Diesel truck

Original instructions

H25D, H30D, H35D

393 807 10 01 EN – 10/2010
 Preface
g

Linde − Your Partner

With over 100,000 fork lift trucks and ware- Your local Linde partner can offer you a
house machines sold annually, Linde is one of complete package from a single source;
the world’s leading manufacturers of material ranging from expert advice on all aspects
handling equipment. There are many reasons of sales and service through, of course, to
for this success: Linde products are renowned appropriate finance options. Our leasing, hire
not only for their innovative, cutting-edge tech- or lease-purchase agreements provide you
nology, but also for their low energy and oper- with the flexibility to tailor decision-making to
ating costs, which are up to 40 per cent lower your individual business requirements.
than those of their competitors.
Linde Material Handling GmbH
The high quality of Linde products is also Carl-von-Linde-Platz
matched by the quality of our service. With ten 63743 Aschaffenburg
production plants worldwide and an extensive Telephone +49 (0) 6021 99-0
network of sales partners, we are at your Fax +49 (0) 6021 99-1570
service round the clock and around the world. Mail: [email protected]
Web: http://www.linde-mh.com

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 Table of contents
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1 Introduction
Your forklift truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Proper usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Impermissible use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Description of use and climatic conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Technical description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Truck operation when using a shovel ...................................... 6
Reception of truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Legal requirements for marketing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Service plan before initial commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2 Safety
Safety guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
In the case of tip-over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Handling consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Specialist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Operation of industrial trucks in plant area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Instructions before fitting attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3 Overview
Identification plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Additional capacity rating plate for attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Truck overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Operating devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Display unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Switch panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

4 Operation
Running-in instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

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Checks before starting work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Standard equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 32
Adjusting the driver’s seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 32
Entering and exiting the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 35
Adjusting the steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 36
Setting the clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 37
Seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 37
Drive engine (dual-pedal operation) . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 39
Driving (dual-pedal operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 42
Drive engine (single-pedal operation) . . . . . . . . . . . . . . . . . . . . . . . . . ............ 45
Driving (single-pedal operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 49
Steering system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 52
Brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 53
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 54
Lifting system and attachments (central lever operation) . . . . . . . . . . . ............ 55
Lifting system and attachments (single lever operation) . . . . . . . . . . . . ............ 60
Special equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Lifting system and attachments (single lever operation with toggle-switch-controlled
3rd auxiliary hydraulics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Lifting system and attachments with 3rd auxiliary hydraulics without toggle switch . . . . 69
Adjust driver’s seat with swivel device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Adjusting the driver’s seat equipped with air suspension . . . . . . . . . . . . . . . . . . . . . . . 73
Lift mast positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Windscreen wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Window heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Driver’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Heating system, air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Linde Forklift Data Management (LFM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Working under load . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 93
Before taking up load . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 93
Adjusting the fork spread .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 95
Taking up loads . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 95
Travelling with load . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 96
Setting down loads . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 97
Tow coupling . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 98
Loading / Transporting . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . ....... 99
Securing the hose pulley against rolling up . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 99
Dismantling the lift mast . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . ....... 100
Driving without lift mast . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . ....... 101
Loading . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . ....... 102

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Transport with lorry or low-bed trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Before leaving the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

5 Maintenance
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Working on Linde lift mast and at the front of the truck . . . . . . . . . . . . . . . . . . . . . . . . . 107
Inspection and maintenance data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Recommendations for consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Inspection and maintenance overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . 113
Service plan as required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . 113
1000 h service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . 114
3000 h Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . 116
6000 h Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . 119
9000 h Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . 122
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Checking the engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Change engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Engine oil filter change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Draining water from the fuel filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Exchanging the fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Cleaning the fuel tank ventilation hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Checking the coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Changing coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Check coolant concentration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Cleaning the water cooler and hydraulic oil cooler, and checking them for leaks . . . . . . 138
Checking the condition and secure positioning of the engine support and engine
mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Check condition of the ribbed vee belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Replacing ribbed V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Checking the condition and tension of toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Renew the toothed belt and idler pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Change the water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Changing the air filter cartridge, checking the vacuum-operated switch . . . . . . . . . . . . 144
Changing the air filter safety cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Check the dust discharge valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Changing the breather for the charge air pressure regulator . . . . . . . . . . . . . . . . . . . . . 146
Cleaning the prefilter (special equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Cleaning the oil bath air filter (special equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Change the oil in the oil bath air cleaner (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

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Check suction and exhaust pipes for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

Regenerating particle filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Regenerating the changing particle filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Checking the particle filter system (special equipment) . . . . . . . . . . . . . . . . . . . . . . . . 155
Draining water from the water trap at the changing particle filter (special equip-
ment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Cleaning the water trap at the changing particle filter (special equipment) . . . . . . . . . . . 156
Cleaning the pressure control device at the changing particle filter (special equip-
ment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 158
Checking the fastenings of the axle clamps and wheel motors . . . . . . . ............ 158
Checking and adjusting the side stops on the drive axle . . . . . . . . . . . . ............ 158
Checking the drive axle bearings for wear . . . . . . . . . . . . . . . . . . . . . . ............ 159
Checking the hydraulic pump’s attachment to the engine . . . . . . . . . . . ............ 159
Chassis, bodywork and fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 160
Cleaning the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 160
Bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 161
Floorplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 163
Servicing the air conditioning (special equipment) . . . . . . . . . . . . . . . . ............ 164
Checking the condition and correct function of the seat belt . . . . . . . . . ............ 165
Checking fastening for frame, tilt cylinders and steering axle . . . . . . . . ............ 166
Check and oil other pivots and joints . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 167
Chassis frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 168
Wheel change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 168
Tighten the wheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 169
Check the tyres for damage and foreign objects . . . . . . . . . . . . . . . . . . ............ 169
Checking the tyre pressure and tyre sizes . . . . . . . . . . . . . . . . . . . . . . ............ 170
Cleaning and greasing the steering axle . . . . . . . . . . . . . . . . . . . . . . . ............ 172
Checking the mountings of the steering cylinder and steering pivot pin . ............ 173
Check the parking brake for correct operation . . . . . . . . . . . . . . . . . . . ............ 173
Operating devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Checking the pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Checking the bellows at the actuating lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Electrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Check the condition and secure positioning of electric cables, cable connectors and
connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Battery: check condition, acid level and acid density . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 179
Change hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 179
Hydraulic system: Check oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 180
Hydraulic system: changing the filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 181

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Check correct operation of breather valve on the hydraulic oil tank . . . . . . . . . . . . . . . . 184
Check the hydraulic system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Check tilt cylinder bearings for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Check the tension of double hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Checking the function and safety system of the third auxiliary hydraulics (special equip-
ment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Load lift system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Cleaning the lift mast chain and applying chain spray . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Mast, lift chains, lift cylinders and end stops: Check for security, condition and proper
operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 189
Adjust lift mast chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 189
Check the forks and fork quick-releases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 191
Clean sideshift (special equipment) and grease, check fastening . . . . . . . . . . . . . . . .. 192
Checking the slide guides on the sideshift (special equipment) for wear . . . . . . . . . . .. 193
Cleaning and lubricating the fork prong positioner (special equipment), checking the
mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Check fork arm adjustment device (special equipment) for wear and tear . . . . . . . . . . . 195
Special equipment, accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Top up the washer system water tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............... .. 197
Opening the cover to the electrical system . . . . . . . . . . . . . . . . . ............... .. 197
Fuses for basic and special equipment . . . . . . . . . . . . . . . . . . . ............... .. 198
Main fuses in engine compartment . . . . . . . . . . . . . . . . . . . . . . ............... .. 198
Diagnostic connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............... .. 199
Jump start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............... .. 199
Fork carriage emergency lowering . . . . . . . . . . . . . . . . . . . . . . ............... .. 201
Emergency exit with attached rear window . . . . . . . . . . . . . . . . ............... .. 202
Towing instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............... .. 203
Placing the forklift truck into storage . . . . . . . . . . . . . . . . . . . . . ............... .. 205
Disposal of old vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............... .. 205
Malfunctions during operation . . . . . . . . . . . . . . . . . . . . . . . . . . ............... .. 207
Malfunctions, Causes and Remedies (diesel engine) . . . . . . . . . ............... .. 209
Malfunctions, causes, remedies (hydraulic equipment) . . . . . . . ............... .. 212

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Table of contents
g

6 Technical data
Type sheet H 25, as at 09/2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Type sheet H 30, as at 09/2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Type sheet H 35, as at 09/2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Type sheet H 25, elevated driver’s compartment, as at 09/2010 . . . . . . . . . . . . . . . . . . 225
Type sheet H 30, elevated driver’s compartment, as at 09/2010 . . . . . . . . . . . . . . . . . . 228
Type sheet H 35, elevated driver’s compartment, as at 09/2010 . . . . . . . . . . . . . . . . . . 231
Load diagrams and lift mast data as at 05/2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Noise emission values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Vibration characteristics for body vibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

Annex

7 Circuit diagrams
Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Basic equipment for diesel with pump injection engine - sheet 1 . . . . . . . . . . . . . . . . . . 252
Basic equipment for diesel with pump injection engine - sheet 2 . . . . . . . . . . . . . . . . . . 254
Basic equipment for diesel with pump injection engine - sheet 3 . . . . . . . . . . . . . . . . . . 256
Special equipment sheet 01 - Working spotlights, interior light . . . . . . . . . . . . . . . . . . . 258
Special equipment sheet 02 − Windscreen wiper, seat heater, radio . . . . . . . . . . . . . . . 260
Special equipment sheet 03 - Heating system, air conditioning, flashing beacon /
rotating beacon, reversing signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Special equipment sheet 04 − Hazard warning system for reverse travel . . . . . . . . . . . 264
Special equipment sheet 05 − Lift mast positioning, hydraulic oil microfilter indicator,
truck deactivation, truck data management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
Special equipment sheet 06 − Particle filter, diesel filter water trap warning . . . . . . . . . . 268
Special equipment sheet 07 - Amount of gas display, 12 V socket, coolant and engine
oil level monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
Special equipment sheet 08 − Battery main switch with display unit power supply,
changing particle filter, rear window heating, camera system . . . . . . . . . . . . . . . . . . 272
Special equipment sheet 09 − Third auxiliary hydraulics with third joystick, centre rear
brake/tail light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
Special equipment sheet 10 - Single lever locked, third auxiliary hydraulics via joy-
stick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Special equipment sheet 11 - Single lever locked, third auxiliary hydraulics via
switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Special equipment sheet 12 - Lighting, direction indicator and hazard warning system,
brake light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

VIII Operating Instructions – 393 807 10 01 EN – 10/2010

 Table of contents
g

Special equipment sheet 13 - Higher lighting, higher direction indicator and hazard
warning system, higher brake light and reversing light . . . . . . . . . . . . . . . . . . . . . . . 282
Special equipment sheet 14 - Higher front / standard rear lighting . . . . . . . . . . . . . . . . . 284
Hydraulic circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
Traction, working and steering hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288

Operating Instructions – 393 807 10 01 EN – 10/2010 IX

 1

Introduction
1 Introduction
Your forklift truck

Your forklift truck

offers optimum economic efficiency, safety Servicing should only be carried out by qual-
and driving comfort. It is primarily down to ified personnel approved by Linde (special-
you to maintain these characteristics for a ists).
long time and take advantage of the resulting
With orders for parts, please specify the
benefits.
following along with the parts numbers:
During manufacture:
Truck model:
• all safety requirements of the relevant EC
directives were observed Production number /
Year of manufacture
• all conformity assessment procedures
stipulated in the applicable directives were Handover date:
carried out
The production number should also be spec-
This is attested by the CE mark shown on the ified for parts from the following units: en-
nameplate. gine, lift mast, hydraulic variable displacement
These operating instructions contain every- pump, drive axle and steering axle.
thing you need to know about commissioning,
Engine number:
driving and maintenance.
Lift mast number:
For trucks which are delivered from the factory
with an attachment, the operating instruc- Lift mast lift:
tions for the attachment are enclosed. Before
Hydraulic variable
starting a truck with an attachment, you must
displacement pump
make sure that loads are handled securely.
number:
Depending on the type of attachment, it may
be necessary to make adjustments, e.g. pres- Drive axle number:
sure settings or adjusting stops and operating Steering axle
speeds. See the attachment operating in- number:
structions for the corresponding notes. The
notes for operation of the attachment must When taking over the truck, this data should
also be observed. be copied from the identification plates of the
units into these operating instructions.
Carry out the specified work regularly, at the
due times and using the consumables envis-
NOTE
aged for this purpose in accordance with the
inspection and maintenance overview. Please In the event of repairs, only use genuine Linde
make sure you record the work performed in spare parts. This is the only way to guarantee
the registration document for the industrial that your truck remains in the same technical
truck; this is essential for any warranty claims. condition as at the time of reception.
The designations used in the text (front, back, Please address all queries and orders for
left, right) always refer to the installation spare parts relating to your truck only to
position of the parts described, with forwards your authorised dealer, stating your mailing
as the drive direction for the truck (fork arms address.
forwards).
Linde is constantly engaged in the further
Servicing work not described here will require development of its products. We ask for your
specialist knowledge, measuring devices and understanding that figures and technical data
frequently also special tools. Please ask your are subject to technical modification in terms of
authorised dealer to carry out this work.

2 Operating Instructions – 393 807 10 01 EN – 10/2010

 Introduction 1
Description of use and climatic conditions

form, equipment and expertise in the interest These operating instructions must not be
of progress. reproduced, translated or made accessible to
third parties—including as excerpts—except
For this reason, no claims can be asserted
with the express written approval of the
on the basis of the following data, figures and
manufacturer.
descriptions in these operating instructions.

Proper usage
The forklift truck is intended for transporting Regulations for proper use of industrial trucks
and stacking the loads indicated in the load must be observed without fail by the personnel
capacity diagram. We expressly draw your responsible, particularly by operating and
attention to: maintenance personnel.
• The VDMA brochure on "Rules for proper Before your truck is used for work not listed
use of industrial trucks", supplied with these in the guidelines, and which require it to be
operating instructions converted or retrofitted, please contact your
• The accident prevention regulations of your authorised dealer.
employer’s liability insurance association No modifications, in particular attachment or
• The special measures for driving on public conversion, should be made to your forklift
roads within the scope of the StVZO (Road truck without the manufacturer’s approval.
Traffic Licensing Regulations)
The user, and not the manufacturer Linde, is
• Other specific national regulations. liable for any hazards caused by improper use.

Impermissible use
The operating company or driver, and not the • for stacking/unstacking operations on
manufacturer, is liable if the truck is used in a slopes
manner that is not permitted. • for stepping onto the fork arms when the lift
It is not permitted to use the truck: mast is raised
• if the maximum load capacity is exceeded.
• for taking passengers
• in areas where there is a risk of fire of
explosion

Description of use and climatic conditions

Normal use Special use (partly with special mea-
• Indoor and outdoor use sures)
• Ambient temperature in tropical and Nordic • Use, e.g. in the event of abrasive dust (such
regions ranging from -15 °C to 50 °C as AL203), lint, acid, leach, salt, corundum,
• Start capability at -15 °C to 50 °C incombustible substances
• Maximum start time of 20 seconds • Ambient temperature in tropical regions up
to 55 °C
• Use at up to 2000 metres above sea level.
• Start capability to -25 °C
• Use at up to 3500 metres above sea level.

Operating Instructions – 393 807 10 01 EN – 10/2010 3

1 Introduction
Technical description

Symbols used
The terms DANGER, WARNING, CAUTION,
NOTE
NOTE and ENVIRONMENT NOTE are used
in these operating instructions for notes on Means that particular attention is drawn to
particular hazards or for unusual information combinations of technical factors which may
that needs to be highlighted: not be evident even to a specialist.
DANGER
ENVIRONMENT NOTE
Means that failure to comply can cause risk to life
and/or major damage to property. The instructions listed here must be complied
with as otherwise environmental damage may
result.
WARNING
CAUTION
Means that failure to comply can cause risk of
serious injury and/or major damage to property. This label is found on the truck in
the areas where particular care and
attention are required.
CAUTION You should refer to the appropriate
section in these operating instructi-
Means that failure to comply can cause risk of ons.
material damage or destruction.

For your safety, additional symbols are also

used. Please heed the various symbols.

Technical description
Forklift trucks in the 393 series are designed to motor. It drives the truck’s hydraulic pumps
handle loading and palletising operations for at a number of revolutions dependent on the
loads up to 2.5 t with H 25, up to 3 t with H 30 load. The engine is cooled by means of a
and up to 3.5 t with H 35. closed coolant circuit with expansion tank.
Details on the exact lift-height-specific maxi- Forced circulation lubrication with an oil pump
mum loads are available in the load capacity in the oil sump is used for engine lubrication.
diagram. The combustion air is cleaned by means of a
dry air filter with a paper insert. Diesel engines
The trucks are eco-friendly and their quiet
with state-of-the-art engine technology are
operational noise and low emission levels
used for:
benefit both the driver and the environment.
They excel on account of their compact design • High torque
and a small turning radius, and they are fully • Low fuel consumption
container compatible. For this reason, the
• Low exhaust emissions
trucks are particularly well-suited to narrow
entrances and operational areas where space • Low particulate emissions
is at a premium. • Low noise levels

Engine Hydraulic system

A 4-cylinder, four-stroke diesel engine with The drive unit consists of a hydraulic variable
turbocharging and state-of-the-art pump displacement pump, two hydraulic fixed
injection technology is installed as the drive displacement wheel motors (assembled as

4 Operating Instructions – 393 807 10 01 EN – 10/2010

 Introduction 1
Technical description

a drive axle unit), as well as a hydraulic pump • Millimetre-precise and secure load handling
(fixed displacement pump) for the working • Effortless finger-tip control of all lift mast
and steering hydraulics. Drive direction and functions
driving speed are regulated by means of two
• Drive and lifting functions are entirely
accelerator pedals via the hydraulic variable
separate.
displacement pump.
The hydraulic fixed displacement wheel Linde Truck Control
motors in the drive axle are supplied by the
hydraulic variable displacement pump and The truck’s Linde Truck Control control
they power the drive wheels. electronics system (LTC) offers:
• Sensitive, smooth driving and reversing
Operation • Automatic regulation of the engine speed to
One accelerator pedal each for forward and match the respective power required by the
reverse travel (dual-pedal operation) is used hydraulics
to simultaneously regulate the hydraulic • Fast service by means of self-diagnosis
variable displacement pump and the engine • Optimum operational reliability.
speed. The hydrostatic drive enables the
driving speed to be continuously varied in
Brakes
both directions, ranging from standstill to the
maximum speed. The dual-pedal control The hydrostatic drive is used as the service
means that operation of the truck is simple, brake. This means that the service brake is
safe, non-fatiguing and efficient. maintenance-free. Two multi-disc brakes
incorporated in the wheel motors are used
The driver always has both hands free for
as the parking brake. When the engine is
steering and controlling operational move-
switched off, the multi-disc brakes engage,
ments. This results in fast reversing and effi-
meaning that the truck has an automatic brake
cient stacking.
function. Always apply the parking brake
An optional version is also available whereby when parking the truck.
the driving speed is regulated by an acceler-
ator pedal (single pedal operation) and the Steering
drive direction controlled by means of a drive
direction switch. The steering is a hydrostatic steering system,
under which the steering wheel acts on the
To control the operational movements of lift- steering cylinder to actuate the rear wheels.
ing, lowering and tilting, there is only one actu- If the power applied to the steering wheel is
ating lever (joystick). Another joystick is fitted increased, the steering system can also be
for actuation of additional attachments. Op- operated when the engine has been switched
erational movements can also be controlled off.
using two or four joysticks (single-lever opera-
tion version).
Lift mast
Linde Load Control The free-view lift mast enables:

The truck’s Linde Load Control (LLC) control • Ideal visibility through slim mast profiles
electronics system enables: • Full load capacity up to maximum lift heights
• Enormous residual load capacity

Operating Instructions – 393 807 10 01 EN – 10/2010 5

1 Introduction
Reception of truck

• Maintenance-free bearings for lift mast and Electrical system

tilt cylinders via rubber-cushioned linkage
The electrical system is powered by the
points
three-phase alternator with 12 V DC voltage. A
• Electric tilt angle limitation. 12 V battery with 88 Ah is installed for starting
the engine. It is located under the driver’s seat
in the engine compartment.

Truck operation when using a shovel

When operating the truck with a shovel, stall
NOTE
protection can be activated by your authorised
dealer. For a period of extended loading of the
engine, the joystick must be switched to the
In this case, extreme loading of the drive
zero position in order to release the working
engine due to the associated engine speed
hydraulics again.
decrease leads to a slight delay in executing
the working hydraulics.

Reception of truck
Before the truck leaves our factory, it is tion. This must be removed after attaching the
subjected to a careful inspection to ensure lift mast by loosening the hexagon head screw
that it is in perfect condition and is received by and removing it along with the hexagon nut
you complete with all equipment according to (see also Driving without lift mast).
your order.
Each forklift truck comes with the following
To avoid subsequent complaints, please be technical documents:
so kind as to carefully check the condition
• operating manual for forklift truck
of the truck and the completeness of the
equipment yourself and to confirm proper • EC Declaration of Conformity (manufac-
handover/reception with your dealer. turer confirms that industrial truck complies
with requirements of EC Machinery Direc-
tive).
NOTE
• Safety rules for the use of industrial trucks
For trucks which leave our factory without a (VDMA)
lift mast, an additional stop screw for speed • Registration document for the industrial
limitation can be found under the forwards/re- truck, provided on handover by your autho-
versing accelerator pedal (dual pedal opera- rised dealer.
tion) or accelerator pedal (single pedal opera-

6 Operating Instructions – 393 807 10 01 EN – 10/2010

 Introduction 1
Legal requirements for marketing

Legal requirements for marketing

Declaration

Linde Material Handling GmbH

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

We declare that the machine

Industrial truck according to these operating instructions

Model according to these operating instructions

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

Personnel authorised to compile the technical documents:

see EC declaration of conformity

Linde Material Handling GmbH

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

quirements of the EC machinery directive.
The manufacturer declares that the truck com-
plies with the requirements of the EC machin- An independent structural change or addition
ery directive and any other EC directives, if to the truck can compromise safety, thus
applicable, that are valid at the time of market- invalidating the EC declaration of conformity.
ing. This is confirmed by the EC declaration
The EC declaration of conformity must be
of conformity and by the CE labelling on the
carefully stored and made available to the
nameplate.
responsible authorities if applicable. It must
The EC declaration of conformity document also be handed over to the new owner if the
is delivered with the truck. The declaration truck is sold on.

Operating Instructions – 393 807 10 01 EN – 10/2010 7

1 Introduction
Service plan before initial commissioning

Service plan before initial commissioning

Carried
out
9 8
Engine
Fill up with fuel
Check the engine oil level
Checking the coolant level
Regenerate the particle filter
Chassis frame
Tighten wheel fastenings
Check the tyre pressure
Checking the brake system
Check steering system.
Electrics / Electronics
Battery: check condition, acid level and acid density
Hydraulics
Hydraulic system: Check the oil level.
Check lifting system and attachments.
Check function and safety system of third auxiliary hydraulics

8 Operating Instructions – 393 807 10 01 EN – 10/2010

 2

Safety
2 Safety
Safety guidelines

Safety guidelines
The "Rules for proper use of industrial trucks" Safety information
supplied with these operating instructions
must be brought to the attention of the persons DANGER
responsible, in particular to those persons The truck must not be used by unauthorised per-
concerned with operating and maintaining the sons.
trucks, before working with or on the trucks. As the operating company, you must ensure that
access to the truck is only possible for authorised
The operating company must ensure that the personnel.
driver understands all the safety information.
Please observe the directives and guidelines
DANGER
listed, e.g.
Safety systems (e.g. the seat switch) are there for
• Operation of industrial trucks, your safety.
• Driving licence, Safety systems - of whatever kind - must never be
• Rules for driveways and the area of opera- disabled.
tion,
• Rights, duties and rules of behaviour for the DANGER
driver,
Loads should be arranged so that they do not
• Special operating areas project beyond the edge of the truck loading surface
• Information regarding setting off, driving and cannot slip, topple over or fall off.
and braking, If necessary, use a load backrest (special equip-
ment).
• Information for maintenance and repair,
• Periodic checks,
• Disposal of greases, oils and battery, DANGER
• Residual risks. When retrofitting a 3rd auxiliary hydraulic system,
using solutions other than those recommended by
As the operating company or responsible the truck manufacturer will render CE conformity
person, ensure that all directives and safety null and void, and is therefore expressly prohibited.
guidelines that are applicable to your industrial Trucks may be retrofitted with a 3rd auxiliary hy-
truck are complied with. draulic system only with the approval of the truck
manufacturer.
When training a forklift truck driver who has
already been trained to BGV D27 standard,
the following must be practised sufficiently by DANGER
training, driving, switching and steering, so It is prohibited for any safety-critical functions such
that they are fully mastered: as a bale clamp or the swivel device for a fluid
container to be connected to any (toggle-switch-
• The special features of the Linde truck controlled) third auxiliary hydraulic system that may
(dual-pedal control, central control lever be fitted.
(joystick), stop pedal), To prevent inadvertent opening of the clamp or
• Any special equipment for attachments, swivel device, the additional function should be
connected to the first auxiliary hydraulic system.
• Peculiarities of operation and the working
area
Only then should training exercises in the
racking commence.

10 Operating Instructions – 393 807 10 01 EN – 10/2010

 Safety 2
Residual risks

DANGER WARNING
Any additional bores or welding to the overhead Depending on the duration of use and
guard will compromise its rigidity. operating time, components carrying
It is therefore strictly prohibited to drill holes in the exhaust gases and exhaust air may
overhead guard or to weld to it. become hot.
Therefore wear protective equip-
ment.
CAUTION
Welding operations on other parts of the truck can
cause damage to the electronics. WARNING
Therefore, always disconnect the battery and all The truck working area must be adequately lit.
connections to the electronic controls beforehand. If it is insufficiently lit, working spotlights must be
installed to ensure that the driver can see properly

CAUTION
For ease of operation, various functions on your CAUTION
truck are gas-spring assisted. Gas springs are Various items of special equipment fitted to your
complex components which contain high internal truck have the "speed reduction" special function
pressures (up to 300 bar). . It is purely an assistance function. This means
They may under no circumstance be opened un- that the driver must not rely solely on the "speed
less so directed, and may be removed only when reduction" function during operation.
not under compression. Any damage, lateral for- The driver is always responsible for safe operation.
ces, buckling, temperatures in excess of 80° C and
heavy contamination must generally be avoided.
Damaged or defective gas springs must be chan-
ged immediately. Please contact your authorised CAUTION
dealer. He will, if necessary, depressurise the gas The functioning of active medical equipment, e g:
spring in accordance with regulations before dis- pace makers or hearing aids, may be impaired.
mantling it. Gas springs must be depressurised
before recycling. Check with a doctor or the medical equipment
manufacturer whether the equipment is sufficiently
protected against electromagnetic interference.
WARNING
The following issues must be observed when an NOTE
accumulator is fitted. Improper handling of the
accumulator can lead to serious injuries. If your truck is equipped with a fire extinguis-
Before starting work on the accumulator it must
her, make sure that you familiarise yourself
be depressurised. Please contact your authorised with it in case of an emergency. Information
dealer. about handling is given on the fire extinguis-
her.

Residual risks
Despite careful work and compliance with its proper purpose and all instructions are fol-
all applicable standards and regulations, the lowed, some residual risk cannot be excluded.
possibility of other dangers when using the
Even beyond the narrow danger areas of the
industrial truck cannot be entirely excluded.
industrial truck itself, a residual risk cannot
The industrial truck and its possible attach- be excluded. Persons in the area around the
ments comply with current safety regulations. industrial truck must exercise a heightened
Nevertheless, even when the truck is used for degree of awareness, so that they can react

Operating Instructions – 393 807 10 01 EN – 10/2010 11

2 Safety
In the case of tip-over

immediately in the event of any malfunction, • Risk of falling, tripping, slipping etc. during
incident or breakdown. movement of the industrial truck, especially
in the wet, with leaking consumables or on
DANGER icy surfaces,
Persons in the vicinity of the industrial truck must • Risk of fire and explosion due to the battery
be instructed with regard to the dangers that arise and electrical voltages,
through use of the truck.
• Human error,
These operating instructions also contain additional
safety regulations. • Disregarding the safety regulations,
• Risk caused by unrepaired damage,
Residual dangers can include: • Risk caused by insufficient maintenance or
• Escape of consumables due to leakages or testing,
the rupture of lines, hoses or containers, • Risk caused by using the wrong consum-
• Risk of accident when driving over difficult ables.
ground such as gradients, smooth or
irregular surfaces, or with poor visibility,

Stability
Stability is guaranteed if your industrial truck is • turning and driving diagonally across
used according to its intended purpose. descents or ascents,
• driving on descents or ascents with the load
Stability will not be guaranteed in the event of:
on the downhill side,
• cornering at excessive speeds,
• loads that are too wide,
• moving with the load raised,
• driving with a swinging load,
• moving with a load that is protruding to the
• ramp edges or steps.
side (e.g. sideshift),

In the case of tip-over

• Stay buckled up The stability of your truck is ensured if used

• Don’t jump properly and as intended. Should the truck
tip over during an unapproved application or
• Hold on tight
due to incorrect operation, always follow the
• Brace feet instructions depicted below.
• Lean away

12 Operating Instructions – 393 807 10 01 EN – 10/2010

 Safety 2
Operation of industrial trucks in plant area

Handling consumables
• Comply with the statutory provisions.
ENVIRONMENT NOTE
• Before performing greasing, filter changes
Consumables must be handled properly or any work on the hydraulic system,
and in accordance with the manufacturer’s carefully clean the area around the part
instructions. involved.
• Consumables should only be stored in • Dispose of used spare parts in an environ-
containers complying with applicable mentally friendly manner.
regulations and at the locations stipulated.
WARNING
• Do not bring flammable consumables into
contact with hot objects or a naked flame. The penetration of pressurised hydraulic fluid into
the skin, e.g. due to leakage, is hazardous. If an
• When topping up consumables, use only injury of this type occurs, always consult a doctor.
clean containers.
Protective equipment must be worn.
• Observe the manufacturer’s instructions
relating to safety and disposal.
• Avoid spilling. WARNING
• Remove any spilled fluid immediately with a The improper handling of coolant and coolant addi-
suitable binder and dispose of it according tives presents a risk to health and the environment.
to applicable regulations. Observe the manufacturer’s instructions without
fail.
• Old and contaminated operating materials
should be disposed of according to the
regulations.

Specialist
A specialist is considered to be someone standards, VDE regulations, technical reg-
whose technical training, experience and re- ulations of other EU member states or other
cent professional activities have enabled them countries that are signatories to the treaty es-
to develop a sufficient depth of knowledge re- tablishing the European Economic Area) in
garding industrial trucks and who is sufficiently order to be able to assess the condition of in-
familiar with the applicable national occupa- dustrial trucks in terms of health and safety.
tional health and safety regulations, accident
prevention regulations, directives and gen-
erally recognised technical conventions (DIN

Operation of industrial trucks in plant area

Many plant areas are so-called limited public claims for damages caused by your truck
traffic areas. In this sense, we would like to in limited public traffic areas in relation to
advise you to check your company liability third parties are included in the insurance
insurance coverage, to ensure that possible coverage.

Operating Instructions – 393 807 10 01 EN – 10/2010 13

2 Safety
Regulations

Regulations
Periodic safety inspection
Periodic safety inspections are essential in
order to keep your truck / industrial truck safe
and in good working order.
Comply with the national regulations for your
country.
Europe: National laws based on the Directives
95/63/EC, 99/92/EC and 2001/45/EC require
that the truck / industrial truck is checked
regularly by a competent person to ensure
it is in good condition.
Germany: Ordinance on Industrial Safety and
Health (BetrSichV).
There is a recommendation setting out the
scope of the inspection, FEM 4.004 of the
European Industrial Truck Association, which
defines a test log to document the current
inspection and an inspection sticker for the
next inspection. The next inspection is shown
by the year number (3) on an adhesive label
(2), the colour of which changes each year, on
the label (1). The scope of the inspection
is extended by Linde in accordance with
the specific truck type. Please ask your
authorised dealer to carry out this work.

Diesel engine emissions (DME)

When using trucks with diesel engines in the
Federal Republic of Germany, please observe
regulation TRGS 554. This classifies DME
as carcinogenic hazardous materials. These
should not be allowed to infiltrate the air in
workplaces. If trucks with diesel engines are
used in fully or partially enclosed spaces,
this must first be reported to the relevant
occupational health and safety authorities.
Operating instructions should be posted in
the working areas (for an example, see the
appendix to TRGS 554).

Particle filter system testing

The relevant authorities prescribe that particle
filter systems must be serviced and tested
by a competent person every 6 months. The

14 Operating Instructions – 393 807 10 01 EN – 10/2010

 Safety 2
Instructions before fitting attachments

test results must be entered in a "certificate

regarding the analysis of the diesel engine
exhaust gases" and enclosed with the report
book.

Instructions before fitting attachments

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

Operating Instructions – 393 807 10 01 EN – 10/2010 15

2 Safety
Instructions before fitting attachments

16 Operating Instructions – 393 807 10 01 EN – 10/2010

 3

Overview
3 Overview
Identification plates

Identification plates

1 Nameplate
9 Lift mast number (adhesive label)
10 Chassis number (stamped into the roofing
sheet)
11 Drive axle identification plate
12 Engine identification plate

18 Operating Instructions – 393 807 10 01 EN – 10/2010

 Overview 3
Identification plates

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

1 Nameplate
2 Manufacturer
3 Model / Production no. / Year of manufac-
ture
4 Tare weight
5 CE mark
6 Nominal driving power
7 Rated capacity

13 Identification plate for the 302 series steer-

ing axle
14 Identification plate for the 1602 series
steering axle

Operating Instructions – 393 807 10 01 EN – 10/2010 19

3 Overview
Additional capacity rating plate for attachments

Additional capacity rating plate

for attachments
DANGER
The entries in the following capacity rating plates
are examples. The information will vary depending
on the truck series, lift mast series, truck equipment
and attachment. If an attachment is fitted, an
additional capacity rating plate must be attached
to your truck within the driver’s field of vision.
If the plate is missing or the information about
the truck equipment, attachments, load data etc.
is not accurate, please contact your authorised
dealer, who will calculate the data using a program
authorised by Linde.

Additional capacity rating plate for attachments with loads that are not clamped

1 Truck series (year of manufacture, from - to) 7 Reference number and note about person
2 Lift mast type (series) calculating the load capacity
3 Lift heights 8 Front tyres
4 Attachments 9 Maximum permissible centre offset of load
5 Load capacities 10 Maximum permissible load height
6 Load centres of gravity 11 Maximum permissible backward tilt of lift
mast

NOTE
Example for reading the load capacity:
• a = 3930 kg at load centre of gravity b =
900 mm to lift height c = 7200 mm.

20 Operating Instructions – 393 807 10 01 EN – 10/2010

 Overview 3
Additional capacity rating plate for attachments

Additional capacity rating plate for attachments with loads that are fixed or clamped

1 Truck series (year of manufacture, from - to) behaviour: at a load centre of gravity
2 Lift mast type (series) 650 mm = 4,560 kg.
3 Lift heights 11 Specifies in mm how much the load centre
4 Attachments of gravity is offset vertically upwards to the
5 Load capacities centre of the attachment (e.g. roller / bale
6 Reduced load capacities taken off).
7 Load centres of gravity Also applicable for attachments with a rotate
8 Reference number and note about person function: The actual centre of gravity of the
calculating the load capacity load during rotation must not lie outside the
9 Front tyres pivot point by more than 100 mm (truck rated
10 Note — If there is sufficient visibility for capacity ≤ 6300 kg) or 150 mm (truck rated
forwards travel when transporting loads, capacity > 6300 kg and ≤ 10,000 kg)!
we recommend that the calculated residual 12 Maximum permissible centre offset of load
load capacity based on the roller height / 13 Maximum permissible load height
load height (value = maximum permissible 14 Maximum permissible backward tilt of lift
load height (13)) is limited to the following in mast
order to achieve a more dynamic driving

NOTE
Example for reading the load capacity:
• a = 4340 kg at load centre of gravity b =
650 mm to lift height c = 6800 mm.

Operating Instructions – 393 807 10 01 EN – 10/2010 21

3 Overview
Truck overview

Truck overview

1 Lift mast 15 Chassis with overhead guard

2 Lift cylinder 16 Bonnet
3 Display unit 17 Step for entering and exiting the truck
4 Tilt cylinder 18 Fuses (in the engine compartment)
5 Toggle switch for additional functions 19 Left-hand wheel motor
(special equipment) 20 Clamping screw for adjusting the steering
6 Steering wheel / hydrostatic steering column
7 Actuating lever (joystick) 21 Fork carriage
8 Driver’s seat 22 Fork arm safety devices
9 Cover for electrical system 23 Fork arms
10 Fuses (behind the cover) 24 Fork arm latch
11 Diagnostic connector 25 Lift mast chain (only with duplex or triplex lift
12 Counterweight masts)
13 Steering axle 26 Handhold for entering and exiting the truck
14 Maintenance covers (special equipment)

22 Operating Instructions – 393 807 10 01 EN – 10/2010

 Overview 3
Operating devices

Operating devices

1 Indicator light for turn indicator and hazard 10 Actuating lever (joystick) for auxiliary hy-
warning system (green) (special equipment) draulics (attachments) (special equipment)
2 Clamping screw for adjusting the steering 11 Symbol label for auxiliary hydraulics (attach-
column ments) (special equipment)
3 Multifunction lever for wiper/washer system 12 Symbol label for working hydraulics
and turn indicator (special equipment) 13 Armrest on driver’s seat
4 Steering wheel / hydrostatic steering 14 Driver’s seat
5 Signal button 15 Forward travel accelerator pedal
6 Parking brake lever 16 Stop pedal
7 Starting switch with switch key 17 Reverse travel accelerator pedal
8 Compartment 18 "Guaranteed sound power level" label
9 Actuating lever (joystick) for working hy-
draulics

Operating Instructions – 393 807 10 01 EN – 10/2010 23

3 Overview
Display unit

Display unit

24 Operating Instructions – 393 807 10 01 EN – 10/2010

 Overview 3
Display unit

1 Display unit 20 Symbol without function

2 Hydraulic oil temperature indicator 21 Function key
3 Charging indicator 22 Reset button
4 Engine oil pressure indicator / engine oil 23 Time display
level indicator (special equipment) 24 "Do not start the engine" symbol
5 Electrical controller fault 25 Symbol for "Parking brake applied"
6 Engine coolant temperature indicator 26 Symbol for "Operating hours until the next
7 Lift height restriction (function / warning) service" (shown for only 5 sec in the display
(special equipment) (17))
8 Particle filter warning 27 Symbol for "Seat belt not fastened" (special
9 Vibration absorption (special equipment) equipment)
10 Water in the fuel filter (special equipment) 28 Text field
11 Hydraulic oil microfilter indicator (special 29 "Lift mast position identification" symbol
equipment) active (special equipment)
12 Level display for diesel tank, LPG tank / 30 Display
replacement cylinders or CNG tank 31 Air filter vacuum indicator
13 Symbol for "Particle filter" 32 Coolant level indicator
14 Symbol without function 33 Preheating indicator (function only available
15 Symbol for "Service interval exceeded" on diesel trucks)
16 Operating hours symbol 34 Gas system error light (function only avail-
17 Operating hours display able on LPG trucks)
18 Symbol without function 35 Engine malfunction warning light
19 Symbol for "Clock display (am/pm)"

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

Possible malfunctions
Display element Function
Remedy
- Lights up if the maximum Insufficient oil in the hydraulic
permissible temperature is circuit
reached. A buzzer also sounds Incorrect oil used
if the temperature limit is
(2) Hydraulic oil temperature exceeded. Oil filter clogged
indicator With activated function "Engine
Oil cooler clogged
(red) protection"*):
- Truck moves at creep speed
(approx. 2 km/h) Switch off the buzzer with the
Display in the text field (28): reset button (22)
- Error code X205

Operating Instructions – 393 807 10 01 EN – 10/2010 25

3 Overview
Display unit

Possible malfunctions
Display element Function
Remedy
V-ribbed belt split or V-ribbed
belt tension too slack
V-ribbed belt tensioner
defective

(3) Charging indicator - Lights up if there are Cable defective

(red) generator malfunctions. Alternator defective
Charging controller or cut-out
relay defective
Short circuit at output D+ of the
display unit
- Lights up and buzzer sounds Insufficient oil in the crankcase
when the oil pressure is too
low. Engine too hot
- If in addition the text field Incorrect oil used
(28) shows Oil with a double
arrow pointing downwards, Internal leakage in the
the engine oil level is too low. lubricating oil circuit
(4) Engine oil pressure (special equipment) Topping up with engine oil
indicator / engine oil level With activated function "Engine
indicator protection"*):
(red) - Truck moves at creep speed
(approx. 2 km/h)
Display in the text field (28): Switch off the buzzer with the
- Error code X202 if the oil reset button (22)
pressure is too low.
- Error code X201 and Oil
with double arrow pointing
down, if the oil level is too low.
- Lights up when an electrical
(5) Electrical controller fault fault is present.
(red) Error code is displayed in the
text field (28).
- Lights up if the maximum Fan motor defective
permissible temperature is
reached. A buzzer also sounds Thermal switch defective
if the temperature limit is Water cooler clogged
(6) Engine coolant tempera- exceeded.
ture indicator With activated function "Engine Leakage in the cooling circuit
(red) protection"*):
Coolant level too low
- Truck moves at creep speed
(approx. 2 km/h) Switch off the buzzer with the
Display in the text field (28): reset button (22)
- Error code X204

26 Operating Instructions – 393 807 10 01 EN – 10/2010

 Overview 3
Display unit

Possible malfunctions
Display element Function
Remedy
(7) Lift height restriction - Lights up green when the
(function / error) specified lift height is reached
Sensor system defective
(green / red) - Lights up red in the event of
(special equipment) an error in the sensor system
- Lights up with activated Regenerate the particle filter
particle filter control system, immediately
if the load period of the particle
filter exceeds 8.5 h.
- Additionally, a buzzer sounds
(8) Particle filter error
and in the text field (28) an error
(red) Error in the particle filter control
code appears in the event of an
error in the particle filter control system
system. The truck moves
only at creep speed (approx.
2 km/h).
(9) Vibration absorption - Lights up if vibration
(yellow) absorption is active for the lift
(special equipment) mast
- Lights up if water has Drain water from the fuel filter
(10) Water in the fuel filter collected in the fuel filter
(yellow) - Additionally, a buzzer sounds Switch off the buzzer with the
(special equipment) if the warning light is activated reset button (22)
for more than 5 seconds
(11) Hydraulic oil microfilter
indicator - Lights up if the pressure filters
Microfilter clogged, change it
(yellow) require maintenance work.
(special equipment)
(12) Level display for diesel Shows the current fuel
tank, LPG tank / replacement level in the diesel tank, the
cylinders or CNG tank current level in the LPG tank /
(green or red depending on replacement cylinders or the
the fuel level) current level in the CNG tank.
(13) Symbol for "Particle - Lights up if the particle filter
filter" control system is active.
(14) Symbol without function
If the number of operating
hours until the next service
(15) Symbol for "Service is less than or equal to 0, the The display can only be reset
Interval Exceeded" symbol flashes for 10 sec every using the diagnostic program.
time the truck is started, and
then lights up continuously.
Flashes when operating hours
are being counted (only when
(16) Operating hours symbol
the ignition is on and the engine
speed exceeds 300 rpm).

Operating Instructions – 393 807 10 01 EN – 10/2010 27

3 Overview
Display unit

Possible malfunctions
Display element Function
Remedy
If a defective display unit
Indicates the operating hours is changed, the operating
of the truck. This display hours up to that point must be
is evidence of the truck’s recorded. Affix the data on an
(17) Operating hours display
operating time and of the embossed strip near the display
inspection and maintenance unit. There is also the option of
work to be performed. updating the new display unit at
a later time.
(18) Symbol without function
For 12-hour format: The diagnostic program can be
(19) Clock display (am/pm) am = morning used to reset the display to a
pm = afternoon 12-hour clock.
(20) Symbol without function
- Adjusting the time
(21) Function key - Scrolling through error
messages
- Adjusting the time
- Scrolling through error
(22) Reset button
messages
- Turning off the warning sound
24-hour clock display The diagnostic program can be
(23) Time display Adjustable using the (21) and used to reset the display to a
(22) push buttons. 12-hour clock.
- Lights up when the engine Always leave the ignition
(24) Symbol for "Do not start has stalled. (A block against switched on until the symbol
the engine" repeat starting is active and the goes out.
engine cannot be started). Then repeat the start attempt.
(25) Symbol for "Parking - Lights up if the parking brake
brake" is activated.
After the ignition has been
switched on, display field (17)
shows the operating hours
until the next service (counting
backwards).
(26) Symbol for "Operating
Symbol (26) lights up. After
hours until the next service"
5 seconds, symbol (26) goes
out and display (17) switches
automatically to the truck’s
operating hours; operating
hours symbol (16) flashes.
(27) Symbol for "Seat belt not
- Lights up if seat belt was not
fastened" Fasten the seat belt.
fastened
(special equipment)

28 Operating Instructions – 393 807 10 01 EN – 10/2010

 Overview 3
Display unit

Possible malfunctions
Display element Function
Remedy
Charge status display:
Serves as display field for error
- 0 symbols blacked out =>
code display and charge status
(28) Text field particle filter empty
display for particle filter (in
- 11 symbols blacked out =>
line 1).
particle filter full
(29) Symbol for "Lift mast - Lights up when the "Lift mast
position identification" position identification" function
(special equipment) is activated.
Serves as a text display and
(30) Display
symbol display
(31) Air filter vacuum
- Lights up when the air filter is
indicator Air filter clogged, change it.
excessively clogged.
(yellow)
- Lights up when the coolant
level is below the minimum.
With activated function "Engine
(32) Coolant level indicator protection"*):
Top up the coolant.
(yellow) - Truck moves at creep speed
(approx. 2 km/h)
Display in the text field (28):
- Error code X203
Function only available on
diesel trucks:
- Lights up whilst the glow plugs
(33) Glow plug indicator Identify the error using the
are preheating, then goes out.
(yellow) diagnostic program.
- Flashes when a malfunction
exists in the engine or in the
engine control unit.
Function only available on LPG
(34) Gas system error light trucks: Identify the error using the
(red) - Lights up if an error is detected diagnostic program.
in the gas system.
(35) Engine malfunction
- Lights up if an error is detected Identify the error using the
warning light
by the engine control unit. diagnostic program.
(yellow)

*) The "engine protection" function (special equipment) can be disabled using the diagnostic
program. Please contact your authorised dealer.

Operating Instructions – 393 807 10 01 EN – 10/2010 29

3 Overview
Switch panel

Switch panel

1 Switch panel at the top right in the driver’s 8 Rear window wiper - intermittent mode or
cab with: continuous operation on/off (washer system
2 Interior lighting is activated)
3 Standard or higher lighting 9 Roof panel wiper - intermittent mode or
4 Working spotlight position 1/2 continuous operation on/off (washer system
5 Working spotlight position 3/4 or working is activated)
spotlight position 5/6 10 Hazard warning light
6 Working spotlight position 7/8 11 Particle filter starting switch
7 Front windscreen wiper - continuous oper- 12 Particle filter stop/reset switch
ation on/off (intermittent mode and washer 13 Changing particle filter system error light
system always activated) 14 Rotating beacon or flashing beacon
15 Rear window heating or other special switch

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

30 Operating Instructions – 393 807 10 01 EN – 10/2010

 4

Operation
4 Operation
Standard equipment

Running-in instructions
The lift truck can be operated at full speed Tighten opposite wheel fasteners to a torque
directly. Avoid sustained high loads on the of
working hydraulic system and the travel
drive in the first 50 hours of operation. The front: 170 Nm
wheel fasteners must be tightened before the rear: 460 Nm
commissioning and after each wheel change.
Thereafter at least every 100 operating hours.

Checks before starting work

Carried
out
9 8
Engine
Check the fuel level
Check the engine oil level
Checking the coolant level
Chassis frame
Check the tyre pressure
Hydraulics
Hydraulic system: Check the oil level.

Standard equipment
Adjusting the driver’s seat

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

32 Operating Instructions – 393 807 10 01 EN – 10/2010

 Operation 4
Standard equipment

Longitudinal adjustment
¾ Pull lever (2) upwards.
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 Allow lever to click back into place.

Adjusting the seat backrest

¾ Push lever (1) upwards and hold in place. 1
¾ Move the seat backrest forward and back
until a comfortable sitting position for the
driver is found.
¾ Release lever (1).
d3921352 2

Adjusting the lumbar support (special

equipment)
¾ Turn the knob (3) until a comfortable sitting
3
position is reached.
Turn in clockwise direction: lumbar support
arches outwards.
Turn in anti-clockwise direction: lumbar 6
support returns to starting position.

Setting the driver’s weight

¾ Turn the adjustment wheel (5) to set the
driver’s weight for the suspension.
The adjustment range between 50 kg and 130
kg can be read off on the adjustment range
display (4).
5 4
Turn in anti-clockwise direction to reduce d3921353

weight.
Turn in clockwise direction to increase weight.

Operating Instructions – 393 807 10 01 EN – 10/2010 33

4 Operation
Standard equipment

Adjusting the seat angle (special

equipment)
¾ Lift the button (6).
The seat is moved to the desired position
by applying pressure to the seat surface or
removing pressure from it.

Adjusting the seat depth (special

equipment)
¾ Lift the button (9).
The seat can be moved to the desired position
by sliding the seat surface forward or to the
rear.

Adjusting the backrest extension (special

equipment)
¾ Push the backrest extension (7)in or pull it
out for individual adjustment.

Activating the seat heater (special

equipment)
¾ Turn the switch (8) on or off.

Adjusting the seat height (special

equipment)
Upwards:

34 Operating Instructions – 393 807 10 01 EN – 10/2010

 Operation 4
Standard equipment

¾ Raise the seat until you hear it engage.

Downwards:
¾ Lift the seat to the stop, then it will sink to its
lowest position.

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

Adjusting the driver’s seat armrest

NOTE
The armrest on the driver’s seat is automa-
tically raised by spring pressure after the
locking screw (1) is released.
¾ Sit down on the driver’s seat and slacken 4
locking screw (1).
3
¾ Push the armrest (3) down against the
spring pressure until a comfortable position
for the arm is found.
¾ Tighten locking screw (1). 2
¾ Slacken locking screw (2) and push the
armrest (3) forwards or backwards until the
actuating levers (4) can easily be reached.
¾ Tighten locking screw (2).
1

d3921416

Entering and exiting the truck

WARNING
Entering and exiting the truck can result in injuries
to the feet or back.
Always face the truck when you enter or exit the
truck.

Operating Instructions – 393 807 10 01 EN – 10/2010 35

4 Operation
Standard equipment

NOTE
Do not use the steering wheel or the actuating
levers as an aid to get in or out.
¾ Use handle (1) (special equipment) or
longitudinal member (2) and step (3).

Adjusting the steering column

DANGER
Safe driving is not guaranteed with the clamping
screw open.
Only adjust the steering column when the vehicle is
stationary.

Angle adjustment
¾ Undo the clamping screw (2) anticlockwise.
¾ Move the steering wheel (1) into the re- 1
quired position.
¾ Tighten the clamping screw (2) clockwise.

Height adjustment
¾ Undo the clamping screw (2) anticlockwise.
¾ Move the steering wheel (1) into the re-
quired position by pulling it up or pushing it
down.
¾ Tighten the clamping screw (2) clockwise.

2 t3921369

36 Operating Instructions – 393 807 10 01 EN – 10/2010

 Operation 4
Standard equipment

Setting the clock

NOTE
The time is displayed in 24-hour format. It is
possible to change to 12-hour format using
the diagnostic device. Please contact your
authorised dealer.
¾ Press both push buttons (2) and (3) simulta-
neously for 3 seconds.
The hour readout in the time display (1)blinks.

NOTE
The hours or minutes can be adjusted gradu-
ally by pressing push button (2) or quickly by
holding down the push button.
¾ Depress button (2) to set the hours.
¾ Depress button (3) to confirm the hour
setting.
Now the minute readout blinks.
¾ Depress button (2) to set the minutes
¾ Depress button (3) to confirm the setting of
the minutes.

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

WARNING
Perfect functioning of the seat belt must be ensured.
For this reason the belt should not become twisted,
trapped or tangled up. The lock and belt retractor
should be protected from foreign bodies, damage
and dirt.

Operating Instructions – 393 807 10 01 EN – 10/2010 37

4 Operation
Standard equipment

NOTE
Driver’s cabs with fixed closed doors or
bracket doors satisfy the safety requirements
for driver restraint systems. The seat belt
can be used in addition. It must, however,
be affixed when driving with doors that are
open or have been removed. PVC doors do
not constitute an operator restraint system.
For trucks with the "speed reduction" special
function, the seat belt must be worn even at
the reduced speed.
The automatic blocking mechanism prevents
the belt from being extended whenever the
industrial truck is on a steep slope. It is then
not possible to pull the belt any further out
of the retractor. To release the automatic
blocking mechanism carefully move the truck
so that it is no longer positioned at an angle.
While using the truck (e.g. driving, operating
lift mast etc.), adopt a sitting position as far
back as possible so that the driver’s back rests
against the seat backrest. The automatic
blocking mechanism of the belt retractor offers
sufficient freedom of movement on the seat for
normal use of the fork-lift truck.
¾ Draw seat belt (1) smoothly from the
retractor on the left.
5 1

¾ Position belt over lap, not over stomach.

¾ Allow buckle (2) to snap into place in catch
lock of belt (4).
¾ Check seat belt tension.
Belt must fit close to the body. 4

Open seat belt 2

¾ Press the red button (5) on the buckle (4).
¾ Feed the buckle (2) manually back into the
retractor (3). 3
d3921415
NOTE
The automatic blocking mechanism may be
triggered if the belt runs in too quickly when the
buckle strikes the housing. The belt cannot be
pulled out with normal force.

38 Operating Instructions – 393 807 10 01 EN – 10/2010

 Operation 4
Standard equipment

Drive engine (dual-pedal operation)

Starting the engine
DANGER
Risk of poisoning!
Do not allow the engine to run in
unventilated areas.

NOTE
Where possible, avoid frequently starting and
stopping the engine over short periods of time,
since this prevents the internal combustion
engine from reaching its operating tempera-
ture. Frequent cold starts increase wear.
¾ The actuating lever (joystick) must be in the
neutral position.
¾ Sit down on the driver’s seat.
¾ Fasten the seat belt.
¾ Place both feet on the accelerator pedals
(3).
¾ Turn the parking brake lever (1) in a clock-
wise direction until it engages.
The parking brake is actuated (it is only
possible to start the engine with the parking
brake actuated).
¾ Insert the switch key (2) into the ignition
and starting switch and turn from the zero
position to position "I".
The electrical system is switched on.

Operating Instructions – 393 807 10 01 EN – 10/2010 39

4 Operation
Standard equipment

¾ Look at the display unit (4).

NOTE
After the ignition has been switched on, the
display 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 display unit (4)
display field (10). During this time the symbol
(13) remains lit. After 5 seconds the display
reverts automatically to the operating hours. If
the buzzer sounds (particle filter system fault),
check the lights (see Malfunctions, Causes
and Remedies — 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 maintenance work that is
due must be performed. Please contact your
authorised dealer.
The following indicators light up:
• Parking brake applied symbol (12)
• Engine oil pressure indicator (6)
• Charging indicator (5)
• Glow plug indicator (14)
• Particle filter symbol (7) (only if particle filter
is present).
¾ Wait until the glow plug indicator (14) goes
out
¾ Turn switch key to position "II".
As soon as the engine starts:
¾ Release the switch key.
Symbol (8) flashes.

CAUTION
Only in trucks with a particle filter system. If the
exhaust continues to be very smoky, switch off the
truck. Please contact your authorised dealer.
Every time the engine is started, watch the exhaust
port 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 idle speed. Depending on the truck,

40 Operating Instructions – 393 807 10 01 EN – 10/2010

 Operation 4
Standard equipment

temperature and altitude, this may take

more than 1 minute.
If the engine stalls, the "Do not start the
engine" symbol will appear (11).

NOTE
A block against repeat starting is active and
the engine cannot be started.
¾ Always leave the ignition switched on until
the symbol goes out.
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 Remedies.
The charging and engine oil pressure indi-
cators 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 idle
speed. When under load, drive the truck at a
brisk speed. The engine will quickly reach its
operating temperature.

Switching off the engine

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

Operating Instructions – 393 807 10 01 EN – 10/2010 41

4 Operation
Standard equipment

¾ Take your feet off the accelerator pedals

(3).
¾ Turn the switch key (2) to the zero position.

NOTE
The brake is applied when the engine is
switched off.
¾ Turn the parking brake lever (1) in a clock-
wise direction until it engages.
The parking brake is now applied.
¾ Remove the switch key (2) when leaving the
truck.

Driving (dual-pedal operation)

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

WARNING
When using mirrors, remember that the rear-view
mirror is only designed for monitoring the area
behind the vehicle.
Reverse travel is therefore only permitted when
looking directly behind you.

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

42 Operating Instructions – 393 807 10 01 EN – 10/2010

 Operation 4
Standard equipment

NOTE
The forklift truck can only be driven with the
driver’s seat under load.
¾ Start the engine.
¾ Slightly raise fork arms and tilt lift mast back.
¾ Release the parking brake (unlock the park-
ing brake lever (1) and move it downwards
as far as the stop).

Forwards travel
¾ Carefully operate the right accelerator pedal
(2).
The driving speed of the truck increases as the
actuation distance of the pedal increases.

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

Reverse travel
¾ Carefully operate the left accelerator pedal
(4).
The truck will reverse slowly or quickly de-
pending on the accelerator pedal position.

Changing direction of travel

¾ Release accelerator pedal pressed.
The hydrostatic drive will act as a service
brake.
¾ Press the accelerator pedal for the opposite
direction of travel.
The forklift truck will now accelerate in the
specified direction.
¾ Both feet should be left on the accelerator
pedals so that the truck is easily controlled
in every driving movement.
The accelerator pedals can be switched over
directly. The hydrostatic drive brakes the
truck until it comes to a standstill and then
accelerates in the opposite drive direction.

Operating Instructions – 393 807 10 01 EN – 10/2010 43

4 Operation
Standard equipment

Approaching gradients
¾ Press the stop pedal (3) all the way down.
¾ Release the parking brake lever (1) and
move it downwards as far as the stop.
¾ Take your foot half way off the stop pedal.
¾ Actuate accelerator pedal (2) or (4).
¾ Slowly take your foot completely off the stop
pedal.
The brake has been released and the truck will
now move without rolling backwards.

Stopping
¾ Slowly release the accelerator pedal after
pressing it.
The hydrostatic drive will act as a service
brake.
¾ When stopping on inclines, leave both
feet on the pedals and press the pedal in
the "uphill" drive direction down slightly to
counterbalance the slip of the drive. This
slip is caused by technical factors.
¾ If stopping for an extended period of time,
press the stop pedal (3).
¾ If you ever have to leave the truck with the
engine still running, e.g. to do minor jobs
in the direct vicinity of the truck (opening
doors, disconnecting trailers etc.), it is
essential to activate the parking brake (turn
the parking brake lever (1) in a clockwise
direction until it engages), and unlatch the
seat belt. If you are leaving the truck for a
longer period of time, switch off the engine
and activate the parking brake.
¾ When leaving the truck, remove the ignition
key.

44 Operating Instructions – 393 807 10 01 EN – 10/2010

 Operation 4
Standard equipment

Drive engine (single-pedal opera-

tion)
Starting the engine
DANGER
Risk of poisoning!
Do not allow the engine to run in
unventilated areas.

NOTE
Where possible, avoid frequently starting and
stopping the engine over short periods of time,
since this prevents the internal combustion
engine from reaching its operating tempera-
ture. Frequent cold starts increase wear.
¾ Sit down on the driver’s seat.
¾ Fasten the seat belt.
¾ Move the actuating lever (joystick and drive
direction (15)) into the neutral position.

Operating Instructions – 393 807 10 01 EN – 10/2010 45

4 Operation
Standard equipment

¾ Place your foot on accelerator pedal (3).

¾ Turn the parking brake lever (1) in a clock-
wise direction until it engages.
The parking brake is actuated (it is only
possible to start the engine with the parking
brake actuated).
¾ Insert the switch key (2) into the ignition
and starting switch and turn from the zero
position to position "I".
The electrical system is switched on.

¾ Look at the display unit (4).

NOTE
After the ignition has been switched on, the
display 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 display unit (4)
display field (10). During this time the symbol
(13) remains lit. After 5 seconds the display
reverts automatically to the operating hours. If
the buzzer sounds (particle filter system fault),
check the lights (see Malfunctions, Causes
and Remedies — 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 maintenance work that is
due must be performed. Please contact your
authorised dealer.
The following indicators light up:
• Parking brake applied symbol (12)
• Engine oil pressure indicator (6)
• Charging indicator (5)
• Glow plug indicator (14)
• Particle filter symbol (7) (only if particle filter
is present).

46 Operating Instructions – 393 807 10 01 EN – 10/2010

 Operation 4
Standard equipment

¾ Wait until the glow plug indicator (14) goes

out
¾ Turn switch key to position "II".
As soon as the engine starts:
¾ Release the switch key.
Symbol (8) flashes.

CAUTION
Only in trucks with a particle filter system. If the
exhaust continues to be very smoky, switch off the
truck. Please contact your authorised dealer.
Every time the engine is started, watch the exhaust
port 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 idle speed. Depending on the truck,
temperature and altitude, this may take
more than 1 minute.
If the engine stalls, the "Do not start the
engine" symbol will appear (11).

NOTE
A block against repeat starting is active and
the engine cannot be started.
¾ Always leave the ignition switched on until
the symbol goes out.
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 Remedies.
The charging and engine oil pressure indi-
cators 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 idle
speed. When under load, drive the truck at a

Operating Instructions – 393 807 10 01 EN – 10/2010 47

4 Operation
Standard equipment

brisk speed. The engine will quickly reach its

operating temperature.

Switching off the engine

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

¾ Remove foot from accelerator pedal (3).

¾ Move the direction selection lever (4) into

the neutral position.
¾ Turn the switch key (2) to the zero position. 4

NOTE
The brake is applied when the engine is
switched off.
¾ Turn the parking brake lever (1) in a clock-
wise direction until it engages.
¾ Remove the switch key (2) when leaving the
truck.

d3921362

48 Operating Instructions – 393 807 10 01 EN – 10/2010

 Operation 4
Standard equipment

Driving (single-pedal operation)

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

WARNING
When using mirrors, remember that the rear-view
mirror is only designed for monitoring the area
behind the vehicle.
Reverse travel is therefore only permitted when
looking directly behind you.

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

NOTE
The forklift truck can only be driven with the
driver’s seat under load.
¾ Start the engine.
¾ Slightly raise fork arms and tilt lift mast back.

Operating Instructions – 393 807 10 01 EN – 10/2010 49

4 Operation
Standard equipment

¾ Release the parking brake (unlock the park-

ing brake lever (1) and move it downwards
as far as the stop).

Forwards travel
¾ Move the direction of travel lever (4) for-
wards.
¾ Press the accelerator pedal (3) carefully.
The driving speed of the truck increases as the
actuation distance of the pedal increases.

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

Reverse travel
¾ Move the direction of travel lever (4) back-
wards.
¾ Press the accelerator pedal (3) carefully. 4
The truck will reverse slowly or quickly de-
pending on the accelerator pedal position.

Changing direction of travel

¾ Release accelerator pedal.
The hydrostatic drive will act as a service
brake.
¾ Operate direction selection lever (4) for the
opposite drive direction.
The forklift truck will now accelerate in the d3921362
specified direction.
The direction selection lever can be switched
over directly. The hydrostatic drive brakes
the truck until it comes to a standstill and then
accelerates in the opposite drive direction.

50 Operating Instructions – 393 807 10 01 EN – 10/2010

 Operation 4
Standard equipment

Approaching gradients
¾ Press the stop pedal (2) all the way down.
¾ Release the parking brake lever (1) and
move it downwards as far as the stop.
¾ Take your foot half way off the stop pedal.
¾ Press accelerator pedal (3).
¾ Slowly take your foot completely off the stop
pedal.
The brake has been released and the truck will
now move without rolling backwards.

Stopping
¾ Slowly release the accelerator pedal.
The hydrostatic drive will act as a service
brake.
¾ When stopping on inclines, leave your
foot on the accelerator pedal, switch the
direction selection lever (4) to "uphill" drive
direction and press the pedal down slightly
to counterbalance the slip of the drive. This
slip is caused by technical factors.
¾ If stopping for an extended period of time,
press the stop pedal (2).
¾ If you ever have to leave the truck with the
engine still running, e.g. to do minor jobs
in the direct vicinity of the truck (opening
doors, disconnecting trailers etc.), it is
essential to activate the parking brake (turn
the parking brake lever (1) in a clockwise
direction until it engages), and unlatch the
seat belt. If you are leaving the truck for a
longer period of time, switch off the engine
and activate the parking brake.
¾ When leaving the truck, remove the ignition
key.

Operating Instructions – 393 807 10 01 EN – 10/2010 51

4 Operation
Standard equipment

Steering system
Steering
The hydrostatic steering system means
that the level of effort required to turn the
steering wheel is very low. This is particularly
advantageous 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.
Apply sufficient force to move the steering
wheel beyond the limit stop making sure that
the position of the wheels on the steering axle
does not change.

DANGER d3921423

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 25 2420 mm
H 30 2444 mm
H 35 2476 mm

52 Operating Instructions – 393 807 10 01 EN – 10/2010

 Operation 4
Standard equipment

Brake system
Service brake
¾ Allow accelerator pedals (1) to move to the
neutral position.
The hydrostatic drive will act as a service
brake. Slow or quick release of the accelerator
pedals to the neutral position allows the
braking effect to be sensitively controlled,
from gentle to hard braking.

NOTE
For emergency braking, press the stop pedal
(2) positioned between the accelerator pedals.
This will result in full application of the brake.

Stop pedal
The stop pedal (2) is not a sensitive service
brake but a sharply applied parking brake. Its
use should be avoided whilst driving, 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 situations, the engine can also
stall; as a result the "Do not start the engine"
symbol (3) appears in the display unit. A block
against repeat starting is active and the engine
cannot be started. Always leave the ignition
switched on until the "Do not start the engine"
symbol (3) goes out. In this time, the variable
displacement pump of the drive unit swivels
to the neutral position. Afterwards, the engine
can be started again.

NOTE
It is recommended that drivers familiarise
themselves with the function and effect of this
brake when there is no load on the truck. For
this purpose they should choose a route with
no other traffic, travelling at a low speed.

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

Operating Instructions – 393 807 10 01 EN – 10/2010 53

4 Operation
Standard equipment

Operating the parking brake

¾ Turn the parking brake lever (2) in a clock-
wise direction to the stop.
The interlock (1) engages and the symbol in
the display unit lights up.

Releasing the parking brake

NOTE
The multi-disc brake will release only if the
engine is running.
¾ Turn the parking brake lever (2) gently in a
clockwise direction to release the interlock.

¾ Press the button (1).

The parking brake is unlocked.
¾ Move the parking brake (2) down as far as
the stop.
The symbol on the indicator unit will go out.

DANGER
The forklift truck must not be driven if the braking
system is defective.
Should there be any defects or wear apparent in
the brake 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.

54 Operating Instructions – 393 807 10 01 EN – 10/2010

 Operation 4
Standard equipment

¾ Press the horn button ((1)) on the steering

wheel to sound the horn.

Lifting system and attachments

(central lever operation)

WARNING
With the moving lift mast or any
attachment there is a danger that
the driver could get trapped between
parts.
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 shovel, see "Using the
truck during shovel operation".

NOTE
With the central lever version, use of the
actuating lever in an intermediate position
(approx. 45°) will activate both functions at the
same time (e.g. lifting and tilting).

Operating Instructions – 393 807 10 01 EN – 10/2010 55

4 Operation
Standard equipment

¾ Take note of the switching symbols with

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

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

d3931329

Tilting the lift mast forwards

¾ Push actuating lever (1) forwards.
1 2
Tilting the lift mast backwards
¾ Pull actuating lever (1) backwards.

Lifting the 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
raised fork arms.

¾ Push actuating lever (1) to the right.

d3921370
Lowering the fork carriage
¾ Push actuating lever (1) to the left.

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

56 Operating Instructions – 393 807 10 01 EN – 10/2010

 Operation 4
Standard equipment

WARNING
For attachments that perform a clamping function
(e.g. a bale clamp), a lockable lever (joystick) must
be used. The lever can be identified by its slightly
longer length.
If your truck is not fitted with this equipment, please
contact your authorised dealer.

NOTE
Before fitting an attachment, depressurisation
(special equipment) can be performed to
depressurise the hydraulic system for the
auxiliary hydraulics so that the connection
on the attachment can be affixed to the
connection on the fork carriage.
¾ Switch off the engine.
¾ Switch on the ignition.
¾ Operate the actuating lever for the respec-
tive auxiliary hydraulics several times.
¾ Unscrew the union nuts on the fork carriage.
¾ Screw on the connecting lines from the
attachment or connect the plug connectors.

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

NOTE
This description of how to operate attach-
ments contains examples. The configuration
of the actuating levers may vary depending on
your truck’s equipment.

Operating Instructions – 393 807 10 01 EN – 10/2010 57

4 Operation
Standard equipment

¾ Take note of the switching symbols with

arrows.

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

Operating the sideshift

NOTE
In order to prevent damage, do not activate
the sideshift when the fork arms are on the
ground.
¾ Push actuating lever (2) to the left.
1 2
Sideshift moves to the left.
¾ Push actuating lever (2) to the right.
Sideshift moves to the right.

Operating the fork prong positioner

NOTE
In order to prevent damage, do not activate
the fork prong positioner with a load, or with
the fork arms on the ground. Do not use the
fork prong positioner as a clamp.
¾ Push actuating lever (2) forwards.
d3921370
Fork arms move outwards.
¾ Pull actuating lever (2) backwards.
Fork arms move inwards.

58 Operating Instructions – 393 807 10 01 EN – 10/2010

 Operation 4
Standard equipment

Operating the clamp

¾ Release actuating lever (3) or (4) depending
on the version by pressing down on the
knob.
¾ Push actuating lever (3) or (4) forwards.
Clamp opens.

¾ Pull actuating lever (3) or (4) backwards.

Clamp closes.
After the actuating lever is released, it is locked
again automatically.

Operating Instructions – 393 807 10 01 EN – 10/2010 59

4 Operation
Standard equipment

Lifting system and attachments

(single lever operation)

WARNING
With the moving lift mast or any
attachment there is a danger that
the driver could get trapped between
parts.
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 shovel, see "Using the
truck during shovel operation".
¾ Take note of the switching symbols with
arrows.
The actuating lever should always be operated
carefully, never jerkily. Moving the actuating
lever determines the lifting, lowering and tilt
speed. After the actuating lever is released, it
automatically returns to its initial position.

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

Lifting the 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
raised fork arms.

60 Operating Instructions – 393 807 10 01 EN – 10/2010

 Operation 4
Standard equipment

¾ Pull actuating lever (1) backwards.

Lowering the fork carriage

¾ Push actuating lever (1) forwards.

Tilting the lift mast forwards

¾ Push actuating lever (2) forwards.

Tilting the lift mast backwards

¾ Pull actuating lever (2) backwards.

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

WARNING
For attachments that perform a clamping function
(e.g. a bale clamp), a lockable lever (joystick) must
be used. The lever can be identified by its slightly
longer length.
If your truck is not fitted with this equipment, please
contact your authorised dealer.

NOTE
Before fitting an attachment, depressurisation
(special equipment) can be performed to
depressurise the hydraulic system for the
auxiliary hydraulics so that the connection
on the attachment can be affixed to the
connection on the fork carriage.
¾ Switch off the engine.
¾ Switch on the ignition.
¾ Operate the actuating lever for the respec-
tive auxiliary hydraulics several times.
¾ Unscrew the union nuts on the fork carriage.
¾ Screw on the connecting lines from the
attachment or connect the plug connectors.

Operating Instructions – 393 807 10 01 EN – 10/2010 61

4 Operation
Standard equipment

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

NOTE
This description of how to operate attach-
ments contains examples. The configuration
of the actuating levers may vary depending on
your truck’s equipment.
¾ Take note of the switching symbols with
arrows.

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

Operating the sideshift

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

62 Operating Instructions – 393 807 10 01 EN – 10/2010

 Operation 4
Standard equipment

¾ Push actuating lever (3) forwards.

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

Operating the fork prong positioner

NOTE
In order to prevent damage, do not activate
the fork prong positioner with a load, or with
the fork arms on the ground. Do not use the
fork prong positioner as a clamp.

¾ Push actuating lever (4) forwards.

Fork arms move outwards.
¾ Pull actuating lever (4) backwards.
Fork arms move inwards.

Operating the clamp

¾ Release actuating lever (3) or (4) depending
on the version by pressing down on the
knob.
¾ Push actuating lever (3) or (4) forwards.
Clamp opens.
¾ Pull actuating lever (3) or (4) backwards.
Clamp closes.
After the actuating lever is released, it is locked
again automatically.

Operating Instructions – 393 807 10 01 EN – 10/2010 63

4 Operation
Special equipment

Special equipment
Lifting system and attachments
(single lever operation with toggle-
switch-controlled 3rd auxiliary
hydraulics)

WARNING
With the moving lift mast or any
attachment there is a danger that
the driver could get trapped between
parts.
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 shovel, see "Using the
truck during shovel operation".

NOTE
The functions for lifting, lowering, tilting
forwards, tilting backwards can be assigned
by both the central lever and the single lever.

64 Operating Instructions – 393 807 10 01 EN – 10/2010

 Operation 4
Special equipment

¾ Take note of the switching symbols with

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

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

Lifting the 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
raised fork arms.

¾ Pull actuating lever (1) backwards.

Lowering the fork carriage

¾ Push actuating lever (1) forwards.

Tilting the lift mast forwards

¾ Push actuating lever (2) forwards.

Tilting the lift mast backwards

¾ Pull actuating lever (2) backwards.

Operating attachments
The truck is equipped with three additional
functions (e.g. fork prong positioner, rotator,
clamp, sideshift etc.). Refer to the working
pressure and operating instructions for the
attachment. Two other actuating levers are
then attached for operating the attachments.
The actuating lever (5) is used to operate two
attachments, which are controlled via a toggle
switch (4).

Operating Instructions – 393 807 10 01 EN – 10/2010 65

4 Operation
Special equipment

DANGER
For attachments that perform a clamping function
(e.g. a bale clamp), a locked lever (joystick) must
be used. The lever can be identified by its slightly
longer length.
If your truck is not fitted with this equipment, please
contact your authorised dealer.

DANGER
It is prohibited to activate a load-bearing clamp via
toggle switch (4).
The function and hydraulic connection must always
take place via the first auxiliary hydraulics and be
operated using actuating lever (1).

NOTE
If the toggle switch (4) affects a second locked
actuating lever, this must not be used for
operating clamps.

NOTE
Before fitting an attachment, depressurisation
(special equipment) can be performed to
depressurise the hydraulic system for the
auxiliary hydraulics so that the connection
on the attachment can be affixed to the
connection on the fork carriage.
¾ Switch off the engine.
¾ Switch on the ignition.
¾ Operate the actuating lever for the respec-
tive auxiliary hydraulics several times.
¾ Unscrew the union nuts on the fork carriage.
¾ Screw on the connecting lines from the
attachment or connect the plug connectors.

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

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 Operation 4
Special equipment

NOTE
This description of how to operate attach-
ments contains examples. The configuration
of the actuating levers may vary depending on
your truck’s equipment.
¾ Take note of the switching symbols with
arrows.

NOTE
For every attachment, a label stating the load
capacity of the truck plus attachment (for a
description, see "Additional capacity rating
plate for attachments") must be affixed within
the driver’s range of vision and a symbol label
for the relevant attachment must be affixed
behind the actuating lever and to the left and
right alongside the toggle switch (4).

Operating the fork prong positioner

NOTE
In order to prevent damage, do not activate
the fork prong positioner with a load, or with
the fork arms on the ground. Do not use the
fork prong positioner as a clamp.
¾ Push actuating lever (1) forwards.
Fork arms move outwards.
¾ Pull actuating lever (1) backwards.
Fork arms move inwards.

Operating the rotator

¾ Press left-hand side (2) of toggle switch (4).
Green switch illumination lit up.
¾ Push actuating lever (5) forwards.
Unit moves anticlockwise.
¾ Pull actuating lever (5) backwards.
Unit moves clockwise.

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4 Operation
Special equipment

Operating the sideshift

NOTE
In order to prevent damage, do not activate
the sideshift when the fork arms are on the
ground.
¾ Press right-hand side (3) of toggle switch
(4).
Orange switch illumination lit up.
¾ Push actuating lever (5) forwards.
Sideshift moves to the left.
¾ Pull actuating lever (5) backwards.
Sideshift moves to the right.

Operating the clamp

¾ Release the actuating lever (1) by pressing
down on the knob.
¾ Push actuating lever (1) forwards.
Clamp opens.
¾ Pull actuating lever (1) backwards.
Clamp closes.
After the actuating lever is released, it is locked
again automatically.

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 Operation 4
Special equipment

Lifting system and attachments

with 3rd auxiliary hydraulics without
toggle switch

WARNING
With the moving lift mast or any
attachment there is a danger that
the driver could get trapped between
parts.
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 shovel, see "Using the
truck during shovel operation".
¾ Take note of the switching symbols with
arrows.
The actuating lever should always be operated
carefully, never jerkily. Moving the actuating
lever determines the lifting, lowering and tilt
speed. After the actuating lever is released, it
automatically returns to its initial position.

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

d3931329

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4 Operation
Special equipment

Tilting the lift mast forwards

¾ Push actuating lever (1) forwards.

Tilting the lift mast backwards

¾ Pull actuating lever (1) backwards.

Lifting the 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
raised fork arms.

¾ Push actuating lever (1) to the right.

Lowering the fork carriage

¾ Push actuating lever (1) to the left.

Operating attachments
The truck is equipped with three additional
functions (e.g. fork prong positioner, rotator,
sideshift etc.). Refer to the working pressure
and operating instructions for the attachment.
Additional actuating levers (cross lever,
joystick) are fitted for operation.

WARNING
For attachments that perform a clamping function
(e.g. a bale clamp), a lockable lever (joystick) must
be used.
If your truck is not fitted with this equipment, please
contact your authorised dealer.

NOTE
Before fitting an attachment, depressurisation
(special equipment) can be performed to
depressurise the hydraulic system for the
auxiliary hydraulics so that the connection
on the attachment can be affixed to the
connection on the fork carriage.
¾ Switch off the engine.
¾ Switch on the ignition.

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 Operation 4
Special equipment

¾ Operate the actuating lever for the respec-

tive auxiliary hydraulics several times.
¾ Unscrew the union nuts on the fork carriage.
¾ Screw on the connecting lines from the
attachment or connect the plug connectors.

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

NOTE
This description of how to operate attach-
ments contains examples. The configuration
of the actuating levers may vary depending on
your truck’s equipment.
¾ Take note of the switching symbols with
arrows.

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

Operating the sideshift

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

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4 Operation
Special equipment

¾ Push actuating lever (2) to the left.

Sideshift moves to the left.
¾ Push actuating lever (2) to the right.
Sideshift moves to the right.

Operating the fork prong positioner

NOTE
In order to prevent damage, do not activate
the fork prong positioner with a load, or with
the fork arms on the ground. Do not use the
fork prong positioner as a clamp.
¾ Push actuating lever (2) forwards.
Fork arms move outwards.
¾ Pull actuating lever (2) backwards.
Fork arms move inwards.

Operating the clamp

¾ Release the actuating lever (3) by pressing
down on the knob.
¾ Push actuating lever (3) forwards.
Clamp opens.
¾ Pull actuating lever (3) backwards.
Clamp closes.
After the actuating lever is released, it is locked
again automatically.

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 Operation 4
Special equipment

Adjust driver’s seat with swivel

device

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

The driver’s seat with swivel device offers

better rear visibility when reversing over long
distances. When driving forwards for long
distances, it is recommended that you return
the seat to the straight position. The swivel is
maintenance free.
¾ Lift locking lever (1).
The swivel device is released and allows the
seat to be swivelled 17° to the right. It can be
locked at 0° and at 17°.
¾ Let the locking bolts engage audibly.

Adjusting the driver’s seat equipped

with air suspension

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

Setting the driver’s weight

¾ Sit on the driver’s seat.

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4 Operation
Special equipment

¾ Check the weight adjustment in viewing

window (3).
The correct driver’s weight has been selected
when the arrow (4) is in the centre of the
inspection window.
¾ Adjust as necessary for the driver’s weight
• Lift lever (2) upwards (5) = increase weight
setting
• Push lever (2) downwards (6) = decrease
weight setting

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

¾ Lift lever (1) upwards.

¾ Move the driver’s seat backwards or for-
wards on the runners to give the driver the
most comfortable position in relation to the
steering wheel and the accelerator pedals.
¾ Allow lever to click back into place.

Adjust the seat angle

¾ Lift lever 2 and hold it there.
The seat surface is moved to the desired
position by applying pressure to the seat
surface or removing pressure from it.

Adjust the seat height

¾ Lift lever 1 and hold it there.
The seat surface can be moved to the desired
position by sliding the seat surface forward or
to the rear.

Seat heater

NOTE
The maximum temperature is pre-set.

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 Operation 4
Special equipment

¾ Switch (1) turns the seat heater ON and

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

Adjusting the lumbar support

The lumbar support enables optimum config-
uration of the seat back contour to the driver’s
body.
¾ Turn the handwheel (2) upwards.
The convexity of the upper part of the backrest
can be adjusted individually.
¾ Turn the handwheel (2) downwards.
The convexity of the lower part of the backrest
can be adjusted individually.

Adjust the seat back

¾ Lift lever (2) and hold it there.
¾ Move the seat backrest forwards and
backwards to find a comfortable seat
position for the driver.
¾ Release lever (2).

Adjusting the backrest extension

¾ Push backrest extension (1) in or pull it out
for individual adjustment.

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4 Operation
Special equipment

Lift mast positioning

Programming
The tilt angle sensor system enables a specific
lift mast tilt angle to be programmed. When
this function is active, the symbol (1) lights up
in the display unit.
¾ Tilt lift mast to required angle.

¾ Press the push button (2) in the front-left

position of the armrest for longer than
2 seconds.
The tilt angle is now permanently stored. As
confirmation, a double acoustic signal sounds
from the display unit and the light in the button
(2) flashes briefly several times.
The lift mast tilt angle is saved in relation to
the truck. The lift mast tilt angle in relation to
the ground depends on a variety of influencing
variables such as the tyre wear, tyre pressure
of pneumatic tyres and load, as well as the
unevenness and gradient of the ground.

Operation

NOTE
The lift mast positioning function is designed to
aid the driver and is purely a comfort feature.
The responsibility and control for activating
the required mast position always lie with the
driver.

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 Operation 4
Special equipment

¾ Press the button (2) in the front-left position

of the armrest briefly. The lamp in the
button lights up and the lift mast positioning
detection is switched on.
¾ Operate joystick and activate stored tilt an-
gle. (For safety reasons, tilting is permitted
only in the direction of the stored tilt angle,
and must be reactivated with each lift mast
positioning).
When the stored lift mast position has been
reached, the lift mast remains stationary and
an acoustic signal is sounded in the display
unit.
¾ Release the joystick or press the button (2)
again briefly. The light in the push button
goes out, and the lift mast positioning is
switched off.
¾ The lift mast can now be operated normally
using the joystick.
¾ Briefly press the push button (2) again. Lift
mast position identification is switched on
again.

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.

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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.

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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 retrofitted
(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 .

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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.

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 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
intermittent 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.

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4 Operation
Special equipment

Window heater
Switching on the rear window heater
¾ Press the toggle switch (1).
Rear window heater is in operation.

Driver’s cab
Opening the cab door
¾ Push handle (4) upwards.
¾ Open driver’s door outwards.

Closing the cab door

NOTE
To make it easier to close the door, open the
side window slightly.
¾ Grip the rod (5) and pull the door towards
you until the interlock engages.

Opening/closing the front side window

¾ Press the interlock (3) upwards.
¾ Keep the interlock pressed, slide the side
window into the desired position until it
engages in one of the grooves (2).
Follow a similar procedure to close the side
window.

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 Operation 4
Special equipment

Opening/closing the rear side window

¾ Press the interlock (1) upwards.
¾ Keep the interlock pressed, slide the side
window into the desired position until it
engages in one of the grooves (2).
Follow a similar procedure to close the side
window.

Heating system, air conditioning

Heating system operating devices
• Turning knob (1) for temperature control
• Turning knob (2) for setting the blower
positions
• Rotary switch (3) for setting the vent posi-
tions for windscreen defrosting / footwell
ventilation
• Cab air vents (4)

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4 Operation
Special equipment

Switching on the heating system

¾ Turn switch (2).
The blower is switched on and there are three
air flow settings.

Defrosting the windows

¾ For maximum defrosting, set the
• Turning knob (1) to the far right position
• Turning knob (3) to the windscreen defrost-
ing position (far left position)
• Rotary switch (2) to level 3
• Cab air vents (4) to open, fins forwards
For normal heating operation, the following
rules apply:
• Select the temperature using turning knob
(1) (far left → cold / far right → hot)
• Use the blower switch (2) (level 1 to 3), air
distribution vent (turning knob (3)) and cab
air vents (4) to select the temperature and
temperature distribution

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 Operation 4
Special equipment

Air conditioning operating devices

• Turning knob (5) for temperature control
• Function display (6)
• Push-button (7) for switching the air condi-
tioning on
• Rotary switch (8) for setting the blower
positions
• Turning knob (9) for setting the vent posi-
tions for windscreen defrosting / footwell
ventilation
• Cab air vents (10)

Switching on the air conditioning

CAUTION
The moving parts must be lubricated and the
compressor 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 your authorised
dealer, preferably before the season starts, and a
record must be kept of the servicing. Otherwise, the
warranty will be void.

NOTE
It is normal for condensation water to build up
in the hoses and under the truck when the air
conditioning is in operation.
¾ Turn switch (8).
The blower is switched on and there are three
air flow settings.

NOTE
The air conditioning only works when the
engine is running and the blower switch is
switched on (setting 1, 2 or 3). The fans in
the roof switch on when necessary. They can
come to a standstill from time to time.
¾ Switch on push-button (7).
The function display (6) lights up green.
To raise the temperature in the cab:
¾ Rotate turning knob (5) clockwise and
reduce the blower speed using switch (8).
To lower the temperature in the cab:

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4 Operation
Special equipment

¾ Close windows and doors, rotate turning

knob (5) anti-clockwise and increase the
blower speed using switch (8).

NOTE
To achieve maximum cooling in the cab:
• the air conditioning must be switched on,
• the turning knob (5) must be fully turned to
the left stop,
• the blower must be set to its highest blower
position,
• the windows and doors must be closed.

NOTE
On cool, humid days, the heater and air
conditioning can be used to dehumidify the
air in the cab (operate the heating system and
air conditioning simultaneously). The truck
heating system counteracts the cooling effect.
This ensures a pleasant temperature inside
the cab and reduces fogging on the windows.

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 Operation 4
Special equipment

Linde Forklift Data Management

(LFM)
Forklift Data Acquisition
The input device (1) for Forklift Data Acquisi-
tion (FDE) is mounted on the front left-hand
post of the overhead guard
The input device has a 12-digit keypad (2).
With the standard setting, the allocation of a
5-digit PIN number to the respective driver
ensures that the truck can only be operated
by authorised personnel. The truck can only
be started after entering this PIN number and
possibly a status code (depending on the
setting).

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

Status code

NOTE
The code indicates the state of the truck.
The following codes are available:
0 = Truck OK
1 = Request service (truck will not start)
2 = Request maintenance (truck starts)
3 = Problem with driving
4 = Problem with lifting
5 = Problem with steering
6 = Accident damage
7 = User-defined
8 = User-defined
9 = User-defined
The status messages 7 , 8 and 9 can be
individually defined by the user. Please

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4 Operation
Special equipment

contact your fleet manager to find out the

definition of these status messages.

NOTE
If you notice one of these states (such as a
problem with driving) only after you have input
the status code 0 (truck OK), you have to log
off.
¾ Rotate the turning knob (5) anticlockwise to
the stop.
¾ Log in again with the status message 3
(problem with driving)

Forklift Data Acquisition - standard

setting (PIN number and status code)
Log on and start the truck:
¾ Apply the parking brake.

¾ Press any button to start the input device.

The green LED (2) flashes.
¾ Enter personal PIN number (factory setting
= 0 0 0 0 0 ) and status code.
Therefore, for a properly set-up truck, the PIN
number should be as follows: 0 0 0 0 0 0 .

NOTE
If the PIN was input incorrectly, press the *
button (4) and enter the correct PIN number.
¾ Confirm the input with the # button (3).
The green LED (2) lights up continuously.

NOTE
If the red LED (1) lights up, an incorrect PIN
number was input. Press the * button (4) and
enter it again. If more than three incorrect
inputs are made (factory setting), the red
LED (1) lights up and the green LED (2)
flashes. The input of a valid PIN is blocked

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 Operation 4
Special equipment

for 10 minutes. The blocking time can be

interrupted by inputting a special PIN number.
Please contact your fleet manager.
¾ Rotate the turning knob (5) in a clockwise
direction to the stop and start the truck.

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

NOTE
If the green (2) and red (1) LEDs both light
up continuously, the data must be read out.
Please inform your fleet manager at once.
Switch off the truck and log off:
¾ Rotate the turning knob (5) anticlockwise to
the stop.
The engine is turned off.

NOTE
After a delay time (factory setting = 10 se-
conds) the red LED (1) lights up briefly, and
the green (2) and red (1) LEDs then flash for
approx. 3 seconds. During this period, the
truck can be started at any time. The LEDs
then go out, and the PIN number is discarded.
The delay time can be set to between 10 se-
conds and 10 minutes using the diagnostic
device. Please contact your authorised dea-
ler.
Pressing the # button (3) after switching
off the engine terminates the delay time
immediately and the PIN number is deleted.

Forklift Data Acquisition - Special setting

(PIN number)
Log on and start the truck:
¾ Apply the parking brake.

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4 Operation
Special equipment

¾ Press any button to start the input device.

The green LED (2) flashes.
¾ Enter personal PIN number (factory setting
= 0 0 0 0 0 ).

NOTE
If the PIN was input incorrectly, press the *
button (4) and enter the correct PIN number.
¾ Confirm the input with the # button (3).
The green LED (2) lights up continuously.

NOTE
If the red LED (1) lights up, an incorrect PIN
number was input. Press the * button (4) and
enter it again. If more than three incorrect
inputs are made (factory setting), the red
LED (1) lights up and the green LED (2)
flashes. The input of a valid PIN is blocked
for 10 minutes. The blocking time can be
interrupted by inputting a special PIN number.
Please contact your fleet manager.
¾ Rotate the turning knob (5) in a clockwise
direction to the stop and start the truck.

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

NOTE
If the green (2) and red (1) LEDs both light
up continuously, the data must be read out.
Please inform your fleet manager at once.
Switch off the truck and log off:
¾ Rotate the turning knob (5) anticlockwise to
the stop.
The engine is turned off.

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 Operation 4
Special equipment

NOTE
After a delay time (factory setting = 10 se-
conds) the red LED (1) lights up briefly, and
the green (2) and red (1) LEDs then flash for
approx. 3 seconds. During this period, the
truck can be started at any time. The LEDs
then go out, and the PIN number is discarded.
The delay time can be set to between 10 se-
conds and 10 minutes using the diagnostic
device. Please contact your authorised dea-
ler.
Pressing the # button (3) after switching
off the engine terminates the delay time
immediately and the PIN number is deleted.

Forklift Data Acquisition with a transpon-

der (chip or magnetic strip card)

NOTE
The input device has a field (3) on which the
corresponding transponder (chip or magnetic
strip card) must be placed. Only then can the
truck be started.
Log on and start the truck:
¾ Apply the parking brake.
¾ Rotate the turning knob (5) in a clockwise
direction and switch on the truck’s power
supply.
The green LED (2) flashes.
¾ Place the valid transponder on the field (3).
Data is read in and the green LED (2) lights up
continuously.

NOTE
If the red LED (1) lights up, the transponder is
invalid or there was a reading error. The input
device is reactivated automatically when a
valid transponder is used and read in.

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4 Operation
Special equipment

¾ Rotate the turning knob (5) in a clockwise

direction to the stop and start the truck.

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

NOTE
If the green (2) and red (1) LEDs both light
up continuously, the data must be read out.
Please inform your fleet manager at once.
Switch off the truck and log off:
¾ Rotate the turning knob (5) anticlockwise to
the stop.
The engine is turned off.

NOTE
After a delay time (factory setting = 10 se-
conds) the red LED (1) lights up briefly, and
the green (2) and red (1) LEDs then flash for
approx. 3 seconds. During this period, the
truck can be started at any time. The LEDs
then go out, and the PIN number is discarded.
The delay time can be set to between 10 se-
conds and 10 minutes using the diagnostic
device. Please contact your authorised dea-
ler.

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 Operation 4
Working under load

Working under load

Before taking up load
Before taking up a load, check the load
capacity diagram above the switch console
on the top right in the overhead guard.

DANGER
The residual load capacity of a truck is determined
by the mast type (standard, duplex, triplex), the
lift height of the attached mast, the tyres on the
front axle, the use of attachments or additional
equipment and the backwards tilt restriction. If one
of these parameters is changed, this can have a
considerable effect on the residual load capacity.
For some conversions, the new residual load
capacity of the truck must be determined and
the load capacity diagram must be changed as
necessary. Please contact your authorised dealer. t3921383

The max. permissible load is determined

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

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

NOTE
Observe the load restriction and consult your
authorised dealer. 1 Max. weight of permissible loads in kg
• before transporting off-centre or swinging 2 Lift height in mm
loads 3 Series designation of truck with max. load
capacity and lift mast series
• before transporting loads with the lift mast 4 Distance between load centre of gravity and
tilted forward or the load not close to the fork back in mm
ground
• loads involving a large centre of gravity
distance
• before transporting loads in a wind force of
6 and upwards.
Example
Load centre of gravity distance: 650 mm

Operating Instructions – 393 807 10 01 EN – 10/2010 93

4 Operation
Working under load

Load height to be lifted: 6500 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 6500 mm.
¾ Read the max. permissible load to the left of
the point of intersection with the horizontal
line.
The maximum load in this example is 1700 kg.
Use the same procedure for other lift heights
and centre of gravity distances. The deter-
mined values refer to both fork arms and
evenly distributed loads.

Wheel-slide protection chains

CAUTION
Mounting wheel-slide protection chains alters the
wheel freedom and the load capacity of the truck
Before wheel-slide protection chains are mounted,
the standard fork carriage must be replaced with a
special fork carriage that is installed 40 mm further
forward. All residual load capacity specifications
in the basic load capacity diagram and on the
additional capacity rating plate must be reduced
by 100 kg. This reduction in load capacity is still
necessary even if wheel-slide protection chains are
not fitted.

¾ In addition, affix the label (5) next to the

basic load capacity diagram.

94 Operating Instructions – 393 807 10 01 EN – 10/2010

 Operation 4
Working under load

Adjusting the fork spread

NOTE
The load centre should be in the centre
between the forks.
¾ Raise the fork quick-release levers(1).
¾ Move the forks further apart or closer
together 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

Taking up loads

DANGER
Danger of a falling load. Standing or
walking in the vicinity of an elevated
mast is extremely dangerous.
During stacking and de-stacking
operations do not allow people to
stand or walk in the working area of
the truck.
Trucks should only be driven with the
load lowered and tilted back. Look
out for people.

Operating Instructions – 393 807 10 01 EN – 10/2010 95

4 Operation
Working under load

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

DANGER
Loads should be arranged so that they do not
project beyond the edge of the truck loading surface
and cannot slip, topple over or fall off.
If necessary, use a load backrest (special equip-
ment).

¾ Approach the load to be taken up carefully

and as accurately as possible.
¾ Position the lift mast so it is vertical.
¾ Lift or lower the fork carriage to the neces-
sary height.
¾ Carefully steer the truck forks beneath the
centre of the load to be taken up, where
possible so the load touches the fork back,
taking account of adjacent loads.
¾ Lift fork carriage until the load is no longer in
contact with the supporting surface.
¾ Reverse the truck until the load is free.
¾ Tilt the lift mast backwards.

d3921430

Travelling with load

NOTE
When transporting cargo, the sender must
ensure that the goods are safely loaded for
transportation and secured if necessary.

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 Operation 4
Working under load

Please therefore make sure that goods are

properly stacked and there is no damage
to packaging, pallets etc. The carrier must
ensure safe loading.
¾ Do not transport loads if they are shifted to
the side (e.g. with sideshift).
¾ Transport loads close to the floor.
¾ On ascending/descending routes, always
travel with the load facing uphill; never travel
diagonally or turn around.
¾ If visibility is poor, instructions should be
provided by a second person.
¾ If the load to be transported is stacked so
high as to obstruct visibility in the direction
of travel, the truck must only be driven in
reverse.

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).

Operating Instructions – 393 807 10 01 EN – 10/2010 97

4 Operation
Working under load

¾ Observe the lift mast position identification

symbol (1) on the display unit if your truck is
equipped with automatic lift mast position-
ing.
¾ Carefully move the load over the load /
storage area.
¾ Carefully lower the load until the fork arms
are clear.
¾ Back the forklift truck away.

Tow coupling

NOTE
The tow coupling is used only for towing
light trailers inside the plant. (Observe the
applicable 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
pressure, turn 90° degrees and let engage
in the retainer.
1

2 d3921373

98 Operating Instructions – 393 807 10 01 EN – 10/2010

 Operation 4
Loading / Transporting

Loading / Transporting
Securing the hose pulley against
rolling up
When fitting single auxiliary hydraulics, a hose
pulley (1) is located beneath the floorplate
(with double auxiliary hydraulics, a second
hose pulley (5) is fitted in mirror image).

WARNING
The hose pulleys are spring-biased.
This is why they should always be secured against
rolling up:

• Before disconnecting the screw joints of the

hose lines at the connection point to the lift
mast (e.g. to remove the lift mast or remove
the hose pulley itself).
• For all other work on the hose pulleys in the
truck.
WARNING
The roll-up protection on the removed hose pulley
must not be opened.
If this cannot be avoided, reduce the spring tension
to 0 beforehand. Please contact your authorised
dealer.

¾ Open the bonnet.

¾ Open floor plate and secure it.
¾ Turn the hexagon head screw (3) on the
hose pulley (1) in the direction of travel
(right) with a wrench (SW 10) to the stop in
the secure position (6).
The safety catch (2) points against the direc-
tion of travel and the slotted spring pin (8) is
visible; the hose pulley is secured against 5 1
rolling up.

4 2

3
d3921468

Operating Instructions – 393 807 10 01 EN – 10/2010 99

4 Operation
Loading / Transporting

¾ For double auxiliary hydraulics, turn the

safety catch (4) of the second hose pulley 2
(5) to the secure position (6) as well.
¾ Disconnect the hoses when removing the
lift mast.
6 7
CAUTION
If the lift mast is extended with the roll-up protection
closed, the hose lines cannot be damaged (ratchet
effect). However, when the mast is then retracted, 8
the hose lines are no longer rolled up and may
therefore be damaged.
Only once the lift mast has been refitted (hoses
connected again), should the roll-up protection be 3
released. To do so, return the safety catch(es) to
the free-wheel setting (7) (safety catch visible).
d3921481

Dismantling the lift mast

This work should only be performed by
specialist staff working for your authorised
dealer .
DANGER
The spring elements on the drive axle are preten-
sioned.
Before dismantling the tilt cylinders, the lift mast
must be tilted back 2 °.

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

100 Operating Instructions – 393 807 10 01 EN – 10/2010

 Operation 4
Loading / Transporting

¾ Fix 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
readjusted after reinstalling the lift mast . When
doing so, the parking brake should be applied for
safety reasons, and any restriction in terms of the
tilt angle taken into account. Please contact your
authorised dealer.

d3921469

Driving without lift mast

CAUTION
When driving without the lift mast, the speed of the
truck must be reduced for safety reasons.
Therefore, before removing the lift mast, an addi-
tional stop screw must be fitted under the reverse
travel accelerator pedal (two-pedal operation) or
accelerator pedal (single-pedal operation) to re-
strict the speed.

¾ Switch off the engine.

¾ Screw the hexagon head screw M8 x 20 (3)
half-way into hexagon nut M8 (2) (DIN 6330,
6331, 6334).
¾ Screw the hexagon nut (2) onto the existing
hexagon head screw M8 (1) until one
hexagon head screw (3) hits the other
hexagon head screw (1). 3
¾ Lock them into the hexagonal nut (2).
¾ Remove lift mast. 2
After refitting the lift mast the additional stop
should be removed.

1
d3921520

Operating Instructions – 393 807 10 01 EN – 10/2010 101

4 Operation
Loading / Transporting

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

WARNING
Loading by crane may cause damage to the tilt
cylinder and the cover sheet 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.
The suspension positions on the truck are not
specially marked.
¾ Place the round sling (2)(min. lifting ca-
pacity: 3000 kg) around the bottom of the
counterweight.
¾ Use edge protectors as a safeguard from
sharp edges on the bridge piece.
¾ Insert round sling (3) (min. lifting capacity:
3000 kg) around bridge piece on outer mast
of lift mast.
¾ Insert all ends into crane hook (1) .
¾ Make sure that the safety lock (4) is closed.

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

102 Operating Instructions – 393 807 10 01 EN – 10/2010

 Operation 4
Loading / Transporting

Crane lifting with crane eyes

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

¾ Attach chains (6) (min. lifting capacity:

3000 kg) to the crane eyes (7) on the
counterweight.
¾ Attach chains (2) (min. lifting capacity:
3000 kg) to the crane eyes (1) on the lift
mast.
¾ Make sure that the safety lock (5) is closed.

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

Transport with lorry or low-bed trailer

¾ Lower the mast.
¾ Engage the parking brake.
¾ Chock the truck.
¾ Tie the truck down.

d3921499

Operating Instructions – 393 807 10 01 EN – 10/2010 103

4 Operation
Loading / Transporting

Before leaving the truck

¾ Set down load / lower fork carriage.
¾ Tilt mast forwards slightly.
The fork arms must touch the ground.

CAUTION
The tractor must be secured against
rolling away.
Apply the parking brake.

¾ Rotate the parking brake lever (1) in a

clockwise direction until it engages.
The parking brake is now applied.
¾ Switch off the engine.
¾ Remove the ignition key (2).

104 Operating Instructions – 393 807 10 01 EN – 10/2010

 5

Maintenance
5 Maintenance
General information

General information
Your forklift truck will only remain in a state WARNING
ready for use at all times if you perform a
Any side doors attached could fall shut during
small number of maintenance and inspection maintenance and trap staff.
tasks according to the information in the
For this reason, both doors should be opened and
registration document for the industrial truck secured in place during servicing.
and the data or instructions in the operating
instructions at regular intervals . Maintenance
may be performed only by qualified persons CAUTION
authorised by the manufacturer. You can The truck must always be properly labelled.
agree to have this work performed on the
Missing or damaged identification plates and/or ad-
basis of a maintenance contract concluded hesive labels must be replaced. For the warehouse
with your authorised dealer. or order number, please consult the spare parts
catalogue.
If you wish to perform this work yourself, we
recommend having at least the first 3 customer
service checks carried out by the dealer’s ENVIRONMENT NOTE
service technician in the presence of your
Observe information regarding working with
workshop representative so that your own
consumables.
workshop staff can be instructed accordingly.
Whenever performing maintenance, the NOTE
forklift truck should be parked on a flat surface
and secured so that it cannot roll away. The When using forklift trucks under extreme
engine should be switched off and the switch conditions (e.g. extreme heat or cold, high
key removed. levels of dust etc.), the time periods given in
the maintenance overview programme should
When working with the fork carriage and/or be reduced accordingly.
lift mast raised, make sure they are secured
against unintentionally dropping.
Maintenance intervals
Whenever work is carried out at the front of the
Under certain conditions there is the option of
forklift truck, the lift mast must be secured to
changing the intervals for some of the mainte-
prevent tilting back.
nance work listed in the maintenance overview
No modifications, in particular attachments or programme. Please make sure you use the
conversions, should be made to your forklift consumables, engine oil and coolant specified
truck without the manufacturer’s approval. for this purpose. The qualities required in this
regard are described in the section "Recom-
All servicing work should be followed by a
mendations for consumables". The inspection
functional check and a test run performed on
and maintenance intervals are dependent on
the forklift truck.
the operating and application conditions of the
forklift truck. For more difficult conditions we
recommend shorter intervals. Please contact
your authorised dealer.

106 Operating Instructions – 393 807 10 01 EN – 10/2010

 Maintenance 5
Working on Linde lift mast and at the front of the truck

Working on Linde lift mast and

at the front of the truck
DANGER
When working on the lift mast there is the risk of
staff becoming trapped and/or accidental sinking of
the lift mast.
When the lift mast or fork carriage is lifted, no work
should be performed on the lift mast and at the front
of the forklift truck without the following safety mea-
sures! These safety precautions are sufficient only
for general maintenance on the forklift truck (in-
spection and greasing). For repairs (e.g. changing
chains, dismantling lift cylinders), additional safety
precautions must be taken. Please contact your
authorised dealer.

Securing against tilting back

The lift mast must be secured from tilting back
accidentally.
¾ Tilt lift mast right back.
¾ Switch off the engine.
¾ Remove the ignition key.

Standard lift mast

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

Secure lifted standard lift mast

DANGER
d3921437
Check chain load!
Select a safety chain with sufficient load bearing
capacity for the lift mast. Take the maximum lift
height into account.

¾ Extend lift mast.

Operating Instructions – 393 807 10 01 EN – 10/2010 107

5 Maintenance
Working on Linde lift mast and at the front of the truck

¾ Connect the chain over the cross traverse

of the outer mast (1) and under the cross 1
traverse of the inner mast (2).
¾ Lower inner mast to end of chain.

Duplex lift mast

NOTE
The benefit of this equipment version is that
full advantage is taken of the special free
lift height, even in very low rooms (cellars,
wagons, ships).
FUNCTION: The fork carriage is lifted to the 2
special free lift height via the chain deflection
d3921482
pulley of the centre cylinder. Here it moves
twice as fast as the centre cylinder. The inner
mast is then lifted via the two outer cylinders,
taking the fork carriage with it. The centre
cylinder is positioned on the extendable inner
mast.

Securing the raised duplex lift mast

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

¾ Extend lift mast.

108 Operating Instructions – 393 807 10 01 EN – 10/2010

 Maintenance 5
Working on Linde lift mast and at the front of the truck

¾ Connect the chain over the cross traverse

of the outer mast (1) and under the cross
traverse of the inner mast (2). 1

¾ Lower lift mast to end of chain.

¾ Lower fork carriage as far as it will go.

Triplex lift mast

FUNCTION: The fork carriage is lifted to the
special free lift height via the chain deflection
pulley of the centre cylinder. Two lift cylinders
then lift the inner mast. Once the inner mast
is fully extended, two additional lift cylinders
lift the centre mast, which is lifted together
with the inner mast and the fork carriage. The 2
centre cylinder is positioned on the extendable d3921483

inner mast.

Securing the raised triplex lift mast

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

¾ Extend lift mast.

¾ Join the chain over the cross traverse of the
outer mast (1) and under the cross traverse 1
of the centre mast (2).
¾ Lower lift mast to end of chain.
¾ Lower fork carriage as far as it will go.

2
d3921484

Operating Instructions – 393 807 10 01 EN – 10/2010 109

5 Maintenance
Recommendations for consumables

Inspection and maintenance data

Unit Devices / Consumables Filling quantity / Set values
Engine Engine oil approx. 4.5 l
Fuel tank Diesel Approx. 40.0 l
Cooling system Coolant additive / drinking with heating system / air
water conditioning: approx. 11.0 l
without heating system / air
conditioning: approx. 9.0 l
Hydraulic system Hydraulic oil Lift height up to 5000 mm:
Approx. 24.0 l
Lift height from 5000 mm to
6900 mm: Approx. 25.5 l
Lift height from 6900 mm to
8000 mm: Approx. 28.0 l
Battery Distilled water As required
See adhesive label on inside
Tyres Pneumatic
of overhead guard
Wheel fastenings Tighten Front: 170 Nm
Rear: 460 Nm
Load chains / mast channels Linde chain spray As required

Air conditioning Refrigerant 1500 grams

Recommendations for consumables

Diesel fuel NOTE
Only diesel fuels to EN 590 with a cetane
As the ambient temperature falls, the fluidity
number (CN) not lower than 51 may be used.
of the diesel fuel is reduced due to paraffin
The fuel sulphur content must not exceed
segregation. If "summer" diesel fuels are used
350 mg/kg.
at low ambient temperatures, this can lead to
If the only diesel fuel available has a sulphur malfunctions. For this reason, cold-resistant
content of more than 350 mg/kg, the engine oil "winter" diesel fuel is available during the
change intervals must be reduced as follows: colder part of the year, which can reliably be
used at temperatures down to about -22°C.
• At a sulphur content more than 350 mg/kg
and less than 2000 mg/kg = engine oil In winter, use only winter diesel fuel, so that
change interval 300 operating hours. the fuel lines do not become blocked by
• At a sulphur content more than 2000 mg/kg segregated paraffin. At very low temperatures
= engine oil change interval 150 operating even winter diesel fuel can suffer from this
hours. problem of segregation. Please contact your
authorised dealer.

110 Operating Instructions – 393 807 10 01 EN – 10/2010

 Maintenance 5
Recommendations for consumables

CAUTION
NOTE
Several important points must be observed for the
use of bio-diesel fuel (RME according to EN 14214). If in doubt, we recommend obtaining the ad-
Please contact your authorised dealer.
vice of your authorised dealer. Recommen-
dations made by representatives from the
mineral oil industry should also be agreed with
Hydraulic oil
your authorised dealer. Manufacturer’s ap-
proval has been granted only for the oils listed
NOTE above. Mixing or using with other hydraulic
The working temperature is the critical factor fluids may result in highly expensive damage.
to be considered when selecting the correct oil
for hydrostatic drive units. The recommenda- Lubricating grease
tions for oils given below can only be taken as
guide values. Linde heavy-duty grease, lithium-saponified
with EP active ingredients and MOS2. Des-
Hydraulic oil recommendations for normal ignation as per DIN 51825-KPF 2N-20 (order
use: no. see spare parts catalogue).
Hydraulic oil ISO - L - HM 68 to ISO 6743 - Mixing lubricating grease types with a soap
4 or HLP ISO VG 68 in accordance with basis other than lithium-saponified is not
DIN 51524, T.2 (factory filling) average permitted.
constant oil temperature 60°C–80°C.
Hydraulic oil recommendations for heavy-duty Coolant
use:
CAUTION
Hydraulic oil ISO - L - HM 100 to ISO 6743
Refer to the coolant specifications!
- 4 or HLP ISO VG 100 in accordance with
DIN 51524, T.2 for heavy-duty and multi-shift In trucks with pump injection engines, coolant ad-
ditive according to VW standard TL 774-F (factory
use, operation in hot climate zones or at high filling) must be used.
ambient temperatures, average constant oil
temperature over 80 °C. This additive must be mixed with water (total
Hydraulic oil recommendations for normal and hardness of water must not be more than 20°
heavy-duty use: according to German hardness standards).
A maximum of 60% coolant additive can be
Hydraulic oil ISO - L - HV 68 to ISO 6743 used.
- 4 or HVLP ISO VG 68 to DIN 51524, T.3
(multi-grade oil) Coolant Drinking
Temperature
additive water
Bio-hydraulic oil -25°C 40% 60%

Highly biodegradable hydraulic fluid -30°C 45% 55%

Aral Forbex SE 46 -35°C 50% 50%

CAUTION -40°C 60% 40%

Bio-oils must not be mixed with mineral oils.
No recommendations for other fluids from other
manufacturers can be made at the present time. Refrigerant for air conditioning
R 134a

Operating Instructions – 393 807 10 01 EN – 10/2010 111

5 Maintenance
Recommendations for consumables

Battery grease • Oil change every 500 operating hours.

Acid-free lubricating grease (battery grease).
NOTE

Chain spray Please note that the engine oil change inter-
vals must be reduced if diesel fuel with an
Linde chain spray (order no.: see spare parts increased sulphur content is used.
catalogue).
NOTE
Engine oil
API or ACEA oils are only permitted if they fulfil
When the engine is running, not only is some the VW standards (referred to above) for the
of the engine oil for piston lubrication burnt pump injection engine.
off ("consumed"), but the temperature stress
and the fuel combustion products that enter For trucks with particulate filter systems, use
the oil lead to "wear", affecting especially the only low-ash oil. The residues of combustion
chemical "additives" in the oil. For this reason, of oil additives (ash) cannot be regenerated.
the entire filling of engine oil must be renewed ¾ When topping up, the various oils may be
at specified intervals. mixed with each other, however the oil
Since this "oil wear" depends on the operating change interval is then determined by the
conditions, the fuel quality and the oil quality oil of the lowest quality.
(the performance characteristics of the oil), oil Since a good engine oil is a pre-requisite for
change intervals vary. problem-free operation and a long service life
The longest time a filling of lubricating oil for the engine, use only good quality engine
may remain in the engine is 12 months. oil even when topping up and also during oil
Irrespective of the change intervals, the change. Due to their limited viscosity range,
lubricating oil must be changed at intervals single-grade oils should generally not be used
no less than every 12 months. all-year-round. These oils should be used only
in extreme climate zones.
Engine oils that are approved for the pump
injection engine must comply with: NOTE
• VW standard 505 01, No additional lubricants of any sort should be
• VW standard 506 01 with viscosity mixed in with the lubricating oils.
SAE 0W-30
• VW standard 507 00 with viscosity SAE ENVIRONMENT NOTE
5W-30 (factory filling).
Used oil must be kept away from children
Depending on the oil quality, oil change until disposed of according to the regulations.
intervals may vary. Under no circumstances should oil be allowed
Engine oil according to VW standard 506 01 to penetrate the mains drainage or the ground.
or 507 00 Because of the problems of disposal and the
• Oil change every 1000 operating hours. special tools and knowledge required, engine
oil and filter changes should only be performed
Engine oil according to VW standard 505 01 by your authorised dealer.

112 Operating Instructions – 393 807 10 01 EN – 10/2010

 Maintenance 5
Inspection and maintenance overview

Inspection and maintenance overview

Service plan as required
Carried
out
9 8
Engine
Clean the fuel tank ventilation hose
Drain water from the fuel filter
Change the air filter cartridge (after no longer than 1000 operating hours)
Change the safety cartridge in the air filter (after no longer than 3000 operating
hours)
Check the dust discharge valve
Change the oil bath air filter oil
Clean the prefilter
Clean the water cooler and hydraulic oil cooler, and check them for leaks
Regenerate the particle filter
Drain water from the water trap at the changing particle filter
Chassis, bodywork and fittings
Clean the truck
Service the air conditioning
Check condition and correct operation of the seat belt
Chassis frame
Wheel change
Clean and grease the steering axle (after no longer than 1000 operating hours)
Check tyres for damage and foreign bodies
Tighten wheel fastenings (after each maintenance or repair, after no longer than
100 operating hours)
Hydraulics
Check function and safety system of third auxiliary hydraulics
Load lift system
Clean the lift mast chain, adjust and apply chain spray
Special equipment
Washer system: Top up the water tank

Operating Instructions – 393 807 10 01 EN – 10/2010 113

5 Maintenance
Inspection and maintenance overview

1000 h service plan

At operating hours
1000 2000 4000 5000 7000
Carried
8000 10000 11000 13000 14000 out
16000 17000 19000 20000 9 8
Information on service plan
Dependent on the consumables used, driving style and application conditions, but
at least after 1, 2, 4, 5, 7, 8, 10, 11, 13, 14, 16, 17, 19 and 20 years of operating time.
Refer also to the recommendation for consumables.
Preparations
Clean the truck if necessary
Read out error log and delete
Calibrate the drive potentiometer and joysticks
Enter the next maintenance interval
Engine
Change engine oil
Change engine oil filter
Change the fuel filter
Check condition and secure positioning of engine cradle and engine mounting
Check condition of V-ribbed belt
Check condition and tension of toothed belt
Clean water and hydraulic oil coolers
Check the coolant concentration
Change air filter cartridge, check vacuum-operated switch
Change the breather for charge air regulation
Clean the oil bath air filter
Check suction and exhaust pipes for leaks
Check the particle filter system
Clean the pressure control device at the changing particle filter
Clean the water trap at the changing particle filter
Gearbox
Axle clamps and wheel motors: Check fastening
Drive axle: Check the side stops

114 Operating Instructions – 393 807 10 01 EN – 10/2010

 Maintenance 5
Inspection and maintenance overview

At operating hours
1000 2000 4000 5000 7000
Carried
8000 10000 11000 13000 14000 out
16000 17000 19000 20000 9 8
Chassis, bodywork and fittings
Chassis, tilt cylinders and steering axle: Check fastening
Check and grease other bearings and joints
Chassis frame
Check the parking brake for correct operation
Clean and grease steering axle
Steering cylinder and steering pivot pin: Check fastening
Controls
Check and oil the pedals
Electrics
Check the condition and secure positioning of electric cables, cable connectors and
connections
Battery: Check condition, acid level and acid density (even for maintenance-free
batteries)
Hydraulics
Hydraulic system: Check the oil level.
Check the bleeder valve on the hydraulic oil tank for correct operation
Check the hydraulic system for leaks
Double hoses: Check the pre-tension
Load lift system
Lift mast, lift mast chain, lift cylinder and end stops: Check condition, secure moun-
ting and function
Adjust lift mast chain and spray with chain spray
Check fork arms and arm safety devices
Clean and grease the sideshift, check fastening
Clean and grease fork positioner, check fastening
Subsequent tasks
Carry out functional test and test drive
Attach maintenance sticker

Operating Instructions – 393 807 10 01 EN – 10/2010 115

5 Maintenance
Inspection and maintenance overview

3000 h Service plan

Carried
At operating hours
out
3000 15000 9 8
Information on service plan
Dependent on the consumables used, driving style and application conditions, but
at least after 3 and 15 years of operating time. Refer also to the recommendation for
consumables.
Preparations
Clean the truck if necessary
Read out error log and delete
Calibrate the drive potentiometer and joysticks
Enter the next maintenance interval
Engine
Change engine oil
Change engine oil filter
Change the fuel filter
Check condition and secure positioning of engine cradle and engine mounting
Change V-ribbed belt
Change toothed belt and tensioner pulley (at latest after 5 years)
Clean water and hydraulic oil coolers
Check the coolant concentration
Change air filter cartridge, check vacuum-operated switch
Change the safety cartridge in the air filter
Change the breather for charge air regulation
Clean the oil bath air filter
Check suction and exhaust pipes for leaks
Check the particle filter system
Clean the pressure control device at the changing particle filter
Clean the water trap at the changing particle filter
Gearbox
Axle clamps and wheel motors: Check fastening
Drive axle: Check the side stops
Drive axle: Check bearing for wear

116 Operating Instructions – 393 807 10 01 EN – 10/2010

 Maintenance 5
Inspection and maintenance overview

Carried
At operating hours
out
3000 15000 9 8
Hydraulic pump on engine: Check fastening
Chassis, bodywork and fittings
Chassis, tilt cylinders and steering axle: Check fastening
Check and grease other bearings and joints
Chassis frame
Check the parking brake for correct operation
Clean and grease steering axle
Steering cylinder and steering pivot pin: Check fastening
Controls
Check and oil the pedals
Check the bellows at the actuating lever
Electrics
Check the condition and secure positioning of electric cables, cable connectors and
connections
Battery: Check condition, acid level and acid density (even for maintenance-free
batteries)
Hydraulics
Hydraulic system: Check the oil level.
Check the bleeder valve on the hydraulic oil tank for correct operation
Change feed/pressure/suction filter and breather of the hydraulic system
Check the hydraulic system for leaks
Check the tilt cylinder bearing for wear
Double hoses: Check the pre-tension
Load lift system
Lift mast, lift mast chain, lift cylinder and end stops: Check condition, secure moun-
ting and function
Adjust lift mast chain and spray with chain spray
Check fork arms and arm safety devices
Clean and grease the sideshift, check fastening
Check slide guides on sideshift for wear
Check fork positioner for wear
Clean and grease fork positioner, check fastening

Operating Instructions – 393 807 10 01 EN – 10/2010 117

5 Maintenance
Inspection and maintenance overview

Carried
At operating hours
out
3000 15000 9 8
Subsequent tasks
Carry out functional test and test drive
Attach maintenance sticker

118 Operating Instructions – 393 807 10 01 EN – 10/2010

 Maintenance 5
Inspection and maintenance overview

6000 h Service plan

Carried
At operating hours
out
6000 12000 9 8
Information on service plan
Dependent on the consumables used, driving style and application conditions, but
at least after 6 and 12 years of operating time. Refer also to the recommendation for
consumables.
Preparations
Clean the truck if necessary
Read out error log and delete
Calibrate the drive potentiometer and joysticks
Enter the next maintenance interval
Engine
Change engine oil
Change engine oil filter
Change the fuel filter
Check condition and secure positioning of engine cradle and engine mounting
Change V-ribbed belt
Change toothed belt and tensioner pulley (at latest after 5 years)
Clean water and hydraulic oil coolers
Check the coolant concentration
Change air filter cartridge, check vacuum-operated switch
Change the safety cartridge in the air filter
Change the breather for charge air regulation
Clean the oil bath air filter
Check suction and exhaust pipes for leaks
Check the particle filter system
Clean the pressure control device at the changing particle filter
Clean the water trap at the changing particle filter
Gearbox
Axle clamps and wheel motors: Check fastening
Drive axle: Check the side stops
Drive axle: Check bearing for wear

Operating Instructions – 393 807 10 01 EN – 10/2010 119

5 Maintenance
Inspection and maintenance overview

Carried
At operating hours
out
6000 12000 9 8
Hydraulic pump on engine: Check fastening
Chassis, bodywork and fittings
Chassis, tilt cylinders and steering axle: Check fastening
Check and grease other bearings and joints
Chassis frame
Check the parking brake for correct operation
Clean and grease steering axle
Steering cylinder and steering pivot pin: Check fastening
Controls
Check and oil the pedals
Check the bellows at the actuating lever
Electrics
Check the condition and secure positioning of electric cables, cable connectors and
connections
Battery: Check condition, acid level and acid density (even for maintenance-free
batteries)
Hydraulics
Change hydraulic oil
Check the bleeder valve on the hydraulic oil tank for correct operation
Change feed/pressure/suction filter and breather of the hydraulic system
Check the hydraulic system for leaks
Check the tilt cylinder bearing for wear
Double hoses: Check the pre-tension
Load lift system
Lift mast, lift mast chain, lift cylinder and end stops: Check condition, secure moun-
ting and function
Adjust lift mast chain and spray with chain spray
Check fork arms and arm safety devices
Clean and grease the sideshift, check fastening
Check slide guides on sideshift for wear
Check fork positioner for wear
Clean and grease fork positioner, check fastening

120 Operating Instructions – 393 807 10 01 EN – 10/2010

 Maintenance 5
Inspection and maintenance overview

Carried
At operating hours
out
6000 12000 9 8
Subsequent tasks
Carry out functional test and test drive
Attach maintenance sticker

Operating Instructions – 393 807 10 01 EN – 10/2010 121

5 Maintenance
Inspection and maintenance overview

9000 h Service plan

Carried
At operating hours
out
9000 18000 9 8
Information on service plan
Dependent on the consumables used, driving style and application conditions, but
at least after 9 and 18 years of operating time. Refer also to the recommendation for
consumables.
Preparations
Clean the truck if necessary
Read out error log and delete
Calibrate the drive potentiometer and joysticks
Enter the next maintenance interval
Engine
Change engine oil
Change engine oil filter
Change the fuel filter
Check condition and secure positioning of engine cradle and engine mounting
Change V-ribbed belt
Change toothed belt and tensioner pulley (at latest after 5 years)
Change the water pump
Clean water and hydraulic oil coolers
Change the coolant
Check the coolant concentration
Change air filter cartridge, check vacuum-operated switch
Change the safety cartridge in the air filter
Change the breather for charge air regulation
Clean the oil bath air filter
Check suction and exhaust pipes for leaks
Check the particle filter system
Clean the pressure control device at the changing particle filter
Clean the water trap at the changing particle filter
Gearbox
Axle clamps and wheel motors: Check fastening

122 Operating Instructions – 393 807 10 01 EN – 10/2010

 Maintenance 5
Inspection and maintenance overview

Carried
At operating hours
out
9000 18000 9 8
Drive axle: Check the side stops
Drive axle: Check bearing for wear
Hydraulic pump on engine: Check fastening
Chassis, bodywork and fittings
Chassis, tilt cylinders and steering axle: Check fastening
Check and grease other bearings and joints
Chassis frame
Check the parking brake for correct operation
Clean and grease steering axle
Steering cylinder and steering pivot pin: Check fastening
Controls
Check and oil the pedals
Check the bellows at the actuating lever
Electrics
Check the condition and secure positioning of electric cables, cable connectors and
connections
Battery: Check condition, acid level and acid density (even for maintenance-free
batteries)
Hydraulics
Change the hydraulic oil (omitted for 9000 operating hours)
Hydraulic system: Check the oil level.
Check the bleeder valve on the hydraulic oil tank for correct operation
Change feed/pressure/suction filter and breather of the hydraulic system
Check the hydraulic system for leaks
Check the tilt cylinder bearing for wear
Double hoses: Check the pre-tension
Load lift system
Lift mast, lift mast chain, lift cylinder and end stops: Check condition, secure moun-
ting and function
Adjust lift mast chain and spray with chain spray
Check fork arms and arm safety devices
Clean and grease the sideshift, check fastening

Operating Instructions – 393 807 10 01 EN – 10/2010 123

5 Maintenance
Inspection and maintenance overview

Carried
At operating hours
out
9000 18000 9 8
Check slide guides on sideshift for wear
Check fork positioner for wear
Clean and grease fork positioner, check fastening
Subsequent tasks
Carry out functional test and test drive
Attach maintenance sticker

124 Operating Instructions – 393 807 10 01 EN – 10/2010

 Maintenance 5
Engine

Engine
Checking the engine oil level

ENVIRONMENT NOTE
Observe information regarding working with
consumables

WARNING
When topping up the oil, no oil should
drip on to hot engine parts — Risk of
fire!
Fill carefully.

CAUTION
Different oil specifications.
Observe the recommendations for consumables.

CAUTION
The oil level should never be above the upper mark.
Drain engine oil if necessary.

¾ Park the forklift truck on level ground.

¾ Open the bonnet.
¾ Take the oil dipstick (2) out of the engine.
¾ Wipe the oil dipstick with a clean cloth.
¾ Push the oil dipstick fully back in and 1
remove it again.
Oil level should be between the marks.
¾ If necessary, pour in engine oil through
the filler opening until it reaches the upper
dipstick mark.
¾ To do so, remove filler cap (1) from the filler
opening.
Difference in quantity between min. and max.
marking: 1.0 l
¾ Fit filler cap and turn to tighten. 2 d3931391

¾ Close the bonnet.

Operating Instructions – 393 807 10 01 EN – 10/2010 125

5 Maintenance
Engine

Change engine oil

(at the latest after 12 months)

CAUTION
Different oil grades result in different maintenance
intervals.
Recommendations for consumables must always
be observed.

Draining the engine oil

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

ENVIRONMENT NOTE
Observe information regarding working with
consumables.

NOTE
Only change engine oil when the engine is at
operating temperature.
¾ Drive truck over pit.
¾ Switch off the engine.
¾ Place a collection vessel under vehicle
chassis.
¾ Open the bonnet. Remove the filler cap (1)
from the filling opening.
¾ Remove cover on floor of chassis. Unscrew 1
the engine oil drain plug (3) underneath
from the oil sump.
¾ Allow all oil to drain off into collection vessel.

d3931395

126 Operating Instructions – 393 807 10 01 EN – 10/2010

 Maintenance 5
Engine

¾ Fit the drain plug (3) with a new sealing ring.

Tightening torque: 30 Nm
¾ Refit the cover (1).

Top up with motor oil

¾ Switch off ignition.

d3921445

¾ Open the filler cap (1) of the filling opening.

¾ Pour new engine oil into the filling opening
according to the recommendations for 1
consumables.
Fill quantity with filter change: max. 4.5 l
¾ Using the dipstick (2), check the engine
oil level after adding oil and top up to max.
mark.
¾ Fit filler cap (1) and turn to tighten.

2 d3931386

Operating Instructions – 393 807 10 01 EN – 10/2010 127

5 Maintenance
Engine

¾ Check the indicator unit (4).

The Oil display (5) (special equipment) in the
display unit must go out. The oil level will not
be displayed reliably in the display unit until
approx. 10 minutes after the oil is added.

NOTE
After changing the oil and the filter, carry out
an engine test run, checking the oil pressure
display and the tightness of the oil drain plug
and oil filter. For an accurate oil level check,
especially after changing the oil filter, it is
necessary to switch off the engine again and
then carry out an oil level check after approx.
one minute.

Engine oil filter change

WARNING
When engine oil is hot there is a risk
of scalding!
Wear protective clothing

ENVIRONMENT NOTE
Take note of information about working
materials.
¾ Open the bonnet.

128 Operating Instructions – 393 807 10 01 EN – 10/2010

 Maintenance 5
Engine

¾ Using a filter wrench, slacken the cap (1) of

the engine oil filter (3) and undo it by hand.
¾ Pull the filter cartridge (2) from the casing.
¾ Catch the oil in a container as it runs out of
the oil filter and dispose of it and the oil filter
responsibly.
¾ Insert a new oil filter cartridge.
¾ Renew the O-ring in the cap.
¾ Screw on the cap (1) by hand until the O-ring
is seated.
¾ Tighten to 25 Nm.
¾ Close the bonnet.

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

Fuel
Check the fuel level

ENVIRONMENT NOTE
Observe information regarding working with
consumables.
¾ Switch on the ignition.

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5 Maintenance
Engine

The fuel tank level display on the display unit

(4) shows the current fuel level.
The tank is full when all 7 LEDs (2) and the
petrol pump illuminated field (1) light up green.
As the fuel tank empties, the LEDs are extin-
guished, starting from the right. Once the re-
serve is reached, the petrol pump illuminated
field (1) turns red and the LEDs (3) light up
green. There is only approx. 5.0 litres of fuel
left in the tank and more fuel must be added.
If only the petrol pump illuminated field (1) is lit
up red, the tank is empty.

CAUTION
Air intake can cause operational faults in the fuel
injection system.
Therefore, never empty the fuel tank completely.

Filling up with fuel

WARNING
Carelessness when refuelling 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.

¾ Open the filler cap (5) on the fuel tank and

add clean diesel fuel.
Max. filling quantity: 40 l
¾ Fit lid and turn to tighten.

d3921414

130 Operating Instructions – 393 807 10 01 EN – 10/2010

 Maintenance 5
Engine

Draining water from the fuel filter.

ENVIRONMENT NOTE
Observe information regarding working with
consumables.
¾ Unscrew 3 screws from the maintenance
cover on the right side of the forklift truck.
¾ Remove the maintenance cover.
¾ Open the drainage screw (1) on the fuel filter
and drain approx. 100 cm3 into a container
until clean fuel emerges.

ENVIRONMENT NOTE
Dispose of the liquid in an environmentally
friendly manner.
¾ Tighten the drainage screw again.
¾ Refit the maintenance cover.

d3921374

Exchanging the fuel filter

(at the latest after 12 months)

ENVIRONMENT NOTE
Observe information about working with
consumables.

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5 Maintenance
Engine

¾ Unscrew 3 screws from the maintenance

cover (1) on the right side of the forklift truck.
¾ Remove the maintenance cover.

1
d3921495

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 Tighten the new filter (2) until the sealing
ring (3) lies against 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.
d3921494
¾ Refit the maintenance cover.

Cleaning the fuel tank ventilation

hose
When operating the truck in dusty and dirty
conditions, the ventilation hose (1) to the fuel
tank can become blocked. It must therefore
be cleaned at regular intervals, depending on
how much it is used.

132 Operating Instructions – 393 807 10 01 EN – 10/2010

 Maintenance 5
Engine

¾ Disconnect the hose (1) from the pipe union

at the fuel signal transmitter and blow dry
compressed air through it.
¾ Slide the hose (1) onto the pipe union as far
as the stop.

Checking the coolant level

ENVIRONMENT NOTE
Observe information regarding working with
consumables.

NOTE
If the display (1) lights up (special equipment),
the coolant level is too low and the coolant
must be topped up. If the coolant continues to
fall below the min. mark, the truck only moves
at creep speed.

NOTE
For models without a display, (1) the coolant
level can be checked at the inspection window
(2).
CAUTION
Only use an approved coolant.
Observe the recommendations for consumables.

Operating Instructions – 393 807 10 01 EN – 10/2010 133

5 Maintenance
Engine

¾ Open the bonnet.

The coolant level should not be below the
mark at the inspection window (2).

d3931389

¾ If necessary, top up the coolant. To do this,

twist and remove the filler cap (3) at the
counterweight.

WARNING 3
The expansion reservoir is under
pressure! Risk of scalding due to hot
coolant.
Unscrew the filler cap (3) slowly, and
only if the expansion reservoir is not
hot.

¾ Fit filler cap and turn to tighten.

¾ Close the bonnet.

d3921408

Changing coolant
The cooling system must be filled all-year-
round with a mixture of water and phos-
phate-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.

134 Operating Instructions – 393 807 10 01 EN – 10/2010

 Maintenance 5
Engine

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

ENVIRONMENT NOTE
Observe information about working with
consumables.
¾ Open the bonnet.
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 Refit the coolant hose (3).

3 d3921460

¾ Add new coolant at filler neck (1).

Coolant level must be between min. and max.
marks on the filler neck. 1 2

AU
F
1,2

GE ES
RM T-
W
AN
Y

ZU

d3921339

Operating Instructions – 393 807 10 01 EN – 10/2010 135

5 Maintenance
Engine

¾ Read off the 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.
Difference in quantity between min. and max.:
5
approx. 0.75 l 5
Filling quantity in cooling system
without heating and air conditioning: 9.0 l
with heating and air conditioning: 11.0 l
The frost protection should be sufficient for
temperatures down to -25°C. The mixture 4
ratio required here is 40% coolant additive and t3921378
60% drinking water.
Mixture 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

bled.
¾ Check coolant level.
¾ Fit filler cap (2) and turn to tighten.
¾ Close the bonnet.

Check coolant concentration

The cooling system has to be filled all year
round with a mixture of water and phos-
phate-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.

136 Operating Instructions – 393 807 10 01 EN – 10/2010

 Maintenance 5
Engine

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

ENVIRONMENT NOTE
Observe information on working materials.
¾ Check coolant concentration in filling port
(1).
The frost protection should be sufficient for 1 2
temperatures down to -25 °C. The mixing ratio
required here is 40% coolant additive and 60%
drinking water. AU
F

1,2
Mixing ratio for lower temperatures:

GE ES
RM T-
W
AN
Y
ZU

Coolant Drinking
Temperature
additive water
-30° C 45% 55%
-35° C 50% 50%
-40° C 60% 40%
d3921339
If coolant additive level is too low:
¾ Open the bonnet.
¾ Place a collection vessel under the coolant
hose (3).
¾ Release hose clip from coolant hose at
cylinder block.
¾ Remove hose from stub and allow some
coolant to drain off.
¾ Push coolant hose back onto stub and
fasten with hose clip. 4
¾ Dispose of removed coolant in an environ-
mentally 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 d3921518
¾ Fit lid (2) and turn to fix in place.
¾ Close the bonnet.

Operating Instructions – 393 807 10 01 EN – 10/2010 137

5 Maintenance
Engine

Cleaning the water cooler and

hydraulic oil cooler, and checking
them for leaks

NOTE
Only clean the water cooler and hydraulic oil
cooler when the engine is switched off and has
cooled down.
¾ Open the bonnet.
¾ Release the 4 screws (2).
¾ Remove the cover sheet (1) from the rear.
1
1,2

GER
MAN

WES

ZU
Y

T-

2
2

d3921387

Cleaning with compressed air

¾ Ventilate the cooler (3) of the engine with
compressed air.
¾ Rinse out the released dirt using a water jet.
3
Cleaning with cleaner solvent
CAUTION
No humidity must penetrate the three-phase gene-
rator.
Therefore, protect it from direct contact with the
water jet.

¾ Spray the cooler (3) with a conventional

cleaner solvent and leave it to work for
approx 10 minutes.
d3921399
¾ Spray the cooler in the engine with a direct
jet of water until it is clean.

138 Operating Instructions – 393 807 10 01 EN – 10/2010

 Maintenance 5
Engine

¾ Warm up the engine.

Vaporise the water residue to prevent the
formation of rust.
¾ Check the connection screw joints, cooling
hoses and the pipes on the water cooler and
hydraulic cooler for leaks.
¾ Replace porous hoses. Re-tighten hose
clips if necessary.
¾ Refit the cover sheet (1).

Checking the condition and secure

positioning of the engine support and
engine mounting
The elastic bearings used for the engine
suspension are subjected to high loads.
Their service life is limited by the operating
conditions.
¾ Check rubber elements for cracks and se-
vere deformation; if necessary, exchange
them.
Please contact your authorised dealer.
¾ Check all screws and nuts in the engine
support and engine mounts for damage.
Check that they are securely attached.
Tightening torques of the mounting screws
and nuts:
Engine, right:

1 SKS M 8 (rear) 23 Nm
2 ZS M 10 (rear) 46 Nm
d3941380
2 ZS M 10 (side) 46 Nm
1 SKM M 12 (bottom) 110 Nm
2 SKS M 12 (spring element) 80 Nm

Engine, left:

1 SKS M 12 (spring element) 80 Nm

1 SKM M 12 (bottom) 110 Nm

Engine, top middle:

Operating Instructions – 393 807 10 01 EN – 10/2010 139

5 Maintenance
Engine

1 spherical collar nut A 14

110 Nm
(rod)
2 SKS M 12 (spring element) 80 Nm

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
excessive 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

140 Operating Instructions – 393 807 10 01 EN – 10/2010

 Maintenance 5
Engine

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
tensioning 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

Checking the condition and tension

of toothed belt

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

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5 Maintenance
Engine

¾ Remove the maintenance cover on the

right-hand side.
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.

d3921410

¾ Check that the pointer (5) is positioned

centrally in front of the gap in the baseplate.
¾ To readjust or change the toothed belt,
please contact your authorised dealer

142 Operating Instructions – 393 807 10 01 EN – 10/2010

 Maintenance 5
Engine

¾ Check the water pump gear (2) for wear.

¾ Place a knife edge (1) on the tooth (4) and
use a feeler gauge to establish the thinning
(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.

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

Operating Instructions – 393 807 10 01 EN – 10/2010 143

5 Maintenance
Engine

Change the water pump

NOTE
Changing the water pump requires specialist
knowledge and special tools. Please contact
your authorised dealer.

d3921410

Changing the air filter cartridge,

checking the vacuum-operated
switch
(After 1000 operating hours at the latest)

NOTE
The air filter cartridge must not be cleaned.
The air filter cartridge must be changed when
the vacuum display (1) lights up in the display
unit.
¾ Open the bonnet.
¾ Open the 3 fasteners (2) and remove the air
filter cover (3).
¾ Pull out the air filter cartridge.

CAUTION
Clean the inside of the air filter housing thoroughly.
Do not blow it out with compressed air.
Wipe the housing clean with a clean cloth.

¾ Insert the new air filter cartridge back into

the housing.
When installing, ensure that the air filter
cartridge is not damaged and that the seal
on the filter housing is securely in place.
¾ Fit the air filter cover.

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 Maintenance 5
Engine

¾ With the engine running, slowly close the air

filter intake opening by covering it (e.g. with
a board or a plate) until the air filter indicator
light (1) illuminates in the display unit.
In order to avoid damage, the intake opening
must not be closed further after the indicator
light has illuminated. If the air filter indicator
light does not illuminate, contact your autho- 1,2

rised dealer.
GER
WE MANY

Z
ST-

U
d3941388

Changing the air filter safety car-

tridge
¾ Change the safety cartridge (1):
• Two years after it has entered operation at
the latest.
• If the air filter vacuum display lights up again
immediately after the air filter cartridge has
been serviced.
• If you have a defective air filter cartridge.

CAUTION
Safety cartridges must not be cleaned or reused.
Do not start the engine without an air filter cartridge.
The function of the safety cartridge is to prevent
dust penetration while the main cartridge is being
changed or if a damaged main cartridge is acciden-
tally used. 2 1
d3941346
¾ Switch off the engine.
¾ Open the bonnet.
¾ Take off the air filter cover and remove the
air filter cartridge (2).
¾ Pull out the safety cartridge.
¾ Insert the new safety cartridge.
¾ Fit the air filter cartridge and attach the air
filter cover.
¾ Close the bonnet.

Operating Instructions – 393 807 10 01 EN – 10/2010 145

5 Maintenance
Engine

Check the dust discharge valve

The dust discharge valve (1) is largely mainte-
nance-free.
¾ Open the bonnet.
¾ Compress the valve (1) and remove the
remaining dust.
¾ If the value is damaged, exchange it.
¾ Close the bonnet.

1 d3931387

Changing the breather for the charge

air pressure regulator

ENVIRONMENT NOTE
Observe information regarding working with
consumables.
¾ Open the bonnet.
Both filters are located at the back right-hand
side next to the engine.

146 Operating Instructions – 393 807 10 01 EN – 10/2010

 Maintenance 5
Engine

¾ Detach hoses (5) and (9) from the filter.

¾ Pull the filter (6) upwards out of the rubber
grommet (7) in the support (8).
¾ Dispose of filter in an environmentally
friendly manner.
¾ Insert the new filter into the support up to the
stop.
¾ Slide on the hose (5) from above as far as
the step.
¾ Slide on the hose (9) from below as far as
the step.
¾ Check that the filter is properly seated.
¾ Change the second filter (10) in the same
way.

Cleaning the prefilter (special

equipment)

NOTE
The dust collecting tank must never be more
than half full with dust. If there is a heavy
accumulation of dust, the tank must be
emptied every day.
¾ Unscrew the wing nut (1).
¾ Remove the cover (2).
¾ Remove and empty the dust collecting tank
(3).
¾ Refit dust collecting tank and secure with
wing nut.

Operating Instructions – 393 807 10 01 EN – 10/2010 147

5 Maintenance
Engine

Cleaning the oil bath air filter (special

equipment)

ENVIRONMENT NOTE
Observe information regarding working with
consumables.
¾ Switch off the engine.
¾ Open fasteners (4) on oil tank (3).
¾ Remove oil tank (downwards), then empty
and clean.
¾ Clean and check seals (2) and change if
damaged.
¾ Loosen the air hose clip on the clean air
connection (1) and remove the hose.
¾ Detach and clean dust collecting tank (8).
¾ Detach upper part of filter (7) on overhead
guard.
¾ Wash out upper part of filter and filter insert
with diesel fuel.
The filter and knotted steel inserts can be
cleaned with a steam jet.
¾ Thoroughly dry the cleaned filter.
¾ Fit upper part of filter and secure air hose
with hose clip.
¾ Fit the dust collecting tank (8).
¾ Fill the oil tank (3) with engine oil as far as
mark (5).
¾ Fit oil tank (3) to upper part of filter (7) ,
ensuring that it is correctly positioned, then
secure with fasteners (4).

Change the oil in the oil bath air

cleaner (Optional)

NOTE
An oil change is necessary when the dirt
sediments have reached half of the oil filling,
and at least whenever the filter element is
renewed. Do not add oil between the oil
change intervals.

148 Operating Instructions – 393 807 10 01 EN – 10/2010

 Maintenance 5
Engine

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

Check suction and exhaust pipes for

leaks
¾ Check the condition and tightness of the
suction air tubes on the air filter.
If you discover leaks, re-tighten the hose clips
or change the porous pipes.
¾ Check the inlet and exhaust manifold on the
cylinder head for leaks.
If you discover leaks, re-tighten the fixing
screws or change the seals.
¾ Check the exhaust pipe connection on the
manifold for leaks. If necessary, re-tighten
the fixing screws or change the seal.

d3921454

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5 Maintenance
Engine

¾ Remove the cover on the counterweight.

¾ Check the connections of the exhaust pipe
in the counterweight, and ensure that it is
securely fastened and there are no leaks.
Re-tighten the fixing screws if necessary.

1,2

GER
MAN

WES
ZU

T-
¾ Refit the covering on the counterweight.

d3921388

Regenerating particle filters

1
The particle filter must be regenerated after
a maximum of 8.5 h engine operation. After
8.0 h of operation, the build-up indicator (4)
flashes in the text field of the display unit to
give a visual warning, and a buzzer sounds
at intervals. The filter must be regenerated
within the next 30 minutes.

d3921492

150 Operating Instructions – 393 807 10 01 EN – 10/2010

 Maintenance 5
Engine

If this time period is exceeded, the build-up

indicator (4) continues to flash and the particle
filter alarm (3) lights up on the display unit.
In addition, a buzzer sounds continuously
and the engine speed is reduced so that the
truck moves only at creep speed. In this
case, switch off the truck engine as quickly
as possible and perform filter 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 particle filter, the
exhaust system and in their vicinity.
For reasons of fire safety do not allow
the regeneration exhaust gases to be
drawn into a fume extraction system.
Perform regeneration only in the
open air with the engine at operating
temperature and away from combu-
stible materials. Do not touch - risk of
burns.

NOTE
Regeneration can be performed only when the
engine is stopped and the glow plug starting
switch is in the zero position (ignition off).
Regeneration is carried out automatically.
Once regeneration has been completed, the
switch illumination (operating display) goes
out and the truck can be operated again.
¾ Clean the exhaust air duct thoroughly.
¾ If more than 30 minutes have elapsed since
the engine was switched off, move the
glow plug starting switch briefly to position I
and then back to the zero position (ignition
briefly switched on, then off again).
The particle filter control system will remain
active for a further 30 minutes and regener-

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5 Maintenance
Engine

ation can be started at any time within this

period.
¾ Press down the starting switch (7) and keep
the switch pressed for approx. 3 seconds
until the integrated yellow switch illumina-
tion (operating display) lights up. The par-
ticle filter alarm (3) goes out in the display
unit.
The operating display stays lit up until the
end of the regeneration process (approx. 23
minutes).
If the particle alarm was activated before
regeneration is restarted, it remains active.
In this case, a full regeneration must be
performed immediately.

CAUTION
The engine cannot be started during regeneration.
If the truck has to be moved from a safety area or
regeneration has to be interrupted for safety rea-
sons, the stop/reset switch (8) must be unlocked
and pressed. The regeneration process will imme-
diately be terminated, and the truck can be started.
If the regeneration process has been interrupted,
the particle filter will not have been regenerated!
Regeneration should only be interrupted in an
emergency as this may lead to system damage.

¾ In the event of an emergency, unlock and

press the stop/reset switch (8) in the switch
panel (1).
In the event of a fault occurring during rege-
neration, the fault light (2) or the particle filter
alarm (3) lights up and a fault code appears in
the text field (5) of the display unit.
Start regeneration again. If the malfunction
still persists, switch off the truck. Please
contact your authorised dealer.

NOTE
To switch off the buzzer, press the reset button
(6). If the buzzer continues to sound, please
contact your authorised dealer. Whilst driving,
the glow plug of the regeneration system
is cleaned after 1.75 hours by intermediate
heating.

152 Operating Instructions – 393 807 10 01 EN – 10/2010

 Maintenance 5
Engine

Regenerating the changing particle

filter
The particle filter must be regenerated after a
maximum of 8.5 h engine operation. After
8.0 hours, the orange indicator light (1)
illuminates in the switch panel at the top-right
as an optical display, and a buzzer sounds.
The clogged up filter must be changed for a
regenerated filter within the next 30 minutes.
If the exhaust gas back pressure exceeds the
admissible level before the 8 hours are up, this
is also shown by the orange indicator light and
the buzzer. In this case, the filter must also be
changed within 30 minutes.

CAUTION
In the event of a power failure (e.g. disconnected
battery), the loading time and filter capacity can be
exceeded.
Therefore, in the interest of safety, regenerate the
particle filter immediately.

NOTE
Select an appropriate location to assemble
the regeneration system. Do not introduce
regeneration exhaust gases into suction
systems or work areas.

Removing the particle filter

¾ Drive to the regeneration station.
¾ Switch off the engine.

Operating Instructions – 393 807 10 01 EN – 10/2010 153

5 Maintenance
Engine

¾ Remove the retaining split pin (3) from the

quick-locking mechanisms.
¾ Release quick-locking mechanisms (2) and
(9) and disconnect the rod (6) at the top at
the filter.
¾ Remove the retaining split pin (7) at the
contact protection.
¾ Fold out the contact protection (4). Use the
bracket (5) to do this.

WARNING
Danger of burns.
Use protective gloves.

¾ Remove the particle filter (8), avoiding

impact stress.

Cleaning the particle filter

¾ Insert the particle filter (8) into the regener-
ation system (10).
¾ Switch on the regeneration system (10)
using the "ON" push-button (15).
¾ The operating display (12) lights up.
Regeneration is complete once the operating
display has gone out by itself.
Regeneration time: approx. 50 minutes.

NOTE
The duration of regeneration is fixed and
depends on the size of the filter. The duration
of the regeneration procedure is not influenced
by the amount of particulate on the filter. An
exchange filter can be burnt out when both
partially and fully covered with particulate.

WARNING
Danger of burns.
Observe the decal information (11).

154 Operating Instructions – 393 807 10 01 EN – 10/2010

 Maintenance 5
Engine

Press the STOP switch (15) in the event of

danger.
Only press the STOP switch in an emergency!
The filter must then be fully regenerated again.
An indicator light (13) will illuminate if there
is a malfunction during regeneration. Press
the acknowledgement button (14). If the
error persists, please contact your authorised
dealer.
¾ Remove the particle filter from the regener-
ator.
¾ Reattach the particle filter to the truck.
The opening of the tailpipe must point to the
right.
¾ Check the filter is securely in place.

NOTE
When closing the quick-locking mechanism
(9), an end limit switch automatically sets the
built-in hour meter to zero.

Checking the particle filter system

(special equipment)
¾ Check electric contacts for secure position-
ing, corrosion and damage.
¾ Check the combustion air ducts for damage,
leaks and secure positioning.
¾ Check the fuel-conducting lines and parts
for damage, leaks and secure positioning.
¾ Check that the system functions correctly
(alarm, buzzer, regeneration).
¾ Check burner fastenings for leaks, defor-
mation and secure positioning.
¾ Clean the corrugated hose and the connec-
tion angle (fan to the burner).
¾ Check that the filter suspension points are
securely fitted.
¾ Check the exhaust-gas-conducting parts
for leaks.
¾ Clean the air intake pipe on the burner.

Operating Instructions – 393 807 10 01 EN – 10/2010 155

5 Maintenance
Engine

To do so, release the olive screw joint and

remove particulate deposits using a round
steel brush.
¾ Check that the screws on the filter housing
and the exhaust-gas-conducting parts are
securely fitted.
¾ Check the glow plug coil for serious defor-
mation and coking.
When performing maintenance work, please
consult your authorised dealer.

Draining water from the water trap at

the changing particle filter (special
equipment)

NOTE
Only for particle filters with a changing particle
filter system.
¾ Press in the pin (2) on the bottom of the
water trap inspection glass (1) until the
water has completely drained out.

Cleaning the water trap at the

changing particle filter (special
equipment)

NOTE
Only for particle filters with a changing particle
filter system.

156 Operating Instructions – 393 807 10 01 EN – 10/2010

 Maintenance 5
Engine

¾ Unscrew the sight glass (1) and wipe out

with a clean cloth.
If necessary, completely dismantle the water
trap and blow out with compressed air.

Cleaning the pressure control device

at the changing particle filter (special
equipment)

NOTE
Only for particle filters with a changing particle
filter system.
¾ Remove the hose clip (1).
¾ Remove the hose (2) from the water trap
(3).
¾ Blow dry compressed air through the hose
and cooling coil towards the filter entrance
chamber.
¾ Reattach the hose and secure with the hose
clip.

Operating Instructions – 393 807 10 01 EN – 10/2010 157

5 Maintenance
Gearbox

Gearbox
Checking the fastenings of the axle
clamps and wheel motors
¾ Check that the 4 fixing screws (M16) (1) of
the axle clamps have a tightening torque of 1
1
275 Nm.
¾ Check that the fixing screws (M12) (arrows)
of the wheel motors have a tightening torque
of 110 Nm.
To do so, the drive wheels must be removed
beforehand.

1 1
d3921397

Checking and adjusting the side

stops on the drive axle
¾ Check the air gap (1) between the stop (2)
and chassis (3).
The air gap should not be larger than 1 mm.
Check the air gap on the left and right of the
axle.
If the air gap is larger, adjust the stop.
¾ Slacken the hexagonal nut (4).
¾ Adjust the stop with the hexagonal nut (5)
until the air gap is 1 mm.
When it is no longer possible to adjust the
air gap, the axle spring element is worn. The
spring element must be changed. Please
advise your authorised dealer.
¾ Tighten the hexagonal nut (4).

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 Maintenance 5
Gearbox

Checking the drive axle bearings for

wear

NOTE
The drive axle is installed in the chassis with
rubber spring elements on both sides.
¾ Remove the drive wheels.
¾ Using a lamp, check the state of the rubber
spring elements (1) between the axle,
chassis and plastic stops.
The rubber spring elements must be checked
on both the left and right of the axle. If the axle
spring elements or the plastic stops are worn,
these must be changed. Please contact your
authorised dealer.
¾ Attach the drive wheels.

1 1
d3921498

Checking the hydraulic pump’s

attachment to the engine
¾ Open the bonnet.
¾ Tighten the 4 hexagon head screws to the
prescribed tightening torque of 80 Nm.
¾ Close the bonnet.

Operating Instructions – 393 807 10 01 EN – 10/2010 159

5 Maintenance
Chassis, bodywork and fittings

Chassis, bodywork and fittings

Cleaning the truck
Cleaning requirements depend on the use of
the truck. For operations with highly abrasive
materials, e.g. salt water, fertiliser, chemicals,
cement etc., thorough cleaning should be
carried out after the task is complete.
Hot steam or cleaning materials with a pow-
erful degreasing effect should only be used
with great caution as they will affect the grease
filling of bearings with lifetime lubrication,
causing it to escape. As relubrication is not
possible, the bearings will be irreparably dam-
aged.
Switch off the engine and wait for it to cool
down before cleaning the truck. d3921437

Deposits/accumulations of combustible
materials, especially on or in the vicinity of
parts with high temperatures (e.g. exhaust
pipes) must be removed regularly.

CAUTION
When cleaning with a water jet (high-pressure
or steam cleaner etc.), it should not be applied
directly to the electric and electronic components,
plug connectors, air duct plastic pipes, any of the
hydraulic and coolant hoses or the area with hose
clips. Water should not be used for cleaning in the
area of the central electrical system and switch
console.
If this cannot be avoided, the affected parts must
be covered in advance or only cleaned using a dry
cloth or clean compressed air

When using high-pressure cleaners, the

minimum distance between the steel pipe
and the truck should be approx. 300 mm.
When using compressed air for cleaning,
remove stubborn contamination with a cleaner
solvent.
Pay particular attention to cleaning the oil
filling openings, their surroundings and the
lubricating nipples before lubricating.

160 Operating Instructions – 393 807 10 01 EN – 10/2010

 Maintenance 5
Chassis, bodywork and fittings

Bonnet
Opening the bonnet
WARNING
Always observe the following when opening the
bonnet with the engine running: The hydraulic drive
and a temperature-dependent 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 steering column all the way forward

and clamp in place.
Only for luxury driver’s seat
¾ Pull the lever (2) outwards and slide the
driver’s seat all the way forwards. 4 1
¾ Release the lever and allow the seat to
engage.

3 d3921405

Operating Instructions – 393 807 10 01 EN – 10/2010 161

5 Maintenance
Chassis, bodywork and fittings

¾ Push the lever (1) fully upwards, hold it

4
there, push the seat backrest (4) fully 5
forwards and release the lever (1). (Only
where rear window fitted)
¾ Push your finger into bore (3) to release the
bonnet catch; whilst doing so, release the
pressure on the bonnet catch by pressing
the bonnet in the direction of the arrow.
¾ Open the bonnet (5) to the rear up to the
stop.

NOTE 7
The bonnet can be opened further for specific
maintenance work. Before opening the
bonnet in this way, the armrest must be moved 6 d3921489

all the way down.

¾ Undo the clamping screw (10) in the armrest
(8), push the armrest fully downwards.
8
¾ Retighten clamping screw.
¾ Release the support mounting (7). Push
support mounting to rear.
If a rear window is installed, the armrest 9
fore/aft adjustment must also be pushed all the
way forwards. To do so release the clamping
screw (9), and push the armrest (8) all the way
forwards. Retighten clamping screw.
¾ Open bonnet all the way. 10

NOTE
The bonnet is held in both open positions by d3921400

gas springs.

162 Operating Instructions – 393 807 10 01 EN – 10/2010

 Maintenance 5
Chassis, bodywork and fittings

Closing the bonnet

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

6 d3921489

Floorplate
Opening the floorplate
Some maintenance operations require that
the floorplate is lifted.
¾ Open the bonnet.
¾ Unscrew the fixing screws (2) from the
floorplate.
¾ Remove plates (5) and (6)
¾ Remove the rubber covering from the
floorplate (1).
¾ Swing the floorplate up.

Operating Instructions – 393 807 10 01 EN – 10/2010 163

5 Maintenance
Chassis, bodywork and fittings

¾ Feed a restraint strap (3) around the steer-

ing wheel and hang it onto the bolt (4).
3

1
Closing the floorplate 4
¾ Lift up the floorplate.
¾ Detach the restraint strap.
¾ Close the floorplate.
¾ Install plates (5) and (6).
¾ Secure the floorplate with the fixing screws
(2).
¾ Replace the rubber covering on the floor-
plate.
¾ Close the bonnet. d3921504

Servicing the air conditioning

(special equipment)
The following maintenance work must be
carried out at the beginning, middle and end of
a season:
¾ Check the belt tension at the compressor.
¾ Check the refrigerant level and moisture
content in the system.
The refrigerant must flow, bubble-free,
through the sight glass of the dryer (1) when
the engine is running.
When changing a component in the cooling
circuit, the dryer must be changed before
refilling.
¾ Clean 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.

164 Operating Instructions – 393 807 10 01 EN – 10/2010

 Maintenance 5
Chassis, bodywork and fittings

Checking the condition and correct

function of the seat belt

NOTE
For safety reasons, the condition and correct
function of the restraint system should be
checked regularly (once a month). When
used under extreme conditions, this should be
carried out on a daily basis before starting up
the truck.
¾ Pull belt (1) right out and check for fraying
and torn stitching. 1

¾ Check that the buckle (3) functions correctly

and that the belt retracts properly.
¾ Check the covers and attachment points for
damage.
Test automatic blocking mechanism. 3
¾ Park truck in a horizontal position.
¾ Pull out belt with a jerk.
The automatic mechanism should block
extension of the belt from the belt retractor
(2). 2
¾ Push the driver’s seat all the way forwards. d3921441

¾ Fold the seat backrest completely forwards.

NOTE
When opening the bonnet, remember that the
rear window may have been installed.

Operating Instructions – 393 807 10 01 EN – 10/2010 165

5 Maintenance
Chassis, bodywork and fittings

¾ Unlock the bonnet and open approx. 30°

with driver’s seat (4).
The automatic mechanism should block
extension of the belt from the belt retractor
(2).
4

WARNING
Do not use industrial trucks if the restraining belt
is defective. After an accident, restraining belts
must be changed. In the case of restraining belts
mounted on the driver’s seat, the driver’s seat and 30˚

the driver’s seat mounting must also be checked

by a technician following an accident. Screw
connections should be checked regularly to make
sure they are secure. If the seat wobbles, this may
indicate loose screw connections or other defects.
Any failure to do so creates a risk to your health and
an increased risk of accidents. d3921442

If you notice any irregularities in the functioning of

the seat (e.g. seat suspension) or the restraining
belt, you should immediately contact your authori-
sed dealer to eliminate the cause.

Checking fastening for frame, tilt

cylinders and steering axle
¾ Check 6 fastening bolts (M 24) (1) of frame 2
have a tightening torque of 660 Nm.
¾ Check the 4 fastening bolts (M16) (2) of the 2 1
tilt cylinders with a torque of 275 Nm.
¾ Check the fastening bolts (M16) of the
steering axle with a torque of 195 Nm.

d3921496
1

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 Maintenance 5
Chassis, bodywork and fittings

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 – 393 807 10 01 EN – 10/2010 167

5 Maintenance
Chassis frame

Chassis frame
Wheel change

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

¾ Position the jack at the front edge of the

chassis (2) on the left or right or beneath the
counterweight (1).
The truck should only be raised at these
suspension points on the left and right.
¾ Release the wheel fastenings on the wheel
in question.
¾ Raise truck with jack until wheels are off the
ground.
1
¾ Prop up securely using square timber 2
supports at the chassis or counterweight.
¾ Unscrew the wheel fastenings.
¾ Change the wheel.
d3921491
¾ Position wheel fastenings and tighten them
manually.
¾ Lower truck.
¾ Tighten wheel fastenings

Front 170 Nm
Rear 460 Nm

NOTE
If new wheel screws are used or a new rim is
fitted, the front tightening torque on the first
occasion should be 195 Nm.

168 Operating Instructions – 393 807 10 01 EN – 10/2010

 Maintenance 5
Chassis frame

Tighten the wheel bolts

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

front 170 Nm
rear 460 Nm

NOTE
If new wheel bolts are used or a new wheel is
fitted the tightening torque on the first occasion
only should be 195 Nm

Check the tyres for damage and

foreign objects
¾ Secure the truck against rolling (apply
parking 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
movement.
¾ Replace worn or damaged tyres.

d3921440

Operating Instructions – 393 807 10 01 EN – 10/2010 169

5 Maintenance
Chassis frame

Checking the tyre pressure and tyre

sizes

CAUTION
If the air pressure is too low, the tyres’ service life
will be reduced and the stability of the truck will be
compromised.
Therefore, regularly check the air pressure.

¾ Check that the tyres have the prescribed air

pressure.

d3921385

¾ If necessary, adjust the tyre pressures in

accordance with the information on the
adhesive label (1) on the right-hand side of
the truck next to the drive wheel:
Drive axle

Single tyre
H 25, 27x10-12/20 PR 10.0 bar
H 30,
H 35 27x10 R12 10.0 bar
250/75 R12 10.0 bar
28x12.5-15 SE
660/250-480 -- 1
23x10-12 SE -- d3921515

Twin tyres
H 25, 7.00-12/16 PR 7.5 bar
H 30,
H 35 7.00 R12 7.5 bar
7.00-12 SE --

Steering axle

170 Operating Instructions – 393 807 10 01 EN – 10/2010

 Maintenance 5
Chassis frame

Single tyre
H 25, 23x9-10/14 PR 7.0 bar
H 30,
H 35 6.50-10/14 PR 7.0 bar
6.50 R10 7.0 bar
23x9-10/20 PR 7.0 bar
23x9 R10 7.0 bar
6.50-10 SE --
23x9-10 SE --
200/50-10 SE --

Example
Tyre pressure adhesive label (1)

Drive axle
Single tyre 10.0 bar
Twin tyres 7.5 bar

Steering axle
Single tyre 7.0 bar

Rim sizes
Tyre size Rim size
27x10-12 8.00G-12
250/75-12 8.00G-12
7.00-12 5.00S-12
6.50-10 5.00F-10
23x9-10 6.50F-10
660/250-480 480
23x10-12 8.00G-12
200/50-10 6.50F-10

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5 Maintenance
Chassis frame

Cleaning and greasing the steering

axle

ENVIRONMENT NOTE
Observe information regarding working with
consumables.
When used indoors in clean, dry conditions, it
is generally sufficient to perform maintenance
every 1000 operating hours. It is advisable to
halve these lubrication intervals if the vehicle
is used both indoors and outdoors.
If used in areas with constant exposure to dust,
dirt, water, road salt or chemicals, weekly
lubrication will considerably lengthen the
service life of the spherical bearings.

NOTE
It is better to apply a little grease to the
bearings frequently than a lot of grease
infrequently.
¾ Clean steering axle with water or cleaner
solvent.

NOTE
Lubricating grease should be used for grea-
sing in accordance with consumables recom-
mendations. First grease the axle stub bear-
ings on top, then underneath.
¾ Grease the tie rod and axle stubs at the
lubricating nipples (see arrows) using
lubricating grease.
¾ Grease with grease gun until fresh lubricat-
ing grease escapes at bearings.

d3921344

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 Maintenance 5
Chassis frame

Checking the mountings of the

steering cylinder and steering pivot
pin
¾ Check that the 4 mounting screws (1) are
secure. 2
Tightening torque: 210 Nm
¾ Check that the nut (2) on the steering pivot
pin is securely attached.
Tightening torque: 290 Nm 1
(Item (2) does not exist for the H 35 with
steering axle, series 1602)

d3921345

Check the parking brake for correct

operation
¾ Drive the fork lift truck, carrying its maximum
load, up a gradient of 15 %.
¾ Pull the parking brake handle (1) upwards.
The vehicle must remain stationary.
¾ Switch off the engine.
Version 1:
¾ Release the parking brake handle (1).
The vehicle must remain stationary.
Version 2:

1 d3921457

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5 Maintenance
Chassis frame

¾ Place the parking brake lever (2) in a

horizontal position.
The vehicle must remain stationary.
¾ Switch off the engine.
¾ Press the button (1) and unlock the parking
brake lever (2).
¾ Move the parking brake 90° downwards.
The vehicle must remain stationary.

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

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 Maintenance 5
Operating devices

Operating devices
Checking the pedals

ENVIRONMENT NOTE
Observe information regarding working with
consumables.
¾ Lift up the floorplate and secure in place.
¾ Unscrew the 4 nuts of the pedal box.
¾ Check pedals for smooth action.
¾ If necessary, grease the bearings slightly.
¾ Re-attach the pedal box.

d3921378

Checking the bellows at the actuat-

ing lever
¾ Check that the bellows (1), (2) and (3)
(depending on the version) are securely
positioned and show no signs of damage.
Change if necessary.

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5 Maintenance
Electrics

Electrics
Check the condition and secure
positioning of electric cables, cable
connectors and connections

NOTE
Oxidised connections and brittle cables lead
to voltage drops and thus to difficulties during
start-up and operation.
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 oxidation residues and replace
brittle cables.

d3921449

Battery: check condition, acid level

and acid density
When handling starter batteries, the following
should be complied with:
¾ Wear industrial goggles and a protection
suit.
¾ Before touching the battery, first grasp
conductive 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).

176 Operating Instructions – 393 807 10 01 EN – 10/2010

 Maintenance 5
Electrics

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
without 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.

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5 Maintenance
Electrics

¾ Inspect battery (1) for cracked housing,

1
raised plates and acid leaks.
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
2
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.
d3921383
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.

178 Operating Instructions – 393 807 10 01 EN – 10/2010

 Maintenance 5
Hydraulics

Hydraulics
Change hydraulic oil
Drain hydraulic oil

ENVIRONMENT NOTE
Observe information regarding working with
consumables.
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 bonnet. Unscrew breather filter
with oil dipstick (2).

¾ Unscrew hydraulic oil drain plug (1) on

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

Refill/top up hydraulic oil

NOTE
The oil dipstick has markings that apply to the 1
various lift heights.

d3921335

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5 Maintenance
Hydraulics

¾ Add hydraulic oil to filling port.

Total fill quantity:
• for lift heights up to 5000 mm marking
potentiometer (5): approx. 24.0 l
• for lift heights 5000 mm - 6900 mm between
marking 3 and 5 (4): approx. 25.5 l
• for lift heights 6900 mm - 8000 mm marking
(3): approx. 28.0 l
¾ Check oil level with dipstick (2) and top up
until upper marking on dipstick for relevant
lift height is reached.
¾ Allow engine 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 bonnet.

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

Hydraulic system: Check oil level

ENVIRONMENT NOTE
Observe information about working with
consumables.

NOTE
Oil specifications: see Recommendations for
working materials
¾ Fully lower the fork carriage.

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 Maintenance 5
Hydraulics

¾ Unscrew the breather filter (1) with oil

dipstick on the left side of the vehicle.

NOTE
Tank under low pressure. A small amount of
air will escape.
¾ Wipe the oil dipstick with a clean cloth.

NOTE
There are 2 markings on the oil dipstick (2)
that are used according to the height of the lift
mast. The various lift heights are stamped into
the dipstick

¾ Only check the marking which applies to

your truck.
• Marking (3) for lift heights of 6900 to 8000
mm.
• Marking (5) for lift heights up to 5000 mm.
• Between marking 3 and 5 (4) for lift heights
from 5000 mm to 6900 mm.
¾ Screw the breather filter with oil dipstick in
completely and then unscrew it again.
The oil level shown on the dipstick should be
between the two markings for the relevant lift
height.
¾ If necessary, add more hydraulic oil until it
reaches the marking for your truck.
The difference in quantity between the max.
and min. mark
for all lift heights is approx. 2 l

Hydraulic system: changing the filter

Feed and pressure filter

ENVIRONMENT NOTE
Observe information regarding working with
consumables.
¾ Unscrew the side maintenance cover on the
left.

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5 Maintenance
Hydraulics

¾ Lower the lift mast. Loosen the lower

mounting screw (2) and the upper mounting
screw (1) on the filter carrier.
4
¾ Swing out the filter carrier.
¾ Place a collection vessel underneath.
3
¾ Loosen the pressure filter housing (3) and
the feed filter housing (4) at the hexagonal
section. 1
¾ Unscrew the filter housing manually and
pull out the filter cartridges from the base.

ENVIRONMENT NOTE 2
Dispose of the filter cartridges in an environ-
mentally friendly manner. d3921369

¾ Apply oil to the seals on the new filter

cartridges.
¾ Attach the filter cartridges to the base on the
filter head.
¾ Screw on the filter housing and tighten it
hand-tight.
Tightening torque: 10+5 Nm; then slack it back
¼ turn.
¾ Fold the filter carrier up and tighten it
¾ Check the filter flange for leaks during a test
run.
¾ Mount the side maintenance cover.

Suction filter
CAUTION
The oil must have an optimal purity level at all times.
When servicing the device after 6,000 operating
hours, it is therefore absolutely essential to change
the hydraulic oil before changing the suction filter.

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 Maintenance 5
Hydraulics

¾ Open the bonnet.

¾ Open the breather (1).
This allows the air to escape so that the oil
will not overflow when the filter cartridge is
inserted.
¾ Turn the filter cover (2) in an anti-clockwise
direction and unscrew it.
¾ Slowly remove the filter cartridge.
This will allow the oil to flow back into the
reservoir.
¾ Pull filter cartridge out entirely.
¾ Carefully insert new filter cartridge in
hydraulic tank.
Ensure that it is correctly centred in the filter
bottom.
¾ Clean seal of filter cover and wet with oil.
¾ Replace the filter cover (2) and turn it in the
clockwise direction.
¾ Tighten the filter cover to 25 Nm.
The hydraulic system will vent itself automati-
cally when the motor is running.
¾ Screw breather filter on.
¾ Perform a trial run to check the filter cover
for leakage.
¾ Close the bonnet.

Breather

NOTE
If there are high levels of dust, it may be
necessary to change the filter earlier.

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5 Maintenance
Hydraulics

¾ Open the bonnet.

¾ Unscrew the filter (1) for the hydraulic oil
tank from the filler neck.
¾ Remove the dipstick (2) from the breather
filter and attach it to the new filter.
¾ Screw in the filter and tighten it.
¾ Close the bonnet.

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
consumables.
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.

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 Maintenance 5
Hydraulics

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 chaffing and replace, if
necessary.
¾ Close the floor plate.

d3921455

Check tilt cylinder bearings for wear

NOTE
The tilt cylinders are mounted in rubber
bearings at both ends.
¾ Remove the screw (1) at the disc (2).
1 2
¾ Make a visual inspection of the rubber
bearings 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

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5 Maintenance
Hydraulics

Check the tension of double hoses

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

d3921519

Checking the function and safety

system of the third auxiliary hy-
draulics (special equipment)

NOTE
If a toggle-switch-controlled third auxiliary hy-
draulics system is fitted, a functional test and
safety check must be carried out when perfor-
ming the initial start-up and after carrying out
repairs to the third auxiliary hydraulics system.

Functional test:
¾ Activate all three additional functions one
after the other.
The functions performed by the attachment
must comply with the signs on the operating
console.

Safety check:
¾ Switch on the ignition.
¾ Remove a cable connector from the sole-
noid valve on the fork carriage.

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 Maintenance 5
Hydraulics

¾ Operate the pre-selector (1) from the

second to the third auxiliary hydraulic
function.
The following safety precautions / warning
messages are activated:
• Switchable auxiliary hydraulic function
blocked.
• Truck switched to creep mode.
• Error code displayed in text field of indicator
unit.
• Buzzer sounds.
If there are any malfunctions, please contact
your authorised dealer.

Operating Instructions – 393 807 10 01 EN – 10/2010 187

5 Maintenance
Load lift system

Load lift system

Cleaning the lift mast chain and
applying chain spray

DANGER
Lift mast chains are safety elements. Incorrect
cleaning materials may cause direct damage to
chains.
Do not use cold / chemical cleaners or fluids that
are corrosive or contain acid or chlorine.

If the lift mast chain is so dusty that penetration

of the lubricating oil is not ensured, the chain
must be cleaned.
¾ Place a collection vessel under the lift mast.
¾ Clean lift mast chain with paraffin deriva- d3921398

tives such as petroleum ether.

Take note of the manufacturer’s safety infor-
mation. When cleaning with a steam jet, do
not use additives.
¾ After cleaning, immediately use com-
pressed air to remove any water remaining
on the surface of the chain and in the chain
joints.
The chain should be moved several times
during this process.
¾ Immediately apply Linde chain spray to
chain, also moving chain while doing so.

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 Maintenance 5
Load lift system

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
condition and security.
¾ Check stops for condition, mounting 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 lift mast chain

Standard lift mast

NOTE
The lift mast chain stretches over time during
operation and therefore has to be readjusted
on the right and left.
¾ Lower the lift mast completely.

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5 Maintenance
Load lift system

¾ Loosen locknut (1).

¾ Adjust chain at adjustment nut (2) of chain
anchor.
The lower guide roller of the fork carriage
should only protrude max. 25 mm from the
guide rail of the inner lift mast.
¾ Tighten the locknut (1).
¾ Also adjust second chain.

CAUTION
When extended, the lift mast should not touch the
end stops.
Fully extend lift mast and check clearance to end
stops.

Apply chain spray.

NOTE
In the case of trucks that are used in the food
production sector, chain spray should not be
used. Instead, use a low-viscosity oil licensed
for use in the food industry.
¾ Apply Linde chain spray to guide surfaces
and chain.

Duplex or triplex lift mast

NOTE
The lift mast chain stretches over time during
operation and therefore has to be readjusted.
¾ Lower the lift mast and fork carriage com-
pletely.

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 Maintenance 5
Load lift system

¾ Loosen locknut (4). Adjust chain at adjust-

ment nut (3) of chain anchor.
The lower guide roller of the fork carriage
should only protrude max. 25 mm from the
guide rail of the inner lift mast.
¾ Tighten the locknut (4).

CAUTION
When extended, the lift mast should not touch the
end stops.
Fully extend lift mast and check clearance to end
stops.
3
Apply chain spray.
4 d3921486
NOTE
In the case of trucks that are used in the food
production sector, chain spray should not be
used. Instead, use a low-viscosity oil licensed
for use in the food industry.
¾ Apply Linde chain spray to guide surfaces
and chain.

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
damage.
¾ Replace any defective parts.

d3921451

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5 Maintenance
Load lift system

Clean sideshift (special equipment)

and grease, check fastening

ENVIRONMENT NOTE
Observe information about working materials.

NOTE
The sideshift should be greased whenever
the truck is washed. Use lubricating grease
complying with the recommendations for
working materials.
¾ Clean sideshift with steam jet.
¾ Check hydraulic lines for scuffing and
replace 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
nipples (1) of support rollers on fork carriage
until grease escapes at the side.
¾ Apply lubricating grease to lubricating
nipples (2) of wear strips on fork carriage
at top until grease escapes at the side.

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 Maintenance 5
Load lift system

Checking the slide guides on the

sideshift (special equipment) for
wear
¾ Dismantle sideshift.
¾ Clean sideshift.
¾ Remove the slide guides from the upper
guide (1).
¾ Measure the wall thickness of the slide
guide (3).
If wall thickness is less than 2.5 mm, change
the 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 Lubricate the sideshift at lubricating nipples
(2) and (4).

Cleaning and lubricating the fork

prong positioner (special equip-
ment), checking the mounting
¾ Clean the fork prong positioner using a
steam jet.
¾ Check condition of fork prong positioner
and check for leaks.
¾ Check hydraulic lines for chafing and
replace if necessary.
¾ Check hydraulic connections for tightness,
replace if necessary.
¾ Check cylinders for leaks.
¾ Check piston rods for damage.

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5 Maintenance
Load lift system

¾ Tighten mounting screws (1) to 106 Nm.

¾ Screw in the screws (2) to the fork arm stop,
tighten lock nut to 50 Nm.
¾ Tighten mounting screws (3) to 120 Nm.

¾ Tighten mounting screws (7) to 145 Nm (for

H 25 trucks with fork carriage load-bearing
class 2A).
¾ Tighten mounting screws (7) to 235 Nm
(for H 30 / H 35 trucks with fork carriage
load-bearing class 3A).
¾ Lubricate slide guides (4) with lubricating
grease.
¾ Apply lubricating grease to lubricating
nipples (5) of the sliding shoes until grease
escapes at the side.
¾ Apply lubricating grease to lubricating
nipples (6) of the slide rollers until grease
escapes at the side.

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 Maintenance 5
Load lift system

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.

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5 Maintenance
Special equipment, accessories

Special equipment, accessories

Top up the washer system water tank
¾ Open the bonnet.
¾ Remove the filler cap (1) from the water tank
(2) at the right-hand side at the chassis wall.
¾ Fill up with water until it is visible in the filling
neck.
¾ Refit the cap.
¾ Close the bonnet.

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 Maintenance 5
Troubleshooting

Troubleshooting
Opening the cover to the electrical
system
Depending on the set-up, up to 40 fuses may
be installed in the electrical system in order to
protect it. The fuse box can be accessed after
removing the cover of the electrical system.
¾ Unscrew both handles(2).
¾ Take off the cover (1).
¾ Take off the fuse box cover.

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5 Maintenance
Troubleshooting

Fuses for basic and special equipment

Checking and changing fuses

1 12 V socket (9F10)*, 15 A 21 Toothed belt seal blower (0F1)*, 10 A

2 Heater/air conditioning (9F9)*, 20 A Time-delayed lighting off (F17)*, 2 A
3 Seat heater (9F6)*, 15 A 22 Particle filter (7F3)*, 30 A
4 Warning light and rotating beacon (4F3)*, 23 Particle filter (7F2)*, 20 A
7.5 A 24 Particle filter (7F1)*, 5 A
5 Working headlight positions 3, 4 (5F2)*, 15 A 25 Vehicle Data Management (6F1)*, 5 A
6 Working spotlight positions 5, 6 (5F3)*, 15 A 26 Reverse motion (4F1)*, 10 A
(with attachment of one 7.5 A headlight) 27 Radio (terminal 58) (9F8)*, 10 A
7 Working spotlight positions 7, 8 (5F4)*, 15 A 28 Radio (terminal 30) (9F7)*, 5 A
(with attachment of one 7.5 A headlight) 29 Washer pumps (9F4)*, 10 A
8 Rear window heater (9F5)*, 20 A 30 Windscreen wiper rear and roof (9F3)*, 10 A
9 Indicator unit (terminal 30) (F5), 2 A 31 Front windscreen wiper (9F2)*, 10 A
10 Indicator unit (terminal 15) (F6), 2 A 32 Windscreen wiper (9F1)*, 2 A
11 Alarm horn (F7), 15 A 33 Interior light (5F12)*, 5 A
12 Traction-lift control (terminal 15) (F8), 2 A 34 Brake light (5F7)*, 5 A
13 Engine control unit (F12), 5 A 35 Warning lights (5F6/5F13)*, 10 A
14 Engine control unit (F11), 20 A 36 Lighting / working spotlight positions 1, 2
15 Not assigned (5F5/5F1)*, 15 A
16 Traction-lift control (terminal 30) (F9), 15 A 37 Right sidelights (5F11)*, 5 A
17 3. Auxiliary hydraulics (F16)* 7.5 A 38 Left sidelights (5F10)*, 5 A
18 Terminal 15 (F15), 10 A 39 Right headlight (5F9)*, 7.5 A
19 Terminal 58 (F14), 2 A 40 Left headlight (5F8)*, 7.5 A
20 Terminal 30 (F13), max. 15 A

* Special equipment

Main fuses in engine compartment

Checking and changing fuses
¾ Open the bonnet.
198 Operating Instructions – 393 807 10 01 EN – 10/2010
 Maintenance 5
Troubleshooting

¾ Open the covering of the fuse box.

In the engine compartment, MTA fuses protect 4
the following circuits: 3
1
• Fuse (F1) (1) for glow and fuel system, 50 A
• Main fuse (F2) (2) for complete electrical 2
system, 30 A
• Main fuse (F3) (3) for complete special
equipment, 70 A
• Fuse (F4) (4) for air conditioning, 30 A

d3921517

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
When the truck battery is discharged, a
jump-start battery can be used with a jumper

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5 Maintenance
Troubleshooting

cable to start the truck. The following must be

taken into consideration when doing this:
• Both batteries must have the same nominal
voltage.
• The capacity (Ah) of the current-giving
battery must not be significantly lower than
the capacity of the discharged battery.
• Use a jumper cable with a sufficient cross-
section and insulated pole clips.
WARNING
A discharged battery can freeze at temperatures
below 0°C. There is then a risk of explosion.
Before connecting the jumper cable, it is essential
that a frozen battery is thawed.

¾ Switch off all current consumers (heater, air

conditioning, lighting).
¾ Open the engine bonnet.
¾ Connect one end of the positive cable (1) to
the positive terminal (+) of the discharged
truck battery (2).
¾ Connect the other end of the positive
cable (1) to the positive terminal (+) of the
current-giving battery (5).
¾ Connect one end of the negative cable (4)
to the negative terminal (-) of the current-
giving battery (5).
¾ Connect the other end of the negative
cable (4) as far away as possible from the
discharged truck battery (2) to a massive
metal component securely connected to the
engine block or to the engine block itself (3).

NOTE
If the jump-start battery is housed in another
vehicle, start the vehicle’s engine and allow to
idle.
¾ Start the engine.
If the engine does not start straightaway, stop
the starting process after 10 seconds and try
again after around 30 seconds.
¾ Once the engine is running, first disconnect
the negative cable (4) from the engine block

200 Operating Instructions – 393 807 10 01 EN – 10/2010

 Maintenance 5
Troubleshooting

(3), and then from the current-giving battery

(5).
¾ First disconnect the positive cable (1) from
the current-giving battery (5), then from the
discharged battery (2).

Fork carriage emergency lowering

If there is a malfunction, the fork carriage can
be lowered manually.
¾ Remove floormat.

DANGER
Risk of accident or danger to life
when lowering the fork carriage with
fork arms.
People are not allowed to stand in the
vicinity of the fork arms when they are
being lowered.
During lowering, leave the socket
wrench on the threaded stud (1) on
the valve block (3) to enable lowering
to be interrupted at any time.

¾ Insert the 8 mm WAF socket wrench

through the opening in the floor plate.
¾ Using the socket wrench slowly rotate
the threaded stud (1) approx. 3 turns
anti-clockwise until the fork carriage has
been completely lowered.
¾ Open the bonnet.
¾ Open floor plate and secure it.
¾ Undo the self-locking nut (2) about 2 turns.

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5 Maintenance
Troubleshooting

¾ Screw the threaded stud (1) back in clock-

wise. Otherwise it will not be possible to lift
the fork carriage using the joystick.
Tightening torque 10 Nm.
¾ Retighten the self locking nut (2).
Tightening torque 9.5 Nm

NOTE
1
After emergency lowering has been perfor-
med three times, a new threaded stud with self
locking nut must be used.
¾ Close floor plate and bonnet.
¾ Insert the floormat. 3 2 d3941386

Emergency exit with attached rear

window
If a truck with an attached front and rear
window breaks down in a narrow aisle, the
driver may possibly be unable to exit the truck
at the side. In the event of acute danger, the
driver can exit the truck via the rear window.
For this purpose, the rear window must be
broken with an emergency hammer.
¾ Bend open split pin (1) from the support
mounting (2) under the rear wiper motor.

WARNING
Glass splinters may cause injuries.
Remove glass splinters carefully.

¾ Take the emergency hammer (3) out of the

support mounting and carefully break the
rear window.
¾ Climb out carefully.
3

2 1
t3921371

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 Maintenance 5
Troubleshooting

Towing instructions
Towing
If the truck needs to be towed away, the
following can be brought about by the towing
device:
• shortcircuiting 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
parking brake does not function 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 load so that fork arms do not scrape
on ground during 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 motor hood.
¾ Release sealing collar nut (1) (size
SW 19 mm) on left on variable pump with
socket at housing.
¾ Unscrew threaded stud (2) (SW 8 mm)
2 turns with socket .
¾ Lock threaded stud with sealing collar nut
(1), tighten to 80 Nm.
¾ Close motor hood. 2

Release multi-disc brake

The brake valve can be found under the floor 1
plate on the truck frame on the left.
¾ Remove floormat.
d3921510

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5 Maintenance
Troubleshooting

¾ Insert Allen key (SW 5 mm) through hole in

floor plate and unscrew socket head screw
(3) about 8 turns.
¾ Sit on driver’s seat.
¾ Press down handle of parking brake.
Symbol on indicator unit will be extinguished.
3
¾ Move Stop pedal several times in easy-
movement range until resistance is felt
(pump max. 10 strokes) until brake is
released .

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

¾ Open motor hood.

¾ Release sealing collar nut (1) on variable
pump.
¾ Insert threaded stud (2) (SW 8 mm), tighten
to 20+5 Nm.
¾ Lock threaded stud with sealing collar nut
(1).
¾ Tighten nut to 80 Nm.

Restore braking
¾ Insert socket head screw (3) until stop in
valve block.
¾ Replace floormat and close motor hood.

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

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 Maintenance 5
Troubleshooting

Placing the forklift truck into storage

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

Disposal of old vehicles

The disposal of old vehicles is regulated The following minimum requirements must
in directive 2000/53/EC of the European also be observed:
Parliament and Council.
• The storage locations for old vehicles
We recommend having this work carried out before their processing must be suitable
by an authorised salvager. If you want to do areas with an impermeable surface. They
this yourself, you must, according to Articles must be provided with collecting facilities
9, 10 and 11 the directive 75/442/EEC, obtain
a permit from the responsible authorities.

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5 Maintenance
Troubleshooting

and separators for fluids running out and must also be removed, collected and stored
grease-cutting cleaning agents. separately: fuel, engine oil, coolant, hy-
• The processing locations must be suitable draulic oil, fluids from air conditioners.
areas with an impermeable surface. They • The following parts can be collected and
must be provided with collecting facilities recycled separately: catalytic converters,
and separators for fluids running out and metal parts containing copper and alu-
grease-cutting cleaning agents. Suitable minium, tyres, big plastic parts (console,
storerooms for removed parts and parts fluid reservoirs), glass.
partially smeared with oil as well as for tyres,
including fire protection measures. Suitable NOTE
storage tanks for fluids such as fuel, engine
oil, hydraulic oil, coolant and fluids from air The owner is responsible for the compliance
conditioners must also be available. with the directives and further national regula-
• For the disposal of harmful substances from
tions.
the old vehicles, the batteries and LPG bot-
tle/tanks must be removed. The following

Malfunctions during operation

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

• Hydraulic oil temperature indicator (1) and

buzzer
• Charging indicator (2)
• Engine oil pressure indicator (3) and/or en-
gine oil level indicator (special equipment)
and buzzer

206 Operating Instructions – 393 807 10 01 EN – 10/2010

 Maintenance 5
Troubleshooting

• Indicator light: error in electrical controller

(4)
• Engine coolant temperature indicator (5)
and buzzer
• Water in the fuel filter (7) (special equip-
ment)
• Hydraulic oil microfilter indicator (8) (special
equipment)
• Air filter vacuum indicator (11)
• Coolant level indicator (12) (special equip-
ment)

CAUTION
Only if a particle filter system is fitted: If the build-up
indicator (9) flashes and the red particle filter alarm
(6) lights up and a buzzer sounds, the filter is
clogged.
The particle filter must be regenerated immediately.

NOTE
• Only if a particle filter is fitted: If the particle
filter build-up indicator (9) flashes and a
buzzer sounds at intervals, the filter must be
regenerated within the next 30 minutes.
• Only if a particle filter is fitted: If the red parti-
cle filter alarm (6) lights up and an error code
appears in the text field (10) of the display
unit, a fault occurred during regeneration.
Restart regeneration procedure.
• Only if a changing particle filter is fitted:
If the orange indicator light (14) lights up
in the switch panel in the top right and a
buzzer sounds, the filter must be changed
or regenerated within the next 30 minutes.
• If the indicator light (4) flashes, there is an
error in the electrical controller. Depending
on the setting and error, it may only be
possible to drive the truck at low speed
or not at all. Each error is indicated by
a numerical code or symbols in the text
field (10). Please contact your authorised
dealer.
• 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.

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5 Maintenance
Troubleshooting

• If the air filter vacuum indicator (11) lights

up on the display unit, maintenance must
be performed on the air filter.
• Only if the 3rd auxiliary hydraulics are
fitted: If the switchable additional function is
blocked, the truck is only travelling at creep
speed or the text field (10) shows error code
L247 and the buzzer sounds, there is a
malfunction in the safety system. Please
contact your authorised dealer.

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 Maintenance 5
Troubleshooting

Malfunctions, Causes and Remedies (diesel engine)

Engine will not start

Possible cause Remedy
Fuel tank empty. Fill up the tank.
Fuel filter clogged, caused in winter by paraffin
Change the filter. Use winter fuel.
segregation.
Water in the fuel filter. Drain water from 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 connectors for leaks and
Leak in fuel line.
tighten screw joints.
Tighten connecting terminals at the battery,
The display unit does not light up.
check line connectors.
Check the current entry, lines and connections
on the glow plug starting switch. If the fault
Preheating system defective.
cannot be remedied, please contact your
authorised dealer.
These faults should be checked and remedied
Pump/nozzle unit defective.
only by a trained technician. Please contact
Engine idle speed incorrect.
your authorised dealer.

Indicator light is illuminated: "Electrical controller fault".

Possible cause Remedy
Fault can be determined using the diagnostic
Fault in the electrical controller
device. Contact your authorised dealer.

Engine starting performance is poor

Possible cause Remedy
Battery power too low Battery terminals loose Have the battery checked, clean the connecting
or oxidised, causing the starter motor to turn terminals, tighten them and smear them with
only slowly. acid-free grease.
Fuel supply insufficient. Blockages or air locks Change fuel filter, check fuel line connectors for
in the fuel system, caused in winter by paraffin leaks and tighten screw joints. In cold climates,
segregation. use winter fuel.
Especially in winter: engine oil used is too Use engine oil appropriate to the outside
viscous. temperature.

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5 Maintenance
Troubleshooting

Particle filter system warning lamp flashes and buzzer sounds when ignition is switched on.
Possible cause Remedy
Check the lamp: switch on the glow plug
starting switch using the switch key. Both
Switch illumination in the start switch and switch illuminations briefly light up once, if
emergency stop switch for the particle filter not, change the indicator light. (Regeneration
system is defective. can still be performed even though the lamp is
defective; acknowledge by pressing the start
switch).
Malfunction in particle filter system. Please contact your authorised dealer.

"Particle filter alarm" indicator light illuminates and the truck only moves at creep speed.
Possible cause Remedy
Load period of the particle filter exceeds 8.5 h. Regenerate the particle filter immediately.

Engine does not run smoothly and loses power.

Possible cause Remedy
Fuel supply insufficient. Blockages or air locks Change fuel filter, check fuel line connectors for
in the fuel system, caused in winter by paraffin leaks and tighten screw joints. In cold climates,
segregation. use winter fuel.
Pump/nozzle unit is not operating correctly. Contact your authorised dealer.
Engine oil level too high. Drain oil until oil level is at upper dipstick mark.

Very smoky exhaust.

Possible cause Remedy
Bad sealing by coked or broken piston rings. Contact your authorised dealer.

Irregular idling.
Possible cause Remedy
Drain water from or change fuel filter. Check
Fuel supply problems.
fuel lines or fuel injection lines for leaks.
This setting should only be made by a trained
Engine speed incorrectly set.
technician. Contact your authorised dealer.

Engine overheating, red indicator light in the display unit lights up. Switch off engine immediately.
Possible cause Remedy
Check the cooling system for leakages, seal
Insufficient coolant in cooling system.
them as required. Top up the coolant.
Coolant pump defective. Contact your authorised dealer.
Water cooler radiator fins partially clogged by Clean the water cooler and the hydraulic oil
dirt or foreign bodies. cooler.

210 Operating Instructions – 393 807 10 01 EN – 10/2010

 Maintenance 5
Troubleshooting

Engine oil pressure too low. Switch off engine immediately.

Possible cause Remedy
Leakages in the lubricating system. Contact your authorised dealer.
Oil level too low Top up with engine oil

Charging current indicator lamp lights up during operation.

Possible cause Remedy
Three-phase alternator speed too low. Check V-ribbed belt tension.
Three-phase alternator fails to charge the
battery, three-phase alternator or cut-out relay Contact your authorised dealer
defective.

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

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

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

The truck only moves at creep speed and the level display lights up in the display unit.
Possible cause Remedy
Coolant level too low. Top up coolant.

Truck only moves at creep speed, the buzzer sounds and error code X204 is displayed in the
text field of the display unit.
Possible cause Remedy
Top up coolant. Water pump defective. Clean
Engine temperature too high. the water cooler. Adjust the fuel injection
system.

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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 Correction
Change the hydraulic oil, top up the hydraulic
Suction line damaged, noisy.
oil.
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.
Change the hydraulic oil; ensure the oil has the
Oil too thin, causing excessive leakage losses.
specified viscosity.
Check hydraulic oil level, clean hydraulic oil
Oil temperature indicator lights up.
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.

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 Maintenance 5
Troubleshooting

No flow or insufficient flow.

Possible cause Correction
Valves clogged. Contact your authorised dealer.
Check the hydraulic oil level, use the specified
Hydraulic system overheats.
hydraulic oil, clean the hydraulic oil cooler.

Hydraulic oil temperature too high.

Possible cause Correction
Pump damage, valves leaking. Contact your authorised dealer.
Check the hydraulic oil level, top up with
hydraulic oil if necessary. Clean the hydraulic
Insufficient oil in the tank or oil cooler clogged.
oil cooler and check for leaks, if defective
contact your authorised dealer.

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 Correction
Check the hydraulic oil level Clean the hydrau-
Hydraulic oil temperature too high.
lic oil cooler.

Malfunction in the third auxiliary hydraulic system (special equipment).

Possible cause Correction
Truck running in crawler mode.
Solenoid valve slider jamming.
Error code L 247 is displayed in the indicator
Wiring damaged.
unit and the buzzer sounds.
Short circuit.
Switchable auxiliary hydraulic functions are
Please contact your authorised dealer.
blocked.

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214 Operating Instructions – 393 807 10 01 EN – 10/2010

 6

Technical data
6 Technical data
Type sheet H 25, as at 09/2010

Type sheet H 25, as at 09/2010

1 Identification
1.1 Manufacturer Linde
1.2 Manufacturer’s type designation H 25 D
1.3 Drive Diesel
1.4 Operation Seated
1.5 Load capacity / Load Q [kg] 2500
1.6 Load centre of gravity c [mm] 500
1.8 Load distance x [mm] 445
1.9 Wheelbase y [mm] 1905

2 Weight
2.1 Net weight kg 3870
2.2 Axle load with front/rear load kg 5670 / 700
2.3 Axle load without front/rear load kg 1930 / 1940

3 Wheels, chassis frame

3.1 Front/rear tyres: polyurethane, rubber SE
3.2 Front tyre size 27x10-121
3.3 Rear tyre size 23x9-102
3.5 Number of wheels, front/rear (x = driven) 2x (4x)/23
3.6 Front track width b10 [mm] 1008 (1204)4,5
3.7 Rear track width b11 [mm] 932

4 Basic dimensions
4.1 Forward/backward fork tilt α/β (°) 5.0/8.06
4.2 Lowered mast height h1 [mm] 22647
4.3 Free lift h2 [mm] 150

1 Optional: 7.00-12 twin tyres (pneumatic/SE). Single tyre, pneumatic 27x10-12 and SE 28x12.5-15.
2 Optional: pneumatic 23x9-10.
3 Bracketed value for twin tyres.
4 1042 mm with tyre size SE 28x12.5–15.
5 Bracketed value for twin tyres.
6 Lift height and equipment can change the backwards tilt.
7 With 150 mm free lift on standard lift mast.

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 Technical data 6
Type sheet H 25, as at 09/2010

4 Basic dimensions
4.4 Lift h3 [mm] 3050
4.5 Raised mast height h4 [mm] 3840
4.7 Overhead guard height (cab) h6 [mm] 2210
4.8 Seat height (min/max) h7 [mm] 1105
4.12 Coupling height h10 [mm] 698
4.19 Total length l1 [mm] 3727
4.20 Length including fork back l2 [mm] 2727
4.21 Total width b1/b2 [mm] 12568
4.22 Fork arm dimensions s/e/l [mm] 45 x 100 x 1000
4.23 Fork carriage DIN 15173, class/form A, B 2A
4.24 Fork carriage width b3 [mm] 11509
4.31 Ground clearance at mast m1 [mm] 119
4.32 Ground clearance at centre of wheelbase m2 [mm] 173
4.33 Aisle width for pallet 1000x1200 crosswise Ast [mm] 4065
4.34 Aisle width for pallet 800x1200 longitudinal Ast [mm] 4265
4.35 Turning radius Wa [mm] 2420
4.36 Smallest pivot point distance b13 [mm] 580

5 Performance data
5.1 Driving speed with/without load km/h 22/22
5.2 Lifting speed with/without load m/s 0.47 / 0.48
5.3 Lowering speed with/without load m/s 0.52 / 0.54
5.5 Pulling force with/without load N 19,790 / 15,150
5.7 Climbing capability with/without load %10 32 / 33
5.9 Acceleration with/without load s 5.6/4.8
5.10 Service brake Hydrostatic

7 Drive / Engine
7.1 Engine manufacturer / model VW / CBHA

8 1337 mm for SE 28x12.5-15; 1611 mm for SE twin tyres 7.00-12; 1289 mm for pneumatic 27x10-
12/20 PR; 1337 mm for pneumatic 250/75 R12; 1624 mm for pneumatic twin tyres 7.00-12.
9 With twin tyres 1600 mm.
10 On short slopes, driving over obstacles (see section: Driving).

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6 Technical data
Type sheet H 25, as at 09/2010

7 Drive / Engine
7.2 Engine power rating as per ISO 1585 kW 44
7.3 Nominal speed rpm 2800
7.4 Number of cylinders / Displacement cm3 4 / 1968
7.5 Fuel consumption according to VDI cycle l/h: kg/h 3.2

8 Miscellaneous
hydrostatic /
8.1 Traction controller type continuously
variable
8.2 Working pressure for attachments bar 170
8.3 Oil volume for attachments l/min 38
8.4 Noise level in driver’s ear dB (A) 77
8.5 Towing hook, type/model DIN 15170-H

218 Operating Instructions – 393 807 10 01 EN – 10/2010

 Technical data 6
Type sheet H 30, as at 09/2010

Type sheet H 30, as at 09/2010

1 Identification
1.1 Manufacturer Linde
1.2 Manufacturer’s type designation H 30 D
1.3 Drive Diesel
1.4 Operation Seated
1.5 Load capacity / Load Q [kg] 3000
1.6 Load centre of gravity c [mm] 500
1.8 Load distance x [mm] 445
1.9 Wheelbase y [mm] 1930

2 Weight
2.1 Net weight kg 4220
2.2 Axle load with front/rear load kg 6419 / 801
2.3 Axle load without front/rear load kg 1950 / 2270

3 Wheels, chassis frame

3.1 Front/rear tyres: polyurethane, rubber SE
3.2 Front tyre size 27x10-1211
3.3 Rear tyre size 23x9-1012
3.5 Number of wheels, front/rear (x = driven) 2x (4x)/213
3.6 Front track width b10 [mm] 1008 (1204)14,15
3.7 Rear track width b11 [mm] 932

4 Basic dimensions
4.1 Forward/backward fork tilt α/β (°) 5.0/8.016
4.2 Lowered mast height h1 [mm] 226417
4.3 Free lift h2 [mm] 150

11 Optional: 7.00-12 twin tyres (pneumatic/SE). Single tyre, pneumatic 27x10-12 and SE 28x12.5-15.
12 Optional: pneumatic 23x9-10.
13 Bracketed value for twin tyres.
14 1042 mm with tyre size SE 28x12.5–15.
15 Bracketed value for twin tyres.
16 Lift height and equipment can change the backwards tilt.
17 With 150 mm free lift on standard lift mast.

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6 Technical data
Type sheet H 30, as at 09/2010

4 Basic dimensions
4.4 Lift h3 [mm] 3050
4.5 Raised mast height h4 [mm] 3840
4.7 Overhead guard height (cab) h6 [mm] 2210
4.8 Seat height (min/max) h7 [mm] 1105
4.12 Coupling height h10 [mm] 698
4.19 Total length l1 [mm] 3755
4.20 Length including fork back l2 [mm] 2755
4.21 Total width b1/b2 [mm] 125618
4.22 Fork arm dimensions s/e/l [mm] 45 x 100 x 1000
4.23 Fork carriage DIN 15173, class/form A, B 3A
4.24 Fork carriage width b3 [mm] 115019
4.31 Ground clearance at mast m1 [mm] 119
4.32 Ground clearance at centre of wheelbase m2 [mm] 173
4.33 Aisle width for pallet 1000x1200 crosswise Ast [mm] 4089
4.34 Aisle width for pallet 800x1200 longitudinal Ast [mm] 4289
4.35 Turning radius Wa [mm] 2444
4.36 Smallest pivot point distance b13 [mm] 580

5 Performance data
5.1 Driving speed with/without load km/h 22/22
5.2 Lifting speed with/without load m/s 0.47 / 0.48
5.3 Lowering speed with/without load m/s 0.52 / 0.54
5.5 Pulling force with/without load N 19,790 / 15,300
5.7 Climbing capability with/without load %20 27 / 30
5.9 Acceleration with/without load s 5.7 / 4.9
5.10 Service brake Hydrostatic

7 Drive / Engine
7.1 Engine manufacturer / model VW / CBHA

18 1337 mm for SE 28x12.5-15; 1611 mm for SE twin tyres 7.00-12; 1289 mm for pneumatic 27x10-
12/20 PR; 1337 mm for pneumatic 250/75 R12; 1624 mm for pneumatic twin tyres 7.00-12.
19 With twin tyres 1600 mm.
20 On short slopes, driving over obstacles (see section: Driving).

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 Technical data 6
Type sheet H 30, as at 09/2010

7 Drive / Engine
7.2 Engine power rating as per ISO 1585 kW 44
7.3 Nominal speed rpm 2800
7.4 Number of cylinders / Displacement cm3 4 / 1968
7.5 Fuel consumption according to VDI cycle l/h 3.4

8 Miscellaneous
hydrostatic /
8.1 Traction controller type continuously
variable
8.2 Working pressure for attachments bar 170
8.3 Oil volume for attachments l/min 38
8.4 Noise level in driver’s ear dB (A) 77
8.5 Towing hook, type/model DIN 15170-H

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6 Technical data
Type sheet H 35, as at 09/2010

Type sheet H 35, as at 09/2010

1 Identification
1.1 Manufacturer Linde
1.2 Manufacturer’s type designation H 35 D
1.3 Drive Diesel
1.4 Operation Seated
1.5 Load capacity / Load Q [kg] 3500
1.6 Load centre of gravity c [mm] 500
1.8 Load distance x [mm] 450
1.9 Wheelbase y [mm] 1965

2 Weight
2.1 Net weight kg 4680
2.2 Axle load with front/rear load kg 7242 / 938
2.3 Axle load without front/rear load kg 2050 / 2630

3 Wheels, chassis frame

3.1 Front/rear tyres: polyurethane, rubber SE
3.2 Front tyre size 27x10-1221
3.3 Rear tyre size 23x9-1022
3.5 Number of wheels, front/rear (x = driven) 2x (4x)/223
3.6 Front track width b10 [mm] 1008 (1204)24,25
3.7 Rear track width b11 [mm] 932

4 Basic dimensions
4.1 Forward/backward fork tilt α/β (°) 5.0/8.026
4.2 Lowered mast height h1 [mm] 226427
4.3 Free lift h2 [mm] 150

21 Optional: 7.00-12 twin tyres (pneumatic/SE). Single tyre, pneumatic 27x10-12 and SE 28x12.5-15.
22 Optional: pneumatic 23x9-10.
23 Bracketed value for twin tyres.
24 1042 mm with tyre size SE 28 x 12.5 - 15.
25 Bracketed value for twin tyres.
26 Lift height and equipment can change the backwards tilt.
27 With 150 mm free lift on standard lift mast.

222 Operating Instructions – 393 807 10 01 EN – 10/2010

 Technical data 6
Type sheet H 35, as at 09/2010

4 Basic dimensions
4.4 Lift h3 [mm] 3050
4.5 Raised mast height h4 [mm] 3840
4.7 Overhead guard height (cab) h6 [mm] 2210
4.8 Seat height (min/max) h7 [mm] 1105
4.12 Coupling height h10 [mm] 690
4.19 Total length l1 [mm] 3795
4.20 Length including fork back l2 [mm] 2795
4.21 Total width b1/b2 [mm] 125628
4.22 Fork arm 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] 115029
4.31 Ground clearance at mast m1 [mm] 117
4.32 Ground clearance at centre of wheelbase m2 [mm] 172
4.33 Aisle width for pallet 1000x1200 crosswise Ast [mm] 4126
4.34 Aisle width for pallet 800x1200 longitudinal Ast [mm] 4326
4.35 Turning radius Wa [mm] 2476
4.36 Smallest pivot point distance b13 [mm] 580

5 Performance data
5.1 Driving speed with/without load km/h 22/22
5.2 Lifting speed with/without load m/s 0.47 / 0.48
5.3 Lowering speed with/without load m/s 0.52 / 0.54
5.5 Pulling force with/without load N 19,790 / 16,090
5.7 Climbing capability with/without load %30 24 - 28
5.9 Acceleration with/without load s 5.7 / 4.9
5.10 Service brake Hydrostatic

7 Drive / Engine
7.1 Engine manufacturer / model VW / CBHA

28 1337 mm for SE 28x12.5-15; 1611 mm for SE twin tyres 7.00-12; 1289 mm for pneumatic 27x10-
12/20 PR; 1337 mm for pneumatic 250/75 R12; 1624 mm for pneumatic twin tyres 7.00-12.
29 With twin tyres 1600 mm.
30 On short slopes, driving over obstacles (see section: Driving).

Operating Instructions – 393 807 10 01 EN – 10/2010 223

6 Technical data
Type sheet H 35, as at 09/2010

7 Drive / Engine
7.2 Engine power rating as per ISO 1585 kW 44
7.3 Nominal speed rpm 2800
7.4 Number of cylinders / Displacement cm3 4 / 1968
7.5 Fuel consumption according to VDI cycle l/h 3.6

8 Miscellaneous
hydrostatic /
8.1 Traction controller type continuously
variable
8.2 Working pressure for attachments bar 170
8.3 Oil volume for attachments l/min 38
8.4 Noise level in driver’s ear dB (A) 77
8.5 Towing hook, type/model DIN 15170-H

224 Operating Instructions – 393 807 10 01 EN – 10/2010

 Technical data 6
Type sheet H 25, elevated driver’s compartment, as at 09/2010

Type sheet H 25, elevated driver’s compartment, as at 09/2010

1 Identification
1.1 Manufacturer Linde
1.2 Manufacturer’s type designation H 25 D
1.3 Drive Diesel
1.4 Operation Seated
1.5 Load capacity / Load Q [kg] 2500
1.6 Load centre of gravity c [mm] 500
1.8 Load distance x [mm] 445
1.9 Wheelbase y [mm] 1905

2 Weight
2.1 Net weight kg 4050
2.2 Axle load with front/rear load kg 5780 / 770
2.3 Axle load without front/rear load kg 2040 / 2010

3 Wheels, chassis frame

3.1 Front/rear tyres: polyurethane, rubber SE
3.2 Front tyre size 27x10-1231
3.3 Rear tyre size 23x9-1032
3.5 Number of wheels, front/rear (x = driven) 2x (4x)/233
3.6 Front track width b10 [mm] 1008 (1204)34,35
3.7 Rear track width b11 [mm] 932

4 Basic dimensions
4.1 Forward/backward fork tilt α/β (°) 5.0/8.036
4.2 Lowered mast height h1 [mm] 271437
4.3 Free lift h2 [mm] 150

31 Optional: 7.00-12 twin tyres (pneumatic/SE). Single tyre, pneumatic 27x10-12 and SE 28x12.5-15.
32 Optional: pneumatic 23x9-10.
33 Bracketed value for twin tyres.
34 1042 mm with tyre size SE 28x12.5–15.
35 Bracketed value for twin tyres.
36 Lift height and equipment can change the backwards tilt.
37 With 150 mm free lift on standard lift mast.

Operating Instructions – 393 807 10 01 EN – 10/2010 225

6 Technical data
Type sheet H 25, elevated driver’s compartment, as at 09/2010

4 Basic dimensions
4.4 Lift h3 [mm] 3950
4.5 Raised mast height h4 [mm] 4740
4.7 Overhead guard height (cab) h6 [mm] 2630
4.8 Seat height (min/max) h7 [mm] 1525
4.12 Coupling height h10 [mm] 698
4.19 Total length l1 [mm] 3727
4.20 Length including fork back l2 [mm] 2727
4.21 Total width b1/b2 [mm] 125638
4.22 Fork arm dimensions s/e/l [mm] 45 x 100 x 1000
4.23 Fork carriage DIN 15173, class/form A, B 2A
4.24 Fork carriage width b3 [mm] 115039
4.31 Ground clearance at mast m1 [mm] 119
4.32 Ground clearance at centre of wheelbase m2 [mm] 173
4.33 Aisle width for pallet 1000x1200 crosswise Ast [mm] 4065
4.34 Aisle width for pallet 800x1200 longitudinal Ast [mm] 4265
4.35 Turning radius Wa [mm] 2420
4.36 Smallest pivot point distance b13 [mm] 580

5 Performance data
5.1 Driving speed with/without load km/h 22/22
5.2 Lifting speed with/without load m/s 0.47 / 0.48
5.3 Lowering speed with/without load m/s 0.52 / 0.54
5.5 Pulling force with/without load N 19,790 / 15,150
5.7 Climbing capability with/without load %40 31 / 33
5.9 Acceleration with/without load s 5.6/4.8
5.10 Service brake Hydrostatic

7 Drive / Engine
7.1 Engine manufacturer / model VW / CBHA

38 1337 mm for SE 28x12.5-15; 1611 mm for SE twin tyres 7.00-12; 1289 mm for pneumatic 27x10-
12/20 PR; 1337 mm for pneumatic 250/75 R12; 1624 mm for pneumatic twin tyres 7.00-12.
39 With twin tyres 1600 mm.
40 On short slopes, driving over obstacles (see section: Driving).

226 Operating Instructions – 393 807 10 01 EN – 10/2010

 Technical data 6
Type sheet H 25, elevated driver’s compartment, as at 09/2010

7 Drive / Engine
7.2 Engine power rating as per ISO 1585 kW 44
7.3 Nominal speed rpm 2800
7.4 Number of cylinders / Displacement cm3 4 / 1968
7.5 Fuel consumption according to VDI cycle l/h: kg/h 3.2

8 Miscellaneous
hydrostatic /
8.1 Traction controller type continuously
variable
8.2 Working pressure for attachments bar 170
8.3 Oil volume for attachments l/min 38
8.4 Noise level in driver’s ear dB (A) 77
8.5 Towing hook, type/model DIN 15170-H

Operating Instructions – 393 807 10 01 EN – 10/2010 227

6 Technical data
Type sheet H 30, elevated driver’s compartment, as at 09/2010

Type sheet H 30, elevated driver’s compartment, as at 09/2010

1 Identification
1.1 Manufacturer Linde
1.2 Manufacturer’s type designation H 30 D
1.3 Drive Diesel
1.4 Operation Seated
1.5 Load capacity / Load Q [kg] 3000
1.6 Load centre of gravity c [mm] 500
1.8 Load distance x [mm] 445
1.9 Wheelbase y [mm] 1930

2 Weight
2.1 Net weight kg 4400
2.2 Axle load with front/rear load kg 6529 / 871
2.3 Axle load without front/rear load kg 2060 / 2340

3 Wheels, chassis frame

3.1 Front/rear tyres: polyurethane, rubber SE
3.2 Front tyre size 27x10-1241
3.3 Rear tyre size 23x9-1042
3.5 Number of wheels, front/rear (x = driven) 2x (4x)/243
3.6 Front track width b10 [mm] 1008 (1204)44,45
3.7 Rear track width b11 [mm] 932

4 Basic dimensions
4.1 Forward/backward fork tilt α/β (°) 5.0/8.046
4.2 Lowered mast height h1 [mm] 271447
4.3 Free lift h2 [mm] 150

41 Optional: 7.00-12 twin tyres (pneumatic/SE). Single tyre, pneumatic 27x10-12 and SE 28x12.5-15.
42 Optional: pneumatic 23x9-10.
43 Bracketed value for twin tyres.
44 1042 mm with tyre size SE 28x12.5–15.
45 Bracketed value for twin tyres.
46 Lift height and equipment can change the backwards tilt.
47 With 150 mm free lift on standard lift mast.

228 Operating Instructions – 393 807 10 01 EN – 10/2010

 Technical data 6
Type sheet H 30, elevated driver’s compartment, as at 09/2010

4 Basic dimensions
4.4 Lift h3 [mm] 3950
4.5 Raised mast height h4 [mm] 4740
4.7 Overhead guard height (cab) h6 [mm] 2630
4.8 Seat height (min/max) h7 [mm] 1525
4.12 Coupling height h10 [mm] 698
4.19 Total length l1 [mm] 3755
4.20 Length including fork back l2 [mm] 2755
4.21 Total width b1/b2 [mm] 125648
4.22 Fork arm dimensions s/e/l [mm] 45 x 100 x 1000
4.23 Fork carriage DIN 15173, class/form A, B 3A
4.24 Fork carriage width b3 [mm] 115049
4.31 Ground clearance at mast m1 [mm] 119
4.32 Ground clearance at centre of wheelbase m2 [mm] 173
4.33 Aisle width for pallet 1000x1200 crosswise Ast [mm] 4089
4.34 Aisle width for pallet 800x1200 longitudinal Ast [mm] 4289
4.35 Turning radius Wa [mm] 2444
4.36 Smallest pivot point distance b13 [mm] 580

5 Performance data
5.1 Driving speed with/without load km/h 22/22
5.2 Lifting speed with/without load m/s 0.47 / 0.48
5.3 Lowering speed with/without load m/s 0.52 / 0.54
5.5 Pulling force with/without load N 19,790 / 15,300
5.7 Climbing capability with/without load %50 27 / 31
5.9 Acceleration with/without load s 5.7 / 4.9
5.10 Service brake Hydrostatic

7 Drive / Engine
7.1 Engine manufacturer / model VW / CBHA

48 1337 mm for SE 28x12.5-15; 1611 mm for SE twin tyres 7.00-12; 1289 mm for pneumatic 27x10-
12/20 PR; 1337 mm for pneumatic 250/75 R12; 1624 mm for pneumatic twin tyres 7.00-12.
49 With twin tyres 1600 mm.
50 On short slopes, driving over obstacles (see section: Driving).

Operating Instructions – 393 807 10 01 EN – 10/2010 229

6 Technical data
Type sheet H 30, elevated driver’s compartment, as at 09/2010

7 Drive / Engine
7.2 Engine power rating as per ISO 1585 kW 44
7.3 Nominal speed rpm 2800
7.4 Number of cylinders / Displacement cm3 4 / 1968
7.5 Fuel consumption according to VDI cycle l/h 3.4

8 Miscellaneous
hydrostatic /
8.1 Traction controller type continuously
variable
8.2 Working pressure for attachments bar 170
8.3 Oil volume for attachments l/min 38
8.4 Noise level in driver’s ear dB (A) 77
8.5 Towing hook, type/model DIN 15170-H

230 Operating Instructions – 393 807 10 01 EN – 10/2010

 Technical data 6
Type sheet H 35, elevated driver’s compartment, as at 09/2010

Type sheet H 35, elevated driver’s compartment, as at 09/2010

1 Identification
1.1 Manufacturer Linde
1.2 Manufacturer’s type designation H 35 D
1.3 Drive Diesel
1.4 Operation Seated
1.5 Load capacity / Load Q [kg] 3500
1.6 Load centre of gravity c [mm] 500
1.8 Load distance x [mm] 450
1.9 Wheelbase y [mm] 1965

2 Weight
2.1 Net weight kg 4860
2.2 Axle load with front/rear load kg 7352 / 1008
2.3 Axle load without front/rear load kg 2160 / 2700

3 Wheels, chassis frame

3.1 Front/rear tyres: polyurethane, rubber SE
3.2 Front tyre size 27x10-1251
3.3 Rear tyre size 23x9-1052
3.5 Wheels, number, front/rear (x = driven) 2x (4x)/253
3.6 Front track width b10 [mm] 1008 (1204)54,55
3.7 Rear track width b11 [mm] 932

4 Basic dimensions
4.1 Forward/backward fork tilt α/β (°) 5.0/8.056
4.2 Lowered mast height h1 [mm] 271457
4.3 Free lift h2 [mm] 150

51 Optional: 7.00-12 twin tyres (pneumatic/SE). Single tyre, pneumatic 27x10-12 and SE 28x12.5-15.
52 Optional: pneumatic 23x9-10.
53 Bracketed value for twin tyres.
54 1042 mm with tyre size SE 28 x 12.5 - 15.
55 Bracketed value for twin tyres.
56 Lift height and equipment can change the backwards tilt.
57 With 150 mm free lift on standard lift mast.

Operating Instructions – 393 807 10 01 EN – 10/2010 231

6 Technical data
Type sheet H 35, elevated driver’s compartment, as at 09/2010

4 Basic dimensions
4.4 Lift h3 [mm] 3950
4.5 Raised mast height h4 [mm] 4740
4.7 Overhead guard height (cab) h6 [mm] 2630
4.8 Seat height (min/max) h7 [mm] 1525
4.12 Coupling height h10 [mm] 690
4.19 Total length l1 [mm] 3795
4.20 Length including fork back l2 [mm] 2795
4.21 Total width b1/b2 [mm] 125658
4.22 Fork arm 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] 115059
4.31 Ground clearance at mast m1 [mm] 117
4.32 Ground clearance at centre of wheelbase m2 [mm] 172
4.33 Aisle width for pallet 1000x1200 crosswise Ast [mm] 4126
4.34 Aisle width for pallet 800x1200 longitudinal Ast [mm] 4326
4.35 Turning radius Wa [mm] 2476
4.36 Smallest pivot point distance b13 [mm] 580

5 Performance data
5.1 Driving speed with/without load km/h 22/22
5.2 Lifting speed with/without load m/s 0.47 / 0.48
5.3 Lowering speed with/without load m/s 0.52 / 0.54
5.5 Pulling force with/without load N 19,790 / 16,090
5.7 Climbing capability with/without load %60 23/29
5.9 Acceleration with/without load s 5.7 / 4.9
5.10 Service brake Hydrostatic

7 Drive / Engine
7.1 Engine manufacturer / model VW / CBHA

58 1337 mm for SE 28x12.5-15; 1611 mm for SE twin tyres 7.00-12; 1289 mm for pneumatic 27x10-
12/20 PR; 1337 mm for pneumatic 250/75 R12; 1624 mm for pneumatic twin tyres 7.00-12.
59 With twin tyres 1600 mm.
60 On short slopes, driving over obstacles (see section: Driving).

232 Operating Instructions – 393 807 10 01 EN – 10/2010

 Technical data 6
Type sheet H 35, elevated driver’s compartment, as at 09/2010

7 Drive / Engine
7.2 Engine power rating as per ISO 1585 kW 44
7.3 Nominal speed rpm 2800
7.4 Number of cylinders / Displacement cm3 4 / 1968
7.5 Fuel consumption according to VDI cycle l/h 3.6

8 Miscellaneous
hydrostatic /
8.1 Traction controller type continuously
variable
8.2 Working pressure for attachments bar 170
8.3 Oil volume for attachments l/min 38
8.4 Noise level in driver’s ear dB (A) 77
8.5 Towing hook, type/model DIN 15170-H

Operating Instructions – 393 807 10 01 EN – 10/2010 233

6 Technical data
Load diagrams and lift mast data as at 05/2008

Load diagrams and lift mast data as at 05/2008

Main dimensions

234 Operating Instructions – 393 807 10 01 EN – 10/2010

 Technical data 6
Load diagrams and lift mast data as at 05/2008

Load diagrams

For standard and duplex masts when fitted as

standard.

Lift mast data

Standard lift mast (in mm)
Overall heights when retracted
h1 2264 2414 2564 2714 2964 3214
with specified free lift
Free lift h2 150 150 150 150 150 150
Lift h3 3050 3350 3650 3950 4450 4950
Overall height when extended h4 3840 4140 4440 4740 5240 5740

Duplex lift mast (in mm)

Overall heights when retracted with speci-
h1 2190 2490 2640
fied free lift
Free lift h2 1424 1724 1874
Lift h3 3115 3715 4015
Overall height when extended h4 3905 4505 4805

Operating Instructions – 393 807 10 01 EN – 10/2010 235

6 Technical data
Vibration characteristics for body vibrations

Triplex lift mast (in mm)

Overall heights when retracted
h1 2191 2241 2491 2641 2841
with specified free lift
Free lift h2 1424 1474 1724 1874 2074
Lift h3 4655 4805 5505 5955 6455
Overall height when extended h4 5445 5595 6295 6745 7245

Noise emission values

Calculated in the test cycle in accordance Sound power level
with EN 12053 from the weighted values for
in the DRIVE
the TRACTION, LIFT and IDLING operating LWc = 96 dB (A)
operating state
states.
Insecurity KWA = 2 dB (A)
Acoustic pressure level on the driver’s
compartment
H 25, H 30, H 35 LPAZ = 77 dB (A) Guaranteed sound power level

in the LIFT in accordance

LPa = 78 dB (A) with 2000/14/EC LWA = 97 dB (A)
operating state
Directive
in the IDLE
RUNNING LPb = 68 dB (A) Under the terms of the directive, it is a statu-
operating state tory requirement to provide this information.
in the DRIVE The value is calculated from the sound power
LPc = 82 dB (A)
operating state levels of the "Lift" and "Drive" operating sta-
Insecurity = 4 dB (A) tuses. It can only be used as a comparative
KPA
value for different fork lift trucks. The value is
less suitable for determining real environmen-
Sound power level tal impact levels, as it is not representative for
H 25, H 30, H 35 LWAZ = 92 dB (A) normal operation, which includes the "Idling"
operating status.
in the LIFT
LWA = 94 dB (A)
operating state
NOTE
in the IDLE
RUNNING LWb = 84 dB (A) Lower or higher noise values may occur when
operating state using industrial trucks, for instance, due to the
method of operation, environmental factors
and other sources of noise.

Vibration characteristics for body vibrations

The values were determined according to EN according to the type sheet (driving over test
13059 using trucks with standard equipment course with humps).

236 Operating Instructions – 393 807 10 01 EN – 10/2010

 Technical data 6

Specified vibration characteristic as per EN

12096 NOTE
Measured The vibration characteristic for body vibrati-
vibration aW,ZS = 0.7 m/s2 ons cannot be used to determine the actual
characteristic vibration load during operation. This depends
Uncertainty K = 0.3 m/s2 on the operating conditions (state of pathway,
method of operation etc.) and should there-
Specified vibration characteristic for hand- fore be determined on site, where appropriate.
arm vibrations It is mandatory to specify the hand-arm vibrati-
ons even where the values do not indicate any
Vibration characteristic < 2.5 m/s2 hazard, as in this case.

Operating Instructions – 393 807 10 01 EN – 10/2010 237

6 Technical data

238 Operating Instructions – 393 807 10 01 EN – 10/2010

 Index
g

A B
Actions prior to placing the forklift truck Basic equipment wiring diagram
into storage . . . . . . . . . . . . . . . . 205 Diesel with pump injection engine . . 252
Activating the seat heater . . . . . . . . . . . . 34 Battery grease . . . . . . . . . . . . . . . . . . . 112
Additional capacity rating plate for Battery: check condition, acid level and
attachments . . . . . . . . . . . . . . . . . 20 acid density . . . . . . . . . . . . . . . . 176
with loads that are fixed or clamped . . 21 Before taking up load . . . . . . . . . . . . . . . 93
with loads that are not clamped . . . . . 20 Bio-hydraulic oil . . . . . . . . . . . . . . . . . . 111
Adjust driver’s seat with swivel device . . . 73 Bonnet
Adjust lift mast chain Closing . . . . . . . . . . . . . . . . . . . . . . 163
Duplex or triplex lift mast . . . . . . . . . 190 Opening . . . . . . . . . . . . . . . . . . . . . 161
Standard lift mast . . . . . . . . . . . . . . 189 Brake system . . . . . . . . . . . . . . . . . . . . . 53
Adjust the seat angle . . . . . . . . . . . . . . . 74 Bringing back into service after storage . 205
Adjust the seat back . . . . . . . . . . . . . . . . 75
Adjust the seat height . . . . . . . . . . . . . . . 74 C
Adjusting the backrest extension . . . 34, 75 Cab door
Adjusting the driver’s seat . . . . . . . . . . . . 32 Closing . . . . . . . . . . . . . . . . . . . . . . . 82
Adjusting the driver’s seat armrest . . . . . 35 Opening . . . . . . . . . . . . . . . . . . . . . . 82
Adjusting the driver’s seat equipped Chain spray . . . . . . . . . . . . . . . . . . . . . 112
with air suspension . . . . . . . . . . . . 73 Change breather . . . . . . . . . . . . . . . . . 183
Adjusting the fork spread . . . . . . . . . . . . 95 Change the water pump . . . . . . . . . . . . 144
Adjusting the lumbar support . . . . . . 33, 75 Changing coolant . . . . . . . . . . . . . . . . . 134
Adjusting the seat angle . . . . . . . . . . . . . 34 Changing direction of travel . . . . . . . 43, 50
Adjusting the seat backrest . . . . . . . . . . . 33 Changing particle filter
Adjusting the seat depth . . . . . . . . . . . . . 34 Cleaning . . . . . . . . . . . . . . . . . . . . . 154
Adjusting the seat height . . . . . . . . . . . . 34 Regenerating . . . . . . . . . . . . . . . . . 153
Adjusting the steering column . . . . . . . . . 36 Changing particle filter system
After towing . . . . . . . . . . . . . . . . . . . . . 204 Removing . . . . . . . . . . . . . . . . . . . . 153
Air conditioning . . . . . . . . . . . . . . . . . . . 83 Changing the breather for the charge
Operating devices . . . . . . . . . . . . . . . 85 air pressure regulator . . . . . . . . . 146
Servicing . . . . . . . . . . . . . . . . . . . . 164 Changing the feed filter . . . . . . . . . . . . 181
Switching on . . . . . . . . . . . . . . . . . . . 85 Changing the pressure filter . . . . . . . . . 181
Air filter Changing the safety cartridge . . . . . . . . 145
Changing the cartridge . . . . . . . . . . 144 Changing the suction filter . . . . . . . . . . 182
an accumulator . . . . . . . . . . . . . . . . . . . 15 Check and oil other pivots and joints . . . 167
Approaching gradients . . . . . . . . . . . 44, 51 Check coolant concentration . . . . . . . . 136
Attach additional consumers . . . . . . . . . . 79 Check correct operation of breather
Attachments valve on the hydraulic oil tank . . . 184
Instructions before fitting . . . . . . . . . . 15 Check the condition and secure
positioning of electric cables . . . . 176
Check the condition and secure
positioning of the cable
connections . . . . . . . . . . . . . . . . 176

Operating Instructions – 393 807 10 01 EN – 10/2010 239

Index
g

Check the condition and secure Clean sideshift and

positioning of the cable grease . . . . . . . . . . . . . . . . . . . . . . 192
connectors . . . . . . . . . . . . . . . . . 176
Cleaning
Check the dust discharge valve . . . . . . 146
Fork prong positioner . . . . . . . . . . . 193
Check the fork quick-releases . . . . . . . . 191
Fuel tank ventilation hose . . . . . . . . 132
Check the forks . . . . . . . . . . . . . . . . . . 191
Lift mast chain . . . . . . . . . . . . . . . . . 188
Check the fuel level . . . . . . . . . . . . . . . 129
Oil bath air filter . . . . . . . . . . . . . . . . 148
Check the tension of double hoses . . . . 186
Prefilter . . . . . . . . . . . . . . . . . . . . . . 147
Check the tyres for damage and foreign
Pressure control device at the
objects . . . . . . . . . . . . . . . . . . . . 169
changing particle filter . . . . . . . . . 157
Check tilt cylinder bearings for wear . . . 185
Sideshift . . . . . . . . . . . . . . . . . . . . . 193
Checking exhaust pipes for leaks . . . . . 149
Steeringaxle . . . . . . . . . . . . . . . . . . 172
Checking frame fastenings . . . . . . . . . . 166
Truck . . . . . . . . . . . . . . . . . . . . . . . 160
Checking slide guides on sideshift for
Water cooler and hydraulic oil
wear . . . . . . . . . . . . . . . . . . . . . 193
cooler . . . . . . . . . . . . . . . . . . . . 138
Checking suction pipes for leaks . . . . . . 149
Water trap at the changing particle
Checking the bellows at the actuating filter . . . . . . . . . . . . . . . . . . . . . . 156
lever . . . . . . . . . . . . . . . . . . . . . 175
Cleaning the fuel tank ventilation hose . 132
Checking the condition and secure
Cleaning the lift mast chain and
positioning of engine mounting . . 139
applying chain spray . . . . . . . . . . 188
Checking the condition and secure Cleaning the prefilter . . . . . . . . . . . . . . 147
positioning of the engine support . 139
Cleaning the pressure control device at
Checking the coolant level . . . . . . . . . . 133
the changing particle filter . . . . . . 157
Checking the fastenings of the axle
Cleaning the truck . . . . . . . . . . . . . . . . 160
clamps . . . . . . . . . . . . . . . . . . . . 158
Climatic conditions . . . . . . . . . . . . . . . ... 3
Checking the fastenings of the wheel
motors . . . . . . . . . . . . . . . . . . . . 158 Clock
Checking the function and safety setting . . . . . . . . . . . . . . . . . . . . . . . 37
system of the third auxiliary Consumables . . . . . . . . . . . . . . . . . . . . 13
hydraulics . . . . . . . . . . . . . . . . . 186 Coolant . . . . . . . . . . . . . . . . . . . . . . . . 111
Checking the hydraulic pump’s Crane lifting . . . . . . . . . . . . . . . . . . . . . 102
attachment to the engine . . . . . . 159 Crane lifting with crane eyes . . . . . . . . . 103
Checking the mountings of the steering
cylinder . . . . . . . . . . . . . . . . . . . 173 D
Checking the mountings of the steering
Defrosting the windows . . . . . . . . . . . . . 84
pivot pin . . . . . . . . . . . . . . . . . . . 173
Depressurisation . . . . . . . . . . . . . . . . . . 15
Checking the particle filter system . . . . . 155
Description of use . . . . . . . . . . . . . . . . .. 3
Checking the pedals . . . . . . . . . . . . . . . 175
Diagnostic connector . . . . . . . . . . . . . . 199
Checking the tyre pressure . . . . . . . . . . 170
Diesel engine emissions . . . . . . . . . . . . . 14
Checking the vacuum-operated switch . 144
Diesel fuel . . . . . . . . . . . . . . . . . . . . . . 110
Checking tilt cylinder fastenings . . . . . . 166
Dismantling the lift mast . . . . . . . . . . . . 100
Checks
Display unit . . . . . . . . . . . . . . . . . . . . . . 24
before starting work . . . . . . . . . . . . . . 32
Disposal of old vehicles . . . . . . . . . . . . 205

240 Operating Instructions – 393 807 10 01 EN – 10/2010

 Index
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Drive axle Fork prong positioner

Adjusting the side stops . . . . . . . . . . 158 Checking mounting . . . . . . . . . . . . . 193
Checking the bearings for wear . . . . 159 Cleaning and lubricating . . . . . . . . . 193
Checking the side stops . . . . . . . . . . 158 Forklift Data Acquisition . . . . . . . . . . . . . 87
Driver’s cab . . . . . . . . . . . . . . . . . . . . . . 82 Transponder (chip or magnetic strip
Driving card) . . . . . . . . . . . . . . . . . . . . . . 91
Dual-pedal operation . . . . . . . . . . . . . 42 Forklift Data Acquisition - special
setting
Single-pedal operation . . . . . . . . . . . 49
PIN number . . . . . . . . . . . . . . . . . . . 89
With load . . . . . . . . . . . . . . . . . . . . . 96
Forklift Data Acquisition - standard
Duplex lift mast . . . . . . . . . . . . . . . . . . 108
setting
Securing the raised mast . . . . . . . . . 108
PIN number and status code . . . . . . . 88
E Forklift Data Management . . . . . . . . . . . 87
Forwards travel . . . . . . . . . . . . . . . . 43, 50
EC declaration of conformity . . . . . . . . . . . 7
Fuel filter
Emergency exit with attached rear
window . . . . . . . . . . . . . . . . . . . 202 Draining water . . . . . . . . . . . . . . . . . 131
Emergency lowering . . . . . . . . . . . . . . 201 exchanging . . . . . . . . . . . . . . . . . . . 131
Engine Fuses
Starting (dual-pedal operation) . . . . . 39 Changing . . . . . . . . . . . . . . . . . . . . 198
Starting (single-pedal operation) . . . . 45 Checking . . . . . . . . . . . . . . . . . . . . 198
Switching off (dual-pedal operation) . . 41 Engine compartment . . . . . . . . . . . . 198
Switching off (single-pedal Fuses for basic and special equipment . 198
operation) . . . . . . . . . . . . . . . . . . 48
G
Engine oil . . . . . . . . . . . . . . . . . . . . . . . 112
Changing . . . . . . . . . . . . . . . . . . . . 126 General information . . . . . . . . . . . . . . . 106
Checking the level . . . . . . . . . . . . . . 125
H
draining . . . . . . . . . . . . . . . . . . . . . 126
Filter change . . . . . . . . . . . . . . . . . . 128 Handling consumables . . . . . . . . . . . . . . 13
top up . . . . . . . . . . . . . . . . . . . . . . . 127 Heating system . . . . . . . . . . . . . . . . . . . 83
Entering the truck . . . . . . . . . . . . . . . . . . 35 Operating devices . . . . . . . . . . . . . . . 83
Exiting the truck . . . . . . . . . . . . . . . . . . . 35 Switching on . . . . . . . . . . . . . . . . . . . 84
Hydraulic circuit diagram
F Accumulator . . . . . . . . . . . . . . . . . . 288
Filling up with fuel . . . . . . . . . . . . . . . . . 130 Traction, working and steering
hydraulics . . . . . . . . . . . . . . . . . 286
Fire extinguisher . . . . . . . . . . . . . . . . . . 11
Hydraulic oil . . . . . . . . . . . . . . . . . . . . . 111
Floorplate
Changing . . . . . . . . . . . . . . . . . . . . 179
closing . . . . . . . . . . . . . . . . . . . . . . 164
draining . . . . . . . . . . . . . . . . . . . . . 179
opening . . . . . . . . . . . . . . . . . . . . . 163
top up . . . . . . . . . . . . . . . . . . . . . . . 179
Fork arm adjustment device
Hydraulic oil cooler
Check wear and tear . . . . . . . . . . . . 195
Checking for leaks . . . . . . . . . . . . . . 138
Fork carriage emergency lowering . . . . 201
Cleaning . . . . . . . . . . . . . . . . . . . . . 138

Operating Instructions – 393 807 10 01 EN – 10/2010 241

Index
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Hydraulic system Lubricating grease . . . . . . . . . . . . . . . . 111

Changing the filter . . . . . . . . . . . . . . 181
Check for leaks . . . . . . . . . . . . . . . . 185
M
Check oil level . . . . . . . . . . . . . . . . . 180 Main fuses in engine compartment . . . . 198
Maintenance data . . . . . . . . . . . . . . . . 110
I Maintenance intervals . . . . . . . . . . . . . 106
Identification plates . . . . . . . . . . . . . . . . 18 Malfunctions during operation . . . . . . . . 207
Impermissible use . . . . . . . . . . . . . . . . . . 3 Malfunctions, Causes and Remedies
Inspection data . . . . . . . . . . . . . . . . . . 110 Diesel engine . . . . . . . . . . . . . . . . . 209
Malfunctions, causes, remedies
J Hydraulic equipment . . . . . . . . . . . . 212
Jump start . . . . . . . . . . . . . . . . . . . . . . 199 Mast, lift chains, lift cylinders and
end stops: Check for security,
L condition and proper operation . . 189
Leaving the truck . . . . . . . . . . . . . . . . . 104 N
Legal requirements for marketing . . . . . .. 7
Lift mast data . . . . . . . . . . . . . . . . . . . . 234 Noise emission values . . . . . . . . . . . . . 236
Lift mast positioning . . . . . . . . . . . . . . . . 76 O
Lifting system and attachments
Central lever operation . . . . . . . . . . . 55 Oil bath air cleaner
Change the oil . . . . . . . . . . . . . . . . . 148
Single lever operation . . . . . . . . . . . . 60
Oil bath air filter
Single lever operation with
toggle-switch-controlled Cleaning . . . . . . . . . . . . . . . . . . . . . 148
3rd auxiliary hydraulics . . . . . . . . . 64 Open shorting plunger of hydraulics . . . 203
With 3rd auxiliary hydraulics without Opening the cover to the electrical
toggle switch . . . . . . . . . . . . . . . . 69 system . . . . . . . . . . . . . . . . . . . . 197
Lifting the fork carriage Operating attachments
Central lever operation . . . . . . . . . . . 56 Central lever operation . . . . . . . . . . . 56
Single lever operation . . . . . . . . . . . . 60 Single lever operation . . . . . . . . . . . . 61
Single lever operation with Single lever operation with
3rd auxiliary hydraulics . . . . . . . . . 65 3rd auxiliary hydraulics . . . . . . . . . 65
with 3rd auxiliary hydraulics . . . . . . . . 70 with 3rd auxiliary hydraulics . . . . . . . . 70
Lighting Operating devices . . . . . . . . . . . . . . . . . 23
switch on . . . . . . . . . . . . . . . . . . . . . 78 Operating the clamp
Load backrest . . . . . . . . . . . . . . . . . . . . 10 Central lever operation . . . . . . . . . . . 59
Load diagrams . . . . . . . . . . . . . . . . . . . 234 Single lever operation . . . . . . . . . . . . 63
Lowering the fork carriage Single lever operation with
Central lever operation . . . . . . . . . . . 56 toggle-switch-controlled
Single lever operation . . . . . . . . . . . . 61 3rd auxiliary hydraulics . . . . . . . . . 68
with 3rd auxiliary hydraulics . . . . . . . . 72
Single lever operation with
3rd auxiliary hydraulics . . . . . . . . . 65
with 3rd auxiliary hydraulics . . . . . . . . 70

242 Operating Instructions – 393 807 10 01 EN – 10/2010

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Operating the fork prong positioner Restore braking . . . . . . . . . . . . . . . . . . 204

Central lever operation . . . . . . . . . . . 58 Reverse travel . . . . . . . . . . . . . . . . . 43, 50
Single lever operation . . . . . . . . . . . . 63 Ribbed V-belt,
Single lever operation with change . . . . . . . . . . . . . . . . . . . . . . 141
toggle-switch-controlled Ribbed vee belt
3rd auxiliary hydraulics . . . . . . . . . 67
check condition . . . . . . . . . . . . . . . . 140
with 3rd auxiliary hydraulics . . . . . . . . 72
Rim sizes . . . . . . . . . . . . . . . . . . . . . . . 171
Operating the horn . . . . . . . . . . . . . . . . . 54 Running-in instructions . . . . . . . . . . . . . . 32
Operating the rotator
Single lever operation with S
toggle-switch-controlled
3rd auxiliary hydraulics . . . . . . . . . 67 Safety guidelines . . . . . . . . . . . . . . . . . . 10
Operating the sideshift Safety information . . . . . . . . . . . . . . . . . 10
Central lever operation . . . . . . . . . . . 58 3rd auxiliary hydraulic system . . . . . . 10
Single lever operation . . . . . . . . . . . . 62 active medical equipment . . . . . . . . . 11
Single lever operation with Driver sight . . . . . . . . . . . . . . . . . . . . 11
toggle-switch-controlled Gas springs . . . . . . . . . . . . . . . . . . . 11
3rd auxiliary hydraulics . . . . . . . . . 68 Speed reduction . . . . . . . . . . . . . . . . 11
with 3rd auxiliary hydraulics . . . . . . . . 71 unauthorised use . . . . . . . . . . . . . . . 10
Operation of industrial trucks in plant Welding operations . . . . . . . . . . . . . . 11
area . . . . . . . . . . . . . . . . . . . . . . . 13 Scope of service
before starting work . . . . . . . . . . . . . . 32
P
Seat belt
parking brake . . . . . . . . . . . . . . . . . . . . . 53 Checking the condition and correct
Parking brake function . . . . . . . . . . . . . . . . . . . 165
Checking for correct operation . . . . . 173 Fastening . . . . . . . . . . . . . . . . . . . . . 37
Operating . . . . . . . . . . . . . . . . . . . . . 54 opening . . . . . . . . . . . . . . . . . . . . . . 38
Releasing . . . . . . . . . . . . . . . . . . . . . 54 Seat heater . . . . . . . . . . . . . . . . . . . . . . 74
Particle filter system testing . . . . . . . . . . 14 Secure the lift mast from tilting back . . . 107
Periodic safety inspection . . . . . . . . . . . . 14 Securing the hose pulley against rolling
Placing the forklift truck into storage . . . 205 up . . . . . . . . . . . . . . . . . . . . . . . . 99
Proper usage . . . . . . . . . . . . . . . . . . . . .. 3 Service brake . . . . . . . . . . . . . . . . . . . . . 53
Service plan
R 1000 h . . . . . . . . . . . . . . . . . . . . . . 114
Reception of truck . . . . . . . . . . . . . . . . .. 6 3000-hour . . . . . . . . . . . . . . . . . . . . 116
Recommendations for consumables . . . 110 6000 h . . . . . . . . . . . . . . . . . . . . . . 119
Refrigerant for air conditioning . . . . . . . 111 9000-hour . . . . . . . . . . . . . . . . . . . . 122
Regenerating particle filters . . . . . . . . . 150 As required . . . . . . . . . . . . . . . . . . . 113
Regulations . . . . . . . . . . . . . . . . . . . . . . 14 before initial commissioning . . . . . . . . . 8
Release multi-disc brake . . . . . . . . . . . 203 Setting down loads . . . . . . . . . . . . . . . . . 97
Renew the idler pulley . . . . . . . . . . . . . 143 Setting the driver’s weight . . . . . . . . . 33, 73
Residual risks . . . . . . . . . . . . . . . . . . . . 11 Shovel operation . . . . . . . . . . . . . . . . . . . 6

Operating Instructions – 393 807 10 01 EN – 10/2010 243

Index
g

Side window warning system, higher brake

Front, closing . . . . . . . . . . . . . . . . . . 82 light and reversing light . . . . . . . . 282
Front, opening . . . . . . . . . . . . . . . . . 82 Sheet 14 - Higher front / standard
rear lighting . . . . . . . . . . . . . . . . 284
Rear, closing . . . . . . . . . . . . . . . . . . . 83
Specialist . . . . . . . . . . . . . . . . . . . . . . . . 13
Rear, opening . . . . . . . . . . . . . . . . . . 83
Stability . . . . . . . . . . . . . . . . . . . . . . . . . 12
Sideshift
Standard lift mast . . . . . . . . . . . . . . . . . 107
Check fastening . . . . . . . . . . . . . . . 192
Securing the raised mast . . . . . . . . . 107
Special equipment wiring diagram
Status code . . . . . . . . . . . . . . . . . . . . . . 87
Sheet 01 - Working spotlights,
interior light . . . . . . . . . . . . . . . . 258 Steering . . . . . . . . . . . . . . . . . . . . . . . . . 52
Sheet 02 - Windscreen wiper, seat Steering axle
heater, radio . . . . . . . . . . . . . . . 260 Checking fastenings . . . . . . . . . . . . 166
Sheet 03 - Heating system, air Cleaning . . . . . . . . . . . . . . . . . . . . . 172
conditioning, flashing beacon greasing . . . . . . . . . . . . . . . . . . . . . 172
/ rotating beacon, reversing
Steering system . . . . . . . . . . . . . . . . . . . 52
signal . . . . . . . . . . . . . . . . . . . . . 262
Stop pedal . . . . . . . . . . . . . . . . . . . . . . . 53
Sheet 04 − Hazard warning system
for reverse travel . . . . . . . . . . . . 264 Stopping . . . . . . . . . . . . . . . . . . . . . 44, 51
Sheet 05 − Lift mast positioning, Switch on hazard warning lights . . . . . . . 78
hydraulic oil microfilter indicator, Switch on interior lighting . . . . . . . . . . . . 78
truck deactivation, truck data Switch on rotating flashing light . . . . . . . . 78
management . . . . . . . . . . . . . . . 266 Switch on the front windscreen wiper . . . 80
Sheet 06 − Particle filter, diesel filter Switch on the rear windscreen wiper . . . . 80
water trap warning . . . . . . . . . . . 268
Switch on the roof windscreen wiper . . . . 81
Sheet 07 - Amount of gas display,
Switch on the wiper/washer system . . . . . 81
12 V socket, coolant and engine
oil level monitoring . . . . . . . . . . . 270 Switch on turn indicator lights . . . . . . . . . 79
Sheet 08 − Battery main switch Switch on working headlights . . . . . . . . . 78
with display unit power supply, Switch panel . . . . . . . . . . . . . . . . . . . . . 30
changing particle filter, rear Switching on the rear window heater . . . . 82
window heating, camera system . 272 Symbols . . . . . . . . . . . . . . . . . . . . . .... 4
Sheet 09 − Third auxiliary
hydraulics with third joystick, T
centre rear brake/tail light . . . . . . 274
Taking up loads . . . . . . . . . . . . . . . . . . . 95
Sheet 10 - Single lever locked, third
auxiliary hydraulics via joystick . . 276 Technical description . . . . . . . . . . . . . . . . 4
Sheet 11 - Single lever locked, third Brakes . . . . . . . . . . . . . . . . . . . . . . . . 5
auxiliary hydraulics via switch . . . 278 Electrical system . . . . . . . . . . . . . . . . . 6
Sheet 12 - Lighting, direction Engine . . . . . . . . . . . . . . . . . . . . . . . . 4
indicator and hazard warning Hydraulic system . . . . . . . . . . . . . . . . 4
system, brake light . . . . . . . . . . . 280 Lift mast . . . . . . . . . . . . . . . . . . . . . . . 5
Sheet 13 - Higher lighting, higher Linde Load Control . . . . . . . . . . . . . . . 5
direction indicator and hazard
Linde Truck Control . . . . . . . . . . . . . . . 5
Operation . . . . . . . . . . . . . . . . . . . . . . 5
Steering . . . . . . . . . . . . . . . . . . . . . . . 5

244 Operating Instructions – 393 807 10 01 EN – 10/2010

 Index
g

Tighten the wheel bolts . . . . . . . . . . . . . 169 Truck operation when using a shovel .... 6
Tilting the lift mast backwards Truck overview . . . . . . . . . . . . . . . . . . . 22
Central lever operation . . . . . . . . . . . 56 Type sheet H 25 . . . . . . . . . . . . . . . . . . 216
Single lever operation . . . . . . . . . . . . 61 Type sheet H 25, elevated driver’s
Single lever operation with compartment . . . . . . . . . . . . . . . 225
3rd auxiliary hydraulics . . . . . . . . . 65 Type sheet H 30 . . . . . . . . . . . . . . . . . . 219
with 3rd auxiliary hydraulics . . . . . . . . 70 Type sheet H 30, elevated driver’s
Tilting the lift mast forwards compartment . . . . . . . . . . . . . . . 228
Central lever operation . . . . . . . . . . . 56 Type sheet H 35 . . . . . . . . . . . . . . . . . . 222
Single lever operation . . . . . . . . . . . . 61 Type sheet H 35, elevated driver’s
compartment . . . . . . . . . . . . . . . 231
Single lever operation with
3rd auxiliary hydraulics . . . . . . . . . 65 Tyre sizes . . . . . . . . . . . . . . . . . . . . . . 170
with 3rd auxiliary hydraulics . . . . . . . . 70
V
Tip-over of the truck . . . . . . . . . . . . . . . . 12
Toothed belt Vibration characteristics for body
vibrations . . . . . . . . . . . . . . . . . . 236
Checking condition . . . . . . . . . . . . . 141
Checking tension . . . . . . . . . . . . . . 141 W
renew . . . . . . . . . . . . . . . . . . . . . . . 143
Warnings . . . . . . . . . . . . . . . . . . . . . . ... 4
Top up the washer system water tank . . 196
Water cooler
Topping up the washer system water
tank . . . . . . . . . . . . . . . . . . . . . . 196 Checking for leaks . . . . . . . . . . . . . . 138
Tow coupling . . . . . . . . . . . . . . . . . . . . . 98 Cleaning . . . . . . . . . . . . . . . . . . . . . 138
Towing . . . . . . . . . . . . . . . . . . . . . . . . 203 Water trap at the changing particle filter
Towing instructions . . . . . . . . . . . . . . . 203 Cleaning . . . . . . . . . . . . . . . . . . . . . 156
Towing process . . . . . . . . . . . . . . . . . . 203 Draining water . . . . . . . . . . . . . . . . . 156
Traction Wheel change . . . . . . . . . . . . . . . . . . . 168
without lift mast . . . . . . . . . . . . . . . . 101 Wheel-slide protection chains . . . . . . . . . 94
Transport with lorry or low-bed trailer . . 103 Windscreen wiper . . . . . . . . . . . . . . . . . 80
Triplex lift mast . . . . . . . . . . . . . . . . . . . 109 Working on Linde lift mast and at the
front of the truck . . . . . . . . . . . . . 107
Securing the raised mast . . . . . . . . . 109

Operating Instructions – 393 807 10 01 EN – 10/2010 245

Linde Material Handling GmbH

393 807 10 01 EN – 10/2010

 Diesel truck

Original instructions

Annex H25D, H30D, H35D

393 807 10 01 EN – 10/2010
 7

Circuit diagrams
7 Circuit diagrams
Wiring diagram

Wiring diagram
Basic equipment for diesel with pump injection engine - sheet 1

252 Operating Instructions – 393 807 10 01 EN – 10/2010

 Circuit diagrams 7
Wiring diagram

Legend :1 − Terminal 30 6X1 10-pin plug connector (display unit), 26–39 The number in front of the wire colour refers
B1 Tank transmitter, 33 :2 − Terminal 15 6X2 7-pin plug connector (diagnostics), 48 to the wire cross-section.
F2 30 A MTA fuse, 4 :6 − Earth :3 − Terminal 15 Wires with unspecified cross-section = 0.75
F5 2 A fuse, 26 S1 Ignition and starting switch, 9–17 :4 − Earth mm2
F6 2 A fuse, 28 S2 Brake pedal switch 2 (start-up prevention),
F7 15 A fuse, 73 13-14 Wire colours Notes
F13 15 A max. fuse, 61 S3 Suction filter vacuum-operated switch, 31 BK Black (a) Wires twisted together
F14 2 A fuse, 64 0S1 Oil pressure switch, 28 BN Brown *) Gold-plated contacts
F15 10 A fuse, 67 4S1 Horn activation, 73 BU Blue
G1 660 W three-phase generator with regulator, X1 10-pin plug connector (S1), 9–15, 73 GN Green
1–5 X2 3-pin plug connector (S2), 13, 14 GY Grey
G2 88 Ah battery, 7 X10 18-pin plug connector (central electrical OG Orange
4H1 60 W signal horn, 73 system), 20, 64–69 RD Red
K2 Electronic starter relay, 10-15 X11 9-pin plug connector (central electrical VT Violet
M1 1.7 kW starter motor, 9–11 system), 13–67 WH White
6P1 Display unit, 25–40 X15 2-pin plug connector (CAN), 42 YE Yellow

Operating Instructions – 393 807 10 01 EN – 10/2010 253

7 Circuit diagrams
Wiring diagram

Basic equipment for diesel with pump injection engine - sheet 2

254 Operating Instructions – 393 807 10 01 EN – 10/2010

 Circuit diagrams 7
Wiring diagram

Legend :33 − Seat switch reference :102 − Tilt forwards/back reference 2Y4 Tilt backwards valve, 138
1B1 Speed actual-value transmitter, 85–86 :36 − Middle :103 − Tilt angle reference 2Y5 Auxiliary valve 1B, 142
1B2 Dual potentiometer for accelerator, 84–89 :37 − Forwards :104 - Auxiliary 1 reference 2Y6 Auxiliary valve 1A, 144
1B4 Hydraulic oil temperature sensor, 88 :38 − Seat switch :105 − Mast vertical 2Y7 Auxiliary valve 2B, 147
2B1 Joystick basic functions, 116–121 :39 − ISO L-drive :106 − 0 V lift/lower 2Y8 Auxiliary valve 2A 149
:1 − 5 V :40 − Mast vertical display :107 − 0 V tilt forwards/backwards 2Y9 Safety valve, 153
:2 − Lift/lower :44 − Auxiliary 2/B (B4) :109 − 0 V safety valve
:3 − Tilt forwards/back :45 − Auxiliary 2/A (A4) :111 − Safety valve Wire colours
:4 − Lift/lower reference :46 − Exhaust valve 1Y4 :112 − 0 V (1/A)/(1/B) BK Black
:5 − Tilt forwards/back reference :47 − Coding :113 − 0 V (2/A)/(2/B) BN Brown
:6 − 0 V :48 − Tilt forwards/back :114 − GND BU Blue
2B2 Joystick additional functions, 123–129 :49 − Drive potentiometer :116 − 5 V lift sensor GN Green
:1 − 5 V :52 − Coding :117 - Auxiliary 2 reference GY Grey
:2 - Auxiliary 1 :53 − Terminal 15 :118 − 5 V sensor, lift OG Orange
:3 - Auxiliary 2 :56 − Code :119 − Earth RD Red
:4 - Auxiliary 1 reference :58 − Brake 1 :120 − Terminal 30 VT Violet
:5 - Auxiliary 2 reference :59 − Brake 3 :121 − Terminal 30 WH White
:6 − 0 V :61 − GND sensor, drive S4 Seat switch, 147–148 YE Yellow
2B3 Dual potentiometer for lift mast tilt angle, :62 − Fan valve 1Y5 1S1 Brake pedal switch 1, 100-101 The number in front of the wire colour refers
137–141 :63 − Speed actual-value transmitter 1S2 Single-pedal drive direction switch, 107-112 to the wire cross-section.
F8 2 A fuse, 81 :68 − GND X4 3-pin plug connector (seat switch), 147, 148 Wires with unspecified cross-section = 0.75
F9 15 A fuse, 83 :69 − GND X10 18-pin plug connector (central electrical mm2
N1 LHC electronic traction controller, 81–156 :70 − GND system), 97-105 Notes
:1 − 5 V sensor, drive :71 − GND X11 9-pin plug connector (central electrical (a) Speed limitation
:6 − Forwards hydraulic pump 1Y2 :72 − Reverse system), 109–111 (b) Brake light
:7 − Reverse hydraulic pump 1Y3 :73 − Brake 2 1X1 3-pin plug connector (1B1), 84 (c) Programmable reversing signal
:8 − Microfilter pressure switch :80 − GND sensor, drive 1X2 3-pin plug connector (1S1), 100, 101 (d) Not assigned
:10 − Coding :81 − GND sensor, drive 1X3 6-pin plug connector (single pedal), 108-112 (e) Shovel operation
:12 − Lift/lower :82 − Auxiliary 1/A (A3) 2X1 2-pin plug connector (microfilter), 125, 126 (f) Coolant level
:13 − Hydraulic oil temperature sensor :85 − ISO K-lift 2X3 6-pin plug connector (2B1), 116–121 (g) Door locking switch
:15 − 0 V forwards hydraulic pump :88 − GND sensor, lift 2X4 6-pin plug connector (2B2), 124-129 (h) Air conditioning
:16 − 0 V reverse hydraulic pump :89 − GND sensor, lift 2X5 10-pin plug connector (valve block), (j) Engine switch-off
:17 − 0 V fan valve :90 − Auxiliary 1/B (B3) 133–153 (k) Air conditioning shut-off
:19 − 0 V exhaust valve :91 − Tilt forwards (A2) 1Y2 Forwards solenoid valve "y", 91 (l) Brake pedal switch 2
:21 − ISO K-drive :92 − Tilt backwards (B2) 1Y3 Solenoid valve "z" backwards, 94 (m) Coded plug for dual pedal identification
:28 − Coding :93 − Lift 1Y4 Exhaust valve, 97 (n) Drive direction switch for single pedal
:29 - Auxiliary 2 :94 − ISO L-lift 1Y5 Fan valve, 91 (o) Engine control unit
:30 − Tilt angle :96 − GND sensor, lift 2Y1 Lower valve, 131 (p) Wires twisted together
:31 - Auxiliary 1 :98 − Lower 2Y2 Lift valve, 133
:32 − Drive potentiometer reference :101 − Lift/lower reference 2Y3 Tilt forwards valve, 136

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Basic equipment for diesel with pump injection engine - sheet 3

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Legend 0N3 Automatic preheating time control unit, BN Brown

0B2 Engine speed transmitter, 225-228 161-169 BU Blue
0B3 Fuel temperature transmitter, 215 0R1 Glow plugs, 161-166 GN Green
0B4 Suction pipe pressure / suction pipe temper- 0X3 3-pin plug connector, 225-228 GY Grey
ature transmitter, 185-188 0X3.1 3-pin plug connector, 225-228 OG Orange
0B6 Air volumeter, 180-182 0X22 8-pin plug connector, 217-225 RD Red
0B18 Camshaft pulse generator, 220-223 0X23 3-pin plug connector, 220-223 VT Violet
0B20 Coolant temperature transmitter, 209 0Y9 Switch valve for turbocharger, 203 WH White
F1 50 A fuse, 161 0Y10 Valve for exhaust gas recirculation, 200 YE Yellow
F11 20 A fuse, 179 0Y11 Pump/nozzle valve for 1st cylinder, 217 The number in front of the wire colour refers
F12 5 A fuse, 184 0Y12 Pump/nozzle valve for 2nd cylinder, 219 to the wire cross-section.
0K2 Terminal 30 relay for engine control unit, 0Y13 Pump/nozzle valve for 3rd cylinder, 221 Wires with unspecified cross-section = 0.75
179-181 0Y14 Pump/nozzle valve for 4th cylinder, 223 mm2
0N1 Control unit for diesel direct injection system, 0Y16 Shut-off flap valve, 206
176-228 Notes
0N1.1 94-pin plug connector, 177-210 Wire colours (a) Wires twisted together
0N1.2 60-pin plug connector, 203-228 BK Black *) Gold-plated contacts

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Special equipment sheet 01 - Working spotlights, interior light

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Arrangement 5E7 Upper rear right working spotlight 55 W 5S1 Working spotlight switch (positions 1, 2), Wire colours
I Working spotlights positions 1+2 (position 8), 41 10-13 BK Black
II Working spotlights positions 1+2 with higher 5E8 6 W interior light, 71 5S2 Working spotlight switch (positions 3, 4, 5, BN Brown
lighting 5E19 Upper rear left working spotlight 55 W 6), 18-34 BU Blue
III Working spotlights positions 5+6 (position 7), 43 5S3 Working spotlight switch (positions 7, 8), GN Green
IV Working spotlights positions 3+4 F3 70A MTA fuse (terminal 58), 3 39-46 GY Grey
V Working spotlights positions 7+8 F14 2A fuse (terminal 58), 1 5S4 Interior light switch, 70-73 OG Orange
VI Interior lighting 5F1 15 A fuse (working spotlight positions 1, 2), X10 18-pin plug connector (for basic equipment), RD Red
11 1, 44 VT Violet
Legend 5F2 15 A fuse (working spotlight positions 3, 4), 5X1 12-pin plug connector (lighting), 17, 19 WH White
5E1 Lower front left working spotlight 55 W 19, 32 5X4 12-pin plug connector (working spotlight YE Yellow
(position 1), 9, 17 5F3 15 A fuse (working spotlight positions 5, 6), positions 1, 2), 9, 11 The number in front of the wire colour refers
5E2 Lower front right working spotlight 55 W 28 5X5 2-pin plug connector (working spotlight to the wire cross-section.
(position 2), 11, 19 5F4 15 A fuse (working spotlight positions 7, 8), positions 3, 4), 19, 32 Wires with unspecified cross-section = 0.75
5E3 Upper front left working spotlight 55 W 42 5X6 2-pin plug connector (working spotlight mm2
(position 3), 30 5F4 7.5 A fuse (working spotlights position 8), 42 positions 7, 8), 41
5E4 Upper front right working spotlight 55 W 5F12 5 A fuse (interior light), 71 5X14 3-pin plug connector (working spotlight Notes
(position 4), 32 K1 Terminal 58 auxiliary relay, 1-3 positions 5, 6), 28 (a) For electronic control
5E5 Lift mast left working spotlight 55 W (posi- 5K1 Flasher unit, 59–62 5X15 2-pin plug connector (working spotlight *1) 7.5 A for working spotlight position 8; 15 A
tion 5), 26 5K4 Working spotlight relay (positions 7, 8), positions 5, 6), 28 for working spotlight positions 7+8
5E6 Lift mast right working spotlight 55 W 44-48
(position 6), 28

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Special equipment sheet 02 − Windscreen wiper, seat heater, radio

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Arrangement 9F3 10A fuse (rear and roof windscreen wipers), 9M6 Roof wash pump, 137 Wire colours
I Windscreen wipers 114 9R2 80W seat heater, 144 BK Black
II Front windscreen wiper 9F4 10A fuse (wash pumps), 86 9S1 Windscreen wiper switch, 82–87 BN Brown
III Rear windscreen wiper 9F6 15A fuse (seat heater), 144 9S2 Front windscreen wiper switch, 82–89 BU Blue
IV Roof windscreen wiper 9F7 5A fuse (radio terminal 30), 149 9S3 Rear windscreen wiper switch, 101–109 GN Green
V Seat heater 9F8 10 A fuse (radio terminal 15), 152 9S4 Roof windscreen wiper switch, 121–128 GY Grey
VI Radio 9K1 Front windscreen wiper relay, 85–93 9W1 Antenna, 154-155 OG Orange
9K2 Rear windscreen wiper relay, 106–111 9X1 9-pin plug connector (windscreen wipers), RD Red
Legend 9K3 Roof windscreen wiper relay, 125–132 83–94 VT Violet
9E3 Radio, 148-156 9M1 Front windscreen wiper motor 55 W, 91–95 9X2 3-pin plug connector (radio), 149-156 WH White
:4 − Terminal 15 9M2 Rear windscreen wiper motor 36 W, 9X5 6-pin plug connector (wash pumps), 98, 116, YE Yellow
:7 − Terminal 30 110–113 137 The number in front of the wire colour refers
:8 − Earth 9M3 Roof windscreen wiper motor 36 W, 9X7 3-pin plug connector (seat heater), 144 to the wire cross-section.
9E4 Left loudspeaker, 147 130–134 9X8 3-pin plug connector (radio), 149-156 Wires with unspecified cross-section = 0.75
9E5 Right loudspeaker, 154 9M4 Front wash pump, 98 9X14 2-pin plug connector (seat heater), 144 mm2
9F1 2A fuse (windscreen wipers, general), 83 9M5 Rear wash pump, 116
9F2 10A fuse (front windscreen wiper), 96

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Special equipment sheet 03 - Heating system, air conditioning, flashing beacon / rotating beacon, reversing signal

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Arrangement 4H4 Warning flashing light, 200, 206, 217, 229 4X4 2-pin plug connector (flashing beacon / GY Grey
I Heater 4H5 Rotating beacon, 200, 206, 217, 229 rotating beacon), 206, 217 OG Orange
II Heater with air conditioning 4K1 Reversing signal relay, 213-217 4X5 2-pin plug connector (buzzer), 224 RD Red
III Flashing beacon / rotating beacon via 9M7 Fan motor 1 for air conditioning, 188 5X11 12-pin plug connector (higher lighting), 232 VT Violet
terminal 58 9M8 Fan motor 2 for air conditioning, 191 9X9 2-pin plug connector (heating system, air WH White
IV Warning flashing light / rotating beacon via 9M9 Fan motor 3 for air conditioning, 194 conditioning), 164, 170, 172 YE Yellow
switch 4S3 Switch for warning flashing light / rotating 9X10 1-pin plug connector (air conditioning), 182 The number in front of the wire colour refers
V Continuous reversing signal and switchable beacon, 205-208, 215-222 9X11 6-pin plug connector (air conditioning), to the wire cross-section.
Off/Reverse travel/On 9S6 Air conditioning pressure switch, 177–179 178–194 Wires with unspecified cross-section = 0.75
9V1 Free-wheeling diode (electric clutch), 172 9X12 2-pin plug connector (heater), 164, 170, 172 mm2
Legend X10 18-pin plug connector (for basic equipment), 9X13 4-pin plug connector (air conditioning
4B1 2W buzzer, 224 213 pressure switch), 178–180 Notes
9E1 Heater, 161–167 X11 9-pin plug connector (for basic equipment), 9Y1 Electric clutch for air conditioning, 174 (a) LHC controller N1:22
9E2 Heater with air conditioning, 170–194 182–184 (b) Alternator G1:L
F4 30A fuse (air conditioning), 182 4X1 2-pin plug connector (warning flashing light / Wire colours (c) LHC controller N1:35
4F1 10A fuse (reversing signal), 217 rotating beacon), 229 BK Black (d) For electronic controller N1:23
4F3 7.5A fuse (warning flashing light / rotating 4X2 6-pin plug connector (buzzer), 220-226 BN Brown (e) For higher reversing light special equipment
beacon), 200, 206 4X3 2-pin plug connector (warning flashing light / BU Blue wiring diagram
9F9 20A fuse (heater), 164, 172 rotating beacon), 200 GN Green

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Special equipment sheet 04 − Hazard warning system for reverse travel

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Arrangement 5H10 Direction indicator light, 2 W, 250 5X9 6-pin plug connector (hazard warning VT Violet
I Hazard warning system for reverse travel 5H20 Right brake light, 3 W, 256 system), 245-256 WH White
with brake light (without lighting) 5H21 Left brake light, 3 W, 259 5X12 4-pin plug connector (right rear light), 247, YE Yellow
II Hazard warning system when reversing 5K2 Brake light relay, 254–257 256 The number in front of the wire colour refers
(with lights) 5K3 Hazard warning system relay for reverse 5X13 4-pin plug connector (left rear light), 245, to the wire cross-section.
travel, 242-245, 281-284 259 Wires with unspecified cross-section = 0.75
Legend 5S12 Warning light switch, 270-277 mm2
5F5 15 A fuse, 267 5S13 Turn indicator switch, 266-268 Wire colours
5F6 10 A fuse, 271 5N1 Flasher unit (electronic), 244-252 BK Black Notes
5F7 5 A fuse (brake light), 256 X10 18-pin plug connector (for basic equipment), BN Brown (a) For electronic controller N1:23
5F13 10 A fuse (hazard warning system), 245 242, 254, 283 BU Blue (b) For electronic controller N1:41
5H1 Left front direction indicator, 21 W, 267 5X2 6-pin plug connector (rear lighting), 245-256 GN Green (c) For electronic controller N1:23
5H2 Right front direction indicator, 21 W, 270 5X3 2-pin plug connector (hazard warning GY Grey
5H3 Left rear direction indicator, 3 W, 245 system), 281 OG Orange
5H4 Right rear direction indicator, 3 W, 247 RD Red

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Special equipment sheet 05 − Lift mast positioning, hydraulic oil microfilter indicator, truck deactivation, truck data management

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Arrangement :2 − Signal X10 18-pin plug connector (for basic equipment), GN Green
I Lift mast positioning :3 − Earth 380 GY Grey
II Hydraulic oil microfilter indicator F15 5A fuse, 380 X11 9-pin plug connector (for basic equipment), OG Orange
III Vehicle deactivation via seat switch 6F1 5A fuse, 378 359, 382 RD Red
IV Linde Forklift Data Management (LFM) 2H1 1.2W lift mast position preselection warning X15 2-pin plug connector (CAN connection), VT Violet
light, 324 370, 376 WH White
Legend K2 Start relay, 363-366 X23 10-pin plug connector (armrest), 322, 324 YE Yellow
6A1 Truck data acquisition unit (FDE), 369-383 K3 Engine shutoff relay, 353-356 2X1 2-pin plug connector (microfilter), 329, 333 The number in front of the wire colour refers
:1 − Terminal 30 N1 LHC electronic control system, 321-325, 2X6 2-pin plug connector (pressure switch), 329 to the wire cross-section.
:2 − Terminal 15 329-333 2X7 2-pin plug connector (pressure switch), 332 Wires with unspecified cross-section = 0.75
:3 − Earth :40 − Lift mast positioning display 6X4 14-pin plug connector (FDE), 369-383 mm2
:4 − Free input :105 − Lift mast positioning 6X5 3-pin plug connector (transfer to FDE), 378,
:5 − Load sensor S1 Ignition and starting switch, 342-349 380 Notes
:6 − Free output 2S1 Lift mast position preselection switch, 6X7 5-pin plug connector (data transfer), 376- (a) For horn activation 4S1 (basic equipment
:7 − Terminal 50 322-324 380 wiring diagram)
:8 − Starter relay 2S2 Feed-pressure filter pressure switch, 329 6X9 4-pin plug connector (Linde Forklift Data (b) For electronic controller N1:42
6A2 Linde Forklift Data Management online 2S3 High-pressure filter pressure switch, 332 Management online module), 386-388 (c) For generator G1:B+
module, 386-391 V1 Decoupling diode, 359 (d) For ignition and starting switch S1:50
:3 − Terminal 15 6W1 GPRS antenna, 390 Wire colours (e) For starter motor M1:50a
:4 − Earth X1 10-pin plug connector, 342-348, 354, 365 BK Black (f) For brake pedal switch X2:3
6B2 Load sensor, 393-397 X1.1 10-pin plug connector, 342-348, 354 BN Brown (g) Wires twisted together
:1 − Terminal 15 BU Blue

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Special equipment sheet 06 − Particle filter, diesel filter water trap warning

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Arrangement :37 − Starter relay 7V1 Decoupling diode, 416 GY Grey

I Particle filter (only with diesel version) :39 − Earth X8 2-pin plug connector, 454 OG Orange
II Diesel filter water trap warning (diesel :40 − Earth X10 18-pin plug connector (for main harness), RD Red
version only) :41 − Consumers voltage supply 428, 454 VT Violet
:42 − Combustion air blower X11 9-pin plug connector (for main harness), WH White
Legend 0B14 Water trap transmitter, 454-455 405, 434 YE Yellow
7A1 Particle filter control unit, 408-455 0B15 Water trap buzzer, 462 X15 2-pin plug connector (CAN), 436, 439 The number in front of the wire colour refers
:5 − Terminal 50 7B2 Flame sensor, 437-438 7X1 9-pin plug connector (central electrical to the wire cross-section.
:6 − Thermocouple (negative) F15 5A fuse, 428, 454 system transfer), 423-430 Wires with unspecified cross-section = 0.75
:10 − Regeneration indicator 7F1 5 A fuse (particle filter), 414 7X2 4-pin plug connector (blower shut-off valve), mm2
:12 − Signal input terminal 15 7F2 20 A fuse (particle filter), 420 412, 415
:13 − Electronics voltage supply 7F3 30A fuse (glow plug), 447 7X3 2-pin plug connector (flame sensor), 437, Notes
:14 − Consumers voltage supply 0H2 Water trap warning light, 458 438 (a) For generator G1:B+ (only in diesel version)
:17 − Regeneration start 7H1 1.2W regeneration warning light, 424 7X4 2-pin plug connector (glow plug), 447 (b) For ignition and starting switch S1:50 (only
:18 − Glow plug controller voltage supply K2 Start relay, 403-405 7X5 2-pin plug connector (metering pump), 419 in diesel version)
:19 − Glow plug indicator 7K1 Glow plug relay, 445-447 7Y1 Shut-off valve, 415 (c) For starter motor M1:50a (only in diesel
:20 − Thermocouple (positive) 7K2 Starting aid relay, 405-408 version)
:24 − Shut-off valve 7M1 60W blower, 412 Wire colours (d) For brake pedal switch X2:3 (only in diesel
:26 − Metering pump 7M2 24W metering pump, 419 BK Black version)
:29 − Relay for glow plug 7R1 200W glow plug, 447 BN Brown (e) Wires twisted together
:30 − Emergency stop switch 7S1 Starting switch, 422-424 BU Blue
:31 − Emergency stop switch 7S2 Stop/reset switch, 428-430 GN Green

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Special equipment sheet 07 - Amount of gas display, 12 V socket, coolant and engine oil level monitoring

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Arrangement B2 Tank transmitter (replacement cylinder), X7 4-pin plug connector (tank transmitter), 490, BN Brown
I 12V socket 490-492 492 BU Blue
II LPG volume display for replacement cylin- :1 − Terminal 15 X10 18-pin plug connector (for basic equipment), GN Green
der (only with LPG version) :2 − Calibration 526, 530 GY Grey
III LPG volume display for volumetric filling :3 − Signal X11 9-pin plug connector (for basic equipment), OG Orange
(only with LPG version) :4 − Earth 533 RD Red
IV LPG residual volume display (only with LPG 0B16 Oil level sensor, 529-530 X14 1-pin plug connector (calibration), 490 VT Violet
version) F15 10 A fuse, 530 X15 2-pin plug connector (CAN), 532, 537 WH White
V Natural gas volume display and tank shutoff 9F10 15A fuse (12V socket), 483 0X19 6-pin plug connector (logic controller), YE Yellow
valve (with natural gas version only) 0N3 LOC logic controller, 529-536 530-534 The number in front of the wire colour refers
VI Coolant and engine oil level monitoring :1 − Terminal 15 0X20 3-pin plug connector, 537-541 to the wire cross-section.
:2 − Earth 9X15 3-pin plug connector (12 V socket), 483 Wires with unspecified cross-section = 0.75
Legend :3 − Signal 9X16 2-pin plug connector (12 V socket), 483 mm2
B1 Tank transmitter (volumetric filling), 500, S6 LPG residual volume switch, 507 9X30 5-pin plug connector (oil and coolant con-
512-514 0S3 Coolant level switch, 526 nection), 526-530 Notes
:1 − Terminal 15 X6 5-pin plug connector (for main harness), 1Y12 Natural gas tank shutoff valve, 518 (a) Switch shown in "Coolant level OK" position
:2 − Earth 490-518 (b) Basic equipment wiring diagram (with gas
:3 − Signal Wire colours version only)
BK Black (c) LHC controller (N1:27)

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Special equipment sheet 08 − Battery main switch with display unit power supply, changing particle filter, rear window heating, camera system

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Wiring diagram

Arrangement G1 660W three-phase alternator with regulator, 7X8 2-pin plug connector (pressure switch), 601, RD Red
I Battery main switch with indicator unit 562-565 602 VT Violet
voltage supply G2 88Ah battery, 567 9X26 5-pin plug connector (camera system), WH White
II Changing particle filter (diesel version only) 7H4 Indicator light (orange), 607 625-627 YE Yellow
III Rear window heater M1 1.7 kW starter motor, 569-571 9X27 5-pin plug connector (camera system), The number in front of the wire colour refers
IV Camera system 9R1 Rear window heater, 617 630-632 to the wire cross-section.
S5 Battery main switch, 567 9X28 5-pin plug connector (camera system), Wires with unspecified cross-section = 0.75
Legend 7S3 Changing particle filter switch, 596-597 625-627 mm2
7A2 Changing particle filter controller, 597-609 7S4 Changing particle filter pressure switch, 9X29 3-pin plug connector (camera system),
9A5 Monitor, 625-635 601-602 625-634 Notes
7B3 Changing particle filter buzzer, 610 9S5 Rear window heater switch, 614-620 (a) to wiring diagram for basic equipment
9E6 Camera 1, 625-627 X10 18-pin plug connector (for basic equipment), Wire colours (b) To electronic control N1:22
9E7 Camera 2, 630-632 597, 601, 625, 632 BK Black *1) Switch opens when the changing particle
F2 30A fuse, 567 6X1 10-pin plug connector, 577-590 BN Brown filter is fitted and the cover is closed (diesel
F15 10A fuse, 601, 625 7X6 9-pin plug connector (changing particle BU Blue version only)
6F2 2A fuse, 574 filter), 597-601 GN Green *2) Switch is shown in the pressure differential
7F4 2A fuse, 607 7X7 3-pin plug connector (reset switch), 596, 597 GY Grey OK position (diesel version only).
9F5 20A fuse, 617 OG Orange

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Special equipment sheet 09 − Third auxiliary hydraulics with third joystick, centre rear brake/tail light

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Wiring diagram

Arrangement 5K2 Brake light relay, 691-693 2V12 Free-wheeling diode for third auxiliary GN Green
I Third auxiliary hydraulics with third joystick N1 LHC electronic control system, 643-655 hydraulics valve, 669 GY Grey
II Centre rear brake/tail light :9 − auxiliary 3 X10 18-pin plug connector, 693 OG Orange
:20 − 0V third auxiliary hydraulics 2X9 6-pin plug connector, 658-674 RD Red
Legend changeover relay 2X10 6-pin plug connector, 658-674 VT Violet
2B6 Third auxiliary hydraulics joystick, 646-648 :25 − 12V third auxiliary hydraulics 2X11 10-pin plug connector, 658-674 WH White
:3 − Auxiliary 3 changeover relay 2X13 6-pin plug connector, 646-648 YE Yellow
:4 − Auxiliary 3 reference :64 − Auxiliary 3 reference 5X20 4-pin plug connector (brake/tail light), 688, The number in front of the wire colour refers
2B11 End position sensor 1, 658-661 :84 − end position 1 691 to the wire cross-section.
2B12 End position sensor 2, 672-674 :96 − Lift earth sensor 2Y11 Third auxiliary hydraulics valve, 665 Wires with unspecified cross-section = 0.75
5E20 10W centre rear sidelight, 688 :99 − end position 2 2Y12 Third auxiliary hydraulics valve, 668 mm2
F16 7.5A fuse (terminal 15), 666 116 − 5V lift sensor
5F7 5A fuse, 691 5S2 Switch for working headlights positions 3 Wire colours Notes
5H22 21W centre rear brake light, 691 and 4, 682-685 BK Black (a) For electronic controller (N1:41)
2K1 Third auxiliary hydraulics changeover relay, 2V11 Free-wheeling diode for third auxiliary BN Brown
662-666 hydraulics valve, 666 BU Blue

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Special equipment sheet 10 - Single lever locked, third auxiliary hydraulics via joystick

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Wiring diagram

Arrangement 2B11 End position sensor 1, 748-751 :117 - Auxiliary 2 reference GN Green
I Single lever locked for single auxiliary 2B12 End position sensor 2, 761-764 2V11 Free-wheeling diode for third auxiliary GY Grey
hydraulics, in accordance with ISO 3691 F16 7.5 A fuse (terminal 15), 756 hydraulics valve, 756 OG Orange
II Third auxiliary hydraulics via joystick 2K1 Third auxiliary hydraulics changeover relay, 2V12 Free-wheeling diode for third auxiliary RD Red
752-756 hydraulics valve, 759 VT Violet
Legend N1 LHC electronic control, 721-744 2X4 6-pin plug connector, 726-738 WH White
2B2 Additional joystick functions, 727-732 :9 − Auxiliary 3 2X4.1 6-pin plug connector, 726-738 YE Yellow
:1 − 5 V :20 − 0 V third auxiliary hydraulics 2X9 6-pin plug connector, 748-764 The number in front of the wire colour refers
:2 − Auxiliary 1 changeover relay 2X10 6-pin plug connector, 748-764 to the wire cross-section.
:3 − Auxiliary 2 :25 − 12 V third auxiliary hydraulics 2X11 10-pin plug connector, 748-764 Wires with unspecified cross-section = 0.75
:4 − Auxiliary 1 reference changeover relay 2X15 4-pin plug connector, 731-738 mm2
:5 − Auxiliary 2 reference :29 - Auxiliary 2 2X15.1 4-pin plug connector, 731-738
:6 − 0 V :31 - Auxiliary 1 2Y11 Third auxiliary hydraulics valve, 755 Notes
2B6 Joystick locked for single auxiliary hy- :64 − Reference. Auxiliary 3 2Y12 Third auxiliary hydraulics valve, 757 (a) 1st auxiliary hydraulics electrically reversed
draulics, 736-738 :84 − End position 1 with 2nd auxiliary hydraulics, 2nd auxiliary
:1 − 5 V :96 − GND sensor, lift Wire colours hydraulics electrically reversed with 3rd
:2 − 0 V :99 − End position 2 BK Black auxiliary hydraulics, 3rd auxiliary hydraulics
:3 − Auxiliary 3 :104 - Auxiliary 1 reference BN Brown electrically reversed with 1st auxiliary
:4 − Auxiliary 3 reference :116 − 5 V lift BU Blue hydraulics

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Special equipment sheet 11 - Single lever locked, third auxiliary hydraulics via switch

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Arrangement :4 − Auxiliary 3 reference 2S4 Third auxiliary hydraulics switch, 836-841 BU Blue
I Single lever locked for single auxiliary 2B11 End position sensor 1, 829-832 2V11 Free-wheeling diode for third auxiliary GN Green
hydraulics, in accordance with ISO 3691 2B12 End position sensor 2, 844-846 hydraulics valve, 837 GY Grey
II Third auxiliary hydraulics via switch F16 7.5 A fuse (terminal 15), 837 2V12 Free-wheeling diode for third auxiliary OG Orange
III Single lever locked for double auxiliary 2H2 Third auxiliary hydraulics indicator light hydraulics valve, 840 RD Red
hydraulics, in accordance with ISO 3691 (orange), 840 X23 10-pin plug connector, 838-840 VT Violet
2H3 Third auxiliary hydraulics indicator light 2x4 6-pin plug connector, 806-818, 862-873 WH White
Legend (green), 839 2X4.1 6-pin plug connector, 806-818, 862-873 YE Yellow
2B2 Additional joystick functions, 807-810, N1 LHC electronic control, 801-826, 855-874 2x9 6-pin plug connector, 829-846 The number in front of the wire colour refers
862-866 :9 − Auxiliary 3 2x10 6-pin plug connector, 829-846 to the wire cross-section.
:1 − 5 V :29 - Auxiliary 2 2x11 10-pin plug connector, 829-846 Wires with unspecified cross-section = 0.75
:2 - Auxiliary 1 :31 - Auxiliary 1 2x15 4-pin plug connector, 816-818, 833, 872 mm2
:4 - Auxiliary 1 reference :64 − Auxiliary 3 reference 2X15.1 4-pin plug connector (2B6), 816-818, 871-
:6 − 0 V :84 − End position 1 873 Notes
2B6 Single lever locked for single auxiliary :96 − GND sensor, lift 2Y11 Third auxiliary hydraulics valve, 837 (a) 1st auxiliary hydraulics electrically reversed
hydraulics / double auxiliary hydraulics, :99 − End position 2 2Y12 Third auxiliary hydraulics valve, 839 with 2nd auxiliary hydraulics, 3rd auxiliary
816-818, 870-873 :104 - Auxiliary 1 reference hydraulics electrically reversed with 1st
:1 − 5 V :116 − 5 V lift sensor Wire colours auxiliary hydraulics
:2 − 0 V :117 - Auxiliary 2 reference BK Black (b) 3rd auxiliary hydraulics electrically reversed
:3 − Auxiliary 3 BN Brown with 2nd auxiliary hydraulics

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Special equipment sheet 12 - Lighting, direction indicator and hazard warning system, brake light

280 Operating Instructions – 393 807 10 01 EN – 10/2010

 Circuit diagrams 7
Wiring diagram

Arrangement 5F9 7.5 A fuse (right headlight), 886 5X1 12-pin plug connector (overhead guard Wire colours
I Lighting 5F10 5 A fuse (left sidelight), 889 lighting), 884-916 BK Black
II Direction indicator and hazard warning 5F11 5 A fuse (right sidelight), 897 5X2 6-pin plug connector (rear lighting), 891-926 BN Brown
system 5H1 Left front direction indicator, 21 W, 907 5X3 2-pin plug connector (reversing signal BU Blue
III Brake light 5H2 Right front direction indicator, 21 W, 910 transfer), 918 GN Green
5H3 Left rear direction indicator, 3 W, 905 5X7 6-pin plug connector (left headlight), 884, GY Grey
Legend 5H4 Right rear direction indicator, 3 W, 913 889, 907 OG Orange
5E9 10 W left licence plate lamp, 899 5H10 Direction indicator light, 2 W, 916 5X8 6-pin plug connector (right headlight), 886, RD Red
5E10 10 W right licence plate lamp, 901 5H20 Right brake light, 3 W, 926 894, 910 VT Violet
5E11 55 W right dipped beam, 884 5H21 Left brake light, 3 W, 928 5X10 2-pin plug connector (licence plate lighting), WH White
5E12 55 W left dipped beam, 886 5K2 Brake light relay, 924-926 899 YE Yellow
5E13 5 W left front sidelight, 889 5N1 Flasher unit, 905-918 5X12 4-pin plug connector (right rear light), 896, The number in front of the wire colour refers
5E14 5 W right front sidelight, 894 5S11 Light switch, 885-890 913, 926 to the wire cross-section.
5E15 0.5 W left rear sidelight, 891 5S12 Warning light switch, 910-916 5X13 4-pin plug connector (left rear light), 891, Wires with unspecified cross-section = 0.75
5E16 0.5 W right rear sidelight, 896 5S13 Turn indicator switch, 906-908 905, 928 mm2
5F5 15 A fuse (lighting terminal 15), 907 X10 18-pin plug connector (for basic equipment), 5X16 2-pin plug connector (licence plate lamp),
5F6 10 A fuse (lighting terminal 30), 912 924 899 Notes
5F7 5 A fuse (brake light), 926 (a) For electronic controller (N1:41)
5F8 7.5 A fuse (left headlight), 884

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7 Circuit diagrams
Wiring diagram

Special equipment sheet 13 - Higher lighting, higher direction indicator and hazard warning system, higher brake light and reversing light

282 Operating Instructions – 393 807 10 01 EN – 10/2010

 Circuit diagrams 7
Wiring diagram

Arrangement 5F8 7.5 A fuse (left headlight), 963 5X1 12-pin plug connector (overhead guard BU Blue
I Higher lighting 5F9 7.5 A fuse (right headlight), 965 lighting), 970-992 GN Green
II Higher direction indicator and hazard 5F10 5 A fuse (left sidelight), 968 5X7 6-pin plug connector (left headlight), 963, GY Grey
warning system 5F11 5 A fuse (right sidelight), 973 968, 984 OG Orange
III Higher brake light and reversing light 5H1 Left front direction indicator, 21 W, 984 5X8 6-pin plug connector (right headlight), 965, RD Red
5H2 Right front direction indicator, 21 W, 987 973, 987 VT Violet
Legend 5H3 Left rear direction indicator, 3 W, 982 5X11 12-pin plug connector (higher lighting), WH White
5E11 55 W left dipped beam, 963 5H4 Right rear direction indicator, 3 W, 989 963-1008 YE Yellow
5E12 55 W right dipped beam, 965 5H10 Direction indicator light, 2 W, 992 5X12 6-pin plug connector (right rear light), 975, The number in front of the wire colour refers
5E13 5 W left front sidelight, 968 5H20 Right brake light, 3 W, 1003 989, 1003, 1011 to the wire cross-section.
5E14 5 W right front sidelight, 973 5H21 Left brake light, 3 W, 1006 5X13 6-pin plug connector (left rear light), 970, Wires with unspecified cross-section = 0.75
5E15 0.5 W left rear sidelight, 970 5K2 Brake light relay, 1001-1004 981, 1006, 1008 mm2
5E16 0.5 W right rear sidelight, 975 5N1 Flasher unit, 981-995 5X16 2-pin plug connector (licence plate lamp),
5E17 0.5 W left reversing light, 1008 5S11 Light switch, 963-969 978 Notes
5E18 0.5 W right reversing light, 1011 5S12 Warning light switch, 987-992 (a) For electronic controller (N1:41)
5F5 15 A fuse (lighting terminal 15), 983 5S13 Turn indicator switch, 982-984 Wire colours (b) For reversing signal special equipment
5F6 10 A fuse (lighting terminal 30), 988 X10 18-pin plug connector (for basic equipment), BK Black wiring diagram
5F7 5 A fuse (brake light), 1003 1001 BN Brown

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7 Circuit diagrams
Wiring diagram

Special equipment sheet 14 - Higher front / standard rear lighting

284 Operating Instructions – 393 807 10 01 EN – 10/2010

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Wiring diagram

Arrangement 5H1 Left front direction indicator, 21 W, 1066 5X2 6-pin plug connector (rear lighting), 1050- BN Brown
I Higher front / standard rear lighting 5H2 Right front direction indicator, 21 W, 1069 1084 BU Blue
5H3 Left rear direction indicator, 3 W, 1063 5X7 6-pin plug connector (left headlight), 1043, GN Green
Legend 5H4 Right rear direction indicator, 3 W, 1071 1048, 1069 GY Grey
5E11 55 W left dipped beam, 1043 5H10 Direction indicator light, 2 W, 1074 5X8 6-pin plug connector (right headlight), 1045, OG Orange
5E12 55 W right dipped beam, 1045 5H20 Right brake light, 3 W, 1084 1053, 1069 RD Red
5E13 5 W left front sidelight, 1048 5H21 Left brake light, 3 W, 1087 5X11 12-pin plug connector (higher lighting), VT Violet
5E14 5 W right front sidelight, 1053 5N1 Flasher unit, 1063-1077 1043-1084 WH White
5E15 0.5 W left rear sidelight, 1050 5K2 Brake light relay, 1082, 1085 5X12 4-pin plug connector (right rear light), 1055, YE Yellow
5E16 0.5 W right rear sidelight, 1055 5S11 Light switch, 1043-1049 1071, 1084 The number in front of the wire colour refers
5F5 15 A fuse (lighting terminal 15), 1065 5S12 Warning light switch, 1068-1074 5X13 4-pin plug connector (left rear light), 1050, to the wire cross-section.
5F6 10 A fuse (lighting terminal 30), 1070 5S13 Turn indicator switch, 1064-1066 1063, 1087 Wires with unspecified cross-section = 0.75
5F7 5 A fuse (brake light), 1084 X10 18-pin plug connector (for basic equipment), 5x16 2-pin plug connector (licence plate lamp), mm2
5F8 7.5 A fuse (left headlight), 1043 1082 1058
5F9 7.5 A fuse (right headlight), 1045 5X1 12-pin plug connector (overhead guard Notes
5F10 5 A fuse (left sidelight), 1048 lighting), 1050-1074 Wire colours (a) For electronic controller (N1:41)
5F11 5 A fuse (right sidelight), 1053 BK Black

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7 Circuit diagrams
Hydraulic circuit diagram

Hydraulic circuit diagram

Traction, working and steering hydraulics

286 Operating Instructions – 393 807 10 01 EN – 10/2010

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Hydraulic circuit diagram

A Auxiliary hydraulics with duplex or triplex 18 Directional control valve - auxiliary hy- 33 Brake valve (servo valve) 49 Pedal group
1 Left hose pulley (double auxiliary hydraulics) draulics 2 34 Purge valve 13 bar 50 3/2 directional control valve
2 Right hose pulley (single auxiliary hy- 35 Combined feed maximum valve 435+20 bar 51 Pump for releasing brake
draulics) C Depressurisation (special equipment) 36 Choke plunger (towing unit) 52 Non-return valve
19 Control valve 37 Shuttle valve 53 Pressure relief valve
B Working hydraulics 20 Accumulator 38 Servo piston Y→forwards Z→backwards 54 2/2 directional control valve
3 Tilt cylinder 21 Non-return valve 39 2/2 directional control valve
4 Standard lift mast BR 188 40 Proportional valve (drive direction) N Pressure filter (feed pressure) / microfilter
5 Connection for auxiliary hydraulics 2 D Linde Truck Control
6 Connection for auxiliary hydraulics 1 22 Central lever for working hydraulics H Tandem pump O Fan drive
7 Solenoid valve 23 Central lever for auxiliary hydraulics 1+2 41 3/3 directional control valve (priority valve) 55 Solenoid valve
8 Tilt brake valve 42 Gear pump 14 cm3 56 Hydraulic motor 9 cm3
E Internal combustion engine n = 1000 to 2800 rpm
9 Load holding valve 43 Gear pump 23 cm3 P Radiator
10 Non-return valve F Engine speed regulator
11 Pressure relief valve 1 (with H 25 stan- I Working hydraulics pressure filter / microfilter R Drive axle AH 35-03 consisting of:
G Hydraulic variable displacement pump assembly 57 Multi-disc brake (brake release min. 16 bar)
dard/duplex/triplex 200+5 bar, with H 30 consisting of: K Steering control valve with:
standard/duplex/triplex 225+5 bar, with H 35 44 Suction valve 58 Hydraulic fixed-displacement motor
24 Hydraulic variable displacement pump HMF 550R
standard/duplex/triplex 245+5 bar) HPV 75-02 45 Hose safety valve (H 25, H 30 = 185+20 bar,
12 2/2 directional control valve (pressure 25 Exhaust valve (traction hydraulics) H 35 = 210+20 bar) S Oil tank consisting of:
governor) 26 Actuator piston A→forwards B→backwards 46 Servostat 59 Breather filter with suction valve and
13 Exhaust valve (working hydraulics) 27 Non-return valve 1 bar 47 Maximum valve (H 25, H 30 = 125+5 bar, counter-balance valve 0.35±0.15 bar
14 Directional control valve - lifting/lower 28 Sensor (hydraulic oil temperature) H 35 = 150+5 bar) 60 Suction filter with bypass valve 0.25 bar
15 Directional control valve - tilting 29 4/2 directional control valve
16 Pressure relief valve 2 L Steering cylinder
30 Pilot valve
17 Directional control valve - auxiliary hy- 31 Feed pressure valve 19+0.5 bar M Brake release valve
draulics 1 32 Brake valve (main control valve) 48 Towing unit

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7 Circuit diagrams
Hydraulic circuit diagram

Accumulator

288 Operating Instructions – 393 807 10 01 EN – 10/2010

 Circuit diagrams 7
Hydraulic circuit diagram

1 Left drive axle AH35-03 3 Raise/lower junction, (lift mast BR 188) Nitrogen filling pressure of accumulator H 30 standard/duplex/triplex 150 bar
2 High-pressure relief valve 4 Accumulator H 25 standard/duplex/triplex 133 bar H 35 standard/duplex/triplex 163 bar

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Linde Material Handling GmbH

393 807 10 01 EN – 10/2010