . . . . . . . . . . 110
clean . . . . . . . . . . . . . . . . . . . . . . . 122
cleaning . . . . . . . . . . . . . . . . . . . . . 110
Refrigerant for air conditioning . . . . . . . . 92
Regenerating the particulate filter . . . . . 111
Regulations . . . . . . . . . . . . . . . . . . . . . . 10
Release multi-disc brake . . . . . . . . . . . 167
Release the
parking brake . . . . . . . . . . . . . . . . . . 45
Renew the idler pulley . . . . . . . . . . . . . 153
Replace
fuses . . . . . . . . . . . . . . . . . . . . . . . 161
Replace breather of boost pressure
control system . . . . . . . . . . . . . . 130
Replace the feed filter . . . . . . . . . . . . . . 149
197
Index
g
Replace the pressure filter . . . . . . . . . . 149
Replace the water pump . . . . . . . . . . . . 158
Restore braking . . . . . . . . . . . . . . . . . . 167
Reversing . . . . . . . . . . . . . . . . . . . . 34, 41
Ribbed V-belt,
change . . . . . . . . . . . . . . . . . . . . . . 152
Ribbed vee belt
check condition . . . . . . . . . . . . . . . . 131
Running-in instructions . . . . . . . . . . . . . . 24
S Switch on hazard warning lights . . . . . . . 60
Safety information . . . . . . . . . . . . . . . . . . 2
Safety inspection . . . . . . . . . . . . . . . . . . 10
Safety instructions . . . . . . . . . . . . . . . . . . 8
3rd auxiliary hydraulic system . . . . . . . 8
active medical equipment . . . . . . . . . . 9
Driver sight . . . . . . . . . . . . . . . . . . . . . 9
Gas springs . . . . . . . . . . . . . . . . . . . . 9
Welding operations . . . . . . . . . . . . . . . 8
Safety regulations . . . . . . . . . . . . . . . . . . 8
Seat heater . . . . . . . . . . . . . . . . . . . . . . 57
Seat heating, turning on/off . . . . . . . . . . . 26
Seat position adjustment . . . . . . . . . . . . 26
Securing the hose reel against rewind-
ing . . . . . . . . . . . . . . . . . . . . . . . . 76
Securing the mast against tilting back . . . 85
Service brake . . . . . . . . . . . . . . . . . . . . . 44
Setting down loads . . . . . . . . . . . . . . . . . 75
Sideshift
Check fastening . . . . . . . . . . . . . . . 137
Soot filter inspection . . . . . . . . . . . . . . . . 11
Standard mast . . . . . . . . . . . . . . . . . . . . 85
securing raised mast . . . . . . . . . . . . . 85
Starting on gradients . . . . . . . . . . . . 35, 42
Starting the
engine (single-pedal operation) . . . . . 35
engine (two-pedal operation) . . . . . . . 30
Steering . . . . . . . . . . . . . . . . . . . . . . . . . 43
198
Steering axle
Check fastenings . . . . . . . . . . . . . . 144
cleaning . . . . . . . . . . . . . . . . . . . . . 137
greasing . . . . . . . . . . . . . . . . . . . . . 137
lubricate bearings . . . . . . . . . . . . . . 116
Steering system . . . . . . . . . . . . . . . . . . . 43
Stop pedal . . . . . . . . . . . . . . . . . . . . . . . 44
Stopping . . . . . . . . . . . . . . . . . . . . . 35, 42
Switch on
heating . . . . . . . . . . . . . . . . . . . . . . . 64
Switch on interior lighting . . . . . . . . . . . . 60
Switch on rotating flashing light . . . . . . . . 60
Switch on the front windscreen wiper . . . 62
Switch on the rear windscreen wiper . . . . 62
Switch on the roof windscreen wiper . . . . 63
Switch on the wiper/washer system . . . . . 63
Switch on turn indicator lights . . . . . . . . . 61
Switch on working headlights . . . . . . . . . 60
Switching off
the engine (single-pedal operation) . . 39
the engine (two-pedal operation) . . . . 32
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . 2
T
Takeover of forklift truck . . . . . . . . . . . . .. 5
Technical specification . . . . . . . . . . . . . .. 3
Brakes . . . . . . . . . . . . . . . . . . . . . . .. 4
Electrical system . . . . . . . . . . . . . . . .. 4
Hydraulic system . . . . . . . . . . . . . . .. 3
Lift mast . . . . . . . . . . . . . . . . . . . . . .. 4
Linde Load Control . . . . . . . . . . . . . .. 4
Linde Truck Control . . . . . . . . . . . . . .. 4
Operation . . . . . . . . . . . . . . . . . . . . .. 4
Steering . . . . . . . . . . . . . . . . . . . . . .. 4
Switching off . . . . . . . . . . . . . . . . . . .. 3
Tighten the wheel nuts . . . . . . . . . . . . . 105
Tilt lift mast backwards
central lever operation . . . . . . . . . . . . 47
single lever operation with 3rd
additional hydraulics . . . . . . . . . . . 54
Operating Instructions – EN – 03/2007

Tilt lift mast backwards.
Single-lever operation . . . . . . . . . . . . 50
Tilt lift mast forwards
central lever operation . . . . . . . . . . . . 47
single lever operation with 3rd
additional hydraulics . . . . . . . . . . . 54
Tilt lift mast forwards.
Single-lever operation . . . . . . . . . . . . 50
Tip-over of the truck . . . . . . . . . . . . . . . . . 9
Toothed belt
check condition . . . . . . . . . . . . . . . . 131
check tension . . . . . . . . . . . . . . . . . 131
renew . . . . . . . . . . . . . . . . . . . . . . . 153
Top up hydraulic oil/
refill . . . . . . . . . . . . . . . . . . . . . . . . 157
Top up motor
oil . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Topping up washer system water tank . . 115
Tow coupling . . . . . . . . . . . . . . . . . . . . . 76
Towing . . . . . . . . . . . . . . . . . . . . . . . . 166
Towing process . . . . . . . . . . . . . . . . . . 166
Towing regulations . . . . . . . . . . . . . . . . 166
Transport with lorry or low-bed trailer . . . 81
Transporting
a load . . . . . . . . . . . . . . . . . . . . . . . . 74
Triplex mast . . . . . . . . . . . . . . . . . . . . . . 87
securing raised mast . . . . . . . . . . . . . 87
Truck data acquisition . . . . . . . . . . . . . . 66
Truck data acquisition - default setting
PIN number and condition code . . . . . 67
Truck data acquisition - special setting
PIN number . . . . . . . . . . . . . . . . . . . 69
Operating Instructions – EN – 03/2007
Index
g
Truck Data Management . . . . . . . . . . . . 66
Truck operation with a bucket . . . ....... 5
Type plates . . . . . . . . . . . . . . . . . . . . . . 14
Type sheet H 40 . . . . . . . . . . . . . . . . . . 180
Type sheet H 45 . . . . . . . . . . . . . . . . . . 183
Type sheet H 50-500 . . . . . . . . . . . . . . 186
tyre sizes . . . . . . . . . . . . . . . . . . . . . . . 100
V
Vacuum indicator
Air filter . . . . . . . . . . . . . . . . . . . . . . . 20
Vibration characteristic values for
bodily vibrations . . . . . . . . . . . . . 192
W
Wet type air cleaner
Clean . . . . . . . . . . . . . . . . . . . . . . . 123
Wheel change . . . . . . . . . . . . . . . . . . . 104
Wheel motors, check security of . . . . . . 145
Wheel-slide protection chains . . . . . . . . . 72
Windscreen defrosting . . . . . . . . . . . . . . 64
Windscreen wiper . . . . . . . . . . . . . . . . . 62
Wiring diagram basic equipment
Diesel . . . . . . . . . . . . . . . . . . . . . . . 206
Work on the mast and front part of the
truck . . . . . . . . . . . . . . . . . . . . . . 85
Y
ylinders FrameCheck fastenings . . . . . . 144
199
Linde Material Handling GmbH & Co. KG

EN – 03/2007
 Operating Instructions
Diesel forklift truck

H40D, H45D, H50-500D

Annex EN – 03/2007
 7

Circuit diagrams
7 Circuit diagrams
Wiring diagram

Wiring diagram
Basic equipment for diesel sheet 1

206 Operating Instructions – EN – 03/2007

 Circuit diagrams 7
Wiring diagram

Legend 6P1 Indicator unit, 25-40 6X1 10-pin plug connector (indicator unit), 26–39 The number in front of the wire colour refers
B1 Tank transmitter, 33 :6 − Earth 6X2 4-pin plug connector (diagnostics), 47 to the wire cross-section.
F2 Fuse MTA 30 A, 4 S1 Ignition and starting switch (9-16) Wires with unspecified cross-section = 0.75
F5 Fuse 2 A, 26 S2 Brake pedal switch 2 (start-up prevention), Wire colours mm2
F6 Fuse 2 A, 28 12-14 BK Black
F7 Fuse 15 A, 73 S3 Suction filter vacuum switch, 31 BN Brown Notes
F13 Fuse max. 15 A, 61 0S1 Oil pressure switch, 28 BU Blue (a) Wires twisted together
F14 Fuse 2 A, 64 4S1 Horn activation, 73 GN Green *) Gold-plated contacts
F15 Fuse max. 15 A, 67 X1 6-pin plug connector (S1), 9-15, 73 GY Grey
G1 Three-phase alternator with regulator X2 3-pin plug connector (S2), 13. 14 OG Orange
660 W, 1-5 X10 18-pin plug connector (central electrical RD Red
G2 Battery 88 Ah, 7 system), 21, 64–69 VT Violet
4H1 Horn 60 W, 73 X11 9-pin plug connector (central electrical WH White
K2 Start relay, 11-13 system), 12–67 YE Yellow
M1 Starter motor 1.7 kW, 9-11 X15 2-pin plug connector (CAN), 41

Operating Instructions – EN – 03/2007 207

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Wiring diagram

Basic equipment diesel sheet 2

208 Operating Instructions – EN – 03/2007

 Circuit diagrams 7
Wiring diagram

Legend :37 − Forwards :114 − Earth GN Green

1B1 Speed actual value transmitter, 85-86 :38 − Seat switch :116 − 5V Lift sensor GY Grey
1B2 Dual potentiometer for accelerator, 85-90 :40 − Mast vertical indicator :118 − 5V Lift sensor OG Orange
1B4 Hydraulic oil temperature sensor, 88 :43 − Retarder 1Y1 :119 − Earth RD Red
2B1 Joystick basic functions, 116-121 :44 − Auxiliary 2/B (B3) S4 Seat switch, 149-150 VT Violet
:1 − 5V :45 − Auxiliary 2/A (A3) 1S1 Brake pedal switch 1, 106-107 WH White
:2 − Raise/lower :46 − Release valve 1Y4 1S2 Travel direction switch, single-pedal, 113- YE Yellow
:3 − Tilt forwards/back :47 − Coding 119 The number in front of the wire colour refers
:4 − Raise/lower reference :49 − Drive potentiometer X4 3-pin plug connector (seat heater)149, 150 to the wire cross-section.
:5 − Tilt forwards/back reference :52 − Coding X10 18-pin plug connector (central electrical Wires with unspecified cross-section = 0.75
:6 − 0V :56 − Code system), 98-108 mm2
2B2 Joystick additional functions, 123-129 :58 − Brake 1 X11 9-pin plug connector (central electrical
:1 − 5V :59 − Brake 3 system), 110, 111 Notes
:2 - Auxiliary 1 :61 − Drive sensor earth 1X1 3-pin plug connector (1B1), 84 (a) Speed restriction
:3 - Auxiliary 2 :62 − Fan valve 1Y5 1X2 3-pin plug connector (1S1), 106. 107 (b) Lift height restriction on/off
:4 - Auxiliary 1 reference :63 − Actual speed sender 1X3 6-pin plug connector (single pedal), 115-119 (c) Brake light
:5 - Auxiliary 2 reference :72 − Reverse 2X1 2-pin plug connector (microfilter)134, 135 (d) Programmable reversing signal
:6 − 0V :73 − Brake 2 2X3 6-pin plug connector (2B1), 116-121 (e) not assigned
2B3 Dual potentiometer lift mast vertical position, :80 − Drive sensor earth 2X4 6-pin plug connector (2B2), 124-129 (f) Shovel insert
137-142 :81 − Drive sensor earth 2X5 10-pin plug connector (valve block), 133-153 (g) Lift height restriction when braking
F8 Fuse 2 A, 81 :82 − Auxiliary 1/A (A1) 1Y1 Retarder (only on H 45/H 50-500), 99 (h) Lift height restriction when stopping
F9 Fuse 15 A, 83 :88 − Lift sensor earth 1Y2 Solenoid valve "y" forwards, 91 (j) Cooling water level
N1 LHC electronic traction control, 81-158 :89 − Lift sensor earth 1Y3 Solenoid valve "z" backwards, 94 (k) Door locking switch
:1 − 5V Drive sensor :90 − Auxiliary 1/B (B1) 1Y4 Release valve, 96 (l) Air conditioning
:6 − Hydraulic pump forwards 1Y2 :91 − Tilt forwards (A2) 1Y5 Fan valve, 92 (m) Engine switch-off
:7 − Hydraulic pump reverse 1Y3 :92 − Tilt back (B2) 1Y10 Sequence valve of 3rd working pump, 95 (n) Air conditioning switch-off
:8 − Microfilter pressure switch :93 − Raise 1Y11 Cold start valve , 101 (o) Brake pedal switch 2
:10 − Coding :96 − Lift sensor earth 2Y1 Lowering valve, 131 (p) Coding plug for two-pedal identification
:13 − Hydraulic oil temperature sensor :98 − Lower 2Y2 Raising valve, 133 (r) Travel direction switch for single-pedal
:14 − Cold start valve 0 V :103 − Tilt angle reference 2Y3 Tilt forwards valve, 136 (s) Wires twisted together
:15 − Hydraulic pump forwards 0V :105 − Mast vertical 2Y4 Tilt backwards valve, 138 (t) Engine control unit
:16 − Hydraulic pump reverse 0V :106 − 0V Raise/lower 2Y5 Auxiliary valve 1B, 142 (u) Coding
:17 − Fan valve 0 V :107 − 0V Tilt forwards/back 2Y6 Auxiliary valve 1A, 144 :10 − H 40, H 45, H 50-500
:18 − Retarder 0 V :108 − Sequence valve of 3rd working pump 2Y7 Auxiliary valve 2B, 148 :28 − H 45, H 50-500
:19 − Release valve 0V 0V 2Y8 Auxiliary valve 2A, 150 :47 − H 45, H 50-500
:24 − Cold start valve 1Y11 :109 − 0V Release valve 2Y9 Release valve, 153 :52 − H 40
:28 − Coding :110 − Sequence valve of 3rd working pump
:30 − Tilt angle 1Y10 Wire colours
:32 − Drive potentiometer reference :111 − Release valve BK Black
:33 − Seat switch reference :112 − 0V (1/A)/(1/B) BN Brown
:36 − Middle :113 − 0V (2/A)/(2/B) BU Blue

Operating Instructions – EN – 03/2007 209

7 Circuit diagrams
Wiring diagram

Basic equipment for diesel sheet 3

210 Operating Instructions – EN – 03/2007

 Circuit diagrams 7
Wiring diagram

Legend 0N1 Control unit for diesel direct fuel injection, GN Green (c) Screened cables
0B1 Coolant temperature transmitter, 187-190 171-236 GY Grey *) Gold-plated contacts
0B2 Engine speed transmitter, 194-197 0N2 Electronic immobiliser, 184-188 OG Orange
0B3 Fuel temperature/governor slide valve 0R1 Glow plugs, 161-166 RD Red
transmitter, 206-214 0X1 10-pin plug connector, 205-220 VT Violet
0B4 Suction pipe pressure / temperature trans- 0X2 2-pin plug connector, 200, 202 WH White
mitter, 178-181 0X3 3-pin plug connector, 194, 197 YE Yellow
0B5 Needle stroke transmitter, 200-202 0Y1 Fuel cut-off valve, 218 The number in front of the wire colour refers
0B6 Air mass flow meter, 173-175 0Y2 Start of injection valve, 220 to the wire cross-section.
F1 Fuse 50 A MTA, 161 0Y4 Valve for charge air pressure limitation, 222 Wires with unspecified cross-section = 0.75
F11 Fuse 15 A, 170 mm2
F12 Fuse 2 A, 175 Wire colours
0K1 Glow plug relay, 161-163 BK Black Notes
0K2 Relay terminal 30 for engine control unit, BN Brown (a) DFM generator terminal
170-173 BU Blue (b) Wires twisted together

Operating Instructions – EN – 03/2007 211

7 Circuit diagrams
Wiring diagram

Special equipment sheet 1 − Work lights, lighting, direction indicator system, brake light

212 Operating Instructions – EN – 03/2007

 Circuit diagrams 7
Wiring diagram

Legend 5F8 7.5A fuse (left headlight), 39 5X4 12-pin plug connector (work lights, items 1, YE Yellow
5E1 Left front lower work light 55W (item 1), 7, 13 5F9 7.5A fuse (right headlight), 41 2), 7, 9 The number in front of the wire colour refers
5E2 Right front lower work light 55W (item 2), 9, 5F10 5A fuse (left side light), 43 5X5 2-pin plug connector (work lights, items 3, to the wire cross-section.
15 5F11 5 A fuse (right side light), 48 4), 15, 21 Wires with unspecified cross-section = 0.75
5E3 Left front upper work light 55W (item 3), 19 5H1 Left front direction indicator, 21 W, 61 5X6 2-pin plug connector (work lights, items 7, mm2
5E4 Right front upper work light 55W (item 4), 21 5H2 Right front direction indicator, 21 W, 64 8), 29
5E7 Right rear upper work light 55W (item 8), 29 5H3 Left rear direction indicator, 21 W, 60 5X7 6-pin plug connector (left headlight), 39, 43, Notes
5E9 Left licence plate light, 10 W, 55 5H4 Right rear direction indicator, 21 W, 66 61 Side lights 5E23 and 5E24 only in conjunc-
5E10 Right licence plate light, 10 W, 57 5H10 Direction indicator control lamp 2 W, 69 5X8 6-pin plug connector (right headlight), 41, tion with dual tyres
5E11 Left dipped beam, 55W, 39 5H20 Right brake light, 21 W, 74 48, 64 (I) Work lights, item 1,2
5E12 Right dipped beam, 55W, 41, 52 5H21 Left brake light, 21 W, 76 5X10 2- pin plug connector (licence plate lighting), (II) Work lights, items 1.2 (with higher lighting)
5E13 Left front side light, 5W, 43 K1 Auxiliary relay terminal 58, 1–3 55 (III) Work lights, items 3,4
5E14 Left front side light, 5W, 48 5K1 Blinker relay, 64-67 5X16 2-pin plug connector (licence plate light), 55 (IV) Work lights, items 7,8
5E15 Left rear side light, 10 W, 47 5K2 Brake light relay, 72-74 5X18 2-pin plug connector (right side light), 50 (a) To electronic control N1:22
5E16 Right rear side light, 10 W, 52 5K4 Work light relay, (tems 7, 8), 32–36 5X19 2-pin plug connector (left side light), 45 (V) Lighting
5E19 Left rear upper work light 55W (item 7), 31 5S1 Work light switch, (items 1, 2), 9–11 (VI) Direction indicator and hazard warning
5E23 Left side light, 5 W, 45 5S2 Work light switch, (items 3, 4), 15–23 Wire colours system
5E24 Right side light, 5 W, 50 5S3 Work light switch, (items 7, 8), 27–35 BK Black (VII) Brake light
F3 Fuse MTA 70 A (terminal 58), 3 5S11 Light switch, 39–45 BN Brown (b) To electronic control N1:41
F14 2A fuse (terminal 58), 1 5S12 Warning light switch, 60-66 BU Blue
5F1 15A fuse (work light items 1, 2), 9 5S13 Direction indicator switch, 62-64 GN Green
5F2 15A fuse (work light items 3, 4), 15, 21 X10 18-pin plug connector (for basic equipment), GY Grey
5F4 15A fuse (work light items 7, 8), 30 1, 32, 72 OG Orange
5F5 15A fuse (lighting terminal 15), 60 5X1 12-pin plug connector (overhead guard RD Red
5F6 10A fuse (lighting terminal 30), 63 lighting), 13, 15, 39–74 VT Violet
5F7 5A fuse (brake light), 74 5X2 6-pin plug connector (rear lighting), 47-74 WH White

Operating Instructions – EN – 03/2007 213

7 Circuit diagrams
Wiring diagram

Special equipment page 2 − Windscreen wipers, seat heater, seat with air suspension

214 Operating Instructions – EN – 03/2007

 Circuit diagrams 7
Wiring diagram

Legend 9M5 Rear wash pump, 116 Wire colours Notes

9F1 2A fuse (windscreen wipers, general), 83 9M6 Roof wash pump, 137 BK Black (I) Windscreen wiper
9F2 10A fuse (front windscreen wiper), 96 9M10 Compressor motor for seat with air suspen- BN Brown (II) Front windscreen wiper
9F3 10A fuse (rear and roof windscreen wipers), sion 90 W BU Blue (III) Rear windscreen wiper
114 9R2 Seat heater 80 W, 144, 151 GN Green (IV) Roof windscreen wiper
9F4 10A fuse (wash pumps), 86 9S1 Windscreen wiper switch, 82–87 GY Grey (V) Seat with seat heater
9F6 20A fuse (seat heater), 144, 152 9S2 Front windscreen wiper switch, 82–89 OG Orange (VI) Seat with seat heater and air suspension
9K1 Front windscreen wiper relay, 85–93 9S3 Rear windscreen wiper switch, 101–109 RD Red
9K2 Rear windscreen wiper relay, 106–111 9S4 Roof windscreen wiper switch, 121–128 VT violet
9K3 Roof windscreen wiper relay, 125–132 9X1 9-pin plug connector (windscreen wipers), WH White
9M1 Front windscreen wiper motor 55 W, 91–95 83–94 YE Yellow
9M2 Rear windscreen wiper motor 36 W, 9X5 6-pin plug connector (wash pumps), 98, 116, The number in front of the wire colour refers
110–113 137 to the wire cross-section.
9M3 Roof windscreen wiper motor 36 W, 9X7 3-pin plug connector (seat heater)144, 152 Wires with unspecified cross-section = 0.75
130–134 9X14 2-pin plug connector (seat heater)144, 152 mm2
9M4 Front wash pump, 98

Operating Instructions – EN – 03/2007 215

7 Circuit diagrams
Wiring diagram

Special equipment page 3 − Heater, air conditioning, rotating beacon, reversing signal, interior light

216 Operating Instructions – EN – 03/2007

 Circuit diagrams 7
Wiring diagram

Legend 9S6 Air conditioning pressure switch, 177–179 9X13 4-pin plug connector (air conditioning Notes
4B1 Buzzer, 222 9V1 Free-wheeling diode (E-coupling), 172 pressure switch), 178–180 (I) Switch on
5E8 Interior light 6 W, 233 X10 18-pin plug connector (for basic equipment), 9Y1 E-coupling for air conditioner, 174 (II) Heating with air conditioning system
9E1 Heater, 161–167 210 (a) LHC control unit N1:
9E2 Heater with air conditioning, 170–194 X11 9-pin plug connector (for basic equipment), Wire colours (b) Alternator G1:L
F4 30A fuse (air conditioning), 182 182–184 BK Black (c) LHC control N1:35
4F1 10A fuse (reversing signal), 214 4X1 2-pin plug connector (warning flashing light / BN Brown (III) Warning flashing light / rotating beacon
4F3 Fuse 7.5 A (warning flashing light / rotating rotating beacon), 226 BU Blue above term. 58
beacon), 199, 204 4X2 6-pin plug connector (buzzer), 216–223 GN Green (IV) Warning flashing light / rotating beacon
5F12 Fuse 5 A, (interior light), 233 4X3 2-pin plug connector (warning flashing light / GY Grey above switch
9F9 20A fuse (heater), 164, 172 rotating beacon), 199 OG Orange (V) Reversing signal duration and switchable
4H4 Warning flashing light 2 W, 199, 204, 214, 4X4 2-pin plug connector (warning flashing light / RD Red Off/Reverse motion/On
226 rotating beacon), 204 VT violet (d) For electronic control N1:22
4H5 Rotating beacon 60 W, 199, 204, 214, 226 4X5 2-pin plug connector (buzzer), 221 WH White (e) For higher reversing light special equipment
4K1 Reversing signal relay, 210–214 5X11 12-pin plug connector (higher lighting), 229 YE Yellow wiring diagram
9M7 Fan motor 1 for air conditioning, 188 9X9 2-pin plug connector (heater, air condition- The number in front of the wire colour refers (VI) Interior light
9M8 Fan motor 2 for air conditioning, 191 ing), 164, 170, 172 to the wire cross-section.
9M9 Fan motor 3 for air conditioning, 194 9X10 1-pin plug connector (air conditioning), 182 Wires with unspecified cross-section = 0.75
4S3 Warning flashing light / rotating beacon 9X11 6-pin plug connector (air conditioning), mm2
switch, 204-206, 212-217 178–194
5S4 Interior light switch, 232-235 9X12 2-pin plug connector (heater), 164, 170, 172

Operating Instructions – EN – 03/2007 217

7 Circuit diagrams
Wiring diagram

Special equipment sheet 4 − hazard warning system for reversing, vehicle deactivation, lift mast positioning

218 Operating Instructions – EN – 03/2007

 Circuit diagrams 7
Wiring diagram

Legend S1 Ignition and starting switch, 285–292 5X2.1 6-pin plug connector (rear lighting), 258, 264 The number in front of the wire colour refers
5F7 5A fuse (brake light), 252 2S1 Lift mast position pre-selection switch, 5X2.2 6-pin plug connector (rear lighting), 258, 264 to the wire cross-section.
5F13 10A fuse (hazard warning system), 244 308–310 5X3 3-pin plug connector (reversing signal Wires with unspecified cross-section = 0.75
2H1 Lift mast position pre-selection warning light, V1 Decoupling diode, 302 transfer), 270 mm2
310 5V1 Decoupling diode, 258 5X9 6-pin plug connector (hazard warning
5H3 Left rear direction indicator, 21 W, 244 5V2 Decoupling diode, 264 system), 244, 248, 252 Notes
5H4 Right rear direction indicator, 21 W, 246 5V3 Decoupling diode, 269 (I) Hazard warning system when reversing with
5H10 Flashing indicator light 2 W, 248 5V4 Decoupling diode, 269 Wire colours brake light (without lights)
5H20 Right brake light, 21 W, 252 X1 10-pin plug connector, 285–297 BK Black (a) For electronic control N1:22
5H21 Left brake light, 21 W, 254 X1.1 10-pin plug connector, 285–297 BN Brown (b) For electronic control N1:41
K2 Start relay, 286–288 X10 18-pin plug connector (for basic equipment), BU Blue (II) Hazard warning system when reversing
K3 Engine shutoff relay, 295-299 241, 250, 272 GN Green (with lights)
5K1 Blinker relay, 243–245 X11 9-pin plug connector (for basic equipment), GY Grey (c) For electronic control N1:22
5K2 Brake light relay, 250–252 302 OG Orange (III) Vehicle deactivation via seat switch
5K3 Hazard warning system relay when revers- 2X2 4-pin plug connector (lift mast position), 308, RD Red (d) For horn activation 4S1 (basic equipment
ing, 241–244, 270–272 310 VT violet wiring diagram)
N1 LHC electronic controller, 308–310 5X2 6-pin plug connector (rear lighting), 244–252 WH White (e) For electronic control N1:42
YE Yellow (IV) Lift mast positioning

Operating Instructions – EN – 03/2007 219

7 Circuit diagrams
Wiring diagram

Special equipment sheet 5 − particulate filter, radio

220 Operating Instructions – EN – 03/2007

 Circuit diagrams 7
Wiring diagram

Legend :40 − Earth 7S1 Start switch, 352–353 BU Blue

7A1 Particulate filter control unit, 327-374 :41 − Consumers voltage supply 7S2 Emergency stop switch, 357–359 GN Green
:2 − Buzzer :42 − Combustion air blower 7V1 Decoupling diode, 336 GY Grey
:3 − Coding 7B1 Buzzer, 348 9W1 Antenna, 395–396 OG Orange
:4 − Coding 7B2 Flame sensor, 367 X10 18-pin plug connector (to main harness), RD Red
:6 − Thermocouple (negative) 9E3 Radio, 389–397 340, 357 VT violet
:10 − Regeneration indicator :4 − Earth X11 9-pin plug connector (to main harness), 325, WH White
:12 − Signal input terminal 15 9E4 Loudspeaker, left, 389 364 YE Yellow
:13 − Electronics voltage supply 9E5 Loudspeaker, right, 394 6X8 4-pin plug connector (diagnostics), 383 The number in front of the wire colour refers
:14 − Consumers voltage supply F15 5A fuse, 357 7X1 9-pin plug connector (central electrical to the wire cross-section.
:16 − Three-phase alternator 7F1 5A fuse (particulate filter), 343 system transfer), 340–359 Wires with unspecified cross-section = 0.75
:17 − Regeneration start 7F2 20A fuse (particulate filter), 349 7X2 4-pin plug connector (blower shut-off valve), mm2
:18 − Glow plug controller voltage supply 7F3 30A fuse (glow plug), 376 332, 335
:19 − Glow plug indicator 9F7 5A fuse (radio circuit terminal 30), 390 7X3 2-pin plug connector (flame sensor), 366, Notes
:20 − Thermocouple (positive) 9F8 10A fuse (radio circuit terminal 15), 393 367 (I) Particulate filter (only in diesel version)
:24 − Shut-off valve 7H1 Regeneration warning light, 353 7X4 2-pin plug connector (glow plug), 376 (a) For generator G1:B+ (only in diesel version)
:25 − Error 7H2 Prewarning and warning light (orange) 342 7X5 2-pin plug connector (metering pump), 339 (b) For ignition and starting switch S1:50 (only
:26 − Metering pump 7H3 Fault light (red), 345 9X2 3-pin plug connector (radio), 390–397 in diesel version)
:29 − Relay for glow plug K2 Start relay, 323–325 9X8 3-pin plug connector (radio), 390–397 (c) For starter motor M1:50a (only in diesel
:30 − Emergency stop switch 7K1 Glow plug current regulator, 374–376 7Y1 Shut-off valve, 335 version)
:31 − Emergency stop switch 7K2 Starting aid relay, 325–328 (d) For brake pedal switch X2:3 (only in diesel
:37 − Starter relay 7M1 60W blower, 332 Wire colours version)
:38 − Prewarning and warning 7M2 24W metering pump, 339 BK Black (e) ISO interface (only in diesel version)
:39 − Earth 7R1 200W glow plug, 376 BN Brown (II) Radio

Operating Instructions – EN – 03/2007 221

7 Circuit diagrams
Wiring diagram

Special equipment sheet 6 − Higher lighting, 12 V socket, water trap diesel filter warning

222 Operating Instructions – EN – 03/2007

 Circuit diagrams 7
Wiring diagram

Legend 0H2 Water trap warning light, 472 5X11 12-pin plug connector (higher lighting), WH White
0B14 Water trap sensor, 468-469 5H1 Left front direction indicator, 21 W, 426 403-446 YE Yellow
0B15 Water trap buzzer, 476 5H2 Right front direction indicator, 21 W, 429 5X12 5-pin plug connector (right rear light), 417, The number in front of the wire colour refers
5E11 Left dipped beam, 55 W, 403 5H3 Left rear direction indicator, 21 W, 424 432, 441, 448 to the wire cross-section.
5E12 Right dipped beam, 55 W, 405 5H4 Right rear direction indicator, 21 W, 432 5X13 5-pin plug connector (left rear light), 409, Wires with unspecified cross-section = 0.75
5E13 Left front side light, 5 W, 407 5H10 Direction indicator lamp 2 W, 436 424, 443, 446 mm2
5E14 Right front side light 5 W, 415 5H20 Right brake light, 21 W, 441 5X18 2-pin plug connector (right side light), 420
5E15 Left rear side light, 10 W, 409 5H21 Left brake light, 21 W, 443 5X19 2-pin plug connector (left side light), 412 Notes
5E16 Right rear side light, 10 W, 417 5K1 Blinker relay, 430-432 9X15 3-pin plug connector (12 V socket-outlet), (I) Lighting higher
5E17 Reversing light, left, 10 W, 446 5K2 Brake light relay, 439-441 455 (II) Direction indicator and hazard warning
5E18 Reversing light, right, 10 W, 448 5S11 Light switch, 402-408 9X16 2-pin plug connector (12 V socket-outlet), system higher
5E23 Left side light, 5 W, 412 5S12 Warning light switch, 424-432 455 (III) Brake light higher
5E24 Right side light, 5 W, 420 5S13 Direction indicator switch, 427-429 (IV) Reversing light higher
F15 5A fuse (water trap), 468 X8 2-pin plug connector, 468 Wire colours (a) For electronic control N1:41
5F5 15A fuse (lighting terminal 15), 424 X10 18-pin plug connector (for basic equipment), BK Black (b) For wiring diagram, special equipment,
5F6 10A fuse (lighting terminal 30), 428 439, 468 BN Brown reversing signal
5F7 5A fuse (brake light), 441 5X1 12-pin plug connector (overhead guard BU Blue (V) 12 V socket-outlet
5F8 7.5A fuse (left headlight), 403 lighting), 412, 420, 425-436 GN Green (VI) Water trap diesel filter warning (only with
5F9 7.5A fuse (right headlight), 405 5X7 6-pin plug connector (left headlight), 403, GY Grey diesel version)
5F10 5A fuse (left side light), 407 407, 426 OG Orange
5F11 5 A fuse (right side light), 415 5X8 6-pin plug connector (right headlight), 405, RD Red
9F10 15A fuse (12V socket-outlet), 455 415, 429 VT Violet

Operating Instructions – EN – 03/2007 223

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Wiring diagram

Special equipment page 7 − Linde Forklift Data Management, display of LPG volume, motor oil level monitoring, work light items 5 and 6

224 Operating Instructions – EN – 03/2007

 Circuit diagrams 7
Wiring diagram

Legend :2 − Earth 6X7 5-pin plug connector (data transfer), (c) To starter M1:50a
6A1 Data Logger with keypad (LFM), 488–502 :3 − Signal 495–499 (d) To brake pedal switch X2:3
:3 − Earth S6 LPG residual volume switch, 528 6X9 4-pin plug connector (LFM online module), (II) Display of LPG volume for volumetric filling
:4 − Free input 5S2 Work light switch (items 3, 4, 5, 6), 548-555 505–508 (only with LPG version)
:5 − Load sensor 6W1 Antenna (LFM online module), 510 (e) Wiring diagram basic equipment (only with
:6 − Free output X1 10-pin plug connector, 484 Wire colours LPG version)
:8 − Starter relay X6 5-pin plug connector (for main harness), BK Black (III) Display of LPG residual volume (only with
6A2 LFM online module, 505–510 521, 528 BN Brown LPG version)
:4 − Earth X10 18-pin plug connector (for basic equipment), BU Blue (f) Wiring diagram basic equipment (only with
B1 Tank transmitter (volumetric filling), 521 499 GN Green LPG version)
0B16 Oil level sensor, 534-535 X11 9-pin plug connector (for basic equipment), GY Grey (IV) Motor oil level monitoring
6B2 Shock sensor, 512-516 501, 538 OG Orange (V) Work lights, items 5, 6
:2 − Signal X15 2-pin plug connector (CAN connection), RD Red
:3 − Earth 489, 495, 537, 543 VT violet
5E3 Left front top work light, 55 W 0X19 6-pin plug connector (evaluation electron- WH White
5E4 Right front top work light, 55 W ics), 535-538 YE Yellow
5E5 Left lift mast work light, 55 W 0X20 3-pin plug connector, 535 The number in front of the wire colour refers
5E6 Right lift mast work light, 55 W 5X5 2-pin plug connector (work lights items3,4) to the wire cross-section.
F15 Fuse 5 A, 499, 535 5X14 3-pin plug connector (work lights, items6) Wires with unspecified cross-section = 0.75
5F2 Fuse 15 A, 553 5X15 2-pin plug connector (work light item 5), 549 mm2
5F3 Fuse 15 A, 549 6X4 14-pin plug connector (data logger), Notes
6F1 Fuse 5 A, 497 488–502 (I) Linde Forklift Data Management (LFM)
K2 Start relay, 482–485 6X5 3-pin plug connector (transfer to data (a) To alternator G1:B+
0N3 Evaluation electronics, 534-540 logger), 497, 499 (b) To ignition and starting switch S1:50

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Wiring diagram

Special equipment sheet 8 − Display of LPG volume for volumetric filling with shut-off valve, replaceable particulate filter, rear window heater, camera system

226 Operating Instructions – EN – 03/2007

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Wiring diagram

Legend X6 5-pin plug connector (for main harness), 1Y12 Tank shutoff valve, 567 Notes
7A2 Replaceable particulate filter controller, 563, 567 1Y13 Tank shutoff valve, 570 (I) Display of LPG volume for volumetric filling
578-590 X10 18-pin plug connector (for basic equipment), (2x36 l) with shutoff valve (only with LPG
9A5 Monitor, 607-617 578, 582, 607, 614 Wire colours version)
B1 Tank transmitter (volumetric filling), 563 7X6 9-pin plug connector (central electrical BK Black (a) Wiring diagram basic equipment (only with
7B3 Replaceable particulate filter buzzer, 591 system), 578, 582 BN Brown LPG version)
9E6 Camera 1, 607-609 7X7 3-pin plug connector (reset switch), 577. BU Blue (II) Replaceable particulate filter (fitted only to
9E7 Camera 2, 612-614 578 GN Green the diesel version)
F15 Fuse 10 A, 582, 607 7X8 2-pin plug connector (pressure switch), 582, GY Grey (b) Switch opens when the replaceable partic-
7F4 Fuse 2 A, 588, 607 583 OG Orange ulate filter is fitted and the cover is closed
9F5 Fuse 15 A, 596, 607 9X26 5-pin plug connector (camera system), RD Red (fitted only to the diesel version).
7H4 Indicator light (orange), 588 607-609 VT violet (c) Switch is shown in the pressure differential
9R1 Rear window heater, 596 9X27 5-pin plug connector (camera system), WH White OK position (fitted only to the diesel version).
7S3 Replaceable particulate filter switch, 577- 612-614 YE Yellow (III) Rear window heater
578 9X28 5-pin plug connector (camera system), The number in front of the wire colour refers (IV) Camera system
7S4 Replaceable particulate filter pressure 607-609 to the wire cross-section. (d) To electronic control N1:22
switch, 582-583 9X29 5-pin plug connector (camera system), Wires with unspecified cross-section = 0.75
9S5 Rear window heater switch, 596-598 607-616 mm2

Operating Instructions – EN – 03/2007 227

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Wiring diagram

Special equipment page 9 − Battery main switch with voltage supply indicator unit

228 Operating Instructions – EN – 03/2007

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Wiring diagram

Legend Wire colours WH White Notes

F2 Fuse 30 A, 647 BK Black YE Yellow (I) Battery main switch with voltage supply
6F2 Fuse 2 A, 654 BN Brown The number in front of the wire colour refers indicator unit
G1 Three-phase alternator with regulator BU Blue to the wire cross-section. (a) to circuit diagram for basic equipment
660 W, 642-645 GN Green Wires with unspecified cross-section = 0.75
G2 Battery 88 Ah, 647 GY Grey mm2
M1 Starter motor 1.7 kW, 649-651 OG Orange
S5 Battery main switch, 647 RD Red
6X1 10-pin plug connector, 657-670 VT Violet

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Hydraulic circuit diagram

Hydraulic circuit diagram

Traction, operating and steering hydraulics

230 Operating Instructions – EN – 03/2007

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Hydraulic circuit diagram

A Auxiliary hydraulics with duplex or triplex D Linde Truck Control 43 2/2 solenoid valve (only with diesel version) P Radiator
1 Left hose pulley 22 Central lever working hydraulics 44 Gear pump 16 cm3
2 Right hose pulley 23 Central lever auxiliary hydraulics 1+2 45 Gear pump 18 cm3 R Drive axle AH 45-03 consisting of:
46 Throttle valve 61 Multi-disc brake (brake vent. min. 16 bar)
B Working hydraulics E Combustion engine 47 Gear pump 9 cm3 62 Hydraulic fixed displacement motor
3 Tilt cylinders HMF 900 R
4 Standard lift mast F Engine speed regulator I Pressure filter working hydraulics / micro oil filter
5 Connection for auxiliary hydraulics 2 S Oil tank consisting of:
G Hydraulic variable pump assembly consisting of: K Steering control valve with: 63 Breather with suction and counter-balance
6 Connection for auxiliary hydraulics 1 24 Hydraulic variable pump HPV 105-02 R
7 Solenoid valve 48 Suction valve valve 0.35±0.15bar
25 Release valve 49 Hose safety valve 220+10 64 Suction filter with bypass valve 0.25 bar
8 Tilt brake valve 26 Set piston A→forwards B→backwards
9 Load holding valve 50 Servostat
27 Non-return valve 1 bar 51 Maximal valve 120+5
10 Non-return valve 28 Sensor (hydraulic oil temperature)
11 Pressure relief valve 1 (with H 40 stan- 29 4/2 solenoid valve L Steering cylinder
dard/duplex/triplex250+5 bar, with H 45 30 Pilot valve
standard/duplex/triplex 275+5 bar, with H 31 Combined feed maximum valve 425+20 bar M Brake venting valve
50-500 standard/duplex/triplex 275+5 bar) 32 Supply pressure valve 21+0.5 bar 52 Towing unit
12 2/2 solenoid valve (pressure governor) 33 Brake valves (DBV) 53 Pedal group
13 Release valve (working hydraulics) 34 Auxiliary control valve 54 3/2 solenoid valve
14 Solenoid valve - lift / lower 35 Choke plunger (towing unit) 55 Pump for venting brake
15 Solenoid valve - tilt 36 Purge valve 10 bar 56 Pressure relief valve
16 Pressure relief valve 2 (170+10 bar) 37 Shuttle valve 57 Non-return valve
17 Non-return valve 38 Servo piston Y→forwards Z→backwards 58 2/2 solenoid valve
18 Solenoid valve - auxiliary hydraulics 1 39 2/2 solenoid valve N Pressure filter (supply pressure) / micro oil filter
19 Solenoid valve - auxiliary hydraulics 2 40 Proportional valve
O Fan motor
C Depressurisation (special equipment) H Gear pump group 59 Solenoid valve
20 Accumulator 41 Solenoid valve 60 Hydraulic motor 12 cm3
21 Non-return valve 42 3/3 solenoid valve (priority valve)

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Hydraulic circuit diagram

Accumulator

232 Operating Instructions – EN – 03/2007

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Hydraulic circuit diagram

1 Drive axle, right 3 Lift/lower distributor piece, (lift mast BR 189) Nitrogen fill pressure of accumulator H 45 standard/duplex/triplex 175 bar
2 Overpressure valve 4 Accumulator H 40 standard/duplex/triplex 160 bar H 50-500 standard/duplex/triplex 175 bar

Operating Instructions – EN – 03/2007 233

Linde Material Handling GmbH & Co. KG

EN – 03/2007