DFG ITFG 425s 435s - 09.

14-

Operating instructions (gb)

51343827
09.14 DFG 425s
DFG 430s
DFG 435s
TFG 425s
TFG 430s
TFG 435s

dllNGHEINRICH
Machines. Ideas. Solutions.
to

09.14 EN
 Declaration of Conformity

C€
Jungheinrich AG, Am Stadtrand 35, D-22047 Hamburg
Manufacturer or agent acting in the European Union

Type Option Serial no. Year of

manufacture
DFG 425s
DFG 430s
DFG 435s
TFG 425s
TFG 430s
TFG 435s

Additional information

On behalf of

Date

@5 EU Conformity Declaration
The undersigned hereby declare that the powered industrial truck described below in
detail complies with the European Directives 2006/42/EC (Machinery Directive) and
2004/1 08/EEC (Electromagnetic Compatibility - EMC) including amendments as well
as the legislative decree to incorporate the directives in national law. The signatories
are in each case individually authorized to compile the technical documents.

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09.14 EN
 Foreword
Notes on the operating instructions

The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide

sufficient instruction for the safe operation of the industrial truck. The information is
provided clearly and concisely. The chapters are arranged by letter and the pages are
numbered continuously.

The operator manual details different industrial truck models. When operating and
servicing the industrial truck, make sure that the particular section applies to your truck
model.

Our trucks are subject to ongoing development. We reserve the right to alter the
design, equipment and technical features of the system. No guarantee of particular
features of the truck should therefore be assumed from the present operating
instructions.

Safety notices and text mark-ups

Safety instructions and important explanations are indicated by the following graphics:

A DANGER!
Indicates an extremely hazardous situation. Failure to comply with this instruction will
result in severe irreparable injury and even death.

A WARNING!
Indicates an extremely hazardous situation. Failure to comply with this instruction may
result in severe irreparable injury and even death.

A CAUTION!
Indicates a hazardous situation. Failure to comply with this instruction may result in
slight to medium injury.

NOTE

Indicates a material hazard. Failure to comply with this instruction may result in
material damage.

Used before notices and explanations.

# Indicates standard equipment

O Indicates optional equipment
Copyright
z
LD
Copyright of these operating instructions remains with JUNGHEINRICH AG.
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Jungheinrich Aktiengesellschaft

Am Stadtrand 35
22047 Hamburg - Germany

Tel: +49 (0) 40/6948-0

www.jungheinrich.com

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Contents

A Correct Use and Application 11

1 General 11
2 Correct application 11
3 Approved application conditions 12
4 Proprietor responsibilities 13
5 Adding attachments and/or optional equipment 13

B Truck Description 15
1 Application 15
1.1 Truck models and rated capacity 15
2 Assemblies and Functional Description 16
2.1 Travel direction definition 16
2.2 Assembly Overview 17
2.3 Functional Description 18
3 Technical Specifications 20
3.1 Performance data 20
3.2 Dimensions 22
3.3 Weights 24
3.4 Mast versions 25
3.5 Tyre type 28
3.6 Engine Data 28
3.7 EN norms 29
3.8 Conditions of use 30
3.9 Electrical Requirements 30
4 Identification Points and Data Plates.... 31
4.1 Data plate 33
4.2 Truck capacity plate 34
4.3 Attachment capacity plate 36
5 Stability 36
5.1 Wind loads 36

C Transport and Commissioning . 37

1 Transport 37
2 Truck laden 37
2. 1 Centre of gravity of the truck 37
2.2 Lifting the truck by crane 38
2.3 Loading with another industrial truck 39
3 Securing the truck during transport .. 40
4 Using the Truck for the First Time .... 41

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 D Fuelling the Truck 43
1 General 43
1. 1 Safety regulations for handling diesel fuel and LPG 43
1.2 LPG system relief valve 45
2 Adding diesel 46
2.1 Fuelling 46
2.2 Fuelling with fuel containers 47
3 LPG containers 48
3.1 LPG bottles 48
3.2 LPG tank (O) 51
4 Fuel level indicator 52
4.1 Display unit 52
4.2 Level indicator for LPG bottles (O) 52

E Operation 53
1 Safety Regulations for the Operation of the Forklift Truck 53
2 Displays and Controls 55
2.1 Controls 55
2.2 Pilots 57
2.3 Control panel with display unit 58
2.4 Button allocation of the display 59
2.5 Symbols in the display 60
2.6 Armrest Control Panel Switch 63
2.7 Operating Programs 65
3 Preparing the Truck for Operation 66
3.1 Checks and Operations to Be Performed Before Starting Daily Work .... 66
3.2 Entry and exit 69
3.3 Trucks with reduced headroom (O) 69
3.4 Setting up the operator position 70
3.5 Seat Belt 77
4 Industrial Truck Operation 78
4.1 Safety regulations for truck operation 78
4.2 Preparing the truck for operation 81
4.3 Starting procedure for the DFG 82
4.4 Starting procedure for the TFG 83
4.5 Parking the truck securely 84
4.6 Emergency Disconnect 85
4.7 Travel 86
4.8 Steering 89
4.9 Brakes 90
4.10 Setting the Time 94
4. 11 Adjusting the forks 95
4.12 Replacing the forks 96
4.13 Lifting, transporting and depositing loads 97
4.14 Operating the Lift Mechanism and Integrated Attachments 99
4. 15 Safety instructions for operating additional attachments 109
4.16 Operating additional attachments for the SOLO-PILOT 112 z
4.17 Operating additional attachments for the Multi Pilot 114 ÿ
4.18 Operating additional Attachments for Duo-Pilot 116 5
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4.19 Fitting additional attachments 118
5 Towing trailers 121
6 Optional equipment 123
6.1 Keyless Access System 123
6.2 General Information on Using the Display Unit 124
6.3 Commissioning the Keypad and the Transponder Reader 124
6.4 Using the Display: 127
6.5 Using the Keypad 131
6.6 Using the T ransponder Reader 135
6.7 Assistance systems 139
6.8 Steel cab 141
6.9 Split Door 142
6.10 Sliding windows 144
6.11 Gate 144
6.12 Panel door 146
6. 13 Operator position extension 146
6.14 Heating and air conditioning system 147
6.15 USB Charger Module in Armrest 150
6.16 Auxiliary Functions on the Armrest 151
6.17 Operating hydraulics cutout 153
6.18 Load Weighing 153
6. 19 Lift cutout override 153
6.20 Fork Tilt Horizontal 154
6.21 Sideshifter Centre Position 154
6.22 Control layout "N" 155
6.23 Operating the Auxiliary Hydraulics without Pressing the Acknowledge¬
ment Key 157
6.24 Load Damping 161
6.25 Removable load backrest 163
6.26 Fire extinguisher 164
6.27 Rockinger coupling with hand lever or remote control 165
6.28 Camera system 166
6.29 Optional equipment for working in dusty environments 168
6.30 Roof window wiper 169
6.31 Floor spot 170
6.32 Horn Button on Overhead Guard 171
6.33 Travel Direction Switch on Steering Column 172
7 Troubleshooting 174
7.1 Troubleshooting 174
7.2 Operating the truck without its own drive system 178

F Industrial Truck Maintenance 185

1 Operational Safety and Environmental Protection 185

2 Maintenance Safety Regulations 186
2.1 Working on the electrical system 187
2.2 Consumables and used parts 187
2.3 Wheels 187
2.4 Lift Chains 188
2.5 Hydraulic system 188
2.6 Working in the vicinity of the engine 189
3 Lubricants and Lubrication Schedule 190

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 3.1 Handling consumables safely 190
3.2 Lubrication Schedule 192
3.3 Consumables 193
4 Maintenance and repairs 195
4. 1 Preparing the truck for maintenance and repairs 195
4.2 Lifting and jacking up the truck safely 196
4.3 Opening the rear panel 197
4.4 Unlocking the engine bonnet 197
4.5 Opening the engine cover 199
4.6 Replacing wheels 202
4.7 Checking the Wheel Mounting 204
4.8 Hydraulic system 205
4.9 Engine maintenance 208
4.10 Checking electrical fuses 223
4.1 1Cleaning 229
4.12 Starter battery 231
4.13 Exhaust system 232
4.14 Restoring the truck to service after maintenance and repairs 233
5 Decommissioning the Industrial Truck 234
5.1
5.2
5.3
6
7
8
9
Prior to decommissioning
During decommissioning
Restoring the truck to service after decommissioning
Safety tests to be performed at intervals and after unusual incidents
Final de-commissioning, disposal
Human vibration measurement
Servicing and Inspection
.....
235
235
236
237
238
238
239
10 Maintenance checklist DFG 240
10.1 Operating Company 240
10.2 Customer Service 243
11 Maintenance checklist TFG 252
11.1 Operating Company 252
11.2 Customer Service 255

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 A Correct Use and Application
1 General
The truck must be used, operated and serviced in accordance with the present
instructions. All other types of use are beyond its scope of application and may result
in damage to personnel, the industrial truck or property.

2 Correct application

NOTE

The maximum load and load distance are indicated on the capacity plate and must not
be exceeded.
The load must rest on the load handler or be lifted by an attachment approved by the
manufacturer.
The load must be fully raised, see "Lifting, transporting and depositing loads" on
page 97.

The following operations are in accordance with regulations and are permitted:
- Lifting and lowering loads.
- Transporting lowered loads over short distances.
- Occasional towing of trailer loads.
- When towing trailers the load must be secured on the trailer.
- The permissible trailer load must not be exceeded.

The following operations are prohibited:

- Travelling with a raised load (>30 cm).

- Carrying and lifting passengers.

- Pushing or pulling loads.
- Transporting hanging loads. If the truck is to be operated with hanging loads, proof
of sufficient safety distance under local operating conditions must be obtained from
a specialist assessor.

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3 Approved application conditions

A DANGER!
Do not exceed the permissible surface and point loading on the travel lanes.
At blind spots get a second person to assist.
The driver must ensure that the loading dock /dock leveller cannot be removed or
come loose during loading/unloading.

- Operation in industrial and commercial environments.

- Permissible temperature range -20°C to +40°C.
- Operation only on secure, level surfaces with sufficient capacity.
- Do not exceed the permissible surface and spot load limits on the travel routes.
- Operation only on routes that are visible and approved by the operating company.
- Negotiating inclines up to a maximum of 15 %.
- Do not travel across or at an angle on inclines. Travel with the load facing uphill.
- Operation in partially public traffic.
- Do not operate LPG trucks under ground level areas.

A WARNING!
Operating an LPG truck under ground level areas could result in explosions.
LPG is heavier than air. An explosive LPG/air mixture could therefore form under
ground level areas without sufficient ventilation.
ÿ Do not use LPG trucks under ground level areas.

A WARNING!

Use under extreme conditions

Using the truck under extreme conditions can result in malfunctions and accidents.
ÿ Special equipment and authorisation are required if the truck is to be constantly
used in extreme conditions, especially in dusty or corrosive atmospheres.
ÿ The truck cannot be used in areas at risk of explosion.
ÿ In adverse weather conditions (thunder, lightning) the industrial truck must not be
operated outside or in endangered areas.

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 4 Proprietor responsibilities
For the purposes of the present operating instructions the "operating company" is
defined as any natural or legal person who either uses the industrial truck himself, or
on whose behalf it is used. In special cases (e.g. leasing or renting) the proprietor is
considered the person who, in accordance with existing contractual agreements
between the owner and user of the industrial truck, is charged with operational duties.
The proprietor must ensure that the industrial truck is used only for the purpose it is
intended for and that danger to life and limb of the user and third parties are excluded.
Furthermore, accident prevention regulations, safety regulations and operating,
servicing and repair guidelines must be followed. The operating company must
ensure that all users have read and understood these operating instructions.

NOTE
Failure to comply with the operating instructions invalidates the warranty. The same
applies if improper work is carried out on the truck by the customer or third parties
without the permission of the manufacturer.

5 Adding attachments and/or optional equipment

The mounting or installation of additional equipment which affects or enhances the
performance of the industrial truck requires the written permission of the
manufacturer. Local authority approval may also need to be obtained.
Local authority approval however does not constitute the manufacturer's approval.

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09.14 EN
 B Truck Description
1 Application
The DFG /TFG 425s -435s is a four-wheel sit-down industrial truck with a combustion
engine. The DFG series are diesel engine trucks, while the TFG series are fitted with
a petrol engine for LPG operation.

The DFG / TFG 425s - 435s is a cantilever counterbalanced truck which can lift,
transport and deposit loads using the load handler attached in front.

The DFG / TFG 425s - 435s is equipped with a hydrostatic drive. The combustion
engine drives high pressure pumps for the hydraulic operating functions and two
hydraulic motors to drive the wheels.

1.1 Truck models and rated capacity

The rated capacity depends on the model. The rated capacity can be derived from the
model name.

DFG435s
DFG Model name
4 Series
35 Rated capacity x 100 kg
s Hydrostatic Drive System
The rated capacity is not generally the same as the permissible capacity. The capacity
can be found on the capacity plate attached to the truck.

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2 Assemblies and Functional Description
2.1 Travel direction definition

t
Dq
O /

h ST
2 4 ÿ> 3
vi
V
£ Dd
I
The following conventions have been agreed for travel direction specification:

Item Travel direction

1 Left
2 Reverse
3 Forward
4 Right

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 2.2 Assembly Overview

Item Component Item Component

5
6
•• Driver's seat
Overhead guard
13
14
•• Fork carriage
LPG bottle (TFG only)
7
8
•• Steering wheel
Mast
15
16
•• Trailer coupling
Counterweight
9
10
•• Emergency Disconnect switch
Control and display unit
17
18
•• Steering axle
Engine cover
11
12
•• Operating function control
Forks
19
• Drive

• = Standard equipment 0= Optional equipment

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2.3 Functional Description
Chassis

The chassis, in conjunction with the counterweight, forms the supporting base
structure of the truck. It is used to support the main components.

The hydraulic oil reservoir is integrated on the right-hand side and the fuel tank for the
DFG series is on the left side in the chassis.
Operator position and overhead guard

The overhead guard (6) comes in a range of models and protects the driver from
falling objects and other external influences.

All the controls are economically arranged. The steering column and driver's seat can
be adjusted individually.

The controls and warnings on the display unit (10) enable the system to be monitored
during operation, thereby ensuring a very high level of safety.

Steering

The steer cylinder of the hydrostatic steering is integrated in the steer axle (17) and is
controlled by the power steering. The steer axle is fully floating in the chassis to
ensure excellent grip even on non-level surfaces.

Wheels

All wheels are located within the truck geometry. A choice of pneumatic or
superelastic tyres are available.
Engine

High performance, water-cooled diesel and LPG engines with long operating lives and
low consumption and emission levels.

The diesel motors have an additive-free particle filter system. The LPG motors have
a controlled three-way catalytic converter option.

Electrical system

12-volt system with 3-phase alternator. A repeat start block prevents malfunctions
when the truck is powered up. For diesel engines, a rapid pre-heat system is installed;
LPG motors have an electronic ignition system for rapid and trouble-free engine
starting. The engine is started and switched off via the key switch or optionally via the
display unit.

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 Drive system and brakes

Both drive wheels are powered by individual hydraulic motors which in turn are driven
by a hydraulic pump. Forward/reverse or neutral can be set with the travel direction
switch on the control panel (11).

The truck brakes to a halt via the hydraulic motors (service brake), keeping energy
consumption to a minimum. The truck can brake more quickly if you also apply the
emergency stop brake.
The parking brake is an automatic multi-plate brake that can also be applied manually.

Hydraulic system

A multi-function control valve allows for sensitive operation of the functions via the
controls. A volume flow controlled hydraulic pump ensures a proportionate and
efficient supply to the hydraulic functions.

Mast

Two or three-stage masts, optionally with free lift function; narrow mast sections
ensure excellent visibility of the forks and attachments. Fork carriage and mast run on
permanently lubricated and hence maintenance-free support rollers.

Attachments

The trucks can be optionally fitted with mechanical and hydraulic attachments.

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3 Technical Specifications
All technical details refer to standard trucks.
Values indicated with *) may vary, depending on the
types of equipment used (e.g. mast, cabin, tyres etc.).
s The technical specifications comply with the German "Industrial Truck Data Sheet"
Guidelines.
Technical modifications and additions reserved.

3.1 Performance data

DFG 425s-435s
Component DFG 425s DFG 430s DFG 435s
~ Capacity 2500 3000 3500 kg
(where C = 500 mm)1)
C Load centre distance 500 500 500 mm
Travel speed* with /
19.6/19.6 20.8/20.8 20.8/20.8 km/h
without load
Lift speed with / without
0.56/0.56 0.56/0.56 0.48/0.48 m/s
load
Lowering speed with /
0.56/0.56 0.56/0.56 0.56/0.56 m/s
without load
Gradeability 2)*
27 24 21 %
with / without load
Acceleration* with /
4.9/4.4 5.4/4.6 5.4/4.7 s
without load to 15 m
Available working
215 215 215 bar
pressure for attachments
Oil flow for attachments 32 32 32 l/min
1)
for vertical mast.
2) The values shown represent the maximum gradeability to overcome short
differences in height and surface unevenness (surface edges). The truck must not
operate on inclines of more than 15%.

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 TFG 425s-435s
Component TFG 425s TFG 430s TFG 435s
Capacity
Q 2500 3000 3500 kg
(where C = 500 mm)1)
C Load centre distance 500 500 500 mm
Travel speed * with/
19.6/19.6 20.8/20.8 20.8/20.8 km/h
without load
Lift speed with / without
0.56/0.56 0.56/0.56 0.48/0.48 m/s
load
Lowering speed with /
0.56/0.56 0.56/0.56 0.56/0.56 m/s
without load
Gradeability 2)*
27 24 21 %
with / without load
Acceleration* with /
5.7/5.0 6.0/5.1 6.1/5.2 s
without load to 15 m
Available working
215 215 215 bar
pressure for attachments
Oil flow for attachments 32 32 32 l/min
1) for vertical mast.
2)
The values shown represent the maximum gradeability to overcome short
differences in height and surface unevenness (surface edges). The truck must not
operate on inclines of more than 15%.

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3.2 Dimensions

DFG/TFG 425s-435s
Component DFG/TFG DFG/TFG DFG/TFG
425s 430s 435s
a/2 Safety distance 100 100 100 mm
hi Collapsed height* 2321 2325 2405 mm
h2 Free lift* 150 150 150 mm
h3 Lift* 3300 3300 3300 mm
h4 Extended height* 3894 4062 4093 mm
he Overhead guard height* 2220 2238 2238 mm
h7 Seat height* 1058 1076 1076 mm
h10 Coupling height 377 384 387 mm
o
a Mast tilt, fwd.* 6 6 6
o
P Mast tilt, back* 8 8 8
Overall length, including
li forks* 3763 3873 3963 mm
Overall length, including
h fork shank* 2613 2723 2813 mm

b1 Overall width* 1184 1320 1320 mm

s/e/l Fork dimensions* 40/120/1150 45/125/1150 50/125/1150 mm
Ground clearance,
m-j 112 118 147 mm
laden, below mast*
Ground clearance
m2 130 148 148 mm
centre wheelbase*
Fork carriage ISO 2328,
2A 3A 3A
class / type A, B
Aisle width for pallets
ÿst 4158 4275 4353 mm
800 x 1200 lengthways
Working aisle width for
Ast pallets 1000 x 1200 3958 4075 4153 mm
traverse
Wa Turning radius 2285 2377 2455 mm
b13 Smallest turning radius 640 640 640 mm
X Load distance* 473 478 483 mm
C Load centre of gravity 500 500 500 mm
y Wheelbase 1750 1820 1880 mm

*) The data listed in the table corresponds to the standard version.

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09.14 EN
3.3 Weights
s All dimensions in kg.

DFG/TFG 425s DFG/TFG 430s DFG/TFG 435s

Net weight* 3960 4440 4815
Axle loading, unladen load 1740/2220 1909/2530 1975/2896
front / rear*
Axle loading, laden front / rear* 5830 / 830 6520 / 920 7305/1005

*) The data listed in the table corresponds to the standard version.

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 3.4 Mast versions
s All dimensions in mm.

DFG/TFG 425s
Mast chart
Lift h3 Free lift h2 Collapsed Extended Mast
Component height h-j height h4 weight (kg)
2900 150 2121 3494 501
3100 150 2221 3694 517
3300 150 2321 3894 533
3500 150 2421 4094 549
ZT
3700 150 2521 4294 565
4000 150 2671 4594 589
4300 150 2871 4894 634
4500 150 2971 5094 650
3100 1606 2186 3672 525
3300 1706 2286 3872 542
ZZ 3500 1806 2386 4072 559
3700 1906 2486 4272 576
4000 2056 2636 4572 601
4400 1506 2086 4972 691
4700 1606 2186 5272 716
5000 1714 2277 5563 865
5500 1914 2477 6063 923
DZ
6000 2114 2677 6563 1005
6500 2314 2877 7063 1064
7000 2514 3077 7563 1123
7500 2714 3277 8063 1182

Special trucks are not included in this overview.

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 DFG/TFG 430s
Mast chart
Lift h3 Free lift h2 Collapsed Extended Mast
Component height h1 height h4 weight (kg)
2900 150 2125 3662 629
3100 150 2225 3862 647
3300 150 2325 4062 665
3500 150 2425 4262 684
ZT
3700 150 2525 4462 701
4000 150 2675 4762 729
4300 150 2875 5062 785
4500 150 2975 5262 802
3100 1451 2190 3842 681
3300 1551 2290 4042 702
ZZ 3500 1651 2390 4242 723
3700 1751 2490 4442 743
4000 1901 2640 4742 774
4400 1351 2090 5142 848
4700 1451 2190 5442 877
5000 1551 2290 5742 906
5500 1751 2490 6242 965
DZ
6000 1951 2690 6742 1046
6500 2151 2890 7242 1106
7000 2351 3090 7742 1164
7500 2551 3290 8240 1223

Special trucks are not included in this overview.

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 DFG/TFG 435s
Mast chart
Lift h3 Free lift h2 Collapsed Extended Mast
Component height h1 height h4 weight (kg)
2900 150 2205 3693 647
3100 150 2305 3893 665
3300 150 2405 4093 684
3500 150 2505 4293 702
ZT
3700 150 2605 4493 721
4000 150 2755 4793 729
4300 150 2955 5093 785
4500 150 3055 5293 802
3100 1501 2270 3873 677
3300 1601 2370 4073 699
ZZ 3500 1701 2470 4273 720
3700 1801 2570 4473 742
4000 1951 2720 4773 774
4400 1401 2170 5173 885
4700 1501 2270 5473 912
5000 1601 2370 5773 942
5500 1801 2570 6273 1003
DZ
6000 2001 2770 6773 1087
6500 2201 2970 7273 1149
7000 2401 3170 7770 1210
7500 2601 3370 8273 1271

Special trucks are not included in this overview.

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3.5 Tyre type

NOTE
When replacing tyres/rims fitted at the factory, always use original spare parts or tyres
approved by the manufacturer. Otherwise the manufacturer's specification cannot be
guaranteed.
If you have any queries, please contact the manufacturer's customer service
department.

Component DFG/TFG
425s 430s 435s
SE* 7.0 - 12 27 x 10-12 27 x 10-12
27 x 10-12- 27 x 10-12-
Pneumatic* 7.0 - 12-16PR
Front tyres 20PR 20PR
Tyre pressure bar 10 9 9
Torque NM 200 200 200
SE* 6.50 x 10 6.50 x 10 6.50 x 10
6.50 x 10- 6.50 x 10- 6.50 x 10-
Pneumatic*
Rear tyres 10PR 10PR 10PR
Tyre pressure bar 7.75 7.75 7.75
Torque NM 200 200 200

*) The models listed in the table correspond to the standard version. Other tyres can
be used depending on the truck's equipment.

3.6 Engine Data

Component DFG 425s DFG 430s DFG 435s

Cylinder/cubic capacity 4/1968 4/1968 4 / 1968 cm3
Idle speed 1000 1000 1000 rpm
Rated speed 2700 2700 2700 rpm
Engine output 44 44 44 kW
Engine output O 36 36 44 kW
Fuel consumption 3 3.2 3.4 l/h [kg/h]
60 VDI duty cycles/h

Component TFG 425s TFG 430s TFG 435s

Cylinders/cubic capacity 4 h 980 4/1980 4/1980 cm3
Idle speed 900 900 900 rpm
Rated speed (without load) 2700 2700 2700 rpm
Engine output 38 38 38 kW
Fuel consumption 2.6 2.7 2.9 l/h [kg/h]
60 VDI duty cycles/h

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 3.7 EN norms
Noise emission level

- DFG/TFG 425s/430s: 75 dB(A)

- DFG/TFG 435s: 75 dB(A)
*+/- 3 dB(A) depending on the truck's equipment
in accordance with EN 12053 as harmonised with ISO 4871.

The noise emission level is calculated in accordance with standard procedures and
takes into account the noise level when travelling, lifting and when idle. The noise
level is measured at the level of the driver's ear.
Vibration

- DFG/TFG 425s/430s: 0,50 m/s2

- DFG/TFG 435s: 0,50 m/s2

in accordance with EN 13059.

The internal accuracy of the measuring chain for at 21 °C at ± 0,02 m/s2. Further
deviations may occur in particular through the positioning of the sensor and different
driver weights.

The vibration acceleration acting on the body in the operating position is, in
accordance with standard procedures, the linearly integrated, weighted
acceleration in the vertical direction. It is calculated when travelling over thresholds
at constant speed (standard truck version). These recordings were taken on a
single occasion for the industrial truck and must not be confused with the human
vibrations of the "2002/44/EC/Vibrations" operator directive. The manufacturer
offers a special service to measure these human vibrations, see "Human vibration
measurement" on page 238.

Electromagnetic compatibility (EMC)

The manufacturer confirms that the truck adheres to the limits for electromagnetic
emissions and resistance as well as the static electricity discharge test in accordance
with EN 12895 as well as the standardised instructions contained therein.

No changes to electric or electronic components or their arrangement may be made

without the written agreement of the manufacturer.

A WARNING!
Medical equipment can be damaged by non-ionised radiation
Electrical equipment on the truck emitting non-ionised radiation (e.g. wireless data
transmission) can affect operators' medical equipment (pacemakers, hearing aids
etc.) and result in malfunctions. Consult a doctor or the manufacturer of the medical
equipment to clarify whether it can be used near the industrial truck.

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3.8 Conditions of use
Ambient temperature

operating at -20°C to +40°C

Special equipment and authorisation are required if the truck is to be used
continually in conditions of extreme temperature or condensing air humidity
fluctuations.

3.9 Electrical Requirements

The manufacturer certifies compliance with the requirements for the design and
manufacture of electrical equipment, according to EN 1175 "Industrial Truck Safety -
Electrical Requirements", provided the truck is used according to its purpose.

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 4 Identification Points and Data Plates
a Warnings and notices such as capacity charts, strap points and data plates must be
legible at all times. Replace if necessary.

xxxx

|jjHVLP46 36

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 Item Component
20 Fuel
21 Data plate
22 Open the engine cover
23 Serial number, engraved in chassis below the engine cover
24 Noise level
25 Engine off (TFG)
26 Read operating instructions
27 Do not step onto or beneath the load, risk of trapping with moving mast
28 Lift height limits
29 Do not drive, or operate the forward tilt, with the load in the raised position
30 Wear seat belt
31 Strap points for crane lifting
32 Tipover hazard
33 Capacity
34 Max. body size (O)
35 Tyre pressure
36 Hydraulic oil specification
37 Jack contact points
38 Warning symbols on the battery
39 LPG bottle bracket
40 Test plaque (O)
41 E box fuse layout
42 Speed (0)
43 Do not carry passengers warning
44 Model description
45 Fuse layout on the battery

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 4.1 Data plate
a The illustration shows the standard version for EU member states. The data plate
may differ in other countries.

46 47 48 49

XX xxxx
XXX xxxx
xxxxxxx xxxxx
xxxxxxx xxxxxxxxxxxxx
xxxxxxxxxxxx xxxxxxxxxxxxxxx
xxxxxxxxxxx xxxxxxxxxxxxxx
xxxxxxxxxxxx xxxxxxxxxx
xxxxxxxxxxx xxxxxxxxx

54
xxxxxxxx
xxxxxxxx

55

Item Component Item Component

46 Type 51 Year of manufacture
47 Serial number 52 Load centre distance (mm)
48 Rated capacity (kg) 53 Net weight in kg
49 Output 54 Manufacturer
50 Option 55 Manufacturer's logo

For queries regarding the truck or ordering spare parts always quote the truck serial
number (47).

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4.2 Truck capacity plate

A CAUTION!
Accident risk from fork replacement
If you replace the forks with ones that differ from the originals, the capacity will
change.
ÿ When replacing the forks you must attach an additional capacity plate to the truck.
ÿ Trucks supplied without forks are given a capacity plate for standard forks (length:
1150 mm).

The capacity plate (56) gives the capacity (Q in kg) of the truck for a vertical mast. The
maximum capacity is shown as a table with a given load centre of gravity D (in mm)
and the required lift height H (in mm).
The capacity plate (56) of the truck indicates the truck's capacity with the forks as
originally supplied.

Example of how to calculate the maximum capacity:

h3 (mm) a (kg)
4250 850 850 600
56
3600 1105 1105 850
2900 1250 1250 850
"
D (mm) | 500 | 600 | 700 )

Capacity plate version in accordance with Australian guidelines

max
Ik
Ifma**
I
h3 (mm) Q(kq)

D (mm )

For a load centre of gravity D of 600 mm and a max. lift height h3 of 3600 mm the
maximum capacity Q is 1105 kg.

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 Lift height limits

The arrow shaped markings (57 and 58) 57 58

on the inner and outer masts show the
operator when the prescribed lift limits
have been reached.

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4.3 Attachment capacity plate
The attachment capacity plate is next to the truck's capacity plate and gives the truck's
capacity Q (in kg) in conjunction with the respective attachment. The serial number for
the attachment indicated on the capacity plate must match the data plate of the
attachment.

5 Stability
The truck's stability has been tested according to latest technological standards.
These take into account the dynamic and static tipover forces that can occur if used
correctly.

Stability can also be affected by the following factors:

- Tyre type

- Mast
- Attachment
- Transported load (size, weight and centre of gravity)

A WARNING!
Loss of stability can cause accidents
Changing the components can alter the stability.

5.1 Wind loads

Wind forces can affect the stability of a truck when lifting, lowering and transporting
loads with large surface areas.
Light loads must be especially secured when they are subjected to wind forces. This
will prevent the load from sliding or falling.

Stop the truck in both cases.

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 c Transport and Commissioning
1 Transport
Transport can be carried out in two different ways, depending on the height of the
mast and the local conditions.
- Vertically, with the mast assembled (for low heights)
- Vertically, with the mast dismantled (for large heights), all mechanical connections
and hydraulic lines between the basic truck and the mast separated.

2 Truck laden
2.1 Centre of gravity of the truck

A WARNING!
An altered centre of gravity can result in tipovers when cornering.
The overall centre of gravity can vary depending on the truck's equipment (especially
the mast version).
For trucks without a mast the centre of gravity will move significantly in the direction
of the counterweight.
ÿ Drive carefully and with modified speed to avoid tipping over.

The picture shows the

approximate centre of gravity
location.

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2.2 Lifting the truck by crane

A CAUTION!
The mast can get damaged
ÿ Loading by crane is only intended for the initial transport before the truck is used for
the first time.
ÿ Loading must be carried out by specially trained staff in accordance with
recommendations contained in Guidelines VDI 2700 and VDI 2703

A DANGER!
Crane slings can tear, resulting in accidents
ÿ Only use crane lifting gear with sufficient capacity.
ÿ Loading weight = Net weight of truck (+ battery weight for electric trucks).
ÿ The mast must be tilted back fully.
ÿ The crane lifting gear on the mast must have a minimum clear length of 2 m.
ÿ Crane slings should be fastened in such a way that they do not come into contact
with any attachments or the overhead guard when lifting.
ÿ Do not stand under a swaying load.
ÿ The truck should only be handled by people who are trained in using lifting slings
and tools.
ÿ Wear safety shoes when lifting the truck by crane.
ÿ Do not walk into or stand in a hazardous area.
ÿ Always attach the crane lifting gear to the prescribed strap points and prevent them
from slipping.

7*1 Truck net weight: see "Data plate" on page 33.

Lifting the truck by crane

Requirements
- Park the truck securely, see "Parking the
truck securely" on page 84.

Procedure
ÿ
Secure the crane slings to the attachment
points (60) and (59.
ÿ
Raise and load the truck.
• Lower and deposit the truck carefully (see
"Parking the truck securely" on page 84).
ÿ
Secure the truck with wedges to prevent it
from rolling away.
This concludes the loading by crane.

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38
 2.3 Loading with another industrial truck

A WARNING!
The truck can be damaged
The truck to be loaded can be damaged when loading with another industrial truck.
ÿ Only trained specialist personnel should load the truck.
ÿ Use only trucks with sufficient capacity for loading.
ÿ Only for loading and unloading.
ÿ The forks of the second industrial truck must be sufficiently long
ÿ Transporting over long distances prohibited.

Loading the truck with a second industrial truck

Requirements
- Park the truck securely, see "Parking the truck securely" on page 84.
Procedure
• Raise the truck with the forks at the side between the axles.
ÿ
Raise the truck slightly and make sure it is securely positioned on the forks. If
necessary adjust or secure the forks with stops.
• Carefully load/unload the truck, see "Lifting, transporting and depositing loads" on
page 97.
• Lower the truck slowly onto the ground and prevent it from rolling away.
The truck is now loaded.

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3 Securing the truck during transport

A WARNING!
Accidental movement during transport
Improper fastening of the truck and mast during transport can result in serious
accidents.
ÿ Loading must be carried out by specially trained staff in accordance with
recommendations contained in Guidelines VDI 2700 and VDI 2703 In each case
correct measurements must be made and appropriate safety measures adopted.
ÿ The truck must be securely fastened when transported on a lorry or a trailer.
ÿ The loading area must have clamp rings and a wooden floor to secure the retaining
wedges.
ÿ Use wedges to prevent the truck from moving.
ÿ Use only tensioning belts or tie-down straps or with sufficient strength.

Securing with a mast Securing without a mast

62

Securing the industrial truck for transport

Requirements
- Position the industrial truck securely on a lorry or trailer, see "Parking the truck
securely" on page 84.

Tools and Material Required

- 2 fastening belts with a tensioner
- Retaining wedges

Procedure
• Secure the truck with the fastening belt (61) at the top cross member of the mast
(60) and the trailer coupling (59) or over the front axle cross member (62) and the
trailer coupling (59).
• Tighten the fastening belts (61) with the tensioner.

The truck is now secured for transport.

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 4 Using the Truck for the First Time
Safety Instructions for Assembly and Commissioning

A WARNING!
Incorrect assembly can result in accidents
The assembly of the truck at the application site, commissioning and operator training
must only be performed by the manufacturer's customer service representatives who
have been specially trained for these tasks.

Preparing the truck for operation after delivery or transport

Procedure
* Check the equipment is complete.
ÿ
Check the engine oil level.
• Check the hydraulic oil level.
ÿ
Test the battery connections.
• Check the battery acid level (not for maintenance-free batteries).

The truck can now be started, see "Preparing the Truck for Operation" on page 66.

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-fc.

09.14 EN
 D Fuelling the Truck
1 General
1.1 Safety regulations for handling diesel fuel and LPG

A WARNING!
An unsecured industrial truck can cause accidents
The truck can suddenly start to move.
ÿ Park the truck securely before filling it up or replacing the LPG bottle, see page 84.

A WARNING!
Accident risk from ignition
ÿ Fuels and liquefied petroleum gas can ignite.
ÿ Smoking, naked flames and other ignition sources are strictly prohibited in the
immediate vicinity when handling fuels and LPG.
ÿ Labels indicating the hazard are must be positioned where they are clearly visible.
ÿ Do not store flammable materials in this area.
ÿ Powder fire extinguisher must be provided within easy reach of the filling area.
ÿ Use only category A, B or C type powder fire extinguishers to fight LPG fires.
ÿ Bring any unsealed LPG bottles immediately outside, attach visible markings and
notify the supplier.

Storage and Transport

The diesel and LPG storage and transport devices must comply with statutory
requirements.

If there is no filling station available, the fuel must be stored and transported in clean,
approved containers.

The contents must be clearly indicated on the container.

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 NOTE
Fuel can cause environmental damage
ÿ Bind any spilled diesel fuel with suitable methods.
ÿ Then dispose of the diesel and fuel filter in accordance with environmental
regulations.

Fuel filling and LPG bottle replacement personnel

Personnel filling the trucks or replacing LPG bottles must have sufficient knowledge
of the nature of fuels to ensure safe operation.

A CAUTION!
Liquid gas can cause frostbite
ÿ Liquid gas produces frostbite when it comes into contact with bare skin.
ÿ Avoid direct contact with the skin.
ÿ Wear gloves.

Filling up LPG containers

LPG containers remain attached to the truck and are filled up at LPG stations. Always
follow the instructions of the tank system and LPG container manufacturer as well as
statutory and local regulations when filling up.

NOTE
Instructions for the safe operation of LPG systems
ÿ All maintenance and repair work on LPG systems and containers should be carried
out by qualified personnel who have been trained to work on LPG systems.
ÿThe owner must comply with all legal requirements, technical standards and health
and safety regulations applicable to liquid gas.
ÿ Before starting work, the operator must check that all accessible components of the
LPG system are in good working order, in accordance with the regulations of the
country of use.
ÿ Do not operate the truck if there is any damage, corrosion, wear or degradation to
individual components of the LPG system.

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 1.2 LPG system relief valve

LPG powered trucks are fitted with a relief

valve. This is located on the rear cover next to
the gas bottle.
- In the event of a fault the pressure in the gas
system is restricted to a maximum level. The
relief valve is fitted with a plastic cover (63).
- When the valve is activated the plastic cover
comes off, thereby clearly indicating a fault 63
in the gas system.
- In this case the truck must not be operated.
- The gas system must be check by suitably
qualified and trained personnel.
- The operator must check that the plastic cover is in place each time he uses the
truck.

A DANGER!
Danger from escaping liquid gas.
Liquid gas can escape from faulty gas hoses.
ÿ Use only gas bottles with an integrated line break safety valve.
ÿ The gas bottle connection is also fitted with a line break safety valve which prevents
the gas from escaping accidentally during operation.
ÿ When replacing, always use a gas bottle connection with an integrated line break
safety valve.

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2 Adding diesel

A CAUTION!
Air in the fuel system will result in malfunctions.
ÿ Never allow the fuel tank to run dry.

2.1 Fuelling

A WARNING!
Diesel fuel can be hazardous
ÿ Diesel fuel can cause irritation if it comes into contact with the skin. Rinse any
affected areas thoroughly.
ÿ If it comes into contact with the eyes rinse them immediately with flowing water and
call for a doctor.
ÿ Wear safety gloves when handling diesel fuels.

NOTE
ÿ Fuelling must always be performed in designated areas by trained and authorised
personnel.

NOTE
ÿ Capacity: DFG 425s-435s = 60 I.
ÿ Use only DIN EN 590 diesel with a cetane number above 51 . The use of fuels that
do not comply with this standard can result in excess wear and damage to the motor
and exhaust system. The truck might no longer comply with the required exhaust
levels. The owner of the truck is responsible in this case.
ÿ Fuel additives (drag reducers), petrol or other substances must not be mixed with
diesel fuel.
ÿ Do not start the engine if non-approved fuels have been added. You must also
contact the Jungheinrich Service Department to prevent engine damage.

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 2.1.1 Fuelling the tank system

Procedure
• Park the truck securely before fuelling,
see page 84.
• Unscrew the filler cap (64).
• Insert the pump nozzle into the open tank
filler neck.
• Add the fuel.
• Do not overfill the tank.
• Screw the cap (64) back on tightly after
fuelling.
Fuelling is now complete.

2.2 Fuelling with fuel containers

Procedure
• Unscrew the filler cap (64) and open the
fuel container.
• Fit the spout onto the fuel container.
• Insert the spout into the open tank filler
neck.
• Make sure the fuel container and spout
are connected tightly to each other.
ÿ
Raise the fuel container carefully and
slowly add the diesel.
64
• Do not overfill the tank.
ÿ
Screw the cap (64) back on tightly after fuelling.
Fuelling is now complete.

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3 LPG containers
a Only use liquid gas that complies with DIN 51622 or comparable national
regulations.

3.1 LPG bottles

DANGER!
Risk of explosion
ÿ The LPG bottle must only be replaced at designated areas by trained and
authorised personnel.

A CAUTION!
Using unsuitable LPG bottles can cause accidents.
ÿ Use only approved LPG bottles.
ÿ The LPG bottle must always rest on an engaged bottle holder so that the hose
connection of the shutoff valve is facing vertically down.
ÿ For bottle types of other countries note the national regulations.
ÿ Note the indications and markings on the LPG bottle.

3.1.1 Using an LPG bottle

Preparing to change the LPG bottle

Procedure
• Park the truck securely before changing the
LPG bottle, see "Parking the truck securely"
on page 84.
• Close the shut-off valve (65) securely.
• Start the motor and run it in neutral until the
LPG system is empty.
LPG bottle is ready to be changed.

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 Remove the LPG bottle

A CAUTION!
The connection has a left thread

Procedure
• Unscrew the union nut (71) while holding
against the handle (72).
• Remove the hose (73) and immediately
screw the valve cap onto the empty LPG
bottle.
• Remove the stop bolt (67) and rotate the
LPG bottle and bracket around the handle
(66).
• Fold back the lever of the toggle-type
fastener (70) and remove the tensioning
pivot.
• Remove the tensioning belt.
• Carefully remove the LPG bottle from the
bracket (69) and place it down securely.

Inserting a new LPG bottle

Procedure
• Place the LPG bottle in the bracket (69).
• Centre the handle (66) in the hole (68).
• Align the hose connection upwards.
• Fit the tensioning belt around the LPG bottle 73T
again and tension it with the toggle-type
fastener (70).
• Fit the tensioning pivot and tension the belt
with the toggle-type fastener (70).
• Rotate the LPG bottle and the bracket around the handle (66).
• Insert the stop bolt (67).
• Unscrew the valve cap.
ÿ
Fit the hose (73) in accordance with instructions.
• Carefully open the shut-off valve (65).
• Check the hose connection for leaks using a foam-forming agent.
The replacement is now complete.

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3.1.2 Operation with two LPG bottles (O)

A WARNING!
Visibility is restricted when the truck reverses.
ÿ When using two LPG bottles the truck must be fitted with a functional camera
system for reversing.
ÿ External mirrors must also be fitted on either side of the truck.

Operating the twin bottle system

NOTE
Use the additional valve (74) on the
bracket (69) to change the LPG supply.
The correct assignment can be seen
from the LPG hose connection on the
valve (73) and the routing to the LPG
bottles (e.g. toggle valve right = top,
toggle valve left = bottom).

Procedure
• Use the lever (75) to change between the top and
bottom LPG bottles.

Replacing the LPG bottles

Procedure
• see "Using an LPG bottle" on page 48.

0 Replace an empty LPG bottle at the earliest opportunity with a full one.
Switching off the LPG supply

Procedure
• Close both shutoff valves (65) on the LPG bottles to interrupt the supply of LPG.

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 3.2 LPG tank (O)
Refillable liquid gas tanks contain a dispensing valve (77), a filling stop valve (79), a
relief valve (78) and a display (76).

Filling refillable liquid gas tanks (optional

equipment).
7-7®
Requirements //<
- Note all guidelines and regulations
concerning the filling of LPG bottles on the
LPG pump.
Procedure
• Close the dispensing valve (77).
• Unscrew the cap (80) of the filling stop valve
(79).
ÿ
Screw the filling connection of the liquid gas 77 78 79 80
pump onto the filling stop valve (79).
0 Fuelling automatically ends when the tank's
capacity has been reached.
ÿ
After fuelling, unscrew the filling connection and screw the cap (80) of the filling stop
valve (79) back on.

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4 Fuel level indicator
4.1 Display unit

12345h

81 82

The fuel level indicator (81) shows the fuel level (only on DFG or TFG with LPG tank).

The tank must be filled up whenever the filling pump symbol (82) is displayed.

4.2 Level indicator for LPG bottles (O)

The LPG bottle is empty when the filling pump symbol (82) appears.

The remaining travel time will be 8 - 12 minutes, depending on the application and
ambient conditions.
0 Fluctuations in the liquid gas level caused by the travel mode can cause the level
indicator to light up briefly. Only a permanently lit level indicator means that the LPG
bottle is almost empty.

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 E Operation
1 Safety Regulations for the Operation of the
Forklift Truck
Driver authorisation

The truck may only be used by suitably trained personnel, who have demonstrated to
the proprietor or his representative that they can drive and handle loads and have
been authorised to operate the truck by the proprietor or his representative.
Operator's rights, obligations and responsibilities

The operator must be informed of his duties and responsibilities and be instructed in
the operation of the truck and shall be familiar with the operating instructions.
Unauthorised use of truck

The operator is responsible for the truck during the time it is in use. The operator must
prevent unauthorised persons from driving or operating the truck. Do not carry
passengers or lift other people.
Damage and faults

The supervisor must be informed immediately of any damage or faults to the truck or
attachment. Trucks which are unsafe for operation (e.g. wheel or brake problems)
must not be used until they have been rectified.

Repairs

The operator must not carry out any repairs or alterations to the truck without
authorisation and the necessary training to do so. The operator must never disable or
adjust safety mechanisms or switches.

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 Hazardous area

A WARNING!
Risk of accidents/injury in the hazardous area of the truck
A hazardous area is defined as the area in which people are at risk due to travel or
lifting operations of the truck, its load handler or the load. This also includes the area
within reach of falling loads or lowering/falling operating equipment.
ÿ Instruct unauthorised persons to leave the hazardous area.
ÿ In case of danger to third parties, give a warning signal in good time.
ÿ If unauthorised persons are still within the hazardous area, stop the truck
immediately.

A WARNING!
Falling objects can cause accidents
Falling objects can injure the operator while the truck is being operated.
ÿ The operator must remain within the protected area of the overhead guard while the
truck is being operated.

Safety devices, warning signs and warning instructions

Safety devices, warning signs (see "Identification Points and Data Plates" on page 31 )
and warning instructions in the present operating instructions must be strictly
observed.

A CAUTION!
Reduced headroom can cause injuries
Trucks with reduced headroom are equipped with a warning label within the operator's
line of sight.
ÿ The max. recommended body size indicated on this warning sign must be
observed.
ÿ The headroom is also reduced when you wear a protective helmet.

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2 Displays and Controls
2.1 Controls
 Item Control / Function
Display
7
83
Steering wheel
Armrest control panel
•• Steering the industrial truck.
Switches electrical options
on and off.
84 Dashboard control panel
• Switches electrical options
on and off.

85 Key switch
ISM online access O
• Switches the truck on and off.
Switches the truck on. Switch off via the
module* control panel instrument panel.
Keypad
Transponder reader
86 Emergency Disconnect
switch • Switches off all travel, steering and
hydraulic functions as well as the IC engine.
The truck brakes to a halt at maximum
brake force, see "Emergency Disconnect"
on page 85.
87 DUO-PILOT o Controls the following functions:
88 MULTI-PILOT o
89 SOLO-PILOT
• - Fwd/rev. travel direction
- Load handler lift / lower
- Mast forward / reverse tilt
- "Horn" button
- Sideshifter left / right (0)
- Auxiliary hydraulics (0)

90 Twin pedal control o The truck reverses when the accelerator

"Reverse" accelerator pedal is applied.
pedal Provides infinitely variable travel speed.
91
92
Brake pedal
Twin pedal control
•o Provides infinitely variable braking control.
The truck travels forward when the
"Forward" accelerator accelerator pedal is applied.
pedal Provides infinitely variable travel speed.
93 Accelerator pedal
• Infinite travel speed control.

*lf equipped with ISM Online access module, see "ISM Online access module"
operating instructions.

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 2.2 Pilots

Item Control / Function

Display
94 Basic hydraulic functions
lever • Lever for operating the basic lift/tilt
hydraulic functions.
95 Sideshifter/auxiliary
hydraulics 1 optional button • Sideshifter or auxiliary hydraulics 1 button

/ lever
96 Travel direction switch
(not available with dual
pedal control)
• Selects travel direction / neutral position.

97
98
"Horn" button
Fork positioner/ auxiliary
• Activates an audible warning.
O Fork positioner or auxiliary hydraulics 2
hydraulics 2 button /lever - button
optional
99 Toggle switch O Switches to the second function of the
respective lever / button
100 Acknowledgement key o Additional operating means for hydraulic
functions requiring acknowledgement

94 95 94 95

96 99
95/98

94

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2.3 Control panel with display unit

101 102

110 81

Item Control / Function

Display
81 DFG fuel supply display Graphic illustration of the fuel supply.
101 Travel direction selection Shows the direction selected (white semi¬
circle).
102 Travel direction and steering Shows the current travel direction of the truck
angle arrow and the current wheel position (O) in 15°
segments.
103 Information field Displays event messages and optional
information such as speed, load weight.
104 Time Shows the time.
105 Power display Shows the travel and lift performance of the
operating program selected.
106 Icon field Displays the icons see "Symbols in the display"
on page 60.
107 Operating program Shows the operating program selected, see
"Operating Programs" on page 65
108 Hourmeter Service hours are counted as the IC engine is
running.
109 Button allocation see "Button allocation of the display" on
page 59.
110 Key Selection key for the corresponding functions.

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 2.4 Button allocation of the display

Symbol Meaning

P>1 Information field toggle:

Allows the information displayed in the information field to be changed.

Slow travel:
ÿ3 Switches slow travel on and off.

Operating program down:

To switch the operating program down.
Operating program up:
To switch the operating program up.
Settings:
Change to setting mode. Set time and access authorisations (optional).

Switch off (optional):

Allows the truck to be switched off
(if option available).
Start the engine (optional):
1START ÿ Allows the engine to be started (if option available).

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2.5 Symbols in the display
s The symbols shown depend on the truck's equipment.

Symbol Meaning Colour Function

Indicator (warning Green Indicator and warning indicator active

<>0 indicator)

Slow travel Green Slow travel activated by operator

Yellow Slow travel activated by truck
Red Emergency travel operation with reduced
performance, activated by truck
Service note Yellow Service required

\ Yellow
flashing
Red
- next service due in less than 150 service
hours
Safety inspection required
Warning Yellow Operating error

A Red Truck malfunction

n
Impact display (for Yellow Medium impact
ISM Online option) Red Severe impact

Automatic parking Green Automatic parking brake active, see

(O) brake "Parking brake" on page 92.

Manual parking Red Parking brake button applied,

(®) brake "Parking brake" on page 92.

Seat switch Yellow Seat switch not applied or seat switch

applied for more than 6 hours
Red Error on seat switch
Seat belt lock Yellow Seat belt not latched
lit control Red Incorrect operating sequence
tr
Acknowledgement Green Acknowledgement active
active

Acknowledgement Yellow Acknowledgement feature malfunction:

feature malfunction Hydraulic function requiring
acknowledgement activated without
acknowledgement

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 Symbol Meaning Colour Function
Toggle function Yellow Second hydraulic control lever function
activated

Fork tilt Yellow Forks tilted back strongly

Back strongly

Forks tilted back Yellow Forks tilted back slightly

slightly

Fork tilt horizontal Yellow Forks horizontal

Forks tilted froward Yellow Forks tilted forward slightly

slightly

Fork tilt Yellow Forks tilted forward strongly

Forward strongly

u
ÿ14
Sideshifter centred Green
Yellow
Sideshifter centred

Sideshifter not centred

Lift limit switch Green Lift cutout overridden

Yellow Lift cutout introduced

Particle Filter Yellow Continued travel possible

&
—
H -H
(DFG) If the indicator lamp does not go out,
contact the service department
Red Power reduction
Stop using the truck
Park the truck securely
Contact Customer Service
Coolant Yellow Coolant level too low
Check coolant level, top up if necessary.

Charge current Red Battery not charging.

ÿ
Air filter control Yellow Replace air filter

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0 H
Engine indicator
light
Red Error in engine controller or in engine
components

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 Symbol Meaning Colour Function
Engine oil pressure Red Engine oil pressure too low. Switch off
display engine immediately. Operation with error
message can result in engine damage.
Engine oil level Red Engine oil level too low. Add engine oil.
Operation with error message can result
in engine damage.
Engine cover Yellow Open the engine cover

B opened

Door opened Yellow Door open

Si Operating White Operating temperature not yet reached

j- temperature
Red Overtemperature detected, engine
performance reduced.
Pre-heat indicator Yellow Engine (DFG only) preheated
w lamp

Bucket equipment White Bucket mode activated

Lp - Bucket mode can be activated by
Customer Services in operating
program 1
- When you select operating program 1
with bucket mode activated, the bucket
operation symbol appears, see
"Operating Programs" on page 65.

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 2.6 Armrest Control Panel Switch

Symbol Function
Work lights

c Travel light/ auxiliary spotlights

Beacon / strobe light

TT
Front window wipers

P7 - Press once > button flashes green - intermittent

- Press twice > button lit green - permanent operation
- Press three times > off
- Hold down on the button > Switch on the window washer
system
Rear windscreen wiper
- Press once > button flashes green - intermittent
1
- Press twice > button lit green - permanent operation
- Press three times > off

- Hold down on the button > Switch on the window washer

system
Rear window heating
A
-,
<
Parking brake button
a
i
Secure truck parking
FN button
FN Press the FN button. Assignment of buttons display changes to
auxiliary options.

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 NOTE
Not all buttons are assigned. Button assignment depends on the truck's equipment.

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 2.7 Operating Programs

Operating program Function

Operating program 1 - Significantly reduced travel speed
- Slow response
- Consumption-optimised speed pattern
- Significantly reduced lift speed

- Special parameter setting possible:

- Bucket equipment
- Pre-tension (for starting on inclines)
Operating program 2 - Reduced travel speed
- Slow response
- Consumption-optimised speed pattern
- Reduced lift speed
Operating program 3 - Maximum travel speed
- Rapid response
- Consumption-optimised speed pattern
- Slightly reduced lift speed
Operating program 4 - Maximum forward travel speed
- Slightly reduced reverse travel speed
- Rapid response
- Performance-optimised speed pattern
- Slightly reduced lift speed
Operating program 5 - Maximum forward travel speed
- Maximum reverse travel speed
- Rapid response
- Performance-optimised speed pattern
- Maximum lift speed

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3 Preparing the Truck for Operation
3.1 Checks and Operations to Be Performed Before Starting Daily Work

A WARNING!
Damage and other truck or attachment (optional equipment) defects can result
in accidents.
If damage or other truck or attachment (optional equipment) defects are discovered
during the following checks, the truck must be taken out of service until it has been
repaired.
ÿ Report any defects immediately to your supervisor.
ÿ Mark defective truck and take out of service.
ÿ Do not return the industrial truck to service until you have identified and rectified the
fault.

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 112

A CAUTION!
Checking the accelerator pedal
ÿ The accelerator pedal should only be checked when the parking brake is applied
and the engine is idle.

Checks before daily operation

Procedure
' Visually inspect the entire truck (in particular wheels, wheel bolts and load handler)
for damage.
• Check the roof window for cracks or other damage.
If damaged, the roof window must be replaced immediately by the manufacturer's
customer service department. The truck must not be used until it is repaired.
Check that the load chains are evenly tensioned.
ÿ

• Check that the capacity plate and warning labels are legible, see "Identification
Points and Data Plates" on page 31 .
Test the controls and displays.
ÿ

• Check the fork stop (111) and fork retainer mechanism (112).
@ Depending on the fork carriage the forks retainer mechanism (112) will be via bolts
(85 Nm) or welded stops.
• Visually inspect the hydraulic system in the visible area for damage and leaks.
• Test the horn and reversing buzzer (O) where applicable.
• Check other particular equipment as necessary, e.g. buzzer etc.
• Test the steering.
• Check the steer angle display (O), turn the steering wheel in both directions as far
as the stop and check that the wheel position is displayed on the control panel.
• Check the driver's seat has been adjusted to the correct position.
• Check the seat belt, see "Seat Belt" on page 77.
• Test the seat switch: when the driver's seat is vacated it should not be possible to
activate the working hydraulics.
• Test the restraint system (O),
w • Test the Drive Control (O):
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 • Raise the fork carriage without load beyond the reference point on the mast. The
slow travel symbol lights up in the display.
• Slowly apply the accelerator pedal on a clear route with good visibility. The
maximum speed should be reduced to walking pace (approx. 3km/h).
• Test the lift/lower, tilt hydraulic functions and if applicable the attachment.
• Check the accelerator pedal can move freely while the parking brake is applied
(parking brake symbol (114) lit red) and the truck is idling, by pressing it several
times.

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ÿ
Test the service brake, emergency stop brake and parking brake button (113):
Approach carefully and test the effectiveness of the brake pedal.
» Check the fuel supply.

• Check the fluid level of the windscreen washer system (O), see "Adding window
washer system fluid" on page 222.
ÿ
Check the gas system is working correctly, see "LPG containers" on page 48.
• Test the LPG system relief valve, see "LPG system relief valve" on page 45.

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 3.2 Entry and exit

Procedure
• Open the cab door (O).
• To enter and exit the cab, hold onto the
handle (115). Always face the truck when
entering and exiting.

a Always use the entry aid (115) provided to

climb onto the truck.
a An additional step is provided for the driver
position extension (O).
@ Split door (O), see page 142.

3.3 Trucks with reduced headroom (O)

A WARNING!
An unsuitable workplace can damage
your health
Failure to observe the recommended body
size can cause stress and endanger the
operator and may lead to lasting ill health
due to an unhealthy posture and excessive
strain on the operator.
ÿ The operating company must ensure
that truck operators do not exceed the
maximum body size indicated.
ÿ The operating company must check that
Ml max.
the operators can sit in a normal and
upright position without having to strain. Ill A
II mm
II i

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3.4 Setting up the operator position

A WARNING!
Accidents can occur if the driver's seat, steering column and armrest are not
engaged
The driver's seat, steering column and armrest can accidentally adjust during travel
and therefore cannot be operated safely.
ÿ Do not adjust the driver's seat, steering column or armrest while travelling.

Procedure
• Before starting to travel, adjust the driver's seat, steering column and armrest (if
necessary) so that all the controls are within reach and can be applied without
having to strain.
• Adjust the visibility aid equipment (mirrors, camera systems etc. ) so that the working
environment can be clearly seen.

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 3.4.1 Adjusting the driver's seat

A WARNING!
Risk of accidents and damage to health
An unsecured or incorrectly adjusted driver's seat can result in accidents or damage
to health.
ÿ Do not adjust the driver's seat while travelling.
ÿ The driver's seat should lock in position after adjustment.
ÿ Check and, if necessary, adjust the individual seat setting and driver's weight setting
before starting up the truck.

Adjusting the seat position

Procedure
ÿ
Sit on the driver's seat.
• Pull up the driver's seat locking lever (1 18) in the
direction of the arrow.
• Push the driver's seat forwards or backwards to
the desired position.
• Engage the driver's seat locking lever (118) in
position.
The seat position is now correctly set.
118 119
Adjusting the driver's weight

NOTE
Incorrectly adjusted seat cushioning can damage your health
To achieve optimal seat damping, the driver's seat must be adjusted according to the
driver's weight.
Set the driver's weight when the seat is occupied.
ÿ Hold the weight setting lever only by the recess, do not reach through underneath
the lever.

Procedure
• Fold out the weight adjustment lever (116) as far as it will go in the arrow direction.
• Move the weight adjustment lever (116) up and down to set the seat to a higher
weight.
• Move the weight adjustment lever (116) up and down to set the seat to a lower
weight.
@ The driver's weight is correct when the arrow is in the middle of the display window
(117). The minimum or maximum weight setting is reached when you can feel a
return stroke on the lever.
• After setting the weight, move the lever (116) back in full.
The driver's weight is now set.
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 117 1
Adjusting the backrest

Procedure
• Sit on the driver's seat.
ÿ
Pull the lever (1 19) to adjust the backrest.
• Adjust the backrest tilt.
• Release the lever (119) again. The backrest is
locked.
The backrest is now set.

Hold the weight setting lever (116) only by the 118 119
recess, never reach through underneath the
lever.

Driver's seat with pneumatic weight adjustment

(MSG 75) (O) 117

Procedure
• Pull the weight adjustment lever (116) up to set the
seat to a higher weight.
• Push the weight adjustment lever (116) down to set
the seat to a lower weight.
The driver's weight is correct when the arrow is in the middle of the display window
(117).

117 116
Adjusting the lumbar support (O)

Procedure
• Turn the hand wheel (120) to the
required position.
Position 0 = no warping in lumbar
vertebrae area.
Position 1 = increasing warping in upper
lumbar vertebrae area.
Position 2 = increasing warping in lower
lumbar vertebrae area.
The lumbar support is now set. 119 120

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 Switching the seat heating on and off
(O)
Procedure
• Press the seat heating switch (121).
Switch setting 1 = Seat heating on.
Switch setting 0 = Seat heating off.

121 120

Adjusting the backrest extension (O)

A CAUTION!
Accident risk when adjusting the
backrest during travel
ÿ Do not adjust the backrest extension
while travelling.

Procedure
» The backrest extension height can be

adjusted by changing the detent.

• Pull the backrest up and lock it in place
to extend the backrest.
• Push the backrest down and lock it in place to shorten the backrest.

/ >
Adjusting the swivel seat (O)

Procedure
Pull the locking lever (122) back while \
simultaneously turning the seat to the
required position.
• Engage the lock.
The swivel seat is not adjusted and
locked in position.
s Operate the truck only when the
swivel seat is locked in position.
122

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3.4.2 Adjusting the steering wheel / steering column
Individual steering wheel position
@ The steering wheel can be height- and tilt-adjusted to suit the operator.

Procedure
• Pull the steering wheel adjusting lever ÿ ft
(126) in the direction of the arrow (124).
ÿ
Set the steering wheel (7) to the required
position (height and tilt).
• Push the steering wheel adjusting lever
(123) in the direction of the arrow.

Setting the steering column to the

parking position
123
0 The steering column can be moved
forward to the parking position using the
steering column / engine bonnet release
lever (127). The individual steering wheel
position remains intact.
Procedure
• Hold the steering column (125) against the
steering wheel (7).
a It will be under spring tension when the
steering column / engine bonnet release
\>
lever (127) is released.
• Pull the steering column / engine bonnet 5
release lever (127) in the direction of the arrow (124) towards the driver's seat until
the steering column moves forward.
• Move the steering column (125) forward as far as the stop and let go of the release
lever.
• When resuming work, pull the steering column on the steering wheel in the direction
of the arrow (124) towards the driver's seat until you feel it engage.

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 3.4.3 Adjusting the arm rest

Adjusting the Armrest

Procedure
• Press the lock (129) and hold it in this position.
• Move the armrest (128) vertically and horizontally.
• Release the lock (129) at the desired position.
• Push the armrest (128) slightly forward or back until it locks in position.
The armrest is now positioned.

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3.4.4 Adjusting the armrest

Adjusting the armrest

Procedure
• Fold up the armrest (128).
• Set the height adjuster (130) to the desired position (high/low).
• Fold the armrest (128) down.

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 3.5 Seat Belt

A WARNING!
Travelling without a seat belt increases the risk of injury.
Accidents or personal injury can result if the seat belt is not worn or is modified.
ÿ Always put the seat belt on before starting the industrial truck.
ÿ Do not modify the seat belt.
ÿ Damaged or non-operational seat belts must be replaced by trained personnel.
ÿ Seat belts must always be replaced after an accident.
ÿ Only original spare parts must be used for retrofits or repairs.
ÿ Report any defects immediately to your supervisor.
ÿ Remove the truck from service until a functional seat belt has been fitted.

*1 Protect the seat belt from contamination (e.g. cover it when the truck is idle) and
clean it regularly. Frozen belt locks or pulleys must be thawed out and dried to
prevent them from freezing up again.
The temperature of the warm air should not exceed +60 °C!
Starting the industrial truck on steep slopes

The automatic blocking system locks the belt in the retractor when the truck is
positioned on a steep slope. This prevents the belt from being pulled out of the
retractor.
Carefully drive the truck off the slope and then put on the belt.
Checking the seat belt

Procedure
• Check the attachment points for wear and damage.
ÿ
Check the cover for damage.
ÿ
Pull the belt out fully from the retractor and check for damage (loose seams, fraying
and nicks).
• Test the belt buckle and make sure the belt returns correctly into the retractor.

Check the automatic locking system

Procedure
» Park the truck on a level surface.

ÿ
Jerk the seat belt out suddenly.
The locking system should prevent the belt from coming out.
The seat belt has now been checked.

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4 Industrial Truck Operation
4.1 Safety regulations for truck operation

A WARNING!
Risk of accidents from magnetic fields
Electronic components can be affected or damaged by external magnetic fields. This
can lead to malfunctions or accidents.
ÿ Do not use or keep magnets or clamping magnets in the immediate vicinity of the
controls.

Travel routes and work areas

Only use lanes and routes specifically designated for truck traffic. Unauthorised third
parties must stay away from work areas. Loads must only be stored in places specially
designated for this purpose.
The truck must only be operated in work areas with sufficient lighting to avoid danger
to personnel and materials. Additional equipment is necessary to operate the truck in
areas of insufficient lighting.

A DANGER!
Do not exceed the permissible surface and point loading on the travel lanes.
At blind spots get a second person to assist.
The driver must ensure that the loading dock /dock leveller cannot be removed or
come loose during loading/unloading.

NOTE
Loads must not be deposited on travel or escape routes, in front of safety mechanisms
or operating equipment that must be accessible at all times.

Travel conduct

The operator must adapt the travel speed to local conditions. The truck must be driven
at slow speed when negotiating bends or narrow passageways, when passing
through swing doors and at blind spots. The operator must always observe an
adequate braking distance between the forklift truck and the vehicle in front and must
be in control of the truck at all times. Abrupt stopping (except in emergencies), rapid
U turns and overtaking at dangerous or blind spots are not permitted. Do not lean out
or reach beyond the working and operating area.

Do not use a mobile phone or walkie-talkie without a handsfree device while operating
the truck.

Hazardous situations

If the truck is about to tip over, do not loosen the seat belt. The operator must not jump
off the truck. The operator must lean his upper body over the steering wheel and hold
on with both hands. Tilt your body in the opposite direction of fall. z

78
 Travel visibility

The operator must look in the direction of travel and must always have a clear view of
the route ahead. If the truck is carrying loads that affect visibility, the truck must travel
against the load direction. If this is not possible, a second person must walk alongside
the truck as a lookout to observe the travel route while maintaining eye contact with
the operator. Proceed only at walking pace and with particular care. Stop the truck as
soon as you lose eye contact.
Negotiating slopes and inclines

Negotiating slopes and inclines up to 15% is only permitted if they are specifically
designed as travel routes, are clean and have a non-slip surface and providing they
can be safely travelled along in accordance with the truck's technical specifications.
The truck must always be driven with the load facing uphill. The industrial truck must
not be turned, operated at an angle or parked on inclines and slopes. Inclines must
only be negotiated at slow speed, with the driver ready to brake at any moment.
Particular care is required when travelling near slopes and quay walls.

Negotiating lifts, loading ramps and docks

Lifts may only be negotiated if they have sufficient capacity, are suitable for driving on
and authorised for truck traffic by the owner. The driver must satisfy himself of the
above before entering these areas. The truck must enter lifts with the load in front and
must take up a position which does not allow it to come into contact with the walls of
the lift shaft. Persons riding in the lift with the forklift truck must only enter the lift after
the truck has come to a rest and must leave the lift before the truck. The driver must
ensure that the loading ramp / dock cannot move or come loose during loading /
unloading.

Type of loads to be carried

The operator must make sure that the load is in a satisfactory condition. Loads must
always be positioned safely and carefully. Use suitable precautions to prevent parts
of the load from tipping or falling down. Prevent liquid loads from sloshing out.

Inflammable liquids (e.g. molten metal etc.) may only be transported with suitable
auxiliary equipment. Contact the manufacturer's customer service department.

For safety instructions on the nature of loads to be carried with attachments, see
"Lifting, transporting and depositing loads" on page 97.

Towing trailers

The truck may only be used occasionally to tow trailers, see "Towing trailers" on
page 121

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 S DANGER!
Exhaust emissions can be fatal
ÿ The truck must only be operated in well ventilated areas. If the truck is operated in
enclosed areas, this can lead to a build-up of harmful exhaust emissions, resulting
in dizziness, tiredness and even death.
ÿ The operator must comply with legal requirements, technical standards and health
and safety regulations when operating an IC motor powered lift truck in closed
rooms.

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 4.2 Preparing the truck for operation

a The truck should only be operated from the

driver's seat. Do not run up the engine in
idle. The engine soon reaches operating
temperature at a moderate charge and
when the speed alternates. Load the engine
fully only when it has reached operating
temperature.

Switching on the truck

Requirements
-For checks and operations to be performed
before starting daily operation, see "Checks
and Operations to Be Performed Before
Starting Daily Work" on page 66.

Procedure
• Unlock the Emergency Disconnect switch (86), see page 85.

4.2.1 Key switch

0 The key switch has 4 settings. 85

Switch setting Function

0 Switching off the truck
I Not used
II Switch on power supply
III Start the engine

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4.3 Starting procedure for the DFG

Procedure 85
• Insert the key in the key switch (85). Set
key switch to "II".
0 The pre-heat symbol (133) lights up and
goes out automatically as soon as the
required pre-heat time (approx. 4
seconds) has been reached.
0 Keyless access systems (O), see
page 123 .
0 Engine oil pressure (134), parking 114 131
brake (114), seat switch (131) and
charge current (132) symbols light up.
ÿ
Using the key, set the key switch (85) to
"III" to apply the starter.
0 The key switch sends a pulse to the E
box. The E box activates the starter either
until the engine starts, or for a maximum
of 20 seconds.
• Release the key. The key switch
automatically reverts to the "II" position.
0 The charge current (132) and engine oil 132133134
pressure (134) symbols should go out
after the engine starts. If not, stop the engine immediately and rectify the fault.
• Test the brake pedal and parking brake button (113).
Truck is operational.

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 4.4 Starting procedure for the TFG

A DANGER!
Risk of escaping liquid gas if the truck does not start
ÿ Note the safety regulations governing the handling of liquid gas
(see "Safety regulations for handling diesel fuel and LPG" on page 43)
ÿ Close the gas bottle shut-off valve.
ÿ Set the key switch to "0"
ÿ Notify your superior.

Procedure
• Slowly open the shut-off valve on the
LPG bottle, see "LPG bottles" on
page 48.
• Insert the key in the key switch (85). Set
key switch to "II".
0 Keyless access systems (O), see
page 123 .

0 Engine oil pressure (134), parking

brake (114), seat switch (131) and
charge current (132) symbols light up.
ÿ
Using the key, set the key switch (85) to
"III" to start the engine.
0 The key switch sends a pulse to the E
box. The E box activates the starter either
until the engine starts, or for a maximum
of 20 seconds.
• Release the key. The key switch
automatically reverts to the "II" position.
0 The charge current (132) and engine oil
pressure (134) symbols should go out
after the engine starts. If not, stop the engine immediately and rectify the fault.
• Test the brake pedal and parking brake button (113).
Truck is operational.

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4.5 Parking the truck securely

A WARNING!
Switching off an LPG truck under ground level areas could result in explosions.
LPG is heavier than air. An explosive LPG/air mixture could therefore form under
ground level areas without sufficient ventilation.
ÿ LPG trucks may only be switched off in ground level rooms or higher and providing
they are adequately ventilated. They must not be switched off near to cellar doors
and entry points, hollows, drains, drain inlets or other recesses below the parked
truck.

A WARNING!
An unsecured truck can cause accidents
Parking the truck on an incline, without the brakes applied or with a raised load / load
handler is dangerous and is strictly prohibited.
ÿ Always park the truck on a level surface. In special cases the truck may need to be
secured with wedges.
ÿ Always fully lower the mast and load handler.
ÿ Tilt the mast forward.
ÿ Always apply the parking brake button before parking the truck.
ÿ Choose a place to park where no other people are at risk of injury from lowering
forks.
ÿ Do not park and abandon a truck on an incline.

Parking and leaving the truck

Procedure
• Lower the load handler.
• Tilt the mast forward.
• Turn the key in the key switch (85) to the
"0" position.
• Remove the key from the key switch (85).
EE] Keyless access systems (O), see
page 123 .
• Press the Emergency Disconnect switch
(86).
• Close the shutoff valve on LPG bottles and on the LPG tank (TFG only).

a TFG only: If the key is set to "0" while the engine is running, the engine will continue
to run for a short time. This ensures that the remaining gas in the lines between the
engine and the automatic shutoff valve of the LPG system is used up. If the engine
has accidentally switched off, start up the engine and switch it off again in the
correct manner at the end of the journey.

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 4.6 Emergency Disconnect

A CAUTION!
Applying maximum braking can result in accidents
Applying the Emergency Disconnect switch during travel will cause the truck to
decelerate to a halt at maximum force. This may cause the load to slide off the load
handler. There is a higher risk of accidents and injury.
ÿ Do not use the Emergency Disconnect switch as a service brake.
ÿ Use the Emergency Disconnect switch during travel only in emergencies.

A CAUTION!
Faulty or non-accessible Emergency Disconnect switches can cause accidents
A faulty or non-accessible Emergency Disconnect switch can cause accidents. In
dangerous situations the operator cannot bring the truck to a halt in time by applying
the Emergency Disconnect switch.
ÿ The operation of the Emergency Disconnect switch must not be affected by any
objects placed in its way.
ÿ Report any defects on the Emergency Disconnect switch immediately to your
supervisor.
ÿ Mark defective truck and take out of service.
ÿ Do not return the industrial truck to service until you have identified and rectified the
fault.

Applying the Emergency Disconnect

Procedure
• Press the Emergency Disconnect (86).
All travel, steering and hydraulic functions as
well as the IC engine are cut out. The truck
brakes to a halt at maximum brake force.

Unlocking the Emergency Disconnect

Procedure
» Turn the rotary button until the Emergency Disconnect switch (86) is unlocked.

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4.7 Travel

4.7.1 Single pedal

A WARNING!
Improper travel can result in accidents
ÿ Do not get up from the driver's seat during travel.
ÿ Do not drive the truck unless your are wearing a seat belt and the panels and doors
are properly locked.
ÿ Do not lean out of the truck while travelling.
ÿ Make sure that the travel area is clear.
ÿ Adapt your travel speed to the route conditions in the work area and the load.
ÿ Tilt the mast back and raise the fork carriage approx. 200 mm.
ÿ Make sure you have sufficient visibility when reversing.

P<? Po <fc O
113 o o
137 136 135

Travel

Requirements
- Truck prepared for operation, see "Preparing the truck for operation" on page 81 .
Procedure
• Release the parking brake, to do this press the parking brake button (113).
• Select the travel direction with the travel direction switch (96).
• Select the travel speed if necessary, to do this press the slow travel button (137) or
the program selector (136/135).
• Raise the load handler approx. 200 mm.
• Tilt the mast back.
ÿ
Apply the accelerator pedal (93). The travel speed is governed by the accelerator
(93).
The truck travels in the direction selected.

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 09.14 EN

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4.7.2 Twin pedal (O)
Requirements
- System prepared for operation, see "Preparing the
truck for operation" on page 81 o er>

Procedure
0 For trucks with a dual pedal the travel direction is
selected via the accelerator pedals (92;90). When
the driver leaves the truck, the truck is
automatically set to "Neutral".
ÿ
Release the parking brake, to do this press the
parking brake button (113).
» Raise the load handler approx. 200 mm.

• Tilt the mast back.

• Select the travel speed if necessary, to do this press the slow travel button (137) or
the program selector (136/135).
• Apply the accelerator pedal (92) to travel forward. The travel speed is governed by
the accelerator (92).
• Apply the accelerator pedal (90) to reverse. The travel speed is governed by the
accelerator (90).
The truck travels in the direction selected.

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 4.8 Steering

Steering

Procedure
a Very little steering effort is required; you
should therefore turn the steering wheel
(7) sensitively.
ÿ
To negotiate a right-hand bend: Turn the
steering wheel clockwise according to
the required steering radius.
ÿ
To negotiate a left-hand bend: Turn the
steering wheel anti-clockwise according
to the required steering radius.
The truck travels in the direction selected.

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4.9 Brakes

A WARNING!
Accident risk
The brake pattern of the truck depends largely on the ground conditions.
ÿ The operator must take into account the travel route conditions when braking.
ÿ Brake with care to prevent the load from slipping.
ÿ Allow for increased braking distance when travelling with an attached load.
ÿ Use the service brake in emergencies.

There are two ways of braking:

- Service Brake
- Emergency Stop
and for secure parking:
- Parking brake

4.9.1 Service Brake

In normal travel mode you brake by throttling back

using the accelerator pedal (90,93,92). The truck will
brake hydrostatically depending on the travel _ 'l (C5--.
program. This allows for sensitive metering of the
brake force. 91 93
s When the truck comes to a stop it is held by the J /
automatic parking brake and the automatic parking
brake symbol (114) is lit green. Applying the
accelerator pedal releases the automatic parking
brake.

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 4.9.2 Emergency stop brake

NOTE
When you apply the brake pedal (91) the full brake force is available.
ÿ The brake pedal should only be used for emergency braking.
ÿ When the brake pedal is applied the truck will brake irrespective of the position of
the accelerator pedal.
ÿ There is a higher risk of accidents and injury.
ÿ The operator must first familiarise himself with the emergency stop brake without
load and at low speed.

i/
L '
!
Emergency stop brake: "
/
Apply the brake pedal (91).
-i &
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J \

93
'T /

90

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4.9.3 Parking brake

A DANGER!
Accident risk
ÿ The parking brake will hold the truck with maximum load on a clean ground surface,
on inclines of up to 15%.
ÿ Do not park and abandon the truck on an incline.
ÿ Applying the parking brake during travel will cause the truck to brake to a halt at
maximum force. This may cause the load to slide off the forks. There is a greater
risk of accidents and injury.

Automatic parking brake

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Comfort feature, displayed when the green symbol on the automatic parking brake
indicator (114) lights up.
Truck prevented from rolling away but not parked securely. The truck will accelerate
when the accelerator pedal is applied. The automatic parking brake is released and
the green symbol of the automatic parking brake (114) goes out.

The automatic parking brake is automatically activated a set time (0 - 60 sec) after
the truck stops. The time setting can only be adjusted by the manufacturer's
customer service department.

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 Manual parking brake

Truck prevented from rolling away and parked securely. When the accelerator pedal
is applied the truck does not accelerate and the manual parking brake remains active.
a When the truck is switched on the manual parking brake is activated and travel is
disabled. The LEDs above the parking brake button (113) and the manual parking
brake red symbol (138) light up.

08 : 38a

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Po Ro- Mo O
113 o o o o o o

Activating the manual parking brake

Procedure
ÿ
Apply the parking brake button (113) .
a The LED above the parking brake button (113) lights up and the manual parking
brake red symbol (114) is displayed.
a Travel is disabled.
The manual parking brake is activated.

Deactivating the manual parking brake

Requirements
- Manual parking brake activated.

Procedure
• Apply the parking brake button (113) .
The LED above the parking brake button (113) lights up and the manual parking
brake red symbol (1 14) go out.
Travel is enabled.
Manual parking brake is deactivated.

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4.10 Setting the Time

r -A-
\
»y
08 ! 38am
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i
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pi

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I Eo Po Ro Cl) I
o o o o o o

A CAUTION!
ÿ Settings should only be made when the IC engine is switched off.

Setting the Time

Symbol Procedure
Press the button under the settings symbol.
)Q0 J
Press the button under the clock symbol.
|0|
[71 Use the arrow up key to change the time digit selected.

in Use the arrow down key to change the time digit selected.

Press the confirm key to move to the next digit or to confirm the

D time.

The time is now set.

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 4.11 Adjusting the forks

A WARNING!
Unsecured and incorrectly adjusted fork tines can cause accidents
Make sure the fork retaining mechanism (112) is fitted before adjusting the forks.
Depending on the fork carriage the fork retaining mechanism (112) will be either via
bolts (85 Nm) or welded stops.
ÿ Adjust the two fork tines so that they are equidistant from the outside edge of the
fork carriage.
ÿ Engage the locking pin in a groove to prevent the fork tines from moving
accidentally.
ÿ The load centre of gravity must be located centrally between the fork tines.

A WARNING!
Trapping hazard
There is a trapping hazard when you perform this operation.
ÿ Wear work gloves and safety shoes.

Adjusting the forks

Requirements
- Park the truck securely, see page 84.

Procedure
• Lift up the locking lever (138).
ÿ
Push the forks (139) into the correct position on the
fork carriage (140).
a To lift the load securely, the forks (139) must be spread as far apart as possible and
positioned centrally with respect to the fork carriage. The load centre of gravity must
be centrally aligned between the forks (139).
• Push the locking lever down (138) and move the forks until the locking pin engages
in a slot.
The forks are now adjusted.
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4.12 Replacing the forks

A WARNING!
Unsecured forks can cause injury
This is a risk of injury and trapping when replacing the forks.
ÿ Wear work gloves and safety shoes.
ÿ Never pull the forks towards your body.
ÿ Always push the forks away from your body.
ÿ Secure heavy forks with lifting slings and a crane before pushing them down from
the fork carriage.
ÿ After replacing the forks fit the retaining bolts (112) and make sure the bolts are
seated correctly (for fork carriages without welded stops).
ÿ Retaining bolt torque: 85 Nm.

Replacing the forks (fork carriages with

retaining bolts)

Requirements
- Load handler lowered and fork tines not
touching the ground. 5— 112
Procedure
• Disassemble the retaining bolts (112).
• Loosen the fork stop (111).
• Carefully push the fork tines off the fork carriage.
The fork tines are now dismantled from the fork carriage and can be replaced.

Replacing the forks (fork carriages with welded

stops)

Requirements
- Load handler lowered and fork tines not touching
the ground.

Procedure
• Loosen the fork stop (111).
• Carefully push the forks over the recess on the
lower cross beam of the fork carriage.
• Raise the fork tips and lift them out of the top guide.
The fork tines are now dismantled from the fork carriage and can be replaced.

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 4.13 Lifting, transporting and depositing loads

A WARNING!
Unsecured and incorrectly positioned loads can cause accidents.
Before lifting a load the operator must make sure that it has been correctly palletised
and does not exceed the truck's capacity.
ÿ Instruct other people to move out of the hazardous area of the truck. Stop working
with the truck if people do not leave the hazardous area.
ÿ Only carry loads that have been correctly secured and positioned. Use suitable
precautions to prevent parts of the load from tipping or falling down.
ÿ Do not transport loads other than on the authorised load handler.
ÿ Damaged loads must not be transported.
ÿ If the stacked load obscures forward visibility, then you must reverse the truck.
ÿ Do not exceed the maximum loads specified on the capacity plate.
ÿ Check the fork spread before lifting the load and adjust if necessary.
ÿ Insert the forks as far as possible underneath the load.

Lifting loads

Requirements
- Load correctly palletised.
- Fork spread for the pallet checked and adjusted if necessary.
- Load weight matches the truck's capacity.
- Forks evenly loaded for heavy loads.

Procedure
• Drive the truck carefully up to the pallet.
• Set the mast vertical.
• Slowly insert the forks into the pallet until the fork shank touches the pallet.
• Raise the load handler.
• Reverse carefully and slowly until the load is outside the storage area. Make sure
you have enough clear space to reverse into.

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 NOTE
Loads must not be deposited on travel or escape routes, in front of safety mechanisms
or operating equipment that must be accessible at all times.

Transporting loads

Requirements
- Load raised correctly.
- Load handler lowered for transport
(approx. 150 - 200 mm above the
ground).
- Mast tilted back fully.

Procedure
• On slopes and inclines always carry the
load facing uphill, never approach at an
angle or turn.
ÿ
Accelerate and decelerate with care.
• Adapt your travel speed to the conditions of the route and the load you are
transporting.
• Watch out for other traffic at crossings and passageways.
• Always travel with a lookout at blind spots.

Depositing loads

Requirements
- Storage location suitable for storing the load.

Procedure
ÿ
Set the mast vertical.
ÿ
Drive the truck carefully up to the storage location.
• Carefully lower the load handler so that the forks are clear of the load.
a Avoid depositing the load to prevent damage to the load and the load handler.
• Lowers the load handler.
• Carefully remove the forks from the pallet.
The load is deposited.

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 4.14 Operating the Lift Mechanism and Integrated Attachments

A WARNING!
Operating the lifting device and integrated attachments can be hazardous
Other people can be injured in the truck's hazardous area.
The hazardous area is defined as the area in which people are at risk from the truck
movement, the load handler, attachments etc. This also includes areas which can be
reached by falling loads or lowering operating equipment.
Apart from the operator (in the normal operating position) there should be no other
people in the truck's hazardous area.
ÿ Instruct other people to move out of the hazardous area of the truck. Stop working
with the truck if people do not leave the hazardous area.
ÿ If people do not leave the hazardous area despite the warning, prevent the truck
from being used by unauthorised people.
ÿ Only carry loads that have been correctly secured and positioned. Use suitable
precautions to prevent parts of the load from tipping or falling down.
ÿ Do not exceed the maximum loads specified on the capacity plate.
ÿ Do not stand underneath a raised load handler.
ÿ Do not stand on the load handler.
ÿ Do not lift other people on the load handler.
ÿ Do not reach through the mast.
ÿ The controls should only be operated from the driver's seat, and never suddenly.
ÿ The operator must be trained to handle the lift mechanism and the attachments.

A WARNING!
A non-centred load centre of gravity can result in accidents
The capacity of the truck is reduced when using sideshifters with a stroke greater than
100 mm.
ÿ Note the capacity plate with the reduced capacity.

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4.14.1 Operating the lifting device with the Solo-Pilot

S 94
Lifting and lowering

Requirements
- Truck prepared for operation, see page 81 .

Procedure
• Pull the lever (94) in direction H to raise the
load.
• Push the lever (94) in direction S to lower the
load.
The load is now raised or lowered.

a When the limit position for the operation has been reached (there will be a noise
from the pressure relief valve) release the lever. The lever will revert automatically
to neutral.

Tilting the mast forward/backward

A CAUTION!
Trapping hazard from inclined mast
ÿ Make sure no part of your body is between the
mast and driver's cab when tilting the mast
back.

Requirements
- Truck prepared for operation, see page 81 .

Procedure
• Pull the lever (94) in direction R to tilt the mast back.
Push the lever (94) in direction V to tilt the mast forward.
The mast is now tilted back or forward.

When the limit position for the operation has been reached (there will be a noise
from the pressure relief valve) release the lever. The lever will revert automatically
to neutral.

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 Positioning the integrated sideshifter 95
(option)

Requirements
- Truck prepared for operation, see page 81 .

Procedure
• Pull the lever (95) in direction R to move the
load handler to the right (from the driver's
viewpoint).
• Push the lever (95) in direction V to move the
load handler to the left (from the driver's
viewpoint).
The sideshifter is now positioned.

a When the limit position for the operation has been reached (there will be a noise
from the pressure relief valve) release the lever. The lever will revert automatically
to neutral.

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 Positioning the forks with an integrated fork
positioner (option)

A CAUTION!
Do not use the fork positioner to clamp
loads.

Requirements
- Truck prepared for operation, see page 81 .

Procedure
• Press the acknowledgement key (100) and
then within 2 seconds pull the lever (98) in direction H to bring the forks together.
ÿ
Press the acknowledgement key (100) and then within 2 seconds push the
lever (98) in direction S to move the forks apart.
The forks are now positioned.

Synchronising the forks on an integrated

fork positioner (optional equipment)

Requirements
- Truck prepared for operation, see page 81 .

- The fork tines are no longer aligned.

Procedure
Press the acknowledgement key (100) and
ÿ0
then within 2 seconds push the lever (98) in
direction S to move the forks apart as far as ÿ
the stop.
Press the acknowledgement key (100) and then within 2 seconds push the
lever (98) in direction H to move the forks together up to the stop.
The fork tines are now synchronised.

s When the limit position for the operation has been reached (there will be a noise
from the pressure relief valve) release the lever. The lever will revert automatically
to neutral.

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 4.14.2 Operating the Lift Mechanism with the MULTI-PILOT

Lifting and lowering

Requirements
- Truck prepared for operation, see
page 81.
Procedure
• Pull the MULTI-PILOT (94) in direction R
to raise the load.
• Push the MULTI-PILOT (94) in direction V
to lower the load.
The load is now raised or lowered.

a When the limit position for the operation has been reached (there will be a noise
from the pressure relief valve) release the lever. The lever will revert automatically
to neutral.

Tilting the mast forward/backward

A CAUTION!
Trapping hazard from inclined mast
ÿ Make sure no part of your body is
between the mast and driver's cab when
tilting the mast back.

Requirements
- Truck prepared for operation, see
page 81.

Procedure
• Push the MULTI-PILOT (94) in direction H to tilt the mast forward.
• Push the MULTI-PILOT (94) in direction S to tilt the mast back.
The mast is now tilted back or forward.

When the limit position for the operation has been reached (there will be a noise
from the pressure relief valve) release the lever. The lever will revert automatically
to neutral.

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 Positioning the integrated sideshifter (option)

Requirements 95
- Truck prepared for operation, see page 81 .

Procedure
' Press the button (95) to the left to move the load
handler to the left (from the driver's viewpoint).
• Press the button (95) to the right to move the load
handler to the right (from the driver's viewpoint).
The sideshifter is now positioned.

a When the limit position for the operation has been reached (there will be a noise
from the pressure relief valve) release the lever. The lever will revert automatically
to neutral.

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 Positioning the forks with an integrated
fork positioner (option)

A CAUTION!
Do not use the fork positioner to clamp
loads.

Requirements
- Truck prepared for operation, see page 81 .

Procedure
• Press the acknowledgement key (100) and then within 2 seconds push the fork
positioner lever (98) in direction V to move the forks apart.
ÿ
Press the acknowledgement key (100) and then within 2 seconds pull the fork
positioner lever (98) in direction R to bring the forks together.
The forks are now positioned.

Synchronising the forks on an integrated

fork positioner (optional equipment)
98-
Requirements
- Truck prepared for operation, see page 81 . 100
- The fork tines are no longer aligned.
Procedure
Press the acknowledgement key (100) and /
then within 2 seconds push the fork \
positioner lever (98) in direction V to move
the forks apart as far as the stop.
Press the acknowledgement key (100) and then within 2 seconds push the fork
positioner lever (98) in direction R to move the forks together up to the stop.
The fork tines are now synchronised.

S When the limit position for the operation has been reached (there will be a noise
from the pressure relief valve) release the lever. The lever will revert automatically
to neutral.

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4.14.3 Operating the Lift Mechanism with the Duo-Pilot

Lifting and lowering

Requirements
- Truck prepared for operation, see
page 81.

Procedure
ÿ
Pull the lever (94) in direction R to raise
the load.
• Push the lever (94) in direction V to
lower the load.

The load is now raised or lowered.

a When the limit position for the operation has been reached (there will be a noise
from the pressure relief valve) release the lever. The lever will revert automatically
to neutral.

Tilting the mast forward/backward

A CAUTION!
Trapping hazard from inclined mast
ÿ Make sure no part of your body is
between the mast and driver's cab when
tilting the mast back.

Requirements
-Truck prepared for operation, see
page 81.

Procedure
• Push the lever (94) in direction H to tilt the mast forward.
• Pull the lever (94) in direction S to tilt the mast back.
The mast is now tilted back or forward.

When the limit position for the operation has been reached (there will be a noise
from the pressure relief valve) release the lever. The lever will revert automatically
to neutral.

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 Positioning the integrated sideshifter
(option)

Requirements
- Truck prepared for operation, see
page 81.
Procedure
• Pull the lever (95) in direction S to move
the load handler to the left (from the
driver's viewpoint).
• Push the lever(95) in direction H to move
the load handler to the right (from the driver's viewpoint).
The sideshifter is now positioned.

a When the limit position for the operation has been reached (there will be a noise
from the pressure relief valve) release the lever. The lever will revert automatically
to neutral.

Positioning the forks with an integrated

fork positioner (option)

A CAUTION!
Do not use the fork positioner to clamp
loads.

Requirements
- Truck prepared for operation, see
page 81.

Procedure
ÿ
Press the acknowledgement key (100) and then within 2 seconds pull the lever (98)
in direction R to bring the forks together.
ÿ
Press the acknowledgement key (100) and then within 2 seconds push the
lever (98) in direction V to move the forks apart.
The forks are now positioned.

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 Synchronising the forks on an
integrated fork positioner (optional
equipment) 98

Requirements
- Truck prepared for operation, see
"Preparing the truck for operation" on
page 81 .
- The fork tines are no longer aligned.
100
Procedure
• Press the acknowledgement key (100)
and then within 2 seconds push the lever (98) in direction R to move the forks
together up to the stop.
» Press the acknowledgement key (100) and then within 2 seconds push the

lever (98) in direction V to move the forks apart as far as the stop.
The fork tines are now synchronised.

When the limit position for the operation has been reached (there will be a noise
from the pressure relief valve) release the lever. The lever will revert automatically
to neutral.

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 4.15 Safety instructions for operating additional attachments
a Optionally, trucks can be fitted with one or more auxiliary hydraulic functions to
operate attachments. The auxiliary hydraulics are indicated with ZH1 and ZH2.
Auxiliary hydraulic functions for exchangeable equipment are fitted with
replacement couplings on the fork carriage. To fit exchangeable equipment see
"Fitting additional attachments" on page 118.

A DANGER!
Attaching exchangeable equipment can result in accidents.
Other people can be damaged by attaching exchangeable equipment. Use only
exchangeable equipment which has been deemed safe after a risk analysis carried
out by the owner.
ÿ Only use attachments with a CE mark.
ÿ Only use attachments that have been designed by the attachment manufacturer for
use with the respective industrial truck.
ÿ Only use attachments that have been fitted for the purpose by the owner.
ÿ Make sure the operator has been instructed in the use of the attachment and that
he uses it for its correct purpose.
ÿ Re-assess the residual capacity of the truck and if it has been altered, attach an
additional capacity plate to the truck.
ÿ Note the attachment manufacturer's operating instructions.
ÿ Only use attachments that do not restrict visibility in the travel direction.

If visibility in the travel direction is impaired, the operating company must determine
and apply suitable measures to ensure the safe operation of the truck. A lookout
may have to be used or certain hazardous areas may have to be cordoned off. The
truck can also be equipped with optional visual aids such as a camera system or
mirrors. Travelling with visual aids requires plenty of practice at slow speed.

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 Safety instructions for sideshifter and fork positioner attachments

A WARNING!
Restricted visibility and reduced tilt resistance can cause accidents
When using sideshifters and fork positioners, the change in centre of gravity can result
in reduced lateral tilt resistance and accidents. Note that this affects visibility as well.
ÿ Adapt the travel speeds to the visibility and load.
ÿ Make sure you have sufficient visibility when reversing.

Safety instructions for clamping attachments (e.g. baling clamps, barrel

clamps, grabs, etc.)

A WARNING!
Falling loads can cause accidents
Operating errors can occur and the load can fall accidentally.
ÿ Clamping attachments may only be added to trucks which have a button to enable
additional hydraulic functions.
ÿ Clamping attachments must only be operated on trucks will auxiliary hydraulics ZH1
or ZH2 or ZH3.
ÿ When connecting the attachment make sure that the hydraulic lines of the
attachment are connected to the right connections, see "Fitting additional
attachments" on page 118.

Safety instructions for rotary attachments

A WARNING!
A non-centred load centre of gravity can result in accidents
When using rotary devices and non-centred loads, the centre of gravity can be
displaced from the centre with a high risk of accidents.
ÿ Adapt the travel speed to the load.
ÿ Lift the load from the centre.

Safety instructions for telescopic attachments

A WARNING!
Accident risk from increased tipover hazard and reduced residual capacity
There is a greater risk of tipover with extended telescopic attachments.
ÿ Do not exceed the maximum loads specified on the capacity plate.
ÿ Only use the telescopic function for stacking and retrieving.
ÿ Retract the telescopic attachment fully during transport.
ÿ Adapt the travel speed to changed load centre of gravity.

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 Safety instructions for attachments when transporting suspended loads

A WARNING!
Swinging loads and a reduced residual capacity can result in accidents.
Transporting hanging loads can reduce the stability of the truck.
ÿ Adapt the travel speed to the load, less than walking pace.
ÿ Secure swinging loads for example with lifting slings.
ÿ Reduce the residual capacity and have it certified by a expert.
ÿ If the truck is to be operated with hanging loads, proof of sufficient safety distance
under local operating conditions must be obtained from a specialist assessor.

Safety instructions for using loading buckets as attachments

A WARNING!
Increased mast loading can cause accidents.
ÿ When carrying out the daily checks and operations before starting, see "Checks and
Operations to Be Performed Before Starting Daily Work" on page 66, check in
particular check the fork carriage, mast rails and mast rollers for damage.

Fork extension safety instructions

A WARNING!
Unsecured and oversized fork extensions can cause accidents.
ÿ For fork extensions with an open cross sectional area, carry only loads that are
resting along the entire length of the fork extension.
ÿ Use only fork extensions with the same fork cross section and minimum fork length
of the truck and which comply with the details on the fork extension data plate.
ÿ The basic fork length must be at least 60% of the length of the fork extension.
ÿ Lock the fork extensions onto the basic forks.
ÿ When carrying out the daily checks and operations before starting, see "Checks and
Operations to Be Performed Before Starting Daily Work" on page 66, check also the
fork extension lock.
ÿ Mark any fork extensions with an incomplete or faulty lock and take them out of
service.
ÿ Do not use trucks with an incomplete or faulty fork extension lock. Replace the fork
extension.
ÿ Only restore the fork extension to service when the fault has been rectified.
ÿ Use only fork extensions which are free of dirt and foreign bodies near the entry
opening point. Clean the fork extensions as required.

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4.16 Operating additional attachments for the SOLO-PILOT

A WARNING!
Incorrect symbols can cause accidents
Symbols on controls that do not depict the function of the attachments can cause
accidents.
ÿ Mark the controls with symbols that indicate their function.
ÿ Specify the attachments' direction of movement in accordance with ISO 3691-1 so
that they match the controls' direction of movement.

4.16.1 Solo Pilot with control of ZH1 hydraulic port

a Depending on the attachments used the

lever (95) is assigned the function of the
attachment. Unused levers have no
function. For connections see "Fitting
additional attachments" on page 118.

Procedure
• Operating hydraulic port ZH1 :
Move the lever (95) in direction V or R.
The attachment performs its operation.

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 4.16.2 Solo Pilot with control of ZH1 and ZH2 hydraulic ports

0 Depending on the attachments used 98 V

the lever / button (95, 98, 100) is
assigned the function of the
attachment. Unused levers have no
function. For connections see
"Fitting additional attachments" on
page 118.
100
Procedure
• Operating hydraulic port ZH1 :
Move the lever (95) in direction V or
R.
• Operating hydraulic port ZH2:
Press the acknowledgement key (100) and then within 2 seconds move the
lever (98) in direction V or R.
The attachment performs its operation.

4.16.3 Solo Pilot with control of ZH1, ZH2 and ZH3 hydraulic ports

a Depending on the attachments

used the levers / buttons (95, 98,
100, 99) are assigned the
respective functions. Unused
levers have no function. For
connections see "Fitting
additional attachments" on
page 118. 100

Procedure
ÿ
Operating hydraulic port ZH1 :
Move the lever (95) in direction V
or R.
ÿ
Operating hydraulic port ZH2:
Move the lever (98) in direction V or R.
• Operating hydraulic port ZH3:
Apply the toggle switch (99), press the acknowledgement key (100) and then within
2 seconds move the lever (98) in direction V or R.
• Now pull the toggle switch (99).

The attachment performs its operation.

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4.17 Operating additional attachments for the Multi Pilot

A WARNING!
Incorrect symbols can cause accidents
Symbols on controls that do not depict the function of the attachments can cause
accidents.
ÿ Mark the controls with symbols that indicate their function.
ÿ Specify the attachments' direction of movement in accordance with ISO 3691-1 so
that they match the controls' direction of movement.

4.17.1 Multi Pilot with control of ZH1 hydraulic port

a Depending on the attachments used the (95)

button is assigned the function of the attachment.
Unused levers have no function. For connections 95
see "Fitting additional attachments" on page 118.

Procedure
• Operating hydraulic port ZH1 :
Press the (95) button to the left or right.
The attachment performs its operation.

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 4.17.2 Multi Pilot with control of ZH1 and ZH2 hydraulic ports

0 Depending on the attachments used the

98
lever / button (98,94,95) is assigned the 94
function of the attachment. Unused levers 95
have no function. For connections see 100
"Fitting additional attachments" on
page 118.

Procedure
• Operating hydraulic port ZH1 :
Press the (95) button to the left or right.
* Operating hydraulic port ZH2:
Press the acknowledgement key (100) and then within 2 seconds push the
lever (98) in direction V or pull it in direction R.
The attachment performs its operation.

4.17.3 Multi Pilot with control of ZH1, ZH2 and ZH3 hydraulic ports

0 Depending on the attachments used the

levers / buttons (94, 95, 99, 100) are
assigned the respective functions. Unused
levers have no function. For connections
see "Fitting additional attachments" on
page 118.

Procedure
• Operating hydraulic port ZH1 :
Press the (95) button to the left or right.
• Operating hydraulic port ZH2:
Push the lever (98) in direction V or pull it in direction R.
• Operating hydraulic port ZH3:
Push the toggle switch (99), press the acknowledgement key (100) and within 2
seconds move the lever (98) to the left or right.
• Now pull the toggle switch (99).
The attachment performs its operation.

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4.18 Operating additional Attachments for Duo-Pilot

A WARNING!
Incorrect symbols can cause accidents
Symbols on controls that do not depict the function of the attachments can cause
accidents.
ÿ Mark the controls with symbols that indicate their function.
ÿ Specify the attachments' direction of movement in accordance with ISO 3691-1 so
that they match the controls' direction of movement.

4.18.1 Duo-Pilot with control ofZH1 hydraulic port

a Depending on the attachments used the

lever (95) is assigned the function of the
attachment. Unused levers have no
function. For connections see "Fitting
additional attachments" on page 118.

Procedure
• Operating hydraulic port ZH1 :
Press the lever (95) in direction S or H.
The attachment performs its operation.

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 4.18.2 Duo-Pilot with Control ofZH1 and ZH2 Hydraulic Ports

0 Depending on the attachments used the

lever / button (95,98,100) is assigned
the function of the attachment. Unused
levers have no function. For
connections see "Fitting additional
attachments" on page 118.

Procedure
Operating hydraulic port ZH1 :
Push the lever (95) in direction V or R. 100
Operating hydraulic port ZH2:
Press the acknowledgement key (100)
and then within 2 seconds pull the lever(98) in direction H or push it in direction S.
The attachment performs its operation.

4.18.3 Duo-Pilot with control of ZH1, ZH2 and ZH3 hydraulic ports

0 Depending on the attachments used

95/98
the levers / buttons (95,98,99,100)
are assigned the respective
functions. Unused levers have no
function. For connections see "Fitting
additional attachments" on page 1 18.
100
Procedure
• Operating hydraulic port ZH1 :
Push the lever (95) in direction V or
R.
• Operating hydraulic port ZH2:
Pull the lever (98) in direction H or push it in direction S.
• Operating hydraulic port ZH3:
Flip the toggle switch (99) forward, press the acknowledgement key (100) and then
within 2 seconds push the lever(98) in direction S or pull it in direction H.
• Now flip the toggle switch (99) back.
The attachment performs its operation.

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4.19 Fitting additional attachments

A WARNING!
Incorrectly connected attachments can cause accidents.
Attachments with incorrectly connected hydraulic attachments can result in accidents.
ÿ Attachments must only be assembled and commissioned by trained, specialist
personnel.
ÿ Observe the manufacturer's operating instructions.
ÿ Before starting, check the fasteners are positioned correctly and securely and make
sure they are complete.
ÿ Before starting, make sure the attachment is working correctly.

Connect attachment hydraulically

Requirements
- Non-pressurised hydraulic hoses and plug-in coupling.
- The exchange ports on the truck are marked ZH1 and ZH2.
- Attachment movement directions defined to match the direction of movement of the
controls.

Procedure
• Depressurise the hydraulic hoses and plug-in coupling.
• Attach the plug connector and engage it in position.
• Mark the controls with symbols that indicate their function.
The attachment is now hydraulically connected.

A WARNING!
Hydraulic ports for clamping attachments
ÿ Clamping attachments may only be added to trucks which have a button to enable
additional hydraulic functions.
ÿ On trucks with auxiliary hydraulics ZH2 the clamping function should only be
attached to the coupling pair marked ZH2.
ÿ On trucks with auxiliary hydraulics ZH3 the clamping function should only be
attached to the coupling pair marked ZH3.

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09.14 EN
 Spilled hydraulic oil must be set using a suitable agent and disposed of in
accordance with environmental regulations.
If hydraulic oil comes into contact with the skin, wash it off immediately with soap
and water. If it comes into contact with the eyes rinse them immediately with flowing
water and call for a doctor.

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 5 Towing trailers

7K DANGER!
Inappropriate speeds and excessive trailer loads can be dangerous
If you do not adapt your speed and / or use an excessive trailer load, the truck can pull
apart when cornering and braking.
ÿ The truck should only be used occasionally to tow trailers.
ÿ The overall weight of the trailer should not exceed the capacity indicated on the
capacity plate, see "Identification Points and Data Plates" on page 31 . If a load is
also transported on the load handler, the trailer load must be reduced by the same
amount.
ÿ Do not exceed the maximum speed of 5 km/h km/h.
ÿ A truck must not be continually operated with trailers.
ÿ Do not use supporting loads.
ÿ Towing must only be performed on level, secure travel routes.
ÿ The owner must test trailer operation with the permissible tow load by means of a
trial run under the applicable operating conditions on site.

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 Attaching the trailer

A CAUTION!
Trapping hazard
There is a trapping risk when you attach a trailer.
ÿ Follow the instructions of the coupling manufacturer if using special trailer
couplings.
ÿ Secure the trailer to prevent it from rolling away before coupling it.
ÿ Do not get caught between the truck and the tiller when coupling the trailer.
ÿThe tiller must be horizontal, tilted down by no more than 10° and never facing up.

Attaching the trailer

Requirements
- Truck and trailer are on a level surface.
- Trailer prevented from rolling away.

Procedure
• Push the tow pin (141) down and turn it 90°.
• Pull the tow pin up and insert the tiller of the
trailer into the opening.
• Insert the tow pin, push it down, turn it 90
degrees and engage it.
The trailer is now attached to the truck.

0 To additionally ensure safe operation, the truck can be fitted with an electrical
connection for trailers with lighting.

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 6 Optional equipment
6.1 Keyless Access System
The keyless access system allows an individual operator code to be allocated to each
operator or group of operators.

10
142

PIN ••oo
12 3 4

143 144

mode

Item Description
10 Display unit (EasyAccess Softkey):
- Description see "Control panel with display unit" on page 58
- Enter 4-digit master and access codes
- Up to 10 access codes can be saved
- For master and access codes with the numbers 1 to 4
142 Keypad (EasyAccess PINCode):
- consists of the keys 0 to 9 and C (delete)
- Enter 4-digit master and access codes

- Up to 100 access codes can be saved

143 Transponder reader (EasyAccess Transponder):
- Up to 100 transponders can be saved

144 ISM Online:

- If equipped with the ISM Online access module see "ISM online access
module" operating instructions.

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6.2 General Information on Using the Display Unit
The default code is to be found on a sticker. When using the truck for the first time,
change the master code and remove the sticker!
- Default code: 1-2-3-4
- Default master code: 2-4-1-2
@ A green tick is displayed when a valid code is entered.
A red cross is displayed if an invalid code is entered, and the entry must be
repeated.
@ If the truck is not used for a certain length of time, the display unit switches to
standby mode. Pressing any key cancels the standby mode. After a further 5
minutes the code must be entered again, see "Using the Keypad" on page 131.

6.3 Commissioning the Keypad and the Transponder Reader

If the truck is equipped with a keypad or a transponder reader, it can only be operated
using the keys in the display unit. The keypad and the transponder reader have to be
activated by the operating company.

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 6.3.1 Activating the keypad

Procedure
• Release the Emergency Disconnect
switch, see page 85.

"b
• Enter the default code 1-2-3-4 with
the keys below the display unit (10).
The truck is switched on.
ÿ
Press the key below the "Settings"
symbol (145).
• Press the key below the "Change
master code" symbol (146).
• Enter master code 2ÿ4-1-2 with the 145
keypad (142).
The master code entered is
displayed.
146
0 When starting the truck for the first
time, change the master code. The
new master code must not be the
same as the previously set master
code or an access code.
Press the key below the "Delete"
symbol (147). 142
The master code is deleted.
Enter a new master code with the
keypad (142).
Press the key below the "Confirm"
symbol (148). ÿ ÿÿ

24 12
0
The new master code is displayed.
If the new master code was entered
incorrectly, the procedure can be
"b
repeated using the key below the
"Delete" symbol (147). -147

• To return to the main menu, press

the key below the "Back"
symbol (149). 149 148
• Delete the default code, see
"Deleting an access code (keypad)"
on page 134.
• Create access codes, see "Adding a new access code (keypad)" on page 133.

The keypad is active.

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6.3.2 Activating the transponder reader

Procedure
• Release the Emergency Disconnect
switch, see page 85. ÿ ÿÿ

0000
• Enter the default code 1-2-3-4 with the 10
keys below the display unit (10).
\ O

The truck is switched on.

ÿ
Press the key below the "Settings" 1 2 3 4
symbol (145).
• Press the key below the "Change
master code" symbol (146).
• Enter the master code 2-4-1-2 with the
keys below the display unit (10).
The master code entered is displayed.

• Press the key below the "Delete"

symbol (147).
The master code is deleted.
24120000000000
• Hold a transponder in front of the
transponder reader (143).
The transponder thus becomes the
Ss
master transponder.

• Press the key below the "Confirm"

symbol (148). -147
The master transponder code is
displayed.
0 If the wrong transponder has been used, -143
the procedure can be repeated using the
key below the "Delete" symbol (147).
• To return to the main menu, press the
key below the "Back" symbol (149).
EE] The default code can no longer be used
148
and must be deleted.
• Delete the default code, see "Deleting
transponders" on page 138.
• Add new transponders, see "Adding a
new transponder" on page 137.
15789B000107E5
The transponder reader is now active.

£ -147

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 6.4 Using the Display:

6.4.1 Switch on the truck with the access code.

Procedure
• Release the emergency disconnect switch, see page 85.
• Enter the access code with the buttons below the display (10).
The truck is switched on.

The truck can only be switched on when the display unit (10) is lit. If the display unit
is in standby the code or transponder will not be recognised. Pressing any key
cancels standby mode.

oooo
10

6.4.2 Start the engine

Procedure
ÿ
Press the button below the "START" symbol (150).
The engine starts and the truck is operational. START 150

6.4.3 Switching off the truck

Procedure

CD
• Press the key under the "Switch off" symbol (151) in the
display unit. 151
• Press the Emergency Disconnect switch, see "Emergency
Disconnect" on page 85.
The truck is switched off.

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6.4.4 Changing the master code (display unit)

Requirements
- Truck is switched on, see "Switch on the 145
truck with the access code." on
page 127.
146
Procedure
• Press the key below the "Settings"
symbol (145).
• Press the key below the "Change
master code" symbol (146).
ÿ
Enter the master code with the keys ÿÿÿ

below the display unit (10).

The master code entered is shown as
filled-in circles.
"b 10

• Press the key below the "Delete"

symbol (147).
The master code is deleted.
147
• Enter the new master code with the keys
below the display unit (10).
s The new master code must be different
from existing access codes. 148
• Press the key below the "Confirm"
symbol (148).
The new master code is displayed.
ÿ ÿÿ

If the new master code has been

entered incorrectly, delete it and enter
the correct master code.
"b oooo

• To return to the main menu, press the

key below the "Back" symbol (149). 152
The master code has been changed.

149

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 6.4.5 Adding a new access code (display unit)

Requirements
- Truck is switched on, see "Switch on the 145
truck with the access code." on page 127.

Procedure
• Press the key below the "Settings" 153
symbol (145).
ÿ
Press the key below the "Edit access code"
symbol (153).
The master code is requested.
ÿÿÿ
oooo
• Enter the master code with the keys below
the display unit (10).
All the access codes are displayed.
°b 10

• Press the keys below the "Add"

symbol (152).
• Enter the new access code with the keys
below the display unit (10).
B The new access code must be different
from existing access codes.
• Press the key below the "Confirm"
symbol (148). 152
The new access code is displayed.
a If the new master code has been entered 149
incorrectly, delete it see page 130, and
148

enter the correct access code.

• To return to the main menu, press the key below the "Back" symbol (149).
A new access code has been added.

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6.4.6 Deleting an access code (display unit)

Requirements
- Truck is switched on, see "Switch on the 145
truck with the access code." on page 127.

Procedure
• Press the key below the "Settings" 153
symbol (145).
ÿ
Press the key below the "Edit access code"
symbol (153).
The master code is requested. 147
• Enter the master code with the keys below
the display unit (10).
All the access codes are displayed.
ÿ ÿÿ
• Select the access code to be deleted with 0000

ÿ
the key below the "Selection down" symbol
(154).
Press the key below the "Delete"
"b 10

symbol (147).
The access code has been deleted.
ÿ
To return to the main menu, press the key
below the "Back" symbol (149).

147

149 154

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 6.5 Using the Keypad

6.5.1 Switching on the truck with the access code (keypad)

Procedure
ÿ
Release the emergency disconnect switch, see
page 85. I 142
» Enter the access code with the keypad (142).
The truck is switched on.

a The truck can only be switched on when the display unit (10) is lit. If the display unit
is in standby the code or transponder will not be recognised. Pressing any key
cancels standby mode.

6.5.2 Start the engine

Procedure
• Press the button below the "START" symbol (150).
The engine starts and the truck is operational. START 150

6.5.3 Switching the truck off (keypad)

Procedure

0
• Press the key under the "Switch off" symbol (151) in the
display unit. 151
• Press the Emergency Disconnect switch, see "Emergency
Disconnect" on page 85.
The truck is switched off.

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6.5.4 Changing the master code (keypad)

Requirements
- Truck is switched on, see "Switching on 145
the truck with the access code (keypad)"
on page 131.
146
Procedure
• Press the key below the "Settings"
symbol (145).
• Press the key below the "Change master
code" symbol (146).
ÿ
Enter the master code with the 142
keypad (142).
The master code enteredis shown in the
display unit (10) as filled-in circles.

• Press the key below the "Delete"

symbol (147).
ÿÿÿ

The master code is deleted.

• Enter a new master code with the
keypad (142).
"b 10

0 The new master code must be different

from existing access codes. 147
• Press the key below the "Confirm"
symbol (148).
The new master code is displayed.
If the new master code has been ÿÿÿ

oooo
entered incorrectly, delete it and enter
the correct master code.
• To return to the main menu, press the
8b
key below the "Back" symbol (149).
The master code has been changed.
148
149

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 6.5.5 Adding a new access code (keypad)

Requirements
- Truck is switched on, see "Switching on
the truck with the access code
145
(keypad)" on page 131.

Procedure
• Press the button below the "Settings" 153
symbol (145).
• Press the button below the "Edit access
code" symbol (153).
The master code is requested.

• Enter the master code with the 142

keypad (142).
All access codes are shown in the
display unit (10).

• Press the key below the "Add"

symbol (152). ÿ ÿÿ
oooo

0
• Enter a new access code with the
keypad (142).
The new access code must be different
"b 10

from existing access codes.

Press the button below the "Confirm"
symbol (148).
The new access code is shown in the
display unit (10).

If the new master code has been

entered incorrectly, delete it see 152
page 134, and enter the correct access
code.
148
To return to the main menu, press the 149
key below the "Back" symbol (149).
A new access code has been added.

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6.5.6 Deleting an access code (keypad)

Requirements
- Truck is switched on, see "Switching on 145
the truck with the access code (keypad)"
on page 131.

Procedure 153
• Press the key below the "Settings"
symbol (145).
• Press the key below the "Edit access
code" symbol (153).
The master code is requested.
142
• Enter the master code with the
keypad (142).
All access codes are shown in the
display unit (10).

• Select the access code to be deleted with

key below the "Selection down" symbol ÿ ÿÿ
0000
(154).
• Press the key below the "Delete"
symbol (147).
'1? 10

The access code has been deleted.

• To return to the main menu, press the key

below the "Back" symbol (149).

147

149 154

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 6.6 Using the Transponder Reader

NOTE
Take care not to damage the transponder. If the transponder is damaged, the truck
cannot be switched on.

6.6.1 Switching on the truck with the transponder

Procedure
• Release the Emergency Disconnect switch,
see page 85.
• Hold the transponder in front of the 143
transponder reader (143).
A green tick appears and remains until the
transponder has been confirmed. If there is
no confirmation within 20 seconds the access
prompt appears.
Press the button below the "Confirm"
symbol (148). 148
The truck is switched on.

The truck can only be switched on when the display unit (10) is lit. If the display unit
is in standby the code or transponder will not be recognised. Pressing any key
cancels standby mode.

6.6.2 Start the engine

Procedure
• Press the button below the "START" symbol (150).
The engine starts and the truck is operational. START 150

6.6.3 Switching the truck off (transponder reader)

Procedure
• Press the key under the "Switch off" symbol (151) in the
display unit. 151
• Press the Emergency Disconnect switch, see
"Emergency Disconnect" on page 85.
The truck is switched off.

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6.6.4 Changing the master transponder

Requirements
- Truck is switched on, see "Switching on
ÿ145
the truck with the transponder" on
page 135.
146
Procedure
• Press the key below the "Settings"
symbol (145).
• Press the key below the "Change master
code" symbol (146).
ÿ
Place the master transponder on the
143
transponder reader (143).
The master transponder code is shown in
the display unit (10).

• Press the key below the "Delete"

symbol (147). 147
A dashed line is shown.
• Place a new master transponder on the
transponder reader (143).
0 The new master transponder code must
be different from existing master
transponder code.
Press the key below the "Confirm"
symbol (148).
The new master transponder code is
displayed.
0 If the wrong transponder has been used, 148
the procedure can be repeated using the
key below the "Delete" symbol (147).
• To return to the main menu, press the key 10
below the "Back" symbol (149). 15789B000107E5

The master transponder has been changed.

149

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 6.6.5 Adding a new transponder

Requirements
- Truck is switched on, see "Switching on 145
the truck with the transponder" on
page 135.
Procedure 153
• Press the key below the "Settings"
symbol (145).
• Press the key below the "Edit
transponder" symbol (153).
The master transponder is requested.

• Place the master transponder on the 143

transponder reader (143).
All transponder codes are shown in the
display unit (10).

• Press the key below the "Add"

symbol (152).
• Place a new transponder on the 10
transponder reader (143).
0 The new transponder code must be
different from existing transponder
code. 152
Press the key below the "Confirm"
symbol (148).
The new code is displayed. 148
149
If the wrong transponder has been
used, delete it, see page 138, and add a
correct transponder.
• To return to the main menu, press the key below the "Back" symbol (149).
A new transponder has been added.

The transponder codes saved are sorted first of all numerically and then
alphabetically.

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6.6.6 Deleting transponders

Requirements
- Truck is switched on, see "Switching I
- 145
on the truck with the transponder" on
page 135.
Procedure 153
• Press the key below the "Settings"
symbol (145).
• Press the key below the "Edit
transponder" symbol (153).
The master transponder is
143
requested.

• Place the master transponder on the

transponder reader (143).
All transponder codes are shown in
the display unit (10).
ÿ
Select the transponder code to be 78915B51 EAE561
deleted with key below the
"Selection down" symbol (154).
• Press the key below the "Delete"
symbol (147).
The transponder has been deleted. -147
• To return to the main menu, press
the key below the "Back"
symbol (149). 149 154

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 6.7 Assistance systems
The Access, Drive and Lift Control systems help the driver operate the truck with
regard to safety regulations, see "Safety regulations for truck operation" on page 78
of the present operating instructions.

Travel conduct

The operator must adapt the travel speed to local conditions. The truck must be driven
at slow speed when negotiating bends or narrow passageways, when passing
through swing doors and at blind spots. The operator must always observe an
adequate braking distance between the forklift truck and the vehicle in front and must
be in control of the truck at all times. Abrupt stopping (except in emergencies), rapid
U turns and overtaking at dangerous or blind spots are not permitted. Do not lean out
or reach beyond the working and operating area.

6.7.1 Access Control

The truck is only released for operation if:
1)The operator is seated.
2)The truck is switched on via the key switch (ISM O / transponder O / keypad O).
3)He is wearing the seat belt.
If the driver vacates the seat for a short while, the truck can be operated again when
he returns (seat occupied) and puts the seat belt back on again.

If travel is not released, depending on the malfunction either the seat switch or seat
belt lock warning indicators light up. Items 1 to 3 must be performed again in the
order listed.

Symbol Meaning Colour Function

Seat switch Yellow Seat switch not applied or seat switch
applied for more than 6 hours
uninterrupted
Red Error on seat switch
Seat belt lock Yellow Seat belt not latched

L3J1H Red Wrong activation sequence of seat switch

and belt lock

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6.7.2 Drive Control

This option restricts the travel speed of the truck depending on of the steer angle.
From a factory-set lift height (approx. 1.50 metres) the maximum travel speed is
reduced to walking pace (approx. 3 km/h) and the slow travel indicator is activated.
When the forks fall below this height, the truck accelerates at reduced levels to the
speed prescribed by the accelerator pedal to prevent sudden acceleration when
changing from slow travel to normal travel. Normal acceleration is only activated again
when the speed prescribed by the accelerator pedal has been reached or if the
accelerator pedal is set to the 0 position.

a In addition to the daily checks before starting, see "Checks and Operations to Be
Performed Before Starting Daily Work" on page 66 the driver must carry out the
following checks:

- Lift the empty load handler beyond the reference lift height and check if the slow
travel indicator lights up.

6.7.3 Lift Control

This option includes Drive Control and also monitors and controls the mast functions:
Tilt speed reduction as a function of the lift height (from approx. 1,5 m lift height).
- When the load handler is lowered below the limit height, the tilt speed increases
again.
Optional:
- Tilt angle display, see "Control panel with display unit" on page 58.

In addition to the daily checks before starting, the driver must carry out the
following checks:

Procedure
• Lift the empty load handler beyond the reference lift height and check if the slow
travel display lights up and the tilt speed is clearly reduced.
ÿ
Steering when the truck is stationary: check if the steering wheel display is working.
ÿ
Check the tilt angle display by tilting forward and back.

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 6.8 Steel cab
For trucks fitted with a steel cabin, both doors can be closed.

A CAUTION!
Open doors can result in accidents
ÿ Do not travel with an open door. When opening the door make sure there is nobody
in the door's swing range.
ÿ Always close the door tightly and make sure it is locked.
ÿ Closing the door does not release the driver from his responsibility to wear a seat
belt, see "Seat Belt" on page 77.

Opening and closing the door

Procedure
• To unlock the cabin door turn the key anti-
clockwise.
• To lock the cabin door turn the key clockwise.
ÿ
To open the cabin door, unlock the door and
pull out the handle (156).

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6.9 Split Door

A CAUTION!
A fully opened door can result in accidents
ÿ Do not travel if the door is fully opened or not engaged in the cabin mount. When
opening the door make sure there is nobody in the door's swing range.
ÿ Always close the door tightly and make sure it is locked.
ÿ Closing the door does not release the driver from his responsibility to wear a seat
belt, see "Seat Belt" on page 77.

Unlocking the split door

Procedure
• Turn the lever (157) up.
The split door is unlocked.

Opening the split door

Procedure
• Pull out the handle (156) and open the split
door (155).
» Place the split door section (155) against the
cabin.
• Make sure that the split door (155) is engaged
in the cabin mount (158).
The split door is open.

Closing the split door

Procedure
• Press the cabin mount (158) and close the
split door (155).

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 Locking the split door

Procedure
• Move the lever (157) down and
door (155).
The split door is closed.

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6.10 Sliding windows

A CAUTION!
An unlocked sliding window can cause accidents
ÿ The sliding windows must be locked at all times.

Opening and closing the windows

Procedure
• Push the lock (160) up.
• Move the window forward or back.
• Insert the lock in the stop (159).

6.11 Gate

A CAUTION!
A faulty gate can be hazardous
ÿ Never use the truck with a non-functional
gate. Have the gate checked by
authorised specialist personnel after an
accident. Do not modify the gate.
ÿ Always close the gate securely and
make sure it is locked.
ÿ Closing the gate does not release the
driver from his responsibility to wear a
seat belt, see "Seat Belt" on page 77.
ÿ When the driver's seat is occupied,
maintain a 90 mm gap between the gate
(142) and the seat to ensure safety.

Hazardous situations

If the truck is about to tip over, do not loosen the seat belt. The operator must not jump
off the truck. The operator must lean his upper body over the steering wheel and hold
on with both hands. Tilt your body in the opposite direction of fall.

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 Gate operation
Procedure
• To open the gate press the handle (161). /
j'
The gate automatically moves up and
remains in this position.
• To close, push the gate down. : ///NT

s Gate control is available as an option. Travel 1

is only enabled when the left gate is closed.
The right gate is not monitored.

Moving the gate

Procedure
• For service work the gate can be moved
out. To do this, pull the spring pin (162)
up and turn the gate out manually.

Gate control is available as an option, j

Travel is only enabled when the left gate I
is closed. The right gate is not monitored. /
' II

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6.12 Panel door

A CAUTION!
Open doors can result in accidents
ÿ Do not travel with an open door. When opening the door make sure there is nobody
in the door's swing range.
ÿ Always close the door tightly and make sure it is locked.
ÿ Closing the door does not release the driver from his responsibility to wear a seat
belt, see "Seat Belt" on page 77.

Hazardous situations

If the truck is about to tip over, do not loosen the

seat belt. The operator must not jump off the
truck. The operator must lean his upper body
over the steering wheel and hold on with both
hands. Tilt your body in the opposite direction of
fall.

Procedure
• Pull the handle (163) towards the operator
position, the door swings open.
• Pull the door (155) towards the operator; the
door closes.
163 155
Summer door control is available as an option.
Travel is only enabled when the summer door is closed.

6.13 Operator position extension

DANGER!
Altering the tilt resistance can be dangerous
The lateral tilt resistance reduces with a higher truck centre of gravity.
The height above the overhead guard (h6) increases by 300 mm, see "Dimensions"
on page 22.
ÿ Adapt the travel speed of the truck, in particular when cornering.

El For entry and exit see "Entry and exit" on page 69.

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 6.14 Heating and air conditioning system

Replacing the air conditioning filter 164 M III .165

Procedure
• Turn the twist off knob (166) anti-clockwise.
• Pull the filter cassette (165) out in the direction
.166
of the arrow.
ÿ
Replace the filter.
• Insert the filter cassette (165) into the heating (I i(i ]\ <j ]L
console (164). vzJ)
• Turn the twist-off knob clockwise

The filter cassette has been replaced and locked.

Regular servicing is required to ensure the filter can work at a consistently high
level, see "Servicing and Inspection" on page 239.

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6.14.1 Heating

Item Component Item Component

167 Body jets 171 Air distribution control
168 Temperature controller 172 Recirculating air flap:
Recirculates the air in the
cab
169 Windscreen jets 173 Foot compartment jet
170 Fan settings

Heating operation

Procedure
• Press the switch (170) to switch on the fan.
• Set the nozzles (173 and 167) to the required position.
• Turn the temperature controller (168) to the right to increase the cab temperature.
• Turn the temperature controller (168) to the left to decrease the cab temperature.
The air distribution is governed by the controller (171).
• Controller right - The entire airflow is directed to the front window (defrosting).
• Controller centre = The airflow is directed to the front window and the footwell.
• Controller left = The airflow is directed to the upper body of the operator and the
footwell.
lE] At very low outer temperatures the heating level can be increased by opening the
recirculating air flap (172).

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 6.14.2 Air conditioning system

A CAUTION!
Extreme temperature differences can affect your health.
ÿ When using the air conditioning system make sure the temperature is no higher
than 6°C more than the outside air temperature.
ÿ Keep the doors and windows closed when the air conditioning system is switched
on.
ÿ Do not direct discharge jets at other people.
ÿ There should be no draft effect.

Power On and Off

Procedure
ÿ
Turn on the fan switch (170) and press the
toggle switch (174) (green indicator goes
on).
• To control the airflow (see "Heating" on
page 148).
» Set the fan switch (170) to "0" and set the

toggle switch (174) "OFF" (the green light

will be off).
The air conditioning system switches off
before the truck is parked.

Using the air conditioning system at high air humidity and temperature levels

Procedure
ÿ
Press the toggle switch (174).
ÿ
Distribute the air evenly through all discharge jets: Switch (171) in centre position.
• Set the fan (170) to its highest level.
• Set the temperature control (168) according to the outside temperature.
ÿ
Open the rear sliding window by one notch.
ÿ
Close the window again after de-humidifying.
• Set the airflow as required.

The air conditioning system must be switched on at least once a month for approx.
10 minutes to recirculate the refrigerant.

When the air conditioning system is operating condensation water may be visible
underneath the truck.

Regular servicing of the air conditioning system is required to ensure it can work at
a consistently high level, see "Servicing and Inspection" on page 239.

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6.15 USB Charger Module in Armrest
The USB charger module is designed for charging electrical devices such as smart
phones etc. and is located in the storage compartment in the armrest.
Connection data: 5 V max. 1 A

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 6.16 Auxiliary Functions on the Armrest

6.16.1 Activating the auxiliary functions i the armrest

Procedure
ÿ
Press the FN (175) button. Status
lamp above the FN button lights
up. Additional features are shown
in the display.
• Press the corresponding button in 12345h
the armrest control panel and
activate / deactivate the auxiliary
option. The icons of the auxiliary
functions activated have white
backgrounds.
• Press the FN button. The display
automatically switches back to
normal operating mode after 5
seconds or when the "FN" button
is pressed.
Auxiliary function is activated or
deactivated.

s The truck can be switched off at

any time.
0 When the FN button is pressed the
soft keys under the display are
deactivated.

175

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6.16.2 Auxiliary functions in the display unit above the FN button

Symbol Meaning
Lift cutout override:

S3 Allows the lift cutout to be overriden, see page 153.

m Sideshifter centre position:

Activates the sideshifter centre function, see page 154.

Fork tilt horizontal:

IS Activates the fork tilt horizontal function, see page 154.

Spot lights (work lights / front headlights)

Buzzer cut-off

Floor spotlight, see page 170.

Load weighing, see page 153.

Operating hydraulics function cutout, see page 153.

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 6.17 Operating hydraulics cutout
Change over via the FN button in the armrest to deactivate all operating hydraulics
functions (lifting, tilting, auxiliary functions 1, 2, 3).

Symbol Meaning
Operating hydraulics function cutout
l1ÿ
6.18 Load Weighing
Change over via the FN button in the armrest to activate the load weighing display. A
load measurement is performed for each lifting and lowering operation that lasts
longer than 1 second.
The reading appears at the top left of the display.
A tare can be set if requested by the customer.
Contact the manufacturer's customer service department for this specific task.

Symbol Meaning
Load weigh

6.19 Lift cutout override

0 A lift cutout device can be factory fitted when working in areas of restricted height.
This interrupts lifting.

176

To continue lifting:

Procedure
• Press the "lift cutout override" button (see "Control panel with display unit" on
page 58 or see "Button allocation of the display" on page 59).
• Pull the control lever (176): Lift cutout is deactivated.
Lift cutout is re-activated each time the mast falls below the lift cutout height.

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6.20 Fork Tilt Horizontal
176

Operation of automatic fork tilt horizontal.

Requirements
- Inspection and tasks before starting daily operations performed (see page 66).
- "Fork tilt horizontal" function tested, see page 152.

Procedure
• Press the fork tilt horizontal button, see "Symbols in the display" on page 60.
• Pull or push the lever (95) until fork tilt horizontal is reached.

The "Fork tilt horizontal" function is deactivated when the fork tilt horizontal position
has been reached.

6.21 Sideshifter Centre Position

95

Automatic sideshifter centring operation.

Requirements
- Inspection and tasks before starting daily operations performed (see page 66).
- Check automatic sideshifter centring checked with the function key, see "Symbols
in the display" on page 60.

Procedure
• Press the sideshifter centring button, see "Operating the Lift Mechanism and
Integrated Attachments" on page 99.
• Pull or push the lever (95) until the sideshifter cuts out in the middle.
"Sideshifter centring" is deactivated when the fork carriage stops in the middle.

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 6.22 Control layout "N"

A WARNING!
Persons standing under or on a raised load handler are at risk of accidents
Do not allow anyone to stand under or on a raised load.
ÿ Do not stand on the load handler.
ÿ Do not lift any persons on the load handler.
ÿ Instruct other people to move out of the hazardous area of the truck.
ÿ Do not stand underneath a raised and unsecured load handler.

0 With control layout "N", the lift and tilt functions are swapped compared with the
standard operation. The Pilot must only be operated from the driver's seat. The
operator must be trained to handle the lift mechanism and the attachments.

NOTE
ÿ The lift/lower and tilt speeds are determined by the inclination of the Pilot. Do not
deposit the load handler suddenly to avoid damaging the load and the racking.

Multi-Pilot

Lifting

Procedure
• Push the Multipilot to the right (direction H) to raise the load.
• Push the Multipilot to the left (direction S) to lower the load.

Tilting

A CAUTION!
Trapping hazard from inclined mast
ÿ When tilting the mast back, keep all
parts of your body from between the
mast and the front wall.

Procedure
• Push the Multipilot forward (direction V) to tilt the load forward.
• Pull the Multipilot back (direction R) to tilt the load back.
@ When the limit position for the operation has been reached (there will be a noise
from the pressure relief valve) release the lever. The lever will revert automatically
to neutral.

Duo-Pilot

Lifting

g Procedure
? • Push the Duo-Pilot lever (94) to the right (direction H) to raise the load.
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 Push the Duo-Pilot lever (94) to the left (direction S) to lower the load.

Tilting

A CAUTION!
Trapping hazard from inclined mast
ÿ When tilting the mast back, keep all
parts of your body from between the
mast and the front wall.

Procedure
• Push the Duo-Pilot lever (94) forward
(direction V) to tilt the load forward.
• Pull the Duo-Pilot lever (94) back (direction R) to tilt the load back.

When the limit position for the operation has been reached (there will be a noise
from the pressure relief valve) release the lever. The lever will revert automatically
to neutral.

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 6.23 Operating the Auxiliary Hydraulics without Pressing the
Acknowledgement Key

A WARNING!
Hydraulic ports for clamping attachments
ÿ Clamping attachments may only be added to trucks which have a button to enable
additional hydraulic functions.

A WARNING!
Incorrect symbols can cause accidents
Symbols on controls that do not depict the function of the attachments can cause
accidents.
ÿ Mark the controls with symbols that indicate their function.
ÿ Specify the attachments' direction of movement in accordance with ISO 3691-1 so
that they match the controls' direction of movement.

6.23.1 Solo Pilot with Control of ZH1 and ZH2 Hydraulic Ports
a Depending on the attachments used the lever / button (95,98), is assigned the
function of the attachment. Unused levers have no function. For connections see
"Fitting additional attachments" on page 118.

Procedure
• Operating hydraulic port ZH1 :
Move the lever (95) in direction V or R.
• Operating hydraulic port ZH2:
Move the lever (98) in direction V or R.
The function of the attachment is
performed.

6.23.2 Positioning the forks with an

integrated fork positioner (option)

A CAUTION!
Clamping loads with the fork positioner can result in accidents
Do not clamp loads with the fork positioner
ÿ The fork positioner must not be used to clamp loads.

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 Requirements
- Truck prepared for operation see
"Preparing the truck for operation" on
page 81.

Procedure
• Pull the lever (98) in direction H, the
forks move together.
• Push the lever (98) in direction S, the
forks move apart.
The forks are now positioned.

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 6.23.3 Multi-Pilot with Control ofZH1 and ZH2 Hydraulic Ports

a Depending on the attachments used the lever / button 94,95), is assigned the
function of the attachment. Unused levers have no function. For connections see
"Fitting additional attachments" on page 118.

Procedure
ÿ
Operating hydraulic port ZH1 :
95
Press the (95) button to the left or right.
ÿ
Operating hydraulic port ZH2:
Push the lever (94) in direction V or pull it in
direction R.
The function of the attachment is performed.

6.23.4 Positioning the forks with an integrated fork positioner (option)

A CAUTION!
Clamping loads with the fork positioner can result in accidents
Do not clamp loads with the fork positioner
ÿ The fork positioner must not be used to clamp loads.

Requirements
- Truck prepared for operation see "Preparing
the truck for operation" on page 81 .
Procedure
• Pull the button (98) in direction R, the forks
move apart.
• Push the button (98) in direction V, the forks
move together.
The forks are now positioned.

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6.23.5 Duo-Pilot with Control of ZH1 and ZH2 Hydraulic Ports

a Depending on the attachments used the lever / button (95,98), is assigned the
function of the attachment. Unused levers have no function. For connections see
"Fitting additional attachments" on page 118.

95/98
Procedure
ÿ
Operating hydraulic port ZH1 :
Push the lever (95) in direction V or R.
ÿ
Operating hydraulic port ZH2:
Pull the lever (98) in direction H or
push it in direction S.
The function of the attachment is
performed.

6.23.6 Positioning the forks with an integrated fork positioner (option)

A CAUTION!
Clamping loads with the fork positioner can result in accidents
Do not clamp loads with the fork positioner
ÿ The fork positioner must not be used to clamp loads.

Requirements
-Truck prepared for operation see
"Preparing the truck for operation" on
page 81.
Procedure
ÿ
Pull the lever (98) in direction R, the
forks will move apart.
• Push the lever (98) in direction V, the
forks move together.
The forks are now positioned.

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 6.24 Load Damping

A WARNING!
Pressurised components and fluids can cause injury
Pressurised components and fluids can cause severe injury.
ÿ Do not touch pressurised hydraulic lines.
ÿ Report any defects immediately to your supervisor.
ÿ Mark defective truck and take out of service.
ÿ Do not return the industrial truck to service until you have identified and rectified the
fault.
ÿ Remove any spilled hydraulic immediately with an appropriate bonding agent.
ÿ The mixture of bonding agents and consumables must be disposed of in
accordance with relevant regulations.
ÿ Repair and maintenance work on pressure vessels and hydraulic lines must only be
performed by the manufacturer's trained customer service department.

Load damping acts via a hydraulic accumulator to reduce the impacts on the load to
be moved. If pressure fluctuations occur in the hydraulic system e.g. due to potholes,
they will be absorbed and minimised by the hydraulic accumulator. The lift mast
damping consists of a hydraulic accumulator, a separate throttle valve, a
measurement port and a hydraulic hose connecting this unit to the hydraulic system.

3 For the hydraulic accumulator observe the regulations at the assembly site before
commissioning and during operation.
The accumulator operating instructions are included with the truck.

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 Start up and commissioning

Before starting up the truck you must check the hydraulic accumulator, the hose and
the pressure relief valve for damage. If you discover any damage or faults remove the
truck from service immediately.

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 6.25 Removable load backrest

A CAUTION!
Trapping hazard and heavy load backrest weight
ÿ Wear safety gloves and safety shoes when carrying out this operation.
ÿ Two people are required to remove and attach the load backrest.

Loadbackrest disassembly

Procedure
* Loosen the screws (177).
• Remove the load backrest from the fork
carriage and put it down securely.
• Fit the fork retaining screws.

Loadbackrest assembly

Procedure
• Attach the load backrest to the top rail of the
fork carriage.
• Fit the bolts and tighten them with a torque wrench.
@ Torque = 85 Nm

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6.26 Fire extinguisher

Procedure
• Open the fasteners
(178)
• Pull the fire extinguish
out of its bracket
0 To operate, refer to the
illustrations on the fire
extinguisher

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 6.27 Rockinger coupling with hand lever or remote control
s Refer to the instructions for towing trailers, see "Towing trailers" on page 121

180 179
A CAUTIONI
Incorrectly coupled trailers can cause
accidents
ÿ Make sure the coupling is engaged
securely before starting the truck.
ÿ The control pin (181 ) must be flush with
the control sleeve (182).

Rockinger coupling operation (attaching

trailers)

Procedure
ÿ
Prevent the trailer from rolling away.
• Adjusting the trailer pull rod to the height of the coupling.
ÿ
Pull the hand lever (180) / remote control (179) (O) up.
0 The remote control (179) (O) is located in the overhead guard, depending on the
truck model.
• Slowly reverse the truck until the coupling engages.
ÿ
Push the hand lever (180) / remote control (179) (O) down.

Rockinger coupling operation (disconnecting trailers)

Procedure
• Prevent the trailer from rolling away.
• Pull the hand lever (180) / remote control (179) (O) up.
• Drive the truck forward.
• Push the hand lever (180) / remote control (179) (O) down.

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6.28 Camera system

A CAUTION!
Accident risk from hidden work areas
ÿ The camera system acts as an aid to assist safe operation.
ÿ Practice travelling and working with the camera system.
ÿ Align the camera so that the hidden work area can be seen.

When using the camera to reverse, the monitor automatically switches on when you
engage reverse gear.

[W] [co] [77] [2T| (5U uoj

183 184 185 186 187 188189

Key Function
183 Display mode toggle
184 Camera/video input toggle
185 Menu selector key
186 Fwd. selector key
187 Back selector key
188 Brightness reduction / background lighting
189 Switch monitor on/off

±1 Clean a dirty screen or vent slots with a soft cloth or brush.

Switch camera system on
Procedure
ÿ
Press the key (189) on the monitor.
The camera system is switched on or off.
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 Sets the screen brightness
Procedure
• Press the (188) key.
The screen becomes brighter or darker (day/night toggle).

Opening the Menu

Procedure
ÿ
Press the (185) key.
The menu opens.

a Pressing the (185) key several times changes between the menu options or ends
the menu.

Available menus:
- Brightness
- Contrast
- Colour saturation
- Factory setting

- Language
- Reflection
- Video
- Indicator
- Interval
Adjusting the menu items

Procedure
• Press the (187) key.
Menu jumps forward one point.
• Press the (186) key.
Menujumps back one point.

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6.29 Optional equipment for working in dusty environments
When working in areas with high dust levels (lint, splinters) the truck can be fitted with
an optional lint mesh on the cooler.

A CAUTION!
Clogged lint mesh can cause fires
ÿ The lint mesh must be cleaned regularly according to how much it is clogged.
ÿ The assembly area of the lint mesh must be cleaned by suitable means (e.g.
vacuum cleaner).

190 191
Procedure
• Turn the quick release lock (190) to open it.
• Pull the lint mesh up by the handle (191)
and clean it.
• Fit the lint mesh back and lock it.
The lint mesh is now clean.

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 6.30 Roof window wiper

The roof window wiper is activated by pressing the switch in the

dashboard.

Activating the roof windscreen wiper

Procedure
• Operating the roof windscreen wiper:
Press the switch to position 1.
Roof windscreen wiper activated.

Deactivating the roof windscreen wiper

Procedure
ÿ
Operating the roof windscreen wiper:
Set the switch to the home position.
Roof windscreen wiper deactivated.

Activating the washer nozzle

Procedure
• Operating the washer nozzle:
Press the switch to position 2.
Washer nozzle activated.

Deactivating the washer nozzle

Procedure
• Operating the washer nozzle:
Release the switch.
The switch automatically reverts to position 1, the washer nozzle is deactivated.

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6.31 Floor spot
The floor spot serves as an auxiliary device and, with the travel direction switch
engaged, projects a coloured dot on the floor at a distance of 5 m.
When the truck travels forward the coloured dot is in front of the truck and when
reversing it is behind the truck.

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 6 32
Horn Button
The horn
travel.button
Utton " °Verhead
the
G"ard
overbed
during reverse

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6.33 Travel Direction Switch on Steering Column

A WARNING!
Improper travel can result in accidents
ÿ Do not get up from the driver's seat during travel.
ÿ Do not drive the truck unless your are wearing a seat belt and the panels and doors
are properly locked.
ÿ Do not lean out of the truck while travelling.
ÿ Make sure that the travel area is clear.
ÿ Adapt your travel speed to the route conditions in the work area and the load.
ÿ Tilt the mast back and raise the fork carriage approx. 200 mm.
ÿ Make sure you have sufficient visibility when reversing.

12345n

Travel
Requirements
- Truck prepared for operation, see "Preparing the truck for operation" on page 81 .

Procedure
• Release the parking brake, to do this press the parking brake button (113).
• Select the travel direction with the travel direction switch (96).
• Select the travel speed if necessary, to do this press the slow travel button (137) or
the program selector (136/135).
ÿ
Raise the load handler approx. 200 mm.
• Tilt the mast back.
• Apply the accelerator pedal (93). The travel speed is governed by the accelerator
(93).
The truck travels in the direction selected.

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 09.14 EN

-J
CO
7 Troubleshooting
7.1 Troubleshooting
This chapter enables the operator to localize and rectify basic faults or the results of
incorrect operation himself. When trying to locate a fault, proceed in the order shown
in the remedy table.
@ If, after carrying out the following remedial action, the truck cannot be restored to
operation or if a fault in the electronics system is displayed with a corresponding
error code, contact the manufacturer's service department.
Troubleshooting must only be performed by the manufacturer's customer service
department. The manufacturer has a service department specially trained for these
tasks.
In order for customer services to react quickly and specifically to the fault, the
following information is essential:
- Truck serial number
- Event message from the display unit (if applicable)
- Error description
- Current location of truck.

103

(®) (0)

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08:38a»

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ivOT Ul
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Event messages
@ Information messages are shown in the display (103).

Display Meaning
0416 Temperature
- Coolant temperature too high.
0640 Back-up memory error
- Switch off the truck, wait for 5 seconds, switch the truck on
again. If the error is repeated, notify Customer Services.
0934 Particle filter

- Particle filter charge status high

1411 Temperature
- Hydraulic oil temperature too high
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 Display Meaning
1901 Travel direction error

- Combination of seat switch not applied and travel setpoint

1904 Travel direction error
- Combination of travel setpoint and no travel direction selected
1909 Travel direction error

- Combination of travel setpoint and parking brake activated

1917 Travel direction error

- Combination of accelerator pedal and brake pedal invalid

1936 Self test interrupted
- The truck performs a self-test after the start (tests the
controllers and motor). During this time the truck cannot move
or lift.
2931 Anti-stall function active

- The engine speed is too low, hydraulic functions will not be

performed.
2951 Hydraulics zero position on power up
- A hydraulic function or the horn applied during power up.
- The hydraulic function applied will not be performed.
- Depressurised mode activated.

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 Fault Possible cause Remedy
Starter does not turn - Battery charge too low. - Check the battery
- Battery connection cable charge and charge
loose or terminals battery if necessary.
oxidized. - Clean and grease
- Starter motor cable loose terminals, tighten battery
or broken. connection cable.
- Check starter motor
- Starter motor magnetic cable, tighten or replace
switch jammed. as required.
- Faulty fuse. - Check if the magnetic
switch audibly engages.
- Check the fuses.
Engine oil pressure - No oil pressure. Check engine oil level,
indicator lit top up if necessary
Over temperature indicator - Hydraulic oil level too Check hydraulic oil, top
lit low. up if necessary.
Clean radiator.
- Cooler contaminated. Check engine radiator
- Coolant level too low. system for leaks, add
coolant if necessary.
Engine running but truck - Travel direction switch in Set travel direction
does not travel neutral. switch to required travel
direction.
- Parking brake applied. Release the parking
brake.
Check belt lock control
system.
Check seat switch.
Truck does not reach max. Hydraulic reservoir oil Check the hydraulic oil
speed level too low. level, replenish hydraulic
oil if necessary.
Lift speed too low Hydraulic reservoir oil Check hydraulic oil, top
level too low. up if necessary.
Replace hydraulic
Hydraulic reservoir reservoir discharge
discharge system system.
contaminated or
blocked.
Load cannot be raised to Hydraulic reservoir oil Check hydraulic oil, top
max. height. level too low. up if necessary.
Steering is sluggish Steer axle tyre pressure - Check tyre air pressure,
too low. increase to correct
pressure if necessary.

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 Fault Possible cause Remedy
Excessive steering play - Air in steering system. - Check hydraulic oil level
and top up if necessary,
then turn the steering
wheel several times from
one end to the other.
Engine does not start - Air filter contaminated. - Clean or replace air filter.
DFG: Engine does not start - Fuel tank empty, - Fill up with diesel and
injection system has arrange for the injection
suctioned in air. system to be bled by
- Water in the fuel system. Customer Services.
- Incorrect fuel used. - Drain the fuel system, fill
up the truck and arrange
for the fuel system to be
- Fuel filter contaminated. bled by Customer
Services.
- Check the fuel tank, if
- Paraffin separation from necessary replace the
the diesel (flakes fuel filter.
forming). - Park the truck in a warm
room and wait until the
separation has returned
to its original state. If
necessary replace the
fuel filter. Add winter
diesel.
TFG: Engine does not start - LPG bottle shut-off valve - Shut-off valve open.
closed.
- LPG bottle empty.
- Replace the LPG bottle.
- Spark plugs damp, oily - Dry, clean and tighten
or loose. spark plugs.
- Spark plugs faulty - Replace the spark plugs.

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7.2 Operating the truck without its own drive system

7.2.1 Towing the truck

A WARNING!
Accident risk
Other people can be injured if the truck is towed incorrectly.
ÿ Only use vehicles to tow the truck which have sufficient tow and brake forces for the
trailer load without its own braking system.
ÿ Always use a drawbar when towing.
ÿ Tow the truck at a maximum speed of2 km/h.
ÿ Do not park the truck with the parking brake released.
ÿ One person must be seated in the recovery truck to steer it and one person must be
seated on the towed truck.

Towing the truck

Requirements
- Truck switched off securely.

Procedure
• Connect the pull rod to the trailer
coupling (59) of the towing truck and attach it
to the truck to be towed.
• Release the parking brake, see "Release the
parking brake." on page 179.
•Tow the truck to its destination.
• Apply the parking brake, see "Release the
parking brake." on page 179.
• Remove the tow bar.
The truck has now reachedits destination.

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7.2.2 Release the parking brake.

A WARNING!
Uncontrolled truck movement
When the brakes are released the truck must be parked securely on a level surface,
since the brakes are no longer effective.
ÿ Do not release the parking brake on slopes or inclines.
ÿ Apply the parking brake again when you reach your destination.
ÿ Do not park the truck with the parking brake released.

Release the parking brake

Requirements
- Press the Emergency Disconnect and remove
the key from the key switch.
- Prevent the truck from rolling away.
- Open the floor plate (192) by undoing the quick
release locks and remove the plug
connections (193).

Procedure
• Undo the setscrew on the valve block (194) a maximum of 1.5 turns.
• Fully insert the setscrew (187) (torque 2.5 Nm).
ÿ
Turn the steering wheel clockwise.
• Fully insert the setscrew (194) again
(Torque 2.5 Nm).
• Turn the steering wheel back until the wheels are facing the required direction.
• Tow the truck to its destination using the pull rod.

The truck has now reached its destination.

179
 Applying the parking brake

Procedure
* Remove the setscrew (187) from the stop of the cheese head screw (188)
• Assemble the floorboard.
Park the truck securely.

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 7.2.3 Emergency lowering

a The load handler can be lowered manually if a fault occurs in the hydraulic
controller.

A WARNING!
Load handler emergency lowering
ÿ Instruct other people to move out of the hazardous area of the truck during
emergency lowering.
ÿ Never step or stand underneath a raised load handler.
ÿ Only operate the emergency lowering valve when standing next to the truck.
ÿ When the load handler is in the racking, emergency lowering is not permitted.
ÿ Report any defects immediately to your supervisor.
ÿ Mark defective truck and take out of service.
ÿ Do not return the industrial truck to service until you have identified and rectified the
fault.

Requirements
- Press the Emergency Disconnect and remove
the key from the key switch.
- Prevent the truck from rolling away.

- Open the floor plate (192) by undoing the quick

release locks and remove the plug
connections (193).
193
Procedure
• Undo the threaded rod (195) on the valve block
by a maximum of 1.5 turns.
• Slowly lower the load handler.
If necessary the lowering speed can be reduced by turning clockwise or the
emergency lowering can be stopped.
• When the load handler has been lowered, tighten the threaded rod to 2.5 - 3.0 Nm.

The load handler has been lowered.

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 A WARNING!
Only return the truck to service when you have identified and rectified the fault.

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 7.2.4 Starting aid

A WARNING!
Danger from overheating
ÿ Use only an ISO 6722 battery jump lead
with fully insulated terminal pliers and a
lead diameter of at least 25 mm2.

The jump start connection (196) is located in

the main fuse box on the starter battery.

Procedure
Open the engine cover, see "Opening the
engine cover" on page 199.
Attach the red lead of the donor battery to the
jump start connection (196). ÿ \ \V
Attach the black lead to the negative terminal
of the donor battery and the mass point of the crane eye to the engine.
Switch on the ignition by turning the key in the key switch (85) to the "II" position.
Press the override switch (197).
Start the engine by turning the key in the key switch (85) to the "I" position.
When the engine has started first remove the negative lead followed by the positive
lead.

±J If the starter motor does not switch on the motor after connecting the battery
terminals, check that the battery leads are positioned correctly.

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00

09.14 EN
 F Industrial Truck Maintenance
1 Operational Safety and Environmental Protection
The checks and servicing operations contained in this chapter must be performed in
accordance with the maintenance checklist service intervals.

A WARNING!
Risk of accidents and damage to components
Any modification to the truck, in particular the safety mechanisms, is prohibited. Do
not alter the truck's operating speeds under any circumstances.
Do not bond the front window with adhesive.

Exception: Operating companies should only make changes or have changes made
to powered industrial trucks if the manufacturer is no longer operating in the field and
there is no successor to the business; operating companies must however:
- Ensure that the changes to be made are planned, tested and performed by a
specialist engineer in industrial trucks taking safety into account.
- Keep permanent graphic records of the plans, tests and completion of the changes
- Carry out and have authorised the respective changes to the capacity data plates,
decals and stickers as well as the operator and service manuals.
- Attach permanent and clearly visible marking to the truck indicating the types of
changes made, the date of the changes and the name and address of the
organisation responsible for the work.

NOTE

Only original spare parts are subject to the manufacturer's quality control. To ensure
safe and reliable operation, use only the manufacturer's spare parts.
For safety reasons, only components which have been specially agreed by the
manufacturer for this truck may be installed near the computer, controllers and wire
guidance sensors (antennae). These components (computers, controllers, wire
guidance sensors (antennae)) must therefore not be replaced by similar components
from other trucks of the same series.

On completion of inspection and service work, carry out the operations listed in the
"Recommissioning the truck after cleaning or maintenance work" section (see
"Restoring the truck to service after maintenance and repairs" on page 233).

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2 Maintenance Safety Regulations
Maintenance and repair personnel

The manufacturer has a service department specially trained for these tasks. A
maintenance contract with the manufacturer will ensure trouble-free operation.
Truck maintenance and repair work must only be carried out by specially trained
personnel. The following operations are assigned to the following target groups.

Customer Services
Customer Services are specially trained in the use of the truck and are able to carry
out maintenance and repairs independently. Customer Services are aware of the
relevant standards, guidelines and safety regulations as well as potential risks.
Operating company
The maintenance personal of the operating company has the technical expertise and
experience to perform the activities in the maintenance check list for the operating
company. The maintenance and repair work to be performed by the operating
company are also written down, see "Maintenance and repairs" on page 195.

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 2.1 Working on the electrical system

A CAUTION!
Accident risk from Working on the electrical system:
Make sure the electrical system is voltage-free before starting work on it.
ÿ Remove any rings or metal bracelets etc. before working on electrical components.
ÿ Only trained personnel may work on the electrical system.
ÿ Switch off the truck securely (see "Parking the truck securely" on page 84).
ÿ Before working on the electrical system, all precautionary measures must be taken
to avoid electrical accidents.
ÿ Remove the starter battery connecting leads to de-energise the truck.

2.2 Consumables and used parts

A CAUTION!
Consumables and used parts are an environmental hazard
Used parts and consumables must be disposed of in accordance with the applicable
environmental-protection regulations. Oil changes should be carried out by the
manufacturer's customer service department, whose staff are specially trained for this
task.
ÿ Note the safety regulations when handling these materials.

2.3 Wheels

A WARNING!
The use of tyres that do not match the manufacturer's specifications can result
in accidents.
The quality of tyres affects the stability and performance of the truck.
Uneven wear affects the truck's stability and increases the stopping distance.
ÿ When replacing tyres make sure the truck is not skewed.
ÿ Always replace tyres in pairs, i.e. left and right at the same time.

it] When replacing rims and tyres fitted at the factory, only use the manufacturer's
original spare parts. Otherwise the manufacturer's specifications cannot be
ensured. If you have any queries contact the manufacturer's customer service
department.

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2.4 Lift Chains

A WARNING!
Non-lubricated and incorrectly cleaned lift chains can cause accidents
Lift chains are safety-critical parts. They must not contain any serious contamination.
Lift chains and pivot pins must always be clean and well lubricated.
ÿ Lift chains should only be cleaned with paraffin derivatives e.g. petroleum or diesel
fuels.
ÿ Do not clean lift chains with high pressure jets or chemical cleaning agents.
ÿ Immediately after cleaning, dry the lift chain with compressed air and apply a chain
spray.
ÿ Always lubricate a chain when it is discharged.
ÿ Lubricate a lift chain with particular care around the pulleys.

A WARNING!
Diesel fuel can be hazardous
ÿ Diesel fuel can cause irritation if it comes into contact with the skin. Rinse any
affected areas thoroughly.
ÿ If it comes into contact with the eyes rinse them immediately with flowing water and
call for a doctor.
ÿ Wear safety gloves when handling diesel fuels.

2.5 Hydraulic system

A WARNING!
Leaky hydraulic systems can result in accidents
Hydraulic oil can escape from leaky and faulty hydraulic systems.
ÿ Report any defects immediately to your supervisor.
ÿ Mark defective truck and take out of service.
ÿ Do not return the industrial truck to service until you have identified and rectified the
fault.
ÿ Remove any spilled hydraulic immediately with an appropriate bonding agent.
ÿ The bonding agent / consumable mixture must be disposed of in accordance with
regulations.

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 A WARNING!
Faulty hydraulic hoses can result in injury and infection
Pressurised hydraulic oil can escape from fine holes or hairline cracks in the hydraulic
hoses. Brittle hydraulic hoses can burst during operation. People standing near the
truck can be injured by the hydraulic oil.
ÿ Call for a doctor immediately in the event of an injury.
ÿ Do not touch pressurised hydraulic hoses.
ÿ Report any defects immediately to your supervisor.
ÿ Mark defective truck and take it out of service.
ÿ Do not return the industrial truck to service until you have identified and rectified the
fault.

Testing and replacing hydraulic hoses

Hydraulic hoses can become brittle through age and must be checked at regular
intervals. The application conditions of the industrial truck have a considerable impact
on the ageing of the hydraulic hoses.
ÿ Check the hydraulic hoses at least annually and replace if necessary.
ÿ If the operating conditions become more arduous the inspection intervals must be
reduced accordingly.
ÿ In normal operating conditions a precautionary replacement of the hydraulic hoses
is recommended after 6. The owner must carry out a risk assessment to ensure
safe, prolonged use. The resulting protection measures must be observed and the
inspection interval reduced accordingly.

2.6 Working in the vicinity of the engine

A WARNING!
Danger from hot fluids and components
ÿ Consumables (hydraulic oil, engine oil, coolant) and power train components
(engine, manifold, exhaust system, turbo charger etc.) get very hot during
operation.
ÿ When carrying out maintenance and repairs wear suitable protective clothing
(gloves etc.) to avoid getting burned.

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3 Lubricants and Lubrication Schedule
3.1 Handling consumables safely
Handling consumables

Consumables must always be handled correctly. Follow the manufacturer's

instructions.

A WARNING!
Improper handling is hazardous to health, life and the environment
Consumables can be flammable.
ÿ Keep consumables away from hot components and naked flames.
ÿ Always keep consumables in prescribed containers.
ÿ Always fill consumables in clean containers.
ÿ Do not mix up different grades of consumable. The only exception to this is when
mixing is expressly stipulated in the operating instructions.

A CAUTION!
Spilled consumables can cause slipping and endanger the environment
Risk of slipping from spilled consumables. The risk is greater when combined with
water.
ÿ Do not spill consumables.
ÿ Spilled consumables must be removed immediately with an appropriate bonding
agent.
ÿ The bonding agent / consumable mixture must be disposed of in accordance with
regulations.

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 A WARNING!
Improper handling of oils can be hazardous
Oils (chain spray / hydraulic oil) are flammable and poisonous.
ÿ Dispose of used oils in accordance with regulations. Store used oil safely until it can
be disposed of in accordance with regulations.
ÿ Do not spill oil.
ÿ Spilled oils must be removed immediately with an appropriate bonding agent.
ÿ The mixture consisting of the bonding agent and oil must be disposed of in
accordance with regulations.
ÿ Observe national regulations when handling oils.
ÿ Wear safety gloves when handling oils.
ÿ Prevent oil from coming into contact with hot motor parts.
ÿ Do not smoke when handling oil.
ÿ Avoid contact and digestion. If you swallow oil do not induce vomiting but seek
medical assistance immediately.
ÿ Seek fresh air after breathing in oil fumes or vapours.
ÿ If oil has come into contact with your skin, rinse your skin with water.
ÿ If oil has come into contact with your eyes, rinse them with water and seek medical
assistance immediately.
ÿ Replace oil-soaked clothing and shoes immediately.

A CAUTION!
Consumables and used parts are an environmental hazard
Used parts and consumables must be disposed of in accordance with the applicable
environmental-protection regulations. Oil changes should be carried out by the
manufacturer's customer service department, whose staff are specially trained for this
task.
ÿ Note the safety regulations when handling these materials.

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3.2 Lubrication Schedule

T Contact surfaces 0 Hydraulic oil drain plug

I Grease nipple
a Hydraulic oil filler plug
• Coolant filler cap
Engine oil filler neck

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 3.3 Consumables

Code Order no. Quantit Capaci Component Used for

y ty
A 51037495 1L 55 I HVI Hydraulic System
Renolin B46
51037499 5I
A1' 51380210 5L 55 I Renolin Hydraulic System
MR68 MC
A2) 51380205 5L 55 I Renolin xtreme Hydraulic System
Temp 32
E 50354629 400 gr Lubrication Mast roller and
grease sideshifter contact
K-P-2K-N-30 surfaces; steering axle
G 29201280 0.4 L Chain spray Chains
K 51210409 4.0 I 4.5 I Titan GT 1 Pro C- Engine oil
(TFG) 3 SAE 5W-30
4.3 I
(DFG)
M 51332291 1L 7.0 I Fricofin V Coolant*

* The coolant consists of a 1:1 mixture ratio of Fricofin V and demineralised water.
1) This hydraulic oil is used in permanent ambient temperatures in excess of 30°C.
2)
This hydraulic oil is used in permanent ambient temperatures below 0°C.
The volumes indicated are approximate.

A WARNING!
Using incorrect hydraulic oil can be dangerous
ÿ Do not use hydraulic oils with a different specification or viscosity and do not mix
with additives.

Grease guidelines

Code Saponification Dew point Worked NLG1 class Application

°C penetration at temperature °C
25°C
E Lithium >250 265-295 2 -30 to +150

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 Coolant Specification

The quality of the coolant used can have a major impact on the efficiency and service
life of the cooling circuit. The recommendations listed below are useful for servicing a
good cooling circuit with anti-freeze and/or anti-corrosion.
3 Always use clean, demineralised water.

A DANGER!
Anti-freeze is poisonous
ÿ Anti-freeze contains ethylene glycol and other components which can result in
poisoning if ingested.
ÿ Ingression into the human body can also result if poisonous quantities come into
contact with the skin for long or repeated periods.
ÿ Note the manufacturer's safety instructions.

The quality of the anti-freeze must be checked at least annually, e.g. at the start of the
cold season.
If the correct procedures are not applied, the manufacturer cannot be held liable for
frost or corrosion damage.

NOTE
Corrosion damage
ÿ Even if the coolant cannot freeze up due to the application conditions, you must still
use anti-freeze. The anti-freeze provides protection against corrosion and raises the
boiling point of the coolant.

NOTE
Anti-freeze/demineralised water mixture ratio:
ÿ 1:1 (anti-freeze to -35°C)
ÿ Never mix different types of anti-freeze.

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 4 Maintenance and repairs
4.1 Preparing the truck for maintenance and repairs
All necessary safety measures must be taken to avoid accidents when carrying out
maintenance and repairs. The following preparations must be made:

Procedure
ÿ
Park the truck securely, see "Parking the truck
securely" on page 84.
ÿ
Fully lower the load handler.
• Remove the key from the key switch (85) to
prevent the truck from being switched on
accidentally.
• Press the Emergency Disconnect switch (86).

A WARNING!
Risk of accidents when working under
the load handler, driver's cab and lift
truck
ÿ When working under a raised load
handler, driver's cab or a raised truck,
secure them to prevent the truck from
from lowering, tipping or sliding away.
ÿ When raising the truck, follow the
instructions, see "Lifting the truck by
crane" on page 38. When working on the
parking brake, prevent the truck from
accidentally rolling away (e.g. with
wedges).

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4.2 Lifting and jacking up the truck safely

A WARNING!
A truck tipover can cause accidents
In order to raise the truck, use only suitable lifting gear at the points specially provided
for this purpose.
ÿ Note the weight of the truck on the data plate.
ÿ Always use a jack with a minimum capacity of 5000 kg kg.
ÿ Raise the unladen truck on a level surface.
ÿ When raising the truck, take appropriate measures to prevent it from slipping or
tipping over (e.g. wedges, wooden blocks).

Raising andjacking up the truck securely

Requirements
- Prepare the truck for maintenance and repairs (see "Preparing the truck for
maintenance and repairs" on page 195).

Tools and Material Required

- Jack
- Hard wooden blocks

Procedure
• Place the jack against the contact point.
Jack contact point, see "Identification Points and Data Plates" on page 31.
• Raise the truck.
ÿ
Support the truck with hard wooden blocks.
• Remove the jack.

The truck is now securely raised andjacked up.

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 4.3 Opening the rear panel
I
Opening the panel

Requirements
- Prepare the truck for maintenance and
repairs (see "Preparing the truck for
maintenance and repairs" on page 195).

Procedure
• Undo the two quick release fasteners (198).
ÿ
Pull the rear panel back and remove it.
The rear panel is now open. The fuses and 198
other electrical components can now be
reached.

Closing the panel

Procedure
• Place the rear panel in position.
• Secure two quick release fasteners (198).
The rear panel is now closed.

4.4 Unlocking the engine bonnet

Unlocking the engine bonnet

Requirements 123
- For trucks with a closed cab, open both
cab doors before lifting the engine cover
(O).
Procedure
• Set the steering column to the parking
position (see "Adjusting the steering wheel
/ steering column" on page 74).
• Tilt the backrest forward, move the driver's
seat forward and lock it in position (see
"Adjusting the driver's seat" on page 71).
• Pull the lever (126) in the arrow
direction (124) until the engine cover is
unlocked.
The engine cover is now slightly open.

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 Engine cover emergency unlocking 199
Requirements
- The engine cover cannot be unlocked.
Procedure
• Open the floor plate by undoing the quick release
fasteners.
• Pull the cable (200) on the cover lock (199).
• Raise the engine cover until it engages in the first
stage.
\
200

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 4.5 Opening the engine cover

,.-r

<w \
\\vf
\ \V.
- m,
"
'h \ \ N
\ \ v-
1

118
S\ \

Set the seat to the forward position 201 119

Requirements
- The engine cover is unlocked, see "Unlocking the engine bonnet" on page 197.
- The seat is locked in the forward position.

Procedure
• Turn the lever (201) left to unlock the seat.
• Apply the lever (1 18) and pull the seat forward.
• Turn the lever (201) right to lock the seat.
• Pull the lever (1 19) to flip the backrest over.

The seat is locked in the forward position.

202
NOTE
Opening the engine cover
ÿ The engine panel can be locked in the
50° and 70° positions. The 50° position
is locked by gas pressure spring (203)
while the 70° position is locked by gas %
pressure spring (204).

Open the engine cover (18) as far as the 70

stage.

Requirements
- The engine cover is unlocked, see "Unlocking 205
the engine bonnet" on page 197.

Procedure
• Fold the backrest down.
• Move the armrest down, to do this pull the locking lever (196).
• Push the driver's seat forward.
• Push the lock (205) of the gas pressure spring (203) and unlock it.

LLI • Pull the engine cover further up and engage it in the lock (205) of the gas pressure
spring (204).
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199
 The engine cover is now open.

Open the engine cover (18) up to the 700

level.
Requirements
- The engine cover is unlocked, see "Unlocking
the engine bonnet" on page 197.

Procedure
ÿ
Push the lock (205) of the gas pressure
spring (203) and unlock it.
• Pull the engine cover further up and engage it
in the lock (205) of the gas pressure
spring (204).
The engine cover is now open.

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 Closing the engine cover

Procedure
• Raise the engine cover (18) slightly and hold
it in place.
• From the 70° stage push in the red lock
(205) of the right hand gas pressure spring.
The engine cover is unlocked.
• Lower the engine cover as far as the 50°
stage.
• Raise the engine cover again slightly.
• From the 50° stage push in the red lock
(205) of the left hand gas pressure spring.
• Close the engine cover and make sure it is
205
locked correctly.
• Move the backrest back, move the armrest
up, push back and lock the drivers seat.
• To adjust the seating position and steering wheel position to your requirements, see
"Adjusting the driver's seat" on page 71.

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4.6 Replacing wheels

A WARNING!
A truck tipover can cause accidents
In order to raise the truck, use only suitable lifting gear at the points specially provided
for this purpose.
ÿ Note the weight of the truck on the data plate.
ÿ Always use a jack with a minimum capacity of 5000 kg kg.
ÿ Raise the unladen truck on a level surface.
ÿ When raising the truck, take appropriate measures to prevent it from slipping or
tipping over (e.g. wedges, wooden blocks).

A WARNING!
Falling wheels can cause injury
ÿ The wheels of the truck are very heavy. A single wheel can weigh up to 150 kg.
ÿ Always replace wheels with a suitable tool and protective equipment.

Removing the wheels

Requirements
- Prepare the truck for maintenance and repairs
(see "Preparing the truck for maintenance and
lo
repairs" on page 195).
Oq
Tools and Material Required 206
- Jack
- Hard wooden blocks
- Mounting lever
- Torque wrench

Procedure
ÿ
Place the jack against the contact point.
Jack contact point, see "Identification Points and Data Plates" on page 31 .
• Raise the truck.
• Support the truck with hard wooden blocks.
• Undo the wheel attachment (206).
• Remove the wheel, using a suitable mounting lever if necessary.
The wheel has now been removed.

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202
 Fitting the wheels

Procedure
• Fit the wheel using a suitable mounting lever if
necessary.
• Fit the wheel attachment.
• Remove the hard wooden blocks.
• Lower the truck.
ÿ
Torque the wheel attachment (206) crosswise
with a torque wrench; torques see "Tyre type" on
page 28.
The wheel has now been fitted.

0 When using pneumatic tyres check the air pressure, for the air pressure see "Tyre
type" on page 28

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4.7 Checking the Wheel Mounting

A WARNING!
Using different tyres can cause accidents
The quality of tyres affects the stability and performance of the truck.
ÿ The diameter of the wheels must differ by no more than 15 mm.
ÿ Always replace tyres in pairs. After replacing the tyres check the wheel nuts are
secure after 10 service hours.
ÿ Always use tyres of the same make, model and profile.

Checking the wheel attachment

Requirements
- Prepare the truck for maintenance and repairs
(see "Preparing the truck for maintenance and
00
repairs" on page 195).

Tools and Material Required 206

- Torque wrench
Procedure
• Torque the wheel nuts (206) crosswise with a
torque wrench, for torques see "Tyre type" on
page 28.
The wheel attachment is now checked.

When using pneumatic tyres check the air pressure, for the air pressure see "Tyre
type" on page 28

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 4.8 Hydraulic system

A CAUTION!
The hydraulic oil is pressurised during operation and is a hazard to health and to the
environment.
ÿ Do not touch pressurised hydraulic lines.
ÿ Dispose of used oil in accordance with regulations. Store used oil safely until it can
be disposed of in accordance with regulations.
ÿ Do not spill hydraulic oil.
ÿ Remove any spilled hydraulic immediately with an appropriate bonding agent.
ÿThe bonding agent / consumable mixture must be disposed of in accordance with
regulations.
ÿ Observe national regulations when handling hydraulic oil.
ÿ Wear safety gloves when handling hydraulic oil.
ÿ Prevent hydraulic oil from coming into contact with hot motor parts.
ÿ Do not smoke when handling hydraulic oil.
ÿ Avoid contact and digestion. If you swallow oil do not induce vomiting but seek
medical assistance immediately.
ÿ Seek fresh air after breathing in oil fumes or vapours.
ÿ If oil has come into contact with your skin, rinse your skin with water.
ÿ If oil has come into contact with your eyes, rinse them with water and seek medical
assistance immediately.
ÿ Replace oil-soaked clothing and shoes immediately.

A CAUTION!
Consumables and used parts are an environmental hazard
Used parts and consumables must be disposed of in accordance with the applicable
environmental-protection regulations. Oil changes should be carried out by the
manufacturer's customer service department, whose staff are specially trained for this
task.
ÿ Note the safety regulations when handling these materials.

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4.8.1 Checking the hydraulic oil level

Requirements
- Park the truck on a level surface.

- Start the engine and fully raise and lower the

mast once.
- Switch off the engine.
Procedure
• Remove the hydraulic oil dipstick (207) from
the hole, wipe it with a clean cloth and insert it
fully again.
ÿ
Remove the hydraulic oil dipstick and check
the level of the hydraulic oil.
a For cold oil: the oil level should lie between the
MIN and MAX markings.
For hot oil: the oil should lie just above the
MAX marking.
• Add hydraulic oil if necessary.
• Repeat the test.
• When the oil level is correct, fully insert the hydraulic oil dipstick (207) again.

4.8.2 Adding hydraulic oil

208
Procedure
• Unscrew the filler cap (208).
ÿ
Add hydraulic oil in small amounts.
s Use only approved hydraulic oil (see
consumables table).
ÿ
Keep checking the hydraulic oil level with the
dipstick until you have reached the correct oil
level, see "Checking the hydraulic oil level" on
page 206
ÿ
Screw the filler cap back on.
ÿ
Insert the hydraulic oil dipstick back in full.

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 4.8.3 Replacing the hydraulic oil filter

Procedure
• Unscrew the cap of the hydraulic oil filter (209).
• Remove the filter from the cover.
• Insert a new filter and screw the lid back on.

4.8.4 Replacing the ventilation/discharge filter

Procedure
• Unscrew the ventilation/discharge filter (210).
• Visually inspect the filter.
• If contaminated insert a new filter.
• Screw the ventilation/discharge filter back on.

a Collect any spilled hydraulic oil. Dispose of the

hydraulic oil and hydraulic oil filter and fuel in
accordance with environmental regulations.

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4.9 Engine maintenance

A WARNING!
Turning and hot components can cause trapping and burning hazards when the
engine is running.
When the cover is open turning and hot components are freely accessible and can
cause injury if touched.
ÿ Before starting work make sure that the Emergency Disconnect switch can be
reached to switch off the engine.
ÿ Do not touch moving parts (e.g. fans, belt drives etc.) or hot surfaces.
ÿ Truck maintenance and repair work must only be carried out by specially trained
personnel who have been authorised by the owner.

4.9.1 Starting the engine with the cover open

The engine can only be started with the cover

open in exceptional circumstances (e.g. jump
starting).

Procedure
• Switch on the ignition, see page 81
• Press the override switch (197) a single time.
• Start the engine, see page 82.
• Switch off the engine with the Emergency
Disconnect switch (86), the key switch (85) or
the keyless access systems, see "Keyless
Access System" on page 123.

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 4.9.2 DFG engine maintenance

NOTE

Used oil contaminates the environment

ÿ Dispose of used oil and used engine oil filters in accordance with environmental
regulations.

A CAUTION!
Hot oil can burn.
ÿ Wear appropriate safety gloves when replacing the oil and oil filter.

NOTE
When the engine is cold the engine oil can be viscous.
ÿ Only change the engine oil when the engine is at operating temperature and the
industrial truck is horizontal. Always replace the engine oil and engine oil filter
together.

Checking the engine oil level

Park the truck securely on a level surface, see

Wipe the dipstick with a lint-free cloth and put

in back fully into the opening. ->
Remove the dipstick again and check that the f,
oil level is between the MIN and MAX <

If the engine oil level is below the bottom MIN

marking, add more oil (see "Consumables" on
page 193).
The engine oil level has now been checked.

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 Draining the engine oil fir r\
fe cÿ
Procedure s\
• Unscrew the filler cap (208).
ÿ
Remove the floorboard. 7 t es>%
• Thoroughly clean the oil drain plug (212) and 'Ik -/{/ <*=*- \
around the drain hole. A

• Unscrew the oil drain plug.

ÿ
Collect any oil that emerges.
• Screw in the oil drain plug with a new seal
(torque 30 Nm).

__
212

....
Replace the engine oil filter -208

Procedure 3sM eeTmÿ

.
Unscrew and remove the oil filter lid (214).
/SrJi lli'fesll w
Remove the oil filter from the oil filter
W ffli \Y;
—"ii \\
-f \
\\
\

-213
housing (213).
• Collect any oil that emerges. 214
» Thoroughly clean the raised faces of the

oil filter housing and oil filter lid.

• Insert a new oil filter in the oil filter
housing.
ÿ
Apply a thin layer of oil to the seal of the
oil filter lid.
• Torque the oil filter lid to 25 Nm.

Adding engine oil 208-

ui/
Procedure
• Add fresh engine oil (see "Consumables"
on page 193) through the filler port (208).
211
• Check the engine oil level with the dipstick
(21 1) and top up if necessary.
• Screw the filler cap back on.
• Attach the floor plate.

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 NOTE 0 km h

The incorrect amount of oil will damage 08:38™

the engine. f ÿ \ ""

ÿ After replacing the oil and oil filter carry
ÿ 4 12345.
out a test run and check the oil pressure
display (134). [To *< Po Po (!)
ÿ Check that the oil drain plug and oil filter
housing are tight. o o o o
134

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4.9.3 Replacing the fuel filter

NOTE
Fuel can cause environmental damage
ÿ Bind any spilled diesel fuel with suitable 216
absorbing agents.
ÿ Dispose of the absorbed diesel fuel and
the fuel filter in accordance with the
relevant environmental protection laws.
217
- Mark the fuel hoses (216) and loosen the
218
clamps (217) from the fuel filter.
- Slacken the mounting clamp (218) and
remove the fuel filter (215).
- Fill the new fuel filter entirely with clean
diesel and fit it with the collar screw (218). 216
- Refit the fuel hoses and tighten them with
clamps.

4.9.4 Check V-belt for damage

NOTE
A damaged V-belt will result in malfunctions.
ÿ If the V-belt is not in a suitable condition, you must only start to use the truck when
the damage has been rectified.

Procedure
ÿ
Check the V-belt (219) for cracks,
deformation and wear.

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 4.9.5 TFG engine maintenance

NOTE

Used oil contaminates the environment

ÿ Dispose of used oil and used engine oil filters in accordance with environmental
regulations.

A CAUTION!
Hot oil can burn.
ÿ Wear appropriate safety gloves when replacing the oil and oil filter.

NOTE
When the engine is cold the engine oil can be viscous.
ÿ Only change the engine oil when the engine is at operating temperature and the
industrial truck is horizontal. Always replace the engine oil and engine oil filter
together.

Checking the engine oil level

Requirements
- Park the truck securely on a level surface, see
page 84.
Procedure « ÿ

• Remove the dipstick (211).

ÿ
Wipe the dipstick with a lint-free cloth and put
in back fully into the opening.
• Remove the dipstick again and check that the MAX
oil level is between the MIN and MAX MIN 211
markings.
ÿ
If the engine oil level is below the bottom MIN marking, add more oil (see
"Consumables" on page 193).
The engine oil level has now been checked.

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 Draining the engine oil

Procedure
• Remove the floorboard.
ÿ
Unscrew the filler cap (208).
• Thoroughly clean the oil drain plug (212) and
around the drain hole.
• Unscrew the oil drain plug.
ÿ
Collect any oil that emerges.
• Screw in the oil drain plug with a new seal
(torque 30 Nm).

Replace the engine oil filter

Procedure
• Undo the oil filter (220) with a filter wrench and
manually unscrew it.
• Thoroughly clean the sealing faces of the oil
filter flange.
• Apply a thin layer of engine oil to the seal of the
new oil filter.
• Hand-tighten the oil filter.

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 Addling engine oil
211
Procedure
• Add fresh engine oil (see "Consumables" on
page 193) through the filler port (208).
• Check the engine oil level with the dipstick
(21 1) and top up if necessary.
• Screw the filler cap back on.
ÿ
Attach the floor plate.
, J
a
\

NOTE 0 km h

The incorrect amount of oil will damage 08 !38biti

the engine. <ÿ\ tJtr ( [—1 \ *ÿ-

IP 1;
ÿ After replacing the oil and oil filter carry
out a test run and check the oil pressure
ÿ *! ,L,
display (134). [To a- p-o % (!)
ÿ Check that the oil drain plug and oil filter
housing are tight. o o o o
134

221

—aKravsJ:

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4.9.6 Replacing spark plugs

Procedure
• Remove spark plug connector (221).
• Thoroughly clean around the spark plugs on
the cylinder head.
• Unscrew the spark plugs.
• Check the electrode distance of the new
spark plugs with a feeler gauge.
3 Rated value: 1.0 mm ± 0.1mm.
• Screw in the spark plugs by hand and then
torque them to 25 Nm.

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 4.9.7 Check V-belt for damage

NOTE
A damaged V-belt will result in malfunctions.
ÿ If the V-belt (219) is not in good condition, first rectify the damage before using the
truck.

Procedure
• Check the V-belt (219) for cracks,
deformation and wear.

219

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4.9.8 Cooling system

NOTE
Lack of coolant can cause malfunctions
ÿ The coolant level should be between the "MIN" and "MAX" markings on the
expansion vessel.
ÿ If the coolant is below the MIN marking, this indicates possible leakage in the
radiator system.
ÿ Do not continue using the truck.
ÿ The truck may only be started again once the cause has been removed.

A CAUTION!
Hot coolant can cause injury
ÿ If necessary, allow the engine to cool down sufficiently to prevent hot gases/liquids
from escaping when the filler cap is opened.

y.
Checking the coolant level

Procedure
ÿ
Park the truck securely on a level surface. c

ÿ
Open the rear bonnet locks and lift off the
222 rt i-

rear bonnet, see "Opening the rear panel" 7 L

on page 197. =jj 0

• Check the coolant level on the expansion

vessel (222).
• Fit the rear cover (223) and snap it back into
position.

NOTE
The incorrect coolant can cause
malfunctions
ÿ To prevent the build up of lime as well as
front and corrosion damage in the
radiator system, and to raise the boiling
point temperature of the coolant, the
cooling circuit must be filled each year
with a mixture of demineralised water
and anti-freeze with anti-corrosion
additives.
ÿ Coolant can only be checked and added
by experts.

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 Check the coolant concentrate
Tools and Material Required 224
- Anti-freeze tester for coolants
Procedure
• Slowly unscrew the filler cap (224) from the
expansion vessel (222).
• Check the anti-freeze content of the coolant
with an anti-freeze tester.

NOTE
The incorrect coolant concentration
can cause malfunctions
ÿ If there is insufficient anti-freeze content
arrange for trained personnel to restore
the correct mixture ratio.

Screw the filler cap back on.

Fit the rear bonnet again and snap it back into position.

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 Check the cooler and fan and clean if necessary
Requirements
- Park the truck securely on a level surface see page 84.
Procedure
• Remove minor contamination from the fan grille (225) with weak suctioned air.

A CAUTION!
Risk of incorrect disassembly/assembly of fan unit
ÿ Only trained personnel may remove major cooler contamination.

ÿ
Remove the four mounting screws (226) and washers and place the fan unit to the
front.
Take care not to bend or strain the fan unit hydraulic hoses in the process.
• Remove any contamination from the radiator and fan with weak suctioned air.
• Take care not to damage the cooler plates and the fan blades.

A CAUTION!
A damaged cooler and fan can be dangerous
ÿ Check the radiator and fan for damage.
ÿ If the radiator or fan are damaged, only start to use the truck when the damage has
been rectified.

225
Fan unit assembly

Procedure
• Mount the fan unit to its intended place with
the four mounting screws (226).
~ÿ\ Make sure that the fan unit is installed
centrally.

A DANGER!
A broken fan can be dangerous
ÿ Using a suitable tool check and make
sure that the fan can move freely.
ÿ The fan must not touch the deflector.
ÿ Only start the engine when the engine
cover is closed. 226

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 4.9.9 Replace air filter cartridge

A DANGER!
A running engine can be dangerous
ÿ Carry out all maintenance work with the engine switched off.
ÿ Do not start the engine if the air filter cartridge is removed.

Replace air filter cartridge 227

Procedure
• Undo the 3 mounting clamps (227) and remove
the dust collector pot.
• Carefully remove the air filter cartridge from the
filter housing.

Cleaning the filter housing

Procedure
NOTE 227
A faulty engine can cause malfunctions
ÿ Do not clean the air filter housing with
compressed air.
ÿ Always use a clean cloth to clean the air
filter housing.

ÿ
Remove the air filter cartridge.
• Thoroughly clean the dust collector pot. to do this remove the dust extraction valve.
Carefully clean the air filter housing with a clean cloth.
a There must be no residue from the cloth in the air filter housing.
Insert the air filter cartridges back in the filter housing.
Take care not to damage the air filter cartridges when assembling.
Fit the rubber element back into the dust collector pot.
Insert the dust collector pot and secure it with the 3 mounting clamps (227).

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4.9.10 Heating and air conditioning system (O)

Replacing the air conditioning filter 164

-165
Procedure
• Turn the twist off knob (166) anti-clockwise.
• Pull the filter cassette (165) out in the direction .166
of the arrow.
• Replace the filter.
• Insert the filter cassette (165) into the heating
console (164).
• Turn the twist-off knob clockwise
iJ
The filter cassette has been replaced and locked.

@ Regular servicing is required to ensure the filter can work at a consistently high
level, see "Servicing and Inspection" on page 239.

4.9.11 Adding window washer system fluid

Procedure
• Unlock the engine cover, see
"Unlocking the engine bonnet" on
page 197.
• Make sure there is sufficient window
fluid in the container (228).
• If necessary top up with anti-freeze.

Fill with weather-dependent additives.

228

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 4.10 Checking electrical fuses

A WARNING!
Electrical current can cause accidents
Make sure the electrical system is voltage-free before starting work on it. Before
starting maintenance on the electrical system:
ÿ Park the truck securely (see page 84).
ÿ Press the Emergency Disconnect switch.
ÿ Disconnect the battery (remove ground connection with battery quick release).
ÿ Remove any rings or metal bracelets etc. before working on electrical components.

A CAUTION!
The use of incorrect fuses can cause fire and damage components
The use of incorrect fuses can damage the electrical system and result in fire. The
safety and functionality of the truck cannot be ensured.
ÿ Use only fuses with the prescribed rated current, see "Fuse ratings" on page 224.

Checking electrical fuses

Requirements
- Prepare the truck for maintenance and repairs (see "Preparing the truck for
maintenance and repairs" on page 195).

Procedure
• Open the rear cover of the truck, see "Opening the rear panel" on page 197.
ÿ
Remove the electrical system cap.
• Check condition and rating of the fuses in accordance with the table.
• To do this: Insert the fuse to be check in the fuse socket (53 F21).
• If the fuse is intact the LED will be lit.
• Replace any damaged fuses in accordance with the table.
• Close the electrical system cap.
• Close the rear cover of the truck.
The electrical fuses are now checked.

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4.10.1 Fuse ratings

1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
27 roo 29 30 31 32 33 34 35 36 37 CO o 39

it it it it it it it it it it it it it
it it it it it it it it it it it it it
It it II; It it It It It It It It It It
t It t It t t t t t
It It It It It It It It It It It It It
It it It t It t It It t It It It It

45 46 47 48
60

ÿ ÿÿÿ @

Item Component Electric circuit Rating (A)

1 4F4 Beacon / strobe light 7.5
2 9F1 Front window wipers 7.5
RFI dipped lights 5
3 5F5.3
RH dipped lights (set A version) 5
4 Not used
5 5F4.1 LH parking light 7.5
6 4F6 Brake light 10
7 5F4 RH parking light 7.5
8 4F5.1 Left indicator 5
9 4F5.2 Right indicator 5
10 6F5 Road traffic regulations armrest 2
11 4F9 E Box 2
12 3F5 Terminal 30 access 5
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 Item Component Electric circuit Rating (A)
13 9F35 Coolant pump (TFG) 5
ECU supply (DFG)
14 2F1 Wash pump 5
LH dipped lights 5
15 5F5.1
LH dipped lights (set A version) 5
16 4F2 Buzzer 5
17 Not used
18 F1.1 Terminal 15 armrest 5
19 9F26 Sensors on mast 2
20 9F32 Fuel pump (DFG only) 10
21 0F1 Option relay 1 15
22 9F17.2 Terminal 15 options connector 2
23 0F2 Options relay 2 7.5
24 0F3 Options relay 3 5
25 9F17.1 Terminal 15 options connector 2
26 9F17 Terminal 15 options connector 2
27 9F5 Rear window heating 10
28 5F1 Front work lights 10
29 9F2 Seat heating 10
30 9F14 Rear windscreen wiper 7.5
31 5F1.2 Rear work lights 10
Air mass meter (DFG only)
Boost pressure relief (DFG only)
32 9F25 5
Fuel cutout (TFG only)

33 9F31 Charge control generator 5

34 4F1 Florn 10
35 4F11 ECU terminal 15 engine controller 5
36 4F11.1 TCU terminal 15 engine controller 5
37 9F17.5 Option connector XS1 82/6 terminal 30 2
38 9F17.4 Option connector XS182/5 terminal 30 2
39 9F17.3 Option connector XS1 82/4 terminal 30 2
53 Fuse tester
54 9F24 Radio 10
55 5F8 Reading light 5
56 F14 Fl eating 30
57 9F30 TCU terminal 30 truck controller 25
58 Engine controller ECU terminal 30 (DFG 30
9F27
only)

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 Item Component Electric circuit Rating (A)
59 Control valve for common rail (DFG only) 15
Immobiliser (DFG/TFG)
9F29
Ignition (TFG only)

Lambda probe (TFG only) (0)

Pre-heat time control (DFG only)

60 9F28 Injection start valve (DFG only) 10

Fuel control valve (TFG only) (O)

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 Relay
Item Component To protect:
40 9K6 Rear window heating
41 9K25 Fuel pump
42 9K5 Seat heating
43 4K7 Horn
44 7K5 Engine start with bonnet open
45 9K3 Starter relay
46 9K23 Ignition on - engine not running
47 9K24 Ignition on - engine running
48 9K22 Engine main relay
49 9K16 Heating
50 2K63.1 Options relay
51 2K63.2 Options relay
52 2K63.3 Options relay

Check main fuses (engine compartment)

Requirements
-Prepare the truck for maintenance and repairs (see "Preparing the truck for
maintenance and repairs" on page 195).

Procedure
• Open the engine cover, see "Unlocking the engine bonnet" on page 197.
• Remove the fusebox cover.
• Check condition and rating of the fuses in accordance with the table.
• Replace any damaged or incorrect fuses in accordance with the table.
• Close the fusebox cover.
• Close the engine cover, see "Unlocking the engine bonnet" on page 197.
The main fuses (engine compartment) are now checked.

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 Item Component To protect: Rating
(A)
71 9F18 Preheat (DFG only) 50
71 9F35 ECU engine controller (TFG only) 20
72 Not used
73 F21 Load Damping 100
74 Not used
75 F22 Engine main relay 100
76 F19.4 12V 40
77 F19.3 12V 70
78 F21.1 Ignition relay 70
79 9F19 Alternator 125

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 4.11 Cleaning

A CAUTION!
Fire hazard
The truck must not be cleaned with flammable fluids.
If flammable materials are not removed from the engine compartment, they can come
into contact with hot components and cause a fire.
ÿ Carry out all necessary safety measures to prevent sparking before cleaning (e.g.
by short-circuiting).
ÿ Remove all deposits / accumulations of flammable materials from the engine
compartment.

A CAUTION!

Risk of component damage when cleaning the truck

Cleaning with a pressure washer can result in malfunctions due to humidity.
ÿ Cover all electronic system assemblies (controllers, sensors, motors etc.) before
cleaning the truck with a pressure washer.
ÿ Do not hold the jet of the pressure washer by the marked points to avoid damaging
them (see "Identification Points and Data Plates" on page 31).
ÿ Do not clean the truck with pressurised water.

Cleaning the truck

Requirements
- Prepare the truck for maintenance and repairs (see "Preparing the truck for
maintenance and repairs" on page 195).
Tools and Material Required
- Water-based solvents
- Sponge or cloth
Procedure
• Clean the surface of the truck with water-based solvents and water. Use a sponge
or cloth to clean.
• In particular, clean the following areas:
• Windows
• All walk-on areas
• Oil filler ports and their surroundings
• Grease nipples (before lubrication)
• Dry the truck after cleaning, e.g. with compressed air or a dry cloth.
• Carry out all the tasks in the section "Recommissioning the truck after cleaning or
maintenance work" (see "Restoring the truck to service after maintenance and
repairs" on page 233).
The truck is now clean.

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 A CAUTION!
Risk of electrical system damage
Cleaning the assemblies (controllers, sensors, motors etc.) of the electronic system
with water can damage the electrical system.
ÿ Do not clean the electrical system with water.
ÿ Clean the electrical system with weak suction or compressed air (use a compressor
with a water trap) and not a conductive, anti-static brush.

Cleaning the electrical system assemblies

Requirements
- Prepare the truck for maintenance and repairs (see "Preparing the truck for
maintenance and repairs" on page 195).
Tools and Material Required
- Compressor with water separator

- Non-conductive, antistatic brush

Procedure
ÿ
Expose the electrical system, see "Opening the rear panel" on page 197.
• Clean the electrical system assemblies with weak suction or compressed air (use a
compressor with a water trap) and not a conductive, anti-static brush.
• Fit the electrical system panel, see "Opening the rear panel" on page 197.
• Carry out all the tasks in the section "Recommissioning the truck after cleaning or
maintenance work" (see "Restoring the truck to service after decommissioning" on
page 236).
The electrical system assemblies are now clean.

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 4.12 Starter battery
Checking the battery condition, acid level* and acid density*

a *not for maintenance-free batteries

A WARNING!
Batteries can be hazardous
Batteries contain an acid solution which is poisonous and corrosive. Avoid contact
with battery acid at all times.
ÿ Dispose of used battery acid in accordance with regulations.
ÿ Always wear protective clothing and goggles when working with batteries.
ÿ Do not let battery acid come into contact with skin, clothing or eyes. If necessary,
rinse with plenty of clean water.
ÿ in the event of physical damage (e.g. skin or eye contact with battery acid) call for
a doctor immediately.
ÿ Spilled battery acid should be neutralised immediately with plenty of water.
ÿ Only batteries with a sealed battery container may be used.
ÿ Follow national guidelines and legislation.

Check battery
Procedure
• Check the battery housing for cracks and any spilled acid.
• Remove any oxidisation remains from the battery terminals.
» Lubricate the battery terminals with an acid-free grease.

Checking the acid density

Procedure
ÿ
Clean the area around the inspection plugs.
• Unscrew the drain plug.
The acid should lie between the top and bottom markings.
• If necessary, add distilled water to the top mark.
• Check the acid density with an acid siphon.
If the battery is charged sufficiently, the acid density should be 1.24 to 1.28 kg/I.
• Screw the inspection plugs back on.
• Recharge the battery as required.

Battery disposal

Batteries may only be disposed of in accordance with national environmental

protection regulations or disposal laws. The manufacturer's disposal instructions must
be observed.

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4.13 Exhaust system

NOTE
Check emissions at regular intervals
ÿ Check the combustion engine exhaust emissions at regular intervals in accordance
with national regulations.
ÿ Black or blue exhaust smoke is an indicator of high emission levels resulting from
combustion engine damage or wear.
ÿ In this case the truck must be examined by specialist personnel.

Check the exhaust system regularly for leaks.

Procedure
• Open the engine cover.
• Start the engine with the engine cover open see "Starting the engine with the cover
open" on page 208.
• Check for any rising smell of exhaust and altered engine noise level.
• If you detect a rising smell of exhaust and altered engine noise level arrange for the
exhaust system to be inspected by specialist personnel.
The exhaust system has now been checked for leaks.

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 4.14 Restoring the truck to service after maintenance and repairs
Procedure
• Thoroughly clean the truck, see "Cleaning" on page 229.
• Lubricate the truck according to the lubrication schedule, see "Lubrication
Schedule" on page 192.
• Clean the starter battery, grease the terminals and connect the starter battery.

A WARNING!
Faulty brakes can cause accidents
As soon as the truck has been started, test the brakes several times.
ÿ Report any defects immediately to your supervisor.
ÿ Tag out and decommission the faulty industrial truck.
ÿ Only return the truck to service when you have identified and rectified the fault.

• Start up the truck, see "Preparing the Truck for Operation" on page 66.

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5 Decommissioning the Industrial Truck
If the truck is to be out of service for more than a month, it must be stored in a frost-
free and dry room. All necessary measures must be taken before, during and after
decommissioning as described hereafter.
When the truck is out of service it must be jacked up so that all the wheels are clear
of the ground. This is the only way of ensuring that the wheels and wheel bearings are
not damaged.
a Jack up the truck, see "Lifting and jacking up the truck safely" on page 196.
If the truck is to be out of service for more than 6 months, agree further measures with
the manufacturer's customer service department.

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 5.1 Prior to decommissioning
Procedure
• Thoroughly clean the truck, see "Cleaning" on page 229.
• Prevent the truck from rolling away.
• Check the hydraulic oil level and replenish if necessary,
see "Checking the hydraulic oil level" on page 206.
• Apply a thin layer of oil or grease to any non-painted mechanical components.
• Lubricate the truck according to the lubrication schedule, see "Lubrication
Schedule" on page 192.
• Disconnect the battery, clean it and grease the terminals.
In addition, follow the battery manufacturer's instructions.

5.2 During decommissioning

NOTE
Full discharge can damage the battery
Self-discharge can cause the battery to fully discharge. Full discharge shortens the
useful life of the battery.
ÿ Charge the battery at least every 2 months.

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5.3 Restoring the truck to service after decommissioning
Procedure
• Thoroughly clean the truck, see "Cleaning" on page 229.
• Lubricate the truck according to the lubrication schedule, see "Lubrication
Schedule" on page 192.
• Clean the starter battery, grease the terminals and connect the starter battery.
• Charge the starter battery, see "Starter battery" on page 231 .
• Replace engine oil. Condensation water could have formed.
• Replace hydraulic oil. Condensation water could have formed.
@ The manufacturer's customer service department is specially trained to carry out
these operations.
• Start up the truck, see "Preparing the Truck for Operation" on page 66.

A WARNING!
Faulty brakes can cause accidents
As soon as the truck has been started, test the brakes several times.
ÿ Report any defects immediately to your supervisor.
ÿ Tag out and decommission the faulty industrial truck.
ÿ Only return the truck to service when you have identified and rectified the fault.

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 6 Safety tests to be performed at intervals and after unusual
incidents
The truck must be inspected at least annually (refer to national regulations) or after
any unusual event by a qualified inspector. The manufacturer offers a safety
inspection service which is performed by personnel specifically trained for this
purpose.
A complete test must be carried out on the technical condition of the truck with regard
to safety. The truck must also be examined thoroughly for damage.

The operating company is responsible for ensuring that faults are rectified
immediately.

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7 Final de-commissioning, disposal
l±J Final de-commissioning or disposal of the truck in must be performed in accordance
with the regulations of the country of use. In particular, regulations governing the
disposal of batteries, consumables and electronic and electrical systems must be
observed.

The truck must only be disassembled by trained personnel in accordance with the
procedures as specified by the manufacturer.

8 Human vibration measurement

@ Vibrations that affect the operator over the course of the day are known as human
vibrations. Excessive human vibrations will cause the operator long term health
problems. The European "2002/44/EC/Vibration" operator directive has therefore
been established to protect operators. To help operators to assess the application
situation, the manufacturer offers a service of measuring these human vibrations.

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 9 Servicing and Inspection

A WARNING!
Lack of maintenance can result in accidents
Failure to perform regular servicing can lead to truck failure and poses a potential
hazard to personnel and equipment.
ÿ Thorough and expert servicing is one of the most important requirements for the
safe operation of the industrial truck.

The application conditions of an industrial truck have a considerable impact on

component wear. The following service intervals are based on single-shift operation
under normal operating conditions. They must be reduced accordingly if the
equipment is to be used in conditions of extreme dust, temperature fluctuations or
multiple shifts.

NOTE
To prevent damage due to wear, the manufacturer recommends an on-site application
analysis to agree on appropriate service intervals.

The following maintenance checklist lists the activities to be performed and the
respective intervals to be observed. Maintenance intervals are defined as:

W = Every 50 service hours, at least weekly

A = Every 500 service hours
B = Every 1000 service hours, or at least annually
C = Every 2000 service hours, or at least annually
# = Standard maintenance interval
ÿ
_ Cold store maintenance interval (in addition to standard maintenance
interval)

"W" maintenance interval operations should be performed by the operating

company.
During the run-in period,after approx. 100 service hours, the owner must check the
wheel nuts/bolts and re-tighten if necessary.

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10 Maintenance checklist DFG
10.1 Operating Company

10.1.1 Standard Equipment

Braking W A B C
1 Test brakes.
•
Electrical system W A B C
1
Test warning and safety devices in accordance with operating
instructions. •
2 Test displays and controls.
3 Test the panel switch and check for damage.
••
4 Test emergency disconnect switch.
•
Power supply W A B C
Check battery cable connections are secure, check for dirt and ÿ
1
grease terminals if necessary.
2 Check battery and battery components. #
3 Check battery safety labels are present and check for damage.
•
Travel W A B C
1 Check coolant level and top up if necessary.
2 Check and clean radiator.
••
3 Check tyre pressure and correct if necessary.
4 Check wheels for wear and damage.
••
5 Check engine oil level and top up if necessary.
•
Chassis and superstructure W A B C
1 Check doors and/or covers.
2 Check labels are legible, complete and make sense.
••
Check engine compartment for contamination and clean if ÿ
3
necessary.
Check overhead guard and/or cab are secure and check for m
4
damage.
5 Test driver's seat restraint system and check for damage.
•
Hydraulic operations W A B C
1 Check load chain lubrication and lubricate if necessary.
2 Test hydraulic system.
••
3 Check the hydraulic oil level and top up if necessary.
4 Check the forks or load handler for wear and damage.
••
240
 10.1.2 Optional Equipment

Work lights

Electrical system W A B C
1 Test lighting.

Strobe light / beacon

•
Electrical system w A B C
1 Test strobe light / warning beacon and check for damage.

Heating coolant water

•
Chassis and superstructure w A B C
1 Test the heating.
2 Check heating vent filter for contamination and clean if necessary.
••
Clamping device

Hydraulic Operations w A B C
1 Check attachment lubrication; clean and lubricate if necessary.

Sideshifter
•
Hydraulic Operations w A B C
1 Check attachment lubrication; clean and lubricate if necessary.

Road traffic approval (StVZO)

•
Electrical system w A B C
1 Test lighting.

Telescopic forks
•
Hydraulic Operations w A B C
1 Check attachment lubrication; clean and lubricate if necessary.

Weather-proof system
•
Chassis and superstructure w A B C
1 Test the doors and check for damage.
•
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 Wiper/washer system

Chassis and superstructure W A B C

1
Check windscreen washer reservoir for leaks and check volume; top
up if necessary. •
Fork adjuster

Hydraulic Operations w A B C
1 Check attachment lubrication; clean and lubricate if necessary.

Optional equipment
•
Chassis and superstructure w A B C
Check that optional equipment such as mirrors, storage
1 compartments, grips, windscreen wipers and washing systems, etc.
are working correctly and check for damage. •

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 10.2 Customer Service

10.2.1 Standard Equipment

Brakes W A B C
1 Test brakes.
•
Electirical system W A B C
1
Test warning and safety devices in accordance with operating
instructions. •
2 Test displays and controls.
•
3 Test the panel switch and check for damage.
4 Test emergency disconnect switch.
•
•
5
Test key switch or alternative access system including the access
rights. •
6 Check contactors and/or relays.
7 Check fuse ratings.
••
8
Check electric wiring for damage (insulation damage, connections).
Make sure cable connections are secure. •
9
Check the electrical components that can be diagnosed, check
settings and adjust if necessary. •
Power supply W A B C
1 Check fuel system, tank and lines for leaks and damage.
•
2
Check battery cable connections are secure, check for dirt and
grease terminals if necessary. •
3 Check battery and battery components.
4 Check acid density, acid level and battery voltage.
••
5 Check battery safety labels are present and check for damage.
•
Trave1 W A B C
1 Test exhaust system and check for leaks and damage.
2
Note: Any work carried out on the particle filter system must only be
•
performed by specialist personnel.
3 Note: filter replacement depending on the ash loading.
4 Carry out particle filter service regeneration.
5 Check the wheel motor attachments.
••
6
Check the wheel motors and displacement pump for noise and
leakage. •
7
Check that hydraulic connections, hoses and pipes are secure and
check for leaks and damage. •
8 Check anti-freeze and top up if necessary.
9 Note: The radiator system is filled with demineralised water.
•
•
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10 Replace coolant and anti-freeze.
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Travel W A B C
11 Check cooling system for leaks.
12 Check coolant level and top up if necessary.
••
13 Test hydraulic fans, check for dirt, freedom of movement and leaks.
14 Check and clean radiator.
•••
15 Check tyre pressure and correct if necessary.
16 Check wheels for wear and damage.
17 Check wheel bearings and wheel mounting.
••
18 Test starter and alternator; check cables and mounting.
19 Check the low pressure circuit suction filter.
•• •
20 Replace fuel filter.
21 Replace engine oil filter.
•
22
Check V belt / multi-V belt is tensioned and check for damage.
Replace if necessary. •
23 Replace air filter.
24 Check air filter and replace if necessary.
•• •
25 Test the air filter monitor and check for damage.
26 Check engine for noise and leakage.
27 Replace engine oil.
••
28 Check engine oil level and top up if necessary.
29 Check engine mounting.
••
30
Check electrical connections of the glow plug system are secure and
not damaged. •
31 Check glow plugs.
Note: Replace the timing belt and the multi-V belt every 3000 service
•
32 hours and replace the water pump as well if necessary. The engine
could become damaged.
33 Check the timing belt.
34 Check and discharge fuel water separator.
• •
Chassis and superstructure W A B c
1 Check chassis and screw connections for damage.
2 Check doors and/or covers.
••
3 Check labels are legible, complete and make sense.
4 Check mounting and adjustment of the driver's seat.
••
5 Check condition of the driver's seat.
6
Check engine compartment for contamination and clean if
#
•
necessary.
7 Check mast mounting/bearings.
8 Check trailer coupling or tow mechanism stop.
••
Q Check overhead guard and/or cab are secure and check for m
W
damage.
10 Check operator mat and steps are non-slip and free of damage.
11 Test driver's seat restraint system and check for damage.
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 Hydraulic operations W A B c
Test "hydraulic" controls and make sure the labels are legible, m
1 w
complete and make sense.

o.
Test hydraulic controls and check they are assigned to the correct
functions.
Check cylinders and piston rods for damage and leaks, and make
•
#
sure they are secure.
4
Check running surfaces of the integral sideshifter and / or integral
fork positioner for wear and damage, and lubricate if necessary. •
5
Check adjustment and wear of slides and stops and adjust the slides
if necessary. •
6 Check load chain adjustment and tension if necessary.
7 Check load chain lubrication and lubricate if necessary.
•••
8 Check lateral clearance of the mast sections and the fork carriage.

9
Visually inspect the mast rollers and check running surface wear
level. •
10
Check running surfaces of the mast for wear and damage, and
lubricate if necessary. •
11 Test hydraulic system.
12 Replace the hydraulic reservoir discharge lid.
••
13 Replace hydraulic oil filter.
•
14
Check that hydraulic connections, hoses and pipes are secure and
check for leaks and damage. •
15 Test emergency-lowering system.
16 Check the hydraulic oil level and top up if necessary.
••
17 Test relief valve and adjust if necessary.
18 Replace hydraulic oil.
••
19 Check the forks or load handler for wear and damage.
Check the length of thread engagement and locknut/clamp of the
•
20 piston rod. Where two tilt cylinders with the same stroke are used,
check their adjustment relative to each other. •
21 Check tilt cylinders and mounting.
22 Test lift and lowering speeds.
••
Agreed services W A C

1
Carry out a test run with rated load, if necessary with a customer-
specific load. •
2 Lubricate the truck according to the lubrication schedule.
3 Demonstration after maintenance.
••

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Steer ing W A B C
1 Test hydraulic steering and its components.
2 Test the hydraulic steering for leaks.
••
3 Check steering hoses and lines.
4 Check steering axle and steering knuckle for wear and damage.
••
5 Check stub axle bearings and adjust if necessary.
6 Grease the steering axle.
•• •
7 Check mechanical parts of steering column.

10.2.2 Optional Equipment

Discharge strap

Electirical system W A B C
1
Check anti-static discharge strap / chain is present and not
damaged. •
Audible warning devices

Electrical system w A B c
1
Test the buzzer / warning alarm, check for damage and make sure it
is secure. •
Trailer coupling

Chassis and superstructure w A B c

1 Check trailer coupling or tow mechanism stop.

Work platform
•
Hydraulic Operations w A B c
1
Check attachment is properly secured to the truck and the
supporting elements. •
Work lights

Electrical system w A B c
1 Test lighting.

Strobe light / beacon

•
Electrical system w A B c
1 Test strobe light / warning beacon and check for damage.
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 Drive Control

Travel W A B C
1 Test the "Drive Control".

Electrical optional equipment

•
Electrical system W A B C
1 Test the optional electrical equipment and check for damage.

Travel direction switch on steering column

•
Trave I w A B c
1 Replace travel direction switch.

Fire extinguisher
•
Agreed performance levels w A B c
1
Check fire extinguisher is present and secure, and check inspection
interval. •
Belt lock control

Chassis and superstructure w A B c

1 Test the belt lock control and check for damage.

Heating coolant water

•
Chassis and superstructure w A B c
1 Test the heating.
2 Replace heating breather.
••
3 Check hoses for leaks and damage and make sure they are secure.

Clamping device
•
Hydrcjulic Operations w A B c
1 Test the acknowledgement key.
2 Check axial play of the front and rear rollers and adjust if necessary.
••
3
Check attachment is properly secured to the truck and the
supporting elements. •
4 Test attachment, check settings and check for damage.
5 Check sliding blocks are complete.
••
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Hydraulic Operations W A B C
6
Check attachment bearings, guides and stops for wear and damage;
grease and clean these components. •
7 Check attachment lubrication; clean and lubricate if necessary.
8 Check hydraulic connections and tighten if necessary.
••
9 Check cylinder seals.
10 Check cylinder piston rods and bushings.
••
Air conditioning system

Chassis and superstructure W A B C

1
Test air conditioning system and its settings and check its
components for damage.
Note: The air conditioning system must only be serviced every two
•
2
years or 2000 service hours by specialist personnel.
3 Visually inspect the filter and replace if necessary.
•
4
Check temperature reading at the outlet of the ventilation nozzles
against manufacturer's ratings. •
Crane hook

Hydraulic Operations w A B c
1
Check attachment is properly secured to the truck and the
supporting elements. •
Load backrest

Hydraulic Operations w A B c
1
Check attachment is properly secured to the truck and the
supporting elements. •
Lift Control

Hydraulic Operations w A B c
1 Check function and plausibility of "Lift Control"

Safety restraint system / SUN protector

•
Chassis and superstructure w A B c
1
Make sure restraint system is complete, test operation and check for
damage. •
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 Impact sensor / data recorder

Electrical system W A B C
1
Check impact sensor / data recorder are secure and check for
damage. •
Sideshifter

Hydraulic Operations W A B C
1 Check axial play of the front and rear rollers and adjust if necessary.
•
2
Check attachment is properly secured to the truck and the
supporting elements. •
3 Test attachment, check settings and check for damage.
4 Check sliding blocks are complete.
••
5
Check attachment bearings, guides and stops for wear and damage;
grease and clean these components. •
6 Check attachment lubrication; clean and lubricate if necessary.
7 Check hydraulic connections and tighten if necessary.
••
8 Test the sideshifter, check settings and check for damage.
9 Check cylinder seals.
••
10 Check cylinder piston rods and bushings.

Sideshifter centring
•
Hydraulic Operations w A B c
1 Test sideshifter centring operation.

Seat heating
•
Electrical system w A B c
1
Check electric wiring for damage (insulation damage, connections).
Make sure cable connections are secure. •
Road traffic approval (StVZO)

Electrical system w A B c
1 Test lighting.
•

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 Telescopic forks

Hydraulic Operations W A B C
1
Check attachment is properly secured to the truck and the
supporting elements. •
2 Test attachment, check settings and check for damage.
•
3
Check attachment bearings, guides and stops for wear and damage;
grease and clean these components. •
4 Check attachment lubrication; clean and lubricate if necessary.
5 Check hydraulic connections and tighten if necessary.
••
6 Check cylinder seals.
•
7
Check that hydraulic connections, hoses and pipes are secure and
check for leaks and damage. •
8
Check piston and piston rod for damage, check adjustment and
adjust if necessary. •
Boom

Hydraulic Operations W A B C

1
Check attachment is properly secured to the truck and the
supporting elements. •
Video system

System components w A B c
1 Check wiring is secure and check for damage.
2 Test the camera; make sure it is secured and clean.
••
3 Test the monitor; make sure it is secured and clean.

Weigher sensors / switches

•
Electrical system w A B c
1 Test weighing system and check for damage.

Weather-proof system
•
Electrical system w A B c
1 Check fuse ratings.
•
Chassis and superstructure w A B c
1 Test the window heating and check for damage
2 Test the doors and check for damage.
••
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 Wiper/washer system

Chassis and superstructure W A B C

1
Check windscreen washer reservoir for leaks and check volume; top
up if necessary. •
2 Test windscreen wipers and check for damage; replace if necessary.

Fork adjuster
•
Hydraulic Operations W A B C
1 Check axial play of the front and rear rollers and adjust if necessary.
•
2
Check attachment is properly secured to the truck and the
supporting elements. •
3 Test attachment, check settings and check for damage.
4 Check sliding blocks are complete.
••
5
Check attachment bearings, guides and stops for wear and damage;
grease and clean these components. •
6 Check attachment lubrication; clean and lubricate if necessary
7 Check hydraulic connections and tighten if necessary.
••
8 Test the fork positioner and check for damage.
9 Check cylinder seals.
••
10 Check cylinder piston rods and bushings.

Access module
•
Electrical system w A B c
1 Test access module, check for damage and make sure it is secure.

Optional equipment
•
Chassis and superstructure w A B c
Check that optional equipment such as mirrors, storage
1 compartments, grips, windscreen wipers and washing systems, etc.
are working correctly and check for damage. •
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11 Maintenance checklist TFG
11.1 Operating Company

11.1.1 Standard Equipment

Brakes W A B C
1 Test brakes.
•
Electrical system W A B C
1
Test warning and safety devices in accordance with operating
instructions. •
2 Test displays and controls.
3 Test the panel switch and check for damage.
••
4 Test emergency disconnect switch.
•
Power supply W A B C
Check battery cable connections are secure, check for dirt and ÿ
1
grease terminals if necessary.
2 Check battery and battery components. #
3 Check battery safety labels are present and check for damage.
•
Travel W A B C
1 Check coolant level and top up if necessary.
2 Check and clean radiator.
••
3 Check tyre pressure and correct if necessary.
4 Check wheels for wear and damage.
••
5 Check engine oil level and top up if necessary.
•
Chassis and superstructure W A B C
1 Check doors and/or covers.
2 Check labels are legible, complete and make sense.
••
Check engine compartment for contamination and clean if ÿ
3
necessary.
Check overhead guard and/or cab are secure and check for m
4
damage.
5 Test driver's seat restraint system and check for damage.
•
Hydraulic operations W A B C
1 Check load chain lubrication and lubricate if necessary.
2 Test hydraulic system.
••
3 Check the hydraulic oil level and top up if necessary.
4 Check the forks or load handler for wear and damage.
••
252
 11.1.2 Optional Equipment
Work lights

Electrical system W A B C
1 Test lighting.

Strobe light / beacon

•
Electrical system w A B C
1 Test strobe light / warning beacon and check for damage.

Heating coolant water

•
Chassis and superstructure w A B C
1 Test the heating.
2 Check heating vent filter for contamination and clean if necessary.
••
Clamping device

Hydraulic Operations w A B C
1 Check attachment lubrication; clean and lubricate if necessary.

Sideshifter
•
Hydraulic Operations w A B C
1 Check attachment lubrication; clean and lubricate if necessary.

Road traffic approval (StVZO)

•
Electrical system w A B C
1 Test lighting.

Telescopic forks
•
Hydraulic Operations w A B C
1 Check attachment lubrication; clean and lubricate if necessary.

Weather-proof system
•
Chassis and superstructure w A B C
1 Test the doors and check for damage.
•
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 Wiper/washer system

Chassis and superstructure W A B C

1
Check windscreen washer reservoir for leaks and check volume; top
up if necessary. •
Fork adjuster

Hydraulic Operations w A B C
1 Check attachment lubrication; clean and lubricate if necessary.

Optional equipment
•
Chassis and superstructure w A B C
Check that optional equipment such as mirrors, storage
1 compartments, grips, windscreen wipers and washing systems, etc.
are working correctly and check for damage. •

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 11.2 Customer Service

11.2.1 Standard Equipment

Brake>s W A B C
1 Test brakes.
•
Electirical system W A B C
1
Test warning and safety devices in accordance with operating
instructions. •
2 Test displays and controls.
•
3 Test the panel switch and check for damage.
4 Test emergency disconnect switch.
•
•
5
Test key switch or alternative access system including the access
rights. •
6 Check contactors and/or relays.
7 Check fuse ratings.
••
8
Check electric wiring for damage (insulation damage, connections).
Make sure cable connections are secure. •
9
Check the electrical components that can be diagnosed, check
settings and adjust if necessary. •
Power supply W A B c
1
Check battery cable connections are secure, check for dirt and
grease terminals if necessary. •
2 Check battery and battery components.
3 Check acid density, acid level and battery voltage.
••
4 Check battery voltage.
5 Check battery safety labels are present and check for damage.
••
Note: check the exhaust levels every six months and adjust if
6
necessary. Observe other national guidelines and regulations.
Note: The LPG system must only be inspected by LPG system
7
experts.
8 Test the LPG system and check for leaks and damage.
9 Check LPG container is secure and damage-free.
••
10 Replace the LPG filter.
•

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Trave1 W A B C
1 Test exhaust system and check for leaks and damage.
2 Check the wheel motor attachments.
••
3
Check the wheel motors and displacement pump for noise and
leakage. •
4
Check that hydraulic connections, hoses and pipes are secure and
check for leaks and damage. •
5 Check anti-freeze and top up if necessary.
6 Note: The radiator system is filled with demineralised water.
•
7 Replace coolant and anti-freeze.
8 Check cooling system for leaks.
•• •
9 Check coolant level and top up if necessary.
10 Test hydraulic fans, check for dirt, freedom of movement and leaks.
11 Check and clean radiator.
•• •
12 Check tyre pressure and correct if necessary.
13 Check wheels for wear and damage.
14 Check wheel bearings and wheel mounting.
••
15 Test starter and alternator; check cables and mounting.
16 Replace engine oil filter.
••
17
Check V belt / multi-V belt is tensioned and check for damage.
Replace if necessary. •
18 Replace air filter.
19 Check air filter and replace if necessary.
•
••
20 Test the air filter monitor and check for damage.
21 Check engine for noise and leakage.
22 Replace engine oil.
••
23 Check engine oil level and top up if necessary.
24 Check engine mounting.
••
25 Replace the spark plugs.
Note: Replace the timing belt and the multi-V belt every 3000 service
•
26 hours and replace the water pump as well if necessary. The engine
could become damaged.
27 Check the timing belt.
•
Chassis and Superstructure W A B C
1 Check chassis and screw connections for damage.
2 Check doors and/or covers.
••
3 Check labels are legible, complete and make sense.
4 Check mounting and adjustment of the driver's seat.
••
5 Check condition of the driver's seat.
•
6
Check engine compartment for contamination and clean if
necessary. • LU

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 Chassis and Superstructure W A B C
7 Check mast mounting/bearings.
8 Check trailer coupling or tow mechanism stop.
••
9
Check overhead guard and/or cab are secure and check for
damage. •
10 Check operator mat and steps are non-slip and free of damage.
11 Test driver's seat restraint system and check for damage.
••
Hydraulic operations W A C

1
Test "hydraulic" controls and make sure the labels are legible,
complete and make sense. •
2
Test hydraulic controls and check they are assigned to the correct
functions. •
3
Check cylinders and piston rods for damage and leaks, and make
sure they are secure. •
4
Check running surfaces of the integral sideshifter and / or integral
fork positioner for wear and damage, and lubricate if necessary. •
5
Check adjustment and wear of slides and stops and adjust the slides
if necessary. •
6 Check load chain adjustment and tension if necessary.
7 Check load chain lubrication and lubricate if necessary.
•••
8 Check lateral clearance of the mast sections and the fork carriage.

9
Visually inspect the mast rollers and check running surface wear
level. •
10
Check running surfaces of the mast for wear and damage, and
lubricate if necessary. •
11 Test hydraulic system.
12 Replace the hydraulic reservoir discharge lid.
••
13 Replace hydraulic oil filter.
•
14
Check that hydraulic connections, hoses and pipes are secure and
check for leaks and damage. •
15 Test emergency-lowering system.
16 Check the hydraulic oil level and top up if necessary.
••
17 Test relief valve and adjust if necessary.
18 Replace hydraulic oil.
••
19 Check the forks or load handler for wear and damage.
Check the length of thread engagement and locknut/clamp of the
•
20 piston rod. Where two tilt cylinders with the same stroke are used,
check their adjustment relative to each other. •
21 Check tilt cylinders and mounting.
22 Test lift and lowering speeds.
••
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Agretid services W A B C
1
Carry out a test run with rated load, if necessary with a customer-
specific load. •
2 Lubricate the truck according to the lubrication schedule.
3 Demonstration after maintenance.
••
Steering W A B C
1 Test hydraulic steering and its components.
2 Test the hydraulic steering for leaks.
••
3
4
Check steering hoses and lines.
Check steering axle and steering knuckle for wear and damage.
••
5
6
Check stub axle bearings and adjust if necessary.
Grease the steering axle.
•• •
7 Check mechanical parts of steering column.

11.2.2 Optional Equipment

Discharge strap

Electrical system w A B c
1
Check anti-static discharge strap / chain is present and not
damaged. •
Audible warning devices

Electrical system w A B c
1
Test the buzzer / warning alarm, check for damage and make sure it
is secure. •
Trailer coupling

Chassis and superstructure w A B c

1 Check trailer coupling or tow mechanism stop.

Work platform
•
Hydraulic Operations w A B c
1
Check attachment is properly secured to the truck and the
supporting elements. •
Work lights

Electrical system w A B c
1 Test lighting.
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 Strobe light / beacon

Electrical system W A B C
1 Test strobe light / warning beacon and check for damage.

Drive Control
•
Travel W A B C
1 Test the "Drive Control".

Electrical optional equipment

•
Electrical system w A B C
1 Test the optional electrical equipment and check for damage.
Travel direction switch on steering column
•
Travel w A B C
1 Replace travel direction switch.

Fire extinguisher
•
Agreed performance levels w A B c
1
Check fire extinguisher is present and secure, and check inspection
interval. •
Belt lock control

Chassis and superstructure W A B C

1 Test the belt lock control and check for damage.

Heating coolant water

•
Chassis and superstructure W A B C
1 Test the heating.
2 Replace heating breather.
••
3 Check hoses for leaks and damage and make sure they are secure.
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 Clamping device

Hydraulic Operations W A B C
1 Test the acknowledgement key.
2 Check axial play of the front and rear rollers and adjust if necessary.
••
3
Check attachment is properly secured to the truck and the
supporting elements. •
4 Test attachment, check settings and check for damage.
5 Check sliding blocks are complete.
••
6
Check attachment bearings, guides and stops for wear and damage;
grease and clean these components. •
7 Check attachment lubrication; clean and lubricate if necessary.
8 Check hydraulic connections and tighten if necessary.
••
9 Check cylinder seals.
10 Check cylinder piston rods and bushings.
••
Air conditioning system

Chassis and superstructure W A B C

1
Test air conditioning system and its settings and check its
components for damage.
Note: The air conditioning system must only be serviced every two
•
2
years or 2000 service hours by specialist personnel.
3 Visually inspect the filter and replace if necessary.
•
4
Check temperature reading at the outlet of the ventilation nozzles
against manufacturer's ratings. •
Crane hook

Hydraulic Operations w A B c
1
Check attachment is properly secured to the truck and the
supporting elements. •
Load backrest

Hydraulic Operations w A B c
1
Check attachment is properly secured to the truck and the
supporting elements. •
Lift Control

Hydraulic Operations w A B c
1 Check function and plausibility of "Lift Control"
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 Safety restraint system / SUN protector

Chassis and superstructure W A B C

1
Make sure restraint system is complete, test operation and check for
damage. •
Impact sensor / data recorder

Electrical system W A B C
1
Check impact sensor / data recorder are secure and check for
damage. •
Sideshifter

Hydraulic Operations w A B c
1 Check axial play of the front and rear rollers and adjust if necessary.
•
2
Check attachment is properly secured to the truck and the
supporting elements. •
3 Test attachment, check settings and check for damage.
4 Check sliding blocks are complete.
••
5
Check attachment bearings, guides and stops for wear and damage;
grease and clean these components. •
6 Check attachment lubrication; clean and lubricate if necessary.
7 Check hydraulic connections and tighten if necessary.
••
8 Test the sideshifter, check settings and check for damage.
9 Check cylinder seals.
••
10 Check cylinder piston rods and bushings.

Sideshifter centring
•
Hydr.aulic Operations w A B c
1 Test sideshifter centring operation.

Seat heating
•
Electrical system w A B c
1
Check electric wiring for damage (insulation damage, connections).
Make sure cable connections are secure. •
Road traffic approval (StVZO)

Electrical system w A B c

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 Telescopic forks

Hydraulic Operations W A B C
1
Check attachment is properly secured to the truck and the
supporting elements. •
2 Test attachment, check settings and check for damage.
•
3
Check attachment bearings, guides and stops for wear and damage;
grease and clean these components. •
4 Check attachment lubrication; clean and lubricate if necessary.
5 Check hydraulic connections and tighten if necessary.
••
6 Check cylinder seals.
•
7
Check that hydraulic connections, hoses and pipes are secure and
check for leaks and damage. •
8
Check piston and piston rod for damage, check adjustment and
adjust if necessary. •
Boom

Hydraulic Operations W A B C

1
Check attachment is properly secured to the truck and the
supporting elements. •
Video system

System components w A B c
1 Check wiring is secure and check for damage.
2 Test the camera; make sure it is secured and clean.
••
3 Test the monitor; make sure it is secured and clean.

Weigher sensors / switches

•
Electrical system w A B c
1 Test weighing system and check for damage.

Weather-proof system
•
Electrical system w A B c
1 Check fuse ratings.
•
Chassis and superstructure w A B c
1 Test the window heating and check for damage
2 Test the doors and check for damage.
••
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 Wiper/washer system

Chassis and superstructure W A B C

1
Check windscreen washer reservoir for leaks and check volume; top
up if necessary. •
2 Test windscreen wipers and check for damage; replace if necessary.

Fork adjuster
•
Hydraulic Operations W A B C
1 Check axial play of the front and rear rollers and adjust if necessary.
•
2
Check attachment is properly secured to the truck and the
supporting elements. •
3 Test attachment, check settings and check for damage.
4 Check sliding blocks are complete.
••
5
Check attachment bearings, guides and stops for wear and damage;
grease and clean these components. •
6 Check attachment lubrication; clean and lubricate if necessary
7 Check hydraulic connections and tighten if necessary.
••
8 Test the fork positioner and check for damage.
9 Check cylinder seals.
••
10 Check cylinder piston rods and bushings.

Access module
•
Electrical system w A B c
1 Test access module, check for damage and make sure it is secure.

Optional equipment
•
Chassis and superstructure w A B c
Check that optional equipment such as mirrors, storage
1 compartments, grips, windscreen wipers and washing systems, etc.
are working correctly and check for damage. •
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