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Jungheinrich DFG 425s, Operating Instructions Manual, Page: 141 / 229

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Jungheinrich DFG 425s Operating Instructions Manual Download Page 141

03.13 EN

140

6.15 Rockinger coupling with hand lever or remote control

Z

Refer to the instructions for towing trailers, see "Towing trailers" on page 108.

CAUTION!

Incorrectly coupled trailers can cause
accidents

X

Make sure the coupling is engaged
securely before starting the truck.

X

The contro pin (184) must be flush with
the control sleeve (185).

Rockinger coupling operation (attaching
trailers)

Procedure

• Prevent the trailer from rolling away.
• Adjusting the trailer pull rod to the height of the coupling.
• Pull the hand lever (183) / remote control (182) (

o

) up. 

Z

The remote control (182) (

o

) is located in the overhead guard, depending on the

truck model.

• Slowly reverse the truck until the coupling engages.
• Push the hand lever (183) / remote control (182) (

o

) down.

Rockinger coupling operation (disconnecting trailers)

Procedure

• Prevent the trailer from rolling away.
• Pull the hand lever (183) / remote control (182) (

o

) up.

• Drive the truck forward.
• Push the hand lever (183) / remote control (182) (

o

) down.

183

182

184 185

Summary of Contents for DFG 425s

Page 1: ...DFG TFG 425s 435s G 10 07 Operating Instructions 51077936 51209061 01 09 03 13 ...

Page 2: ...04 11 03 13 51209061 DFG TFG 425s 435s Operating instructions G DFG 430s DFG 435s TFG 425s TFG 430s TFG 435s DFG 425s ...

Page 3: ......

Page 4: ...d industrial truck described below in detail complies with the European Directives 2006 42 EC Machinery Directive and 2004 108 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 Type Option Serial no Year of manufacture ...

Page 5: ...03 13 EN 4 ...

Page 6: ...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 DANGER Indicates an extremely hazardous situation Failure to comply with this instruction will result in severe irreparable injury and even death WARNING Indicates an extremely hazardous situation Failure t...

Page 7: ...03 13 EN 6 Jungheinrich Aktiengesellschaft Am Stadtrand 35 22047 Hamburg Germany Tel 49 0 40 6948 0 www jungheinrich com ...

Page 8: ...8 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 27 3 6 Engine Data 27 3 7 EN norms 28 3 8 Conditions of use 28 3 9 Electrical requirements 29 4 Identification points and data plates 30 4 1 Data plate 32 4 2 Truck capacity plate 33 4 3 Attachment capacity plate 34 5 Stability 34 C Transport and Commissioning 35 1 Transport ...

Page 9: ... reduced headroom o 67 3 4 Setting up the operator position 68 3 5 Seat Belt 73 4 Industrial Truck Operation 74 4 1 Safety regulations for truck operation 74 4 2 Preparing the truck for operation 76 4 3 Starting procedure for the DFG 77 4 4 Starting procedure for the TFG 78 4 5 Parking the truck securely 79 4 6 Emergency Disconnect 80 4 7 Travel 81 4 8 Steering 83 4 9 Brakes 83 4 10 Setting the ti...

Page 10: ...ction 153 2 Maintenance Safety Regulations 154 2 1 Working on the electrical system 155 2 2 Consumables and used parts 155 2 3 Wheels 155 2 4 Lift Chains 156 2 5 Hydraulic system 156 2 6 Working in the vicinity of the engine 157 3 Lubricants and Lubrication Schedule 158 3 1 Handling consumables safely 158 3 2 Lubrication Schedule 160 3 3 Consumables 161 4 Maintenance and repairs 163 4 1 Preparing ...

Page 11: ...erformed at intervals and after unusual incidents 202 7 Final de commissioning disposal 203 8 Human vibration measurement 203 9 Servicing and Inspection 204 10 Maintenance checklist DFG 205 10 1 Operating company 205 10 2 Customer service 208 11 Maintenance checklist TFG 217 11 1 Operating company 217 11 2 Customer service 220 ...

Page 12: ...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 90 Lifting and lowering loads Transporting lowered loads over short distances Do not travel with a raised load 30 cm Do not carry or lift passengers Do push or pull load unit...

Page 13: ...cross 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 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 XDo not use LPG trucks under g...

Page 14: ...ties 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 cust...

Page 15: ...03 13 EN 14 ...

Page 16: ...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 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 The rated capacity is not generally the same as the permissible...

Page 17: ...2 Assemblies and Functional Description 2 1 Travel direction definition The following conventions have been agreed for travel direction specification Item Travel direction 1 Left 2 Reverse 3 Forward 4 Right 1 3 4 2 ...

Page 18: ...ency Disconnect switch 7 t Steering wheel 15 t Engine bonnet 8 t Mast 16 t Steer axle 9 t Fork carriage 17 t Counterweight 10 t Fork tines 18 t Trailer coupling 11 t Lifting mechanism control 19 t LPG bottle TFG only 12 t Operating and control unit t Standard equipment o Optional equipment 5 11 12 14 10 13 16 18 17 15 19 6 7 8 9 ...

Page 19: ...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 16 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 ...

Page 20: ...he parking brake is an automatic multi plate brake that can also be applied manually Hydraulic system A MULTI PILOT valve allows for sensitive operation of the functions via the controls A speed 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 visi...

Page 21: ...nces in height and surface unevenness surface edges The truck must not operate on inclines of more than 15 DFG 425s 435s Description DFG 425s DFG 430s DFG 435s Q Capacity where C 500 mm 1 2500 3000 3500 kg C Load centre distance 500 500 500 mm Travel speed with without load 19 6 19 6 20 8 20 8 20 8 20 8 km h Lift speed with without load 0 56 0 56 0 56 0 56 0 48 0 48 m s Lowering speed with without...

Page 22: ...city where C 500 mm 1 2500 3000 3500 kg C Load centre distance 500 500 500 mm Travel speed with without load 19 6 19 6 20 8 20 8 20 8 20 8 km h Lift speed with without load 0 56 0 56 0 56 0 56 0 48 0 48 m s Lowering speed with without load 0 56 0 56 0 56 0 56 0 56 0 56 m s Gradeability 2 with without load 27 24 21 Acceleration with without load to 15 m 5 7 5 0 6 0 5 1 6 1 5 2 s Available working p...

Page 23: ... l1 Overall length including forks 3763 3858 3948 mm l2 Overall length including fork shank 2613 2708 2798 mm b1 Overall width 1184 1320 1320 mm s e l Fork dimensions 40 120 1150 45 125 1150 50 125 1150 mm m1 Ground clearance laden below mast 125 143 143 mm m2 Ground clearance centre wheelbase 130 148 148 mm Fork carriage ISO 2328 class type A B 2A 3A 3A Ast Aisle width for pallets 800 x 1200 leng...

Page 24: ...23 03 13 EN ...

Page 25: ...The data listed in the table corresponds to the standard version DFG TFG 425s DFG TFG 430s DFG TFG 435s Truck weight 4080 4376 4821 Axle load w o load front rear 1943 2137 1958 2488 2009 2812 Axle load with load front rear 5833 747 6578 868 7339 982 ...

Page 26: ...150 3215 5610 5770 935 5500 150 3515 6110 6270 995 5800 150 3665 6410 6570 1025 6000 150 3765 6610 6770 1045 ZZ 2900 1480 1380 2080 3500 3600 735 3100 1580 1480 2180 3700 3800 755 3300 1680 1580 2280 3900 4000 780 3500 1780 1680 2380 4100 4200 800 3700 1880 1780 2480 4300 4400 820 4000 2030 1930 2630 4600 4700 850 4300 2230 2130 2830 4900 5000 904 4500 2330 2230 2930 5100 5200 930 DZ 4400 1480 138...

Page 27: ...ght h1 Extended height h4 Mast weight kg ZT 2900 150 2228 3683 700 3300 150 2428 4083 740 3800 150 2678 4583 810 4300 150 2978 5083 875 4800 150 3228 5583 920 5000 150 3328 5783 940 DZ 4200 1330 2093 4963 920 4500 1430 2193 5263 950 4800 1530 2293 5563 980 5300 1730 2493 6063 1040 5800 1930 2693 6563 1100 6300 2130 2893 7063 1180 ...

Page 28: ...eumatic 7 0 12 16PR 27 x 10 12 20PR 27 x 10 12 20PR Tyre pressure bar 10 9 9 Torque NM 170 170 170 Rear tyres SE 6 50 x 10 6 50 x 10 6 50 x 10 Pneumatic 6 50 x 10 10PR 6 50 x 10 10PR 6 50 x 10 10PR Tyre pressure bar 7 75 7 75 7 75 Torque NM 200 200 200 Component DFG 425s DFG 430s DFG 435s Cylinder cubic capacity 4 1968 4 1968 4 1968 cm Idle speed 900 900 900 rpm Rated speed 2500 2500 2500 rpm Engi...

Page 29: ...rd truck version These recordings were taken on a single occasion 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 203 Electromagnetic compatibility EMC The manufacturer confirms that the truck adheres to the limits for electromagneti...

Page 30: ...xtreme 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 ...

Page 31: ...nd data plates Z Warnings and notices such as capacity charts strap points and data plates must be legible at all times Replace if necessary 1 2 1 1 1 0 9 8 7 6 5 4 3 2 1 2000 32 20 25 21 31 30 34 35 28 24 33 36 22 21 29 26 26 27 37 23 28 ...

Page 32: ... passengers warning 26 Fuel 25 Wear seat belt 27 Serial number engraved in chassis below the engine cover 28 Jack contact points 29 Do not step onto or beneath the load risk of trapping with moving mast 30 Max body size o 31 Tipover hazard 32 Read operating instructions 33 Test plaque o 34 Capacity 35 Capacity with attachment 36 Hydraulic oil specification 37 Model description ...

Page 33: ...ies Z For queries regarding the truck or ordering spare parts always quote the truck serial number 39 Item Component Item Component 38 Type 43 Year of manufacture 39 Serial number 44 Load centre distance mm 40 Rated capacity kg 45 Net weight in kg 41 Output 46 Manufacturer 42 Option 47 Manufacturer s logo 38 39 41 40 47 44 46 43 42 45 ...

Page 34: ...he 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 35 of the truck indicates the truck s capacity with the forks as originally supplied Example of how to calculate the maximum capacity 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 Lift height res...

Page 35: ...te 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 WARNING Loss of stability can c...

Page 36: ...nes between the basic truck and the mast separated 2 Loading the Truck 2 1 Centre of gravity of the truck 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 XDrive ...

Page 37: ... way that they do not come into contact with any attachments or the overhead guard when lifting XDo not stand under a swaying load XThe truck should only be handled by people who are trained in using lifting slings and tools XWear safety shoes when lifting the truck by crane XDo not walk into or stand in a hazardous area XAlways attach the crane lifting gear to the prescribed strap points and prev...

Page 38: ...iently long XTransporting over long distances prohibited Loading the truck with a second industrial truck Requirements Park the truck securely see Parking the truck securely on page 79 Procedure Raise the truck with the forks at the side between the axles 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 ...

Page 39: ...n floor to secure the retaining wedges XUse wedges to prevent the truck from moving XUse only tensioning belts or tie down straps or with sufficient strength Securing with a mast Securing without a mast Securing the industrial truck for transport Requirements Position the industrial truck securely on a lorry or trailer see Parking the truck securely on page 79 Tools and Material Required 2 fasteni...

Page 40: ... be connected to the basic truck mast interface when the mast has been properly assembled XOnly then can the truck be started XIf several trucks have been delivered make sure that the serial numbers of the load handlers masts and basic trucks always match Preparing the truck for operation after delivery or transport Procedure Check the equipment is complete Check the engine oil level Check the hyd...

Page 41: ...03 13 EN 40 ...

Page 42: ...y when handling fuels and LPG XLabels indicating the hazard are must be positioned where they are clearly visible XDo not store flammable materials in this area XPowder fire extinguisher must be provided within easy reach of the filling area XUse only category A B or C type powder fire extinguishers to fight LPG fires XBring any unsealed LPG bottles immediately outside attach visible markings and ...

Page 43: ...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 XAll 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 XThe owner must c...

Page 44: ...ystem In this case the truck must not be operated The gas system must be check by suitably qualified and trained personnel The user must check that the plastic cover is in place each time he uses the truck DANGER Danger from escaping liquid gas Liquid gas can escape from faulty gas hoses XUse only gas bottles with an integrated line break safety valve XThe gas bottle connection is also fitted with...

Page 45: ... 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 XFuel additives drag reducers petrol or other substances must not be mixed with diesel fuel XDo not start the engine if non appr...

Page 46: ...45 03 13 EN Fuelling is now complete ...

Page 47: ...he 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 Raise the fuel container carefully and slowly add the diesel Do not overfill the tank Screw the cap 55 back on tightly after fuelling Fuelling is now complete 55 ...

Page 48: ...le must always rest on an engaged bottle holder so that the hose connection of the shutoff valve is facing vertically down XFor bottle types of other countries note the national regulations XNote 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 ...

Page 49: ... 60 and place it down securely Inserting a new LPG bottle Procedure Place the LPG bottle in the bracket 60 Centre the handle 57 in the hole 59 Align the hose connection upwards Fit the tensioning belt around the LPG bottle again and tension it with the toggle type fastener 61 Fit the tensioning pivot and tension the belt with the toggle type fastener 61 Rotate the LPG bottle and the bracket around...

Page 50: ... 60 to change the LPG supply The correct assignment can be seen from the LPG hose connection on the valve 64 and the routing to the LPG bottles e g toggle valve right top toggle valve left bottom Procedure Use the lever 66 to change between the top and bottom LPG bottles Replacing the LPG bottles Procedure see Using an LPG bottle on page 47 Z Replace an empty LPG bottle at the earliest opportunity...

Page 51: ...nes and regulations concerning the filling of LPG bottles on the LPG pump Procedure Close the dispensing valve 71 Unscrew the cap 68 of the filling stop valve 69 Screw the filling connection of the liquid gas pump onto the filling stop valve 69 Z Fuelling automatically ends when the tank s capacity has been reached After fuelling unscrew the filling connection and screw the cap 68 of the filling s...

Page 52: ...cator for LPG bottles o When the fuel indicator 72 and warning light 73 with an additional warning sound light up this indicates that the LPG bottle is empty The remaining travel time will be 8 12 minutes depending on the application and ambient conditions Z 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...

Page 53: ...03 13 EN 52 ...

Page 54: ...nd 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 wh...

Page 55: ...mmediately WARNING Falling objects can cause accidents Falling objects can injure the operator while the truck is being operated XThe 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 30 and warning instructions in...

Page 56: ...55 03 13 EN 2 Displays and Controls SOLO PILOT MULTI PILOT 7 78 78 81 81 80 80 75 75 77 76 74 79 79 ...

Page 57: ...vation the truck brakes to a halt immediately 7 Steering wheel t Steers the truck 78 SOLO PILOT t Controls the following functions Forward reverse travel direction not with dual pedal operation Load handler raise lower Mast forward reverse tilt Horn button Sideshifter left right o Auxiliary hydraulics o Acknowledgement key o MULTI PILOT o 79 ISM Access Module o Switches the truck on CanCode 80 Eme...

Page 58: ...r t Lever for operating the hydraulic functions 84 Horn button t Activates an audible warning 85 Additional hydraulic function release button o Activates the additional hydraulic functions or hydraulics that require acknowledgement 86 Button o Hydraulic auxiliary function control button t Series equipment o Optional equipment 83 84 82 85 83 82 84 84 86 85 82 ...

Page 59: ...ata the battery charge the service hours and error details and information Pictograms in the left top section of the control panel act as warning indicators km h R 103 104 105 112 111 110 123 118 113 106 107 120 108 109 114 115 116 119 121 122 117 102 73 93 100 92 99 91 98 97 89 96 88 95 87 101 94 90 ...

Page 60: ...utomatically when the truck stops The parking brake is automatically released when the accelerator pedal is applied 90 t Not used 91 t Not used 92 Overtemperature indicator t Hydraulic oil temperature too high Coolant temperature too high As the temperature rises the truck s performance is automatically and steadily reduced to 0 93 Charge current indicator t Battery not charging 94 Indicator lamp ...

Page 61: ...nal see Access Control on page 129 99 Service display t Set service interval exceeded 1000 service hours or carry out FEM test after 12 months display flashes must be set by the manufacturer s customer service department 100 Pre heat indicator lamp t Engine is preheated DFG only Indicator lamp flashing Engine controller error 101 t Not used 102 Display unit t Displays the operating data t Series e...

Page 62: ...g brake is applied when the truck is switched on or when the parking brake button 105 is pressed LED on the parking brake button 105 lights up red and parking brake indicator 89 lights up Travel is not enabled when the accelerator pedal is pressed Travel is enabled by pressing the parking brake button 105 89 Parking brake indicator lit simultaneously t km h R 103 104 105 112 111 110 123 118 113 10...

Page 63: ... seconds stores the current display operating program settings 112 Slow travel button t Switches slow travel on and off Slow travel can only be adjusted by Customer Services 113 P1 function key o Switches auxiliary equipment on and off 114 Parking light o Switches parking light on and off 115 Dipped lights o Switches dipped lights on and off 116 Rear work lights o Switches rear work lights on and ...

Page 64: ... for high throughput levels If necessary the operating programs can also be adapted or restricted to suit the customer Operating program 1 can be modified to adjust it in particular for shovel applications Contact the manufacturer s customer service department 121 Warning indicator o Switches the warning indicator on and off 122 Lift cutout override button o Switches the lift cutout override butto...

Page 65: ...nning Error display If an error Err or a warning Inf occurs the error or info code is displayed If several errors occur they are displayed alternately at intervals of 1 5 seconds displayed A warning sounds 127 Travel direction and speed display t Displays the travel direction pre selected on the travel direction switch forward or reverse and the current speed Travel direction speed and wheel posit...

Page 66: ...s 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 XReport any defects immediately to your supervisor XMark defective truck and take out of service XDo not return the industrial truck to service until you have identified and rectified the fault ...

Page 67: ...op 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 73 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 Test the Drive Control o Raise the fork carriage without load beyond the r...

Page 68: ...kplace 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 XThe operating company must ensure that truck operators do not exceed the maximum body size indicated XThe operating company must check that the operators can sit in a normal and upr...

Page 69: ... 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 3 4 1 Adjusting the driver s seat WARNING Risk of accidents and damage to health An incorrectly adjusted driver s seat can result in accidents and damage to health XDo not adjust the driver s seat whil...

Page 70: ...t the seat to a lower weight Z The driver s weight is correct when the arrow is in the middle of the display window 132 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 131 back in full The driver s weight is now set Adjusting the backrest Procedure Sit on the driver s seat Pull the lever 134 to adjust the backr...

Page 71: ... driver s seat must be locked in position XDo not adjust the driver s seat while travelling Procedure Sit on the driver s seat Pull up the driver s seat locking lever133 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 133 in position The seat position is now correctly set Adjusting the lumbar vertebrae suppor...

Page 72: ...tion using the steering column engine bonnet release lever 140 The individual steering wheel position remains intact Procedure Hold the steering column 138 against the steering wheel 7 Z It will be under spring tension when the steering column engine bonnet release lever 140 is released Pull the steering column engine bonnet release lever 140 in the direction of the arrow 137 towards the driver s ...

Page 73: ...en you have reached the required setting tighten the clamping screw 141 again this will lock the armrest in place Vertical adjustment Procedure Depress the locking button 142 and hold it in place The armrest can now be adjusted upwards or down When you have reached the required setting release the locking button 142 this will lock the armrest in place 141 142 ...

Page 74: ...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 Z Carefully drive the truck off the slope an...

Page 75: ...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 opera...

Page 76: ... 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...

Page 77: ...nd when the speed alternates Only fully charge the engine once 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 operation on page 65 Procedure Unlock the Emergency Disconnect switch 80 to do this Turn the rotary button until the switch un...

Page 78: ... after a short while If not stop the start up process and rectify the fault Using the key set the key switch 81 to II to apply the starter Z Only apply the starter continuously for a maximum of 15 seconds The truck is equipped with an immobiliser which prevents it from starting again while the engine is running Release the key as soon as the engine starts The key switch automatically reverts to th...

Page 79: ...lay 88 parking brake 89 truck operation indicator 102 and charge current indicator 93 should go out after a short while If not stop the start up process and rectify the fault Using the key set the key switch 81 to II to apply the starter Z Only apply the starter continuously for a maximum of 15 seconds The truck is equipped with an immobiliser which prevents it from starting again while the engine...

Page 80: ... may need to be secured with wedges XAlways fully lower the mast and load handler XTilt the mast forward XAlways apply the parking brake button before parking the truck XChoose a place to park where no other people are at risk of injury from lowering forks XDo 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 ke...

Page 81: ...aximum force This may cause the load to slide off the load handler There is a higher risk of accidents and injury XDo not use the Emergency Disconnect switch as a service brake XUse the Emergency Disconnect switch during travel only in emergencies Applying the Emergency Disconnect Procedure Press the Emergency Disconnect 80 All electrical functions are deactivated The truck brakes to a halt 80 81 ...

Page 82: ...approx 200 mm XMake sure you have sufficient visibility when reversing Travel Requirements Truck prepared for operation see Preparing the truck for operation on page 76 Procedure Release the parking brake to do this press the parking brake button 105 Select the travel direction with the travel direction switch 82 Select the travel speed if necessary to do this press the slow travel button 112 or t...

Page 83: ... operation see Preparing the truck for operation on page 76 Procedure Z For trucks with a dual pedal the travel direction is selected via the accelerator pedals 76 74 When the driver leaves the truck the truck is automatically set to Neutral Press the brake pedal gently to enable travel and operating functions Release the parking brake to do this press the parking brake button 105 Raise the load h...

Page 84: ...d steering radius The truck travels in the direction selected 4 9 Brakes WARNING Accident risk The brake pattern of the truck depends largely on the ground conditions XThe operator must take into account the travel route conditions when braking XBrake with care to prevent the load from slipping XAllow for increased braking distance when travelling with an attached load XUse the service brake in em...

Page 85: ...e parking brake is automatically released when the accelerator pedal is applied Emergency stop brake Apply the brake pedal 75 CAUTION When you apply the emergency stop brake 75 the full brake force is available XThe emergency stop brake should only be used for emergency braking XWhen the brake pedal is applied the truck will brake irrespective of the position of the accelerator pedal XThere is a h...

Page 86: ...from rolling away parking brake automatically activated When the truck stops the parking brake is automatically activated prevents the truck from rolling away and the parking brake indicator 89 lights up When the accelerator pedal is applied the parking brake is automatically released and the parking brake indicator 89 goes out Park the truck securely parking brake activated by parking brake butto...

Page 87: ...y released when the accelerator pedal is applied 105 89 LED on parking brake button and t Secure parking of truck The parking brake is applied when the truck is switched on or when the parking brake button 105 is pressed LED on the parking brake button 105 lights up red and parking brake indicator 89 lights up Travel is not enabled when the accelerator pedal is pressed Travel is enabled by pressin...

Page 88: ...3 keys simultaneously The set time appears on the display The first digit hour display will flash Us the up 103 and down 104 keys to set the reading Press the Set key 111 to store the reading The next number minutes now flashes Use the up 103 and down 104 keys to make the required setting Confirm with Set 111 The settings are transferred km h 103 110 111 104 ...

Page 89: ...om moving accidentally XThe load centre of gravity must be located centrally between the forks Adjusting the forks Requirements Park the truck securely see Parking the truck securely on page 79 Procedure Lift up the locking lever 143 Push the forks 144 into the correct position on the fork carriage 145 Z To lift the load securely the forks 144 must be spread as far apart as possible and positioned...

Page 90: ...placing the forks fit the retaining bolts 129 and make sure the bolts are seated correctly Retaining bolt torque 85 Nm WARNING Trapping hazard There is a trapping hazard when you perform this operation XWear work gloves and safety shoes Replacing the forks Requirements Load handler lowered and forks not touching the ground Procedure Disassemble the retaining bolts 129 Loosen the fork stop 128 Care...

Page 91: ...ler XDamaged loads must not be transported XIf the stacked load obscures forward visibility then you must reverse the truck XDo not exceed the maximum loads specified on the capacity plate XCheck the fork spread before lifting the load and adjust if necessary XInsert the forks as far as possible underneath the load Lifting loads Requirements Load correctly palletised Fork spread for the pallet che...

Page 92: ...oad you are transporting Watch out for other traffic at crossings and passageways Always travel with a lookout at blind spots On slopes and inclines always carry the load facing uphill never approach at an angle or turn Depositing loads Requirements Storage location suitable for storing the load Procedure Set the mast vertical Drive the truck carefully up to the storage location Carefully lower th...

Page 93: ... have been correctly secured and positioned Use suitable precautions to prevent parts of the load from tipping or falling down XDo not exceed the maximum loads specified on the capacity plate XDo not stand underneath a raised load handler XDo not stand on the load handler XDo not lift other people on the load handler XDo not reach through the mast XThe controls should only be operated from the dri...

Page 94: ...he lever The lever will revert automatically to neutral Positioning the integrated sideshift option Requirements Truck prepared for operation see Preparing the truck for operation on page 76 Procedure Pull the SOLO PILOT lever 148 in direction R to move the load handler to the right from the driver s viewpoint Push the SOLO PILOT lever 148 in direction V to move the load handler to the left from t...

Page 95: ...e fork tines with an integrated fork positioner optional equipment Requirements Truck prepared for operation see Preparing the truck for operation on page 76 The fork tines are no longer aligned Procedure Press the toggle switch 149 and at the same time push the SOLO PILOT 146 in direction A and spread the fork tines apart as far as they will go Press the toggle switch 149 and at the same time pul...

Page 96: ...ll be a noise from the pressure relief valve release the lever The lever will revert automatically to neutral Tilting the mast forward backward Requirements Truck prepared for operation see Preparing the truck for operation on page 76 Procedure Push the MULTI PILOT lever 78 in direction V to tilt the mast forward Push the MULTI PILOT lever 78 in direction R to tilt the mast back The mast is now ti...

Page 97: ... push the MULTI PILOT forward and to the left The mast is now tilted back forward Positioning the integrated sideshifter option Requirements Truck prepared for operation see Preparing the truck for operation on page 76 Procedure Press the 150 button to move the load handler to the right from the driver s viewpoint Press the 151 button to move the load handler to the left from the driver s viewpoin...

Page 98: ...ynchronising the alignment of the fork tines with an integrated fork positioner optional equipment Requirements Truck prepared for operation see Preparing the truck for operation on page 76 The fork tines are no longer aligned Procedure Press the 85 button and at the same time turn the MULTI PILOT 78 anti clockwise the forks will spread apart Press the 85 button and at the same time turn the MULTI...

Page 99: ...esigned by the attachment manufacturer for use with the respective industrial truck XOnly use attachments that have been fitted for the purpose by the owner XMake sure the operator has been instructed in the use of the attachment and that he uses it for its correct purpose XRe assess the residual capacity of the truck and if it has been altered attach an additional capacity plate to the truck XNot...

Page 100: ...nly be operated on trucks will auxiliary hydraulics ZH1 or ZH2 XWhen connecting the attachment make sure that the hydraulic lines of the attachment are connected to the right ports see Fitting additional attachments on page 105 Safety instructions for rotary attachments WARNING A non centred load centre of gravity can result in accidents When using rotary devices and non centred loads the centre o...

Page 101: ...age Fork extension safety instructions WARNING Unsecured and oversized fork extensions can cause accidents XFor fork extensions with an open cross sectional area carry only loads that are resting along the entire length of the fork extension XUse 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 p...

Page 102: ...hments 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 Z Depending on the attachments used the lever 148 is assigned the function of the attachment Levers that are not required are void For connections see Fitting additional attachments on page 105 Procedure Operating the hydraulic port Z...

Page 103: ...R direction The attachment s function is performed 4 16 3 SOLO PILOT with control of ZH1 ZH2 and ZH3 hydraulic ports Z Depending on the attachments used the levers buttons 146 148 149 152 are assigned the respective functions Unused levers have no function For connections see Fitting additional attachments on page 105 Procedure Operating the hydraulic port ZH1 Move the lever 148 in direction V or ...

Page 104: ... have no function For connections see Fitting additional attachments on page 105 Procedure Operating hydraulic port ZH1 Press the 150 button or the 151 button The attachment performs its operation 4 17 2 MULTI PILOT with control of ZH1 and ZH2 hydraulic ports Z Depending on the attachments used the buttons 150 151 and the lever 78 are assigned the function of the attachment Levers that are not req...

Page 105: ... void For connections see Fitting additional attachments on page 105 Procedure Operating hydraulic port ZH1 Press the 150 button or the 151 button Operating hydraulic port ZH2 Turn the MULTI PILOT 78 clockwise or anti clockwise Operating hydraulic port ZH3 Set the MULTI PILOT 78 to neutral and then turn it clockwise or anti clockwise while at the same time pressing the button 85 The attachment per...

Page 106: ...ositioned correctly and securely and make sure they are complete XBefore starting make sure the attachment is working correctly Connect attachment hydraulically Requirements Hydraulic replacement coupling depressurised The exchange ports on the truck are marked ZH1 and ZH2 Attachment directions of movement defined to match the controls direction of movement Procedure Depressurise the hydraulic rep...

Page 107: ...displayed Fully extend the ZH lever for the required auxiliary function for more than 5 seconds Z For auxiliary functions with the acknowledgement key the key must also be applied at the same time The auxiliary valves are activated alternately and auxiliary ports therefore depressurised Each auxiliary function must be applied separately and in turn Indicator lamp 94 flashes as the valves are activ...

Page 108: ...e 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 ...

Page 109: ... the capacity indicated on the capacity plate see Identification points and data plates on page 30 If a load is also transported on the load handler the trailer load must be reduced by the same amount XDo not exceed the maximum speed of 5 km h km h XA truck must not be continually operated with trailers XDo not use supporting loads XTowing must only be performed on level secure travel routes XThe ...

Page 110: ...XThe 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 153 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 n...

Page 111: ...rogramming mode When you enter one of the following parameters the settings in the code lock can be changed Newly supplied trucks have the code indicated on a sticker When using the truck for the first time change the master and user codes and remove the sticker User code factory setting 2 5 8 0 Master code factory setting 7 2 9 5 Parameter Description 0 0 0 Change master code see Changing the mas...

Page 112: ...key Pressing the o key switches the truck off and sets it to non operational status The o key indicates the follow operating conditions via a red green LED 158 Code lock function commissioning the truck Error display configuring the user code Adjusting the travel program depending on the setting and truck Setting and changing parameters SET key When you change the parameters the SET key 157 acts a...

Page 113: ...ed on Z If the LED 158 flashes red this means the wrong code has been entered Enter the code again The Set key 157 has no function in operating mode 6 1 3 Switching off the truck with the keypad CanCode Switching off the truck Procedure Press the O key 159 The truck is switched off and the LED 158 is lit red Z The truck can cut out automatically after a specified time If no travel steering or hydr...

Page 114: ...the digit keys Confirm with the SET key 157 The LEDs 154 158 flash green Enter the valid master code again with the digit keys Confirm with the SET key 157 The LEDs 155 158 flash green Enter the valid master code with the digit keys Z The new master code must be different from existing user codes Confirm with the SET key 157 The LEDs 156 158 flash green Enter the new master code again with the dig...

Page 115: ... see Change operator code on page 117 Delete the user code so that the required master code can be used see Delete individual user codes on page 119 The master codes to be changed do not match Switch off the truck see Switching off the truck with the keypad CanCode on page 112 Enter the master code again see Changing the master code on page 113 The master code entered is not the same length as the...

Page 116: ...ode must also be different from the existing master code Confirm with the SET key 157 The LEDs 156 158 flash green Enter the new user code again with the digit keys Confirm with the SET key 157 Wait until the LED 158 flashes green The setting is saved Press the O key 159 The truck is switched off and the LED 158 is lit red Check the new user code Switch on the truck with the new user code see Prep...

Page 117: ...y a master code Switch off the truck see Switching off the truck with the keypad CanCode on page 112 Choose a different user code see Add operator code on page 115 The newly entered user codes do not match Switch off the truck see Switching off the truck with the keypad CanCode on page 112 Add the user code again see Add operator code on page 115 Code log full Switch off the truck see Switching of...

Page 118: ...that of the previously entered master code The new user code must also be different from the existing master code Confirm with the SET key 157 The LEDs 156 158 flash green Enter the new user code again with the digit keys Confirm with the SET key 157 Wait until the LED 158 flashes green The setting is saved Press the O key 159 The truck is switched off and the LED 158 is lit red Check the new user...

Page 119: ...e to be changed does not exist Switch off the truck see Switching off the truck with the keypad CanCode on page 112 Check the user code entered The user codes to be changed do not match Switch off the truck see Switching off the truck with the keypad CanCode on page 112 Change the user code again see Change operator code on page 117 Tried to change the operator code to another user code that alrea...

Page 120: ...s Confirm with the SET key 157 The LEDs 156 158 flash green Enter the user code to be deleted again with the digit keys Confirm with the SET key 157 Wait until the LED 158 flashes green The user code is now deleted Press the O key 159 The truck is switched off and the LED 158 is lit red Check that the user code has been deleted Switch the truck on with the user code to be deleted see Preparing the...

Page 121: ...n page 112 Repeat the entry making sure that the master code is the same length as the user code Tried to delete an operator code that does not exist Switch off the truck see Switching off the truck with the keypad CanCode on page 112 Check the user code entered The user codes to be changed do not match Switch off the truck see Switching off the truck with the keypad CanCode on page 112 Delete the...

Page 122: ...flash green Enter the code 3 2 6 5 with the digit keys Confirm with the SET key 157 Wait until the LED 158 flashes green All user codes are deleted Press the O key 159 The truck is switched off and the LED 158 is lit red Check that the user codes have been deleted Switch on the truck with a previous user code see Preparing the truck for operation with the keypad CanCode on page 112 After entering ...

Page 123: ...r code 4 6 digit is always determined by the length of the master code Requirements To prepare the truck for operation see Preparing the truck for operation with the keypad CanCode on page 112 Procedure Delete all user codes see Delete all user codes on page 121 Enter the new master code 4 6 digit see Changing the master code on page 113 Add user codes again see Add operator code on page 115 The l...

Page 124: ...1 minute maximum cutout time is 30 minutes 31 After 10 seconds the truck cuts out automatically Confirm with the SET key 157 Wait until the LED 158 flashes green The setting is saved Press the O key 159 The truck is switched off and the LED 158 lights up red Checking the truck s automatic cutout Switch on the truck with a valid operator code see Preparing the truck for operation with the keypad Ca...

Page 125: ...eriod of the truck For the following events the LED 158 flashes red Cause Remedy Cutout time entered is out of range Switch off the truck see Switching off the truck with the keypad CanCode on page 112 Enter the time again while making sure it is within range ...

Page 126: ... displayed by the 154 155 156 LEDs LED 154 lit travel program 1 activated LED 155 lit travel program 2 activated LED 156 lit travel program 3 activated The configuration code is four digit and is comprised as follows 1st digit Specifies the authorisation for travel program 1 2nd digit Specifies the authorisation for travel program 2 3rd digit Specifies the authorisation for travel program 3 4 digi...

Page 127: ... program 2 is blocked for the user code selected 1 Travel program 2 is enabled for the user code selected 3rd digit 0 Travel program 3 is blocked for the user code selected 1 Travel program 3 is enabled for the user code selected 4th digit 0 When the truck has been switched on with the selected user code no travel program is activated 1 When the truck has been switched on with the selected user co...

Page 128: ...or the travel programs again using the digit keys Confirm with the SET key 157 Wait until the LED 158 flashes green The travel programs are now assigned to the user code Press the O key 159 The truck is switched off and the LED 158 is lit red Checking the travel program configuration to the user code Switch on the truck with the configured user code see Preparing the truck for operation with the k...

Page 129: ... the following events the LED 158 flashes red Cause Remedy Blocked travel program defined as start travel program Switch off the truck see Switching off the truck with the keypad CanCode on page 112 Try again making sure the configuration code is entered correctly ...

Page 130: ...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 2 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 CanCode o 3 He is wearing the seat belt Z If the...

Page 131: ...age 65 the driver must carry out the following checks Lift the empty load handler beyond the reference lift height and check if the slow travel display lights up Steering when the truck is stationary check if the steering wheel display is working 6 2 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 he...

Page 132: ...iver from his responsibility to wear a seat belt see Seat Belt on page 73 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 To open the cabin door unlock the door and pull out the handle 161 6 4 Sliding windows CAUTION An unlocked sliding window can cause accidents XThe sliding windows must be locked at all tim...

Page 133: ...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 Gate operation Procedure To open the gate press the handle 164 The gate automatically moves up and remains in this position To close push the gate down Z Trav...

Page 134: ...ody over the steering wheel and hold on with both hands Tilt your body in the opposite direction of fall Requirements On trucks with a door monitoring sensor travel is only enabled when the panel door is closed o Procedure Pull the handle 166 towards the operator position the door swings open Pull the door 160 towards the operator the door closes 6 7 Operator position extension DANGER Altering the...

Page 135: ...er cassette 168 out in the direction of the arrow Replace the filter Insert the filter cassette 168 into the heating console 167 Turn the twist off knob clockwise The filter cassette has been replaced and locked Z Regular servicing is required to ensure the filter can work at a consistently high level see Servicing and Inspection on page 204 167 168 168 169 ...

Page 136: ...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 Z At very low outer temperatures the heating level can be increased by opening the recirculating air flap 174 Item Description Item Description 170 Body jets 174 Recirculat...

Page 137: ...g system switches off before the truck is parked Using the air conditioning system at high air humidity and temperature levels Procedure Press the toggle switch 177 Distribute the air evenly through all discharge jets Switch 173 in centre position Set the fan 172 to its highest level Set the temperature control 171 according to the outside temperature Open the rear sliding window by one notch Clos...

Page 138: ...Adjusting the backrest extension CAUTION Accident risk when adjusting the backrest during travel XDo 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 178 km h R 120 ...

Page 139: ...backrest assembly Procedure Attach the load backrest to the top rail of the fork carriage Fit the bolts and tighten them with a torque wrench Z Torque 85 Nm 6 11 Lift cutout override Z A lift cutout device can be factory fitted when working in areas of restricted height This interrupts lifting To continue lifting Procedure Press the lift cutout override button see Control panel with display unit o...

Page 140: ...own on the P1 function key 113 The sideshifter moves to the centre position Z Releasing the P1 function key interrupts the movement The sideshifter is centred 6 13 Fire extinguisher Procedure Open the fasteners 180 Pull the fire extinguish out of its bracket Z To operate refer to the illustrations on the fire extinguisher 6 14 Tilt angle display NOTE The current tilt angle is shown in an additiona...

Page 141: ...s Procedure Prevent the trailer from rolling away Adjusting the trailer pull rod to the height of the coupling Pull the hand lever 183 remote control 182 o up Z The remote control 182 o is located in the overhead guard depending on the truck model Slowly reverse the truck until the coupling engages Push the hand lever 183 remote control 182 o down Rockinger coupling operation disconnecting trailer...

Page 142: ...ear Using the camera system Press the button 190 on the monitor to switch the camera system on or off Press the button 189 to lighten or darken the screen day night settings Press the button 186 to open the menu Z Pressing the button several times changes the menu item contrast brightness colour saturation language video light reflection or quits the menu Adjusting the menu items Press the button ...

Page 143: ...ter must be cleaned regularly according to how much it is clogged Procedure Turn the quick release lock 191 to open it Pull the lint mesh up by the handle 192 and clean it Fit the lint mesh back and lock it The lint mesh is now clean 6 18 Roof window wiper The roof window wiper is activated by pressing the switch in the dashboard Procedure Press switch to switch the roof window wiper on Keep press...

Page 144: ...of the MULTI PILOT Do not deposit the load handler suddenly to avoid damaging the load and the racking Lifting Procedure Push the MULTI PILOT to the right direction H to raise the load Push the MULTI PILOT to the left direction S to lower the load Z 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 rever...

Page 145: ...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 in...

Page 146: ... be started again once the fault has been removed Item Display Function 72 DFG fuel supply display Graphic illustration of the fuel supply TFG with gas tank 73 WARNING Lights up a single time to indicate that the fuel supply is too low Lights up in conjunction with err xx xxx or inf xx xxx to indicate a fault or information A warning signal sounds 88 Engine oil pressure display Engine oil pressure...

Page 147: ...gh 173 Parking brake released during initialisation Parking brake must be activated see Release the parking brake on page 150 186 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 Depressurised mode activated 191 Overtemperature Hydraulic oil temperature too high Coolant temperature too high 193 Anti ...

Page 148: ...ssary Clean radiator Check engine radiator system for leaks add coolant if necessary Engine running but truck does not travel Travel direction switch in neutral Parking brake applied Set travel direction switch to required travel direction Release the parking brake Check belt lock control system Check seat switch Truck does not reach max speed Hydraulic reservoir oil level too low Check the hydrau...

Page 149: ...om the diesel flakes forming Fill up with diesel and bleed the injection system Drain the fuel system fill up the truck and bleed the fuel system Check the fuel tank if necessary replace the fuel filter 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 v...

Page 150: ...o not park the truck with the parking brake released XOne 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 50 of the towing truck and attach it to the truck to be towed Release the parking brake see Release the parking brake on pag...

Page 151: ... the truck from rolling away Open the floor plate 193 by undoing the quick release locks and remove the plug connections 194 Procedure Undo the setscrew on the valve block 195 a maximum of 1 5 turns Fully insert the setscrew 196 torque 2 5 Nm Turn the steering wheel clockwise Fully insert the setscrew 195 again Torque 2 5 Nm Turn the steering wheel back until the wheels are facing the required dir...

Page 152: ...port any defects immediately to your supervisor XTag out and decommission a faulty lift truck XOnly return the truck to service when you have identified and rectified the fault Procedure Set the Emergency Disconnect switch and the key switch to the O position Undo the setscrew 198 on the valve block by a maximum of 1 5 turns The mast and load handler will lower slowly Z If necessary the lowering s...

Page 153: ...ery to the jump start connection 199 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 81 to the I position Press the override switch 213 Start the engine by turning the key in the key switch 81 to the I position When the engine has started first remove the negative lead ...

Page 154: ...pletion 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 ...

Page 155: ...oups 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 activiti...

Page 156: ...nmental hazard Used parts and consumables must be disposed of in accordance with the applicable environmental protection regulations To change the oil contact the manufacturer s customer service department who have been specially trained for this task XNote the safety regulations when handling these materials 2 3 Wheels WARNING The use of tyres that do not match the manufacturer s specifications c...

Page 157: ...n Rinse any affected areas thoroughly XIf it comes into contact with the eyes rinse them immediately with flowing water and call for a doctor XWear safety gloves when handling diesel fuels 2 5 Hydraulic system WARNING Brittle hydraulic hose lines can cause accidents The hoses must be replaced every six years The manufacturer s customer service department is specially trained to carry out these ope...

Page 158: ...f service XDo not return the industrial truck to service until you have identified and rectified the fault XRemove any spilled hydraulic immediately with an appropriate bonding agent XThe bonding agent consumable mixture must be disposed of in accordance with regulations 2 6 Working in the vicinity of the engine WARNING Danger from hot fluids and components XConsumables hydraulic oil engine oil co...

Page 159: ...es in prescribed containers XAlways fill consumables in clean containers XDo not mix up different grades of consumable The only exception to this is when mixing is expressly stipulated in the operating instructions CAUTION Spilled consumables can cause slipping and endanger the environment Risk of slipping from spilled consumables The risk is greater when combined with water XDo not spill consumab...

Page 160: ...r parts XDo not smoke when handling oil XAvoid contact and digestion If you swallow oil do not induce vomiting but seek medical assistance immediately XSeek fresh air after breathing in oil fumes or vapours XIf oil has come into contact with your skin rinse your skin with water XIf oil has come into contact with your eyes rinse them with water and seek medical assistance immediately XReplace oil s...

Page 161: ...03 13 EN 160 3 2 Lubrication Schedule g Contact surfaces c Hydraulic oil drain plug s Grease nipple t Coolant filler cap S Hydraulic oil filler neck Ö Engine oil filler neck DFG TFG K K ...

Page 162: ...ves Grease guidelines Code Order no Quantit y Capaci ty Description Used for A 51037495 51037499 1 l 5 l 55l HVI Renolin B46 Hydraulic system E 50055726 400 gr Grease K P 2K Mast roller and sideshifter contact surfaces steer axle G 29201280 0 4 l Chain spray Chains K 51210409 4 0 l 4 5 l Titan GT 1 Pro C 3 SAE 5W 30 Engine oil M 51118018 1 l 7 0 l Fricofin G12 Plus Coolant Code Saponification Dew ...

Page 163: ...result if poisonous quantities come into contact with the skin for long or repeated periods XNote 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 XEven if the coolant cannot f...

Page 164: ...oad handler Remove the key from the key switch 81 to prevent the truck from being switched on accidentally WARNING Risk of accidents when working under the load handler driver s cab and lift truck XWhen 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 XWhen raising the truck follow the instructions see Li...

Page 165: ... truck for maintenance and repairs see Preparing the truck for maintenance and repairs on page 163 Tools and Material Required Jack Hard wooden blocks Procedure Place the jack against the contact point Z Jack contact point see Identification points and data plates on page 30 Raise the truck Support the truck with hard wooden blocks Remove the jack The truck is now securely raised and jacked up 4 3...

Page 166: ...Adjusting the steering wheel steering column on page 71 Tilt the backrest forward move the driver s seat forward and lock it in position see Adjusting the driver s seat on page 68 Pull the lever 139 in the arrow direction L until the engine cover is unlocked The engine cover is now slightly open Engine cover emergency unlocking Requirements The engine cover cannot be unlocked Procedure Open the fl...

Page 167: ...ine cover up by the handle 203 and engage it in the lock 206 of the gas pressure spring 204 The engine cover opens in the first stage Open the engine cover 15 as far as the 70 stage Requirements The engine cover is unlocked see Unlocking the engine bonnet on page 165 Procedure Fold the backrest down Move the armrest down to do this pull the locking lever 207 Push the driver s seat forward Push the...

Page 168: ... the engine cover as far as the 50 stage Raise the engine cover again slightly From the 50 stage push in the red lock 206 of the left hand gas pressure spring Close the engine cover and make sure it is locked correctly Move the backrest back move the armrest up push back and lock the driver s seat To adjust the seating position and steering wheel position to your requirements see Adjusting the dri...

Page 169: ...njury XThe wheels of the truck are very heavy A single wheel can weigh up to 150 kg XAlways replace wheels with a suitable tool and protective equipment Dismantle the wheels Requirements Prepare the truck for maintenance and repairs see Preparing the truck for maintenance and repairs on page 163 Tools and Material Required Jack Hard wooden blocks Mounting lever Torque wrench Procedure Place the ja...

Page 170: ...ary Fit the wheel attachment Remove the hard wooden blocks Lower the truck Torque the wheel attachment 208 crosswise with a torque wrench for torques see Tyre type on page 27 The wheel is now assembled Z When using pneumatic tyres check the air pressure for the air pressure see Tyre type on page 27 208 ...

Page 171: ...cure after 10 service hours XAlways 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 repairs on page 163 Tools and Material Required Torque wrench Procedure Torque the wheel nuts 208 crosswise with a torque wrench for torques see Tyre type on page 27 The wheel attachment...

Page 172: ...om coming into contact with hot motor parts XDo not smoke when handling hydraulic oil XAvoid contact and digestion If you swallow oil do not induce vomiting but seek medical assistance immediately XSeek fresh air after breathing in oil fumes or vapours XIf oil has come into contact with your skin rinse your skin with water XIf oil has come into contact with your eyes rinse them with water and seek...

Page 173: ...e Min and Max levels For hot oil The hydraulic 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 209 again 4 8 2 Adding hydraulic oil Procedure Unscrew the filler cap 210 Add hydraulic oil in small amounts Z Use only approved hydraulic oil see consumables table Keep checking the hydraulic o...

Page 174: ... back on 4 8 4 Replacing the ventilation discharge filter Procedure Unscrew the ventilation discharge filter 212 Visually inspect the filter If contaminated insert a new filter Screw the ventilation discharge filter back on Z Collect any spilled hydraulic oil Dispose of the hydraulic oil and hydraulic oil filter and fuel in accordance with environmental regulations MIN MAX 211 212 ...

Page 175: ...h moving parts e g fans belt drives etc or hot surfaces XTruck 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 Press the override switch 213 a single...

Page 176: ...ating 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 Parking the truck securely on page 79 Procedure Remove the dipstick 214 Wipe the dipstick with a lint free cloth and put in back fully into the port Remove the dipstick again and check that th...

Page 177: ...emove the oil filter from the oil filter housing 217 Collect any oil that emerges Thoroughly clean the raised faces of the oil filter housing and oil filter lid Insert a new oil filter in the oil filter housing 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 Procedure Add fresh engine oil see Consumables on page 161 through the fille...

Page 178: ...e incorrect amount of oil will damage the engine XAfter replacing the oil and oil filter carry out a test run and check the oil pressure display 88 XCheck that the oil drain plug and oil filter housing are tight km h R 88 ...

Page 179: ... cotter pin and take off the return lines Slacken the collar screw 220 and take off the fuel filter 221 Fill the new fuel filter entirely with clean diesel and fit it with the collar screw 220 Reconnect the fuel hoses and tighten them with clamps or the cotter pin 4 9 4 Check V belt for damage Procedure Check the V belt 222 for cracks deformation and wear NOTE A damaged V belt will result in malfu...

Page 180: ...ating 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 Parking the truck securely on page 79 Procedure Remove the dipstick 214 Wipe the dipstick with a lint free cloth and put in back fully into the port Remove the dipstick again and check that th...

Page 181: ...oil drain plug 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 223 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 215 210 223 ...

Page 182: ...XAfter replacing the oil and oil filter carry out a test run and check the oil pressure display 88 XCheck that the oil drain plug and oil filter housing are tight 4 9 6 Replacing spark plugs Procedure Remove spark plug connector 224 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 Z Rated va...

Page 183: ...V belt for damage NOTE A damaged V belt will result in malfunctions XIf the V belt 222 is not in good condition first rectify the damage before using the truck Procedure Check the V belt 222 for cracks deformation and wear 222 ...

Page 184: ...scaping when the filler cap is opened Checking the coolant level Procedure Park the truck securely on a level surface Open the rear bonnet locks and lift off the rear bonnet see Opening the rear panel on page 164 Check the coolant level on the expansion vessel 225 Fit the rear cover 226 and snap it back into position NOTE The incorrect coolant can cause malfunctions XTo prevent the build up of lim...

Page 185: ...ansion vessel 225 Check the anti freeze content of the coolant with an anti freeze tester NOTE The incorrect coolant concentration can cause malfunctions XIf 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 227 225 ...

Page 186: ...n 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 CAUTION A damaged cooler and fan can be dangerous XCheck the radiator and fan for damage XIf the radiator or fan are damaged only start to use the truck when the damage has been rectified Fan unit assembly Procedure Mount the fan unit to its intended...

Page 187: ...an cause malfunctions XDo not clean the air filter housing with compressed air XAlways use a clean cloth to clean the air filter housing 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 Z There must be no residue from the cloth in the air filter housing Insert the air filter...

Page 188: ... Turn the twist off knob clockwise The filter cassette has been replaced and locked Z Regular servicing is required to ensure the filter can work at a consistently high level see Servicing and Inspection on page 204 4 9 11 Adding window washer system fluid Procedure Unlock the engine cover see Unlocking the engine bonnet on page 165 Make sure there is sufficient window fluid in the container 231 I...

Page 189: ...er of the truck see Opening the rear panel on page 164 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 ...

Page 190: ...ail light RH parking light 7 5 21 8 4F5 1 o Left indicator 5 31 9 4F5 2 o Right indicator 5 31 10 6F5 o Road traffic regulations armrest 5 11 4F9 t E BOX 2 12 3F5 t Emergency Disconnect switch 5 13 9F24 o Radio constant current 5 14 2F1 o Wash pump 5 15 5F5 1 o LH dipped lights 5 o LH dipped lights set A version 5 31 16 9F23 o not used pre 11 09 changeover valve 5 xs 182 xs 180 1 2 3 4 5 6 7 8 9 1...

Page 191: ... mass meter DFG 425s 435s only 5 Shutoff valve TFG only 33 9F31 t Charge control generator 5 34 4F1 t Horn 10 35 4F11 t ECU terminal 15 engine controller 5 36 Not used 37 9F17 5 o Option connector XS182 6 terminal 30 3 38 9F17 4 o Option connector XS182 5 terminal 30 3 39 9F17 3 o Option connector XS182 4 terminal 30 3 40 F21 t Fuse tester 41 9F2 1 o Jumper for relay 25 42 9F14 1 o Option 10 43 5F...

Page 192: ...191 03 13 EN t Series equipment o Optional equipment ...

Page 193: ... with bonnet open 6 9K3 t Starter relay 7 9K23 t Ignition on engine not running 8 9K24 t Ignition on engine running 9 9K22 t Engine main relay 10 9K16 o Heating 11 OF1 o Option relay 2K63 1 max 15A 12 OF2 o Option relay 2K63 2 max 7 5A 13 OF3 o Option relay 2K63 3 max 5A t Series equipment o Optional equipment xs 182 xs 180 1 2 3 4 5 6 7 8 9 10 11 12 13 ...

Page 194: ... fusebox cover Close the engine cover see Unlocking the engine bonnet on page 165 The main fuses engine compartment are now checked Item Component To protect Rating A 1 9F18 t Preheat DFG only 50 ECU engine controller TFG only 20 2 6F8 o Soot particle filter DFG only 100 3 F21 t Engine ignition off 100 4 9F20 o External air conditioning system 30 5 F22 t Terminal 30 constant positive 100 6 F19 4 t...

Page 195: ... of the pressure washer by the marked points to avoid damaging them see Identification points and data plates on page 30 XDo 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 163 Tools and Material Required Water based solvents Sponge or cloth Procedure Clean the surfa...

Page 196: ...ee Preparing the truck for maintenance and repairs on page 163 Tools and Material Required Compressor with water separator Non conductive antistatic brush Procedure Expose the electrical system see Opening the rear panel on page 164 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...

Page 197: ... water XOnly batteries with a sealed battery container may be used XFollow 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 Clean the area around the inspection plugs Unscrew the d...

Page 198: ...XIn 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 174 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 ex...

Page 199: ...an the starter battery grease the terminals and connect the starter battery WARNING Faulty brakes can cause accidents As soon as the truck has been started test the brakes several times XReport any defects immediately to your supervisor XTag out and decommission the faulty industrial truck XOnly return the truck to service when you have identified and rectified the fault Start up the truck see Pre...

Page 200: ...ssioning 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 Z Jack up the truck see Lifting and jacking up the truck safely on page 164 If the truck is to be out of service for more than 6 months agree further measures with the manufacturer s ...

Page 201: ...se to any non painted mechanical components Lubricate the truck according to the lubrication schedule see Lubrication Schedule on page 160 Disconnect the battery clean it and grease the terminals Z 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 sh...

Page 202: ... engine oil Condensation water could have formed Replace hydraulic oil Condensation water could have formed Z 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 65 WARNING Faulty brakes can cause accidents As soon as the truck has been started test the brakes several times XReport any de...

Page 203: ...ces The inspector must be sufficiently instructed and experienced to be able to assess the condition of the truck and the effectiveness of the safety mechanisms based on the technical regulations and principles governing the inspection of forklift trucks A thorough test of the truck must be undertaken with regard to its technical condition from a safety aspect The truck must also be examined for d...

Page 204: ...isassembled by trained personnel in accordance with the procedures as specified by the manufacturer 8 Human vibration measurement Z 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 ope...

Page 205: ...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 Z W maintenance interval activities should be performed by t...

Page 206: ... coolant level and top up if necessary t 2 Check tyre air pressure and top up if necessary t 3 Check wheels for wear and damage t 4 Check engine oil level top up if necessary t Chassis and Superstructure W A B C 1 Check doors and or covers t 2 Check labels are legible and complete t 3 Check engine compartment for contamination and clean if necessary t 4 Check overhead guard and or cab are secure a...

Page 207: ...eating vent filter for contamination and clean if necessary t Hydraulic operations W A B C 1 Check attachment lubrication clean and lubricate if necessary t Hydraulic operations W A B C 1 Check attachment lubrication clean and lubricate if necessary t Electrical System W A B C 1 Test lighting t Hydraulic operations W A B C 1 Check attachment lubrication clean and lubricate if necessary t Chassis a...

Page 208: ... A B C 1 Check attachment lubrication clean and lubricate if necessary t Chassis and Superstructure W A B C 1 Check that optional equipment such as mirrors storage compartments grips windscreen wipers and washing systems etc are working correctly and check for damage t ...

Page 209: ...k battery and battery components t 4 Check battery voltage t Travel W A B C 1 Test exhaust system and check for leaks and damage t 2 Check the wheel motor attachments t 3 Check the wheel motors and displacement pump for noise and leakage t 4 Check that hydraulic ports hose and pipe lines are secure check for leaks and damage t 5 Test anti freeze top up if necessary t 6 Replace radiator fluid and a...

Page 210: ... driver s seat t 6 Check engine compartment for contamination and clean if necessary t 7 Check mast attachment mounting t 8 Check trailer coupling or tow mechanism stop t 9 Check overhead guard and or cab are secure and check for damage t 10 Check operator mat and steps are non slip and damage free t 11 Test driver s seat restraint system and check for damage t Hydraulic operations W A B C 1 Test ...

Page 211: ...damage t 20 Check piston rod screw depth and counter fixing clamp Where two tilt cylinders with the same stroke length are used check the setting in respective of each other t 21 Check tilt cylinders and mounting t 22 Test lift and lowering speeds t Agreed performance levels W A B C 1 Carry out a test run with rated load if necessary with a customer specific load t 2 Lubricate truck according to t...

Page 212: ...m stop t Hydraulic operations W A B C 1 Check attachment is properly secured to the truck and the supporting elements t Electrical System W A B C 1 Test lighting t Electrical System W A B C 1 Test strobe light beacon and check for damage t Electrical System W A B C 1 Check data recorder is secure and check for damage t Travel W A B C 1 Check the Drive Control t Electrical System W A B C 1 Test the...

Page 213: ...ocks are complete t 6 Check attachment bearing points guides and stops for wear and damage grease and clean these components t 7 Check attachment lubrication clean and lubricate if necessary t 8 Check hydraulic ports and tighten if necessary t 9 Check cylinder seals t 10 Check cylinder piston rods and bushings t Chassis and Superstructure W A B C 1 Test air conditioning system and its settings and...

Page 214: ...setting and check for contamination clean if necessary t 4 Measure the soot index according to the manufacturer s specifications or national regulations o Chassis and Superstructure W A B C 1 Make sure restraint system is complete test operation and check for damage t Electrical System W A B C 1 Check impact sensor is secure and check for damage t Hydraulic operations W A B C 1 Check axial play of...

Page 215: ...System W A B C 1 Test lighting t Hydraulic operations W A B C 1 Check attachment is properly secured to the truck and the supporting elements t 2 Test attachment check settings and check for damage t 3 Check attachment bearing points guides and stops for wear and damage grease and clean these components t 4 Check attachment lubrication clean and lubricate if necessary t 5 Check hydraulic ports and...

Page 216: ... Check wiper water container for leaks and check volume top up if necessary t 2 Test windscreen wipers and check for damage replace if necessary t Hydraulic operations W A B C 1 Check axial play of the front and rear rollers and adjust if necessary t 2 Check attachment is properly secured to the truck and the supporting elements t 3 Test attachment check settings and check for damage t 4 Check sli...

Page 217: ...ical System W A B C 1 Test access module check for damage and make sure it is secure t Chassis and Superstructure W A B C 1 Check that optional equipment such as mirrors storage compartments grips windscreen wipers and washing systems etc are working correctly and check for damage t ...

Page 218: ... coolant level and top up if necessary t 2 Check tyre air pressure and top up if necessary t 3 Check wheels for wear and damage t 4 Check engine oil level top up if necessary t Chassis and Superstructure W A B C 1 Check doors and or covers t 2 Check labels are legible and complete t 3 Check engine compartment for contamination and clean if necessary t 4 Check overhead guard and or cab are secure a...

Page 219: ...eating vent filter for contamination and clean if necessary t Hydraulic operations W A B C 1 Check attachment lubrication clean and lubricate if necessary t Hydraulic operations W A B C 1 Check attachment lubrication clean and lubricate if necessary t Electrical System W A B C 1 Test lighting t Hydraulic operations W A B C 1 Check attachment lubrication clean and lubricate if necessary t Chassis a...

Page 220: ... A B C 1 Check attachment lubrication clean and lubricate if necessary t Chassis and Superstructure W A B C 1 Check that optional equipment such as mirrors storage compartments grips windscreen wipers and washing systems etc are working correctly and check for damage t ...

Page 221: ...nd battery components t 4 Check battery voltage t 5 Note check the exhaust levels every six months and adjust if necessary Observe other national guidelines and regulations 6 Note The LPG system must only be inspected by LPG system experts 7 Test the LPG system and check for leaks and damage t 8 Replace the LPG filter t Travel W A B C 1 Test exhaust system and check for leaks and damage t 2 Check ...

Page 222: ...Check labels are legible and complete t 4 Check attachment and setting function of the driver s seat t 5 Check condition of the driver s seat t 6 Check engine compartment for contamination and clean if necessary t 7 Check mast attachment mounting t 8 Check trailer coupling or tow mechanism stop t 9 Check overhead guard and or cab are secure and check for damage t 10 Check operator mat and steps ar...

Page 223: ...cessary t 18 Replace hydraulic oil t 19 Check forks or load handler for wear and damage t 20 Check piston rod screw depth and counter fixing clamp Where two tilt cylinders with the same stroke length are used check the setting in respective of each other t 21 Check tilt cylinders and mounting t 22 Test lift and lowering speeds t Agreed performance levels W A B C 1 Carry out a test run with rated l...

Page 224: ...mage and make sure it is secure t Chassis and Superstructure W A B C 1 Check trailer coupling or tow mechanism stop t Hydraulic operations W A B C 1 Check attachment is properly secured to the truck and the supporting elements t Electrical System W A B C 1 Test lighting t Electrical System W A B C 1 Test strobe light beacon and check for damage t Electrical System W A B C 1 Check data recorder is ...

Page 225: ... truck and the supporting elements t 4 Test attachment check settings and check for damage t 5 Check sliding blocks are complete t 6 Check attachment bearing points guides and stops for wear and damage grease and clean these components t 7 Check attachment lubrication clean and lubricate if necessary t 8 Check hydraulic ports and tighten if necessary t 9 Check cylinder seals t 10 Check cylinder pi...

Page 226: ...ical System W A B C 1 Check impact sensor is secure and check for damage t Hydraulic operations W A B C 1 Check axial play of the front and rear rollers and adjust if necessary t 2 Check attachment is properly secured to the truck and the supporting elements t 3 Test attachment check settings and check for damage t 4 Check sliding blocks are complete t 5 Check attachment bearing points guides and ...

Page 227: ...ge t 3 Check attachment bearing points guides and stops for wear and damage grease and clean these components t 4 Check attachment lubrication clean and lubricate if necessary t 5 Check hydraulic ports and tighten if necessary t 6 Check cylinder seals t 7 Check that hydraulic ports hose and pipe lines are secure check for leaks and damage t 8 Check piston and piston rod for damage check setting an...

Page 228: ...cessary t Hydraulic operations W A B C 1 Check axial play of the front and rear rollers and adjust if necessary t 2 Check attachment is properly secured to the truck and the supporting elements t 3 Test attachment check settings and check for damage t 4 Check sliding blocks are complete t 5 Check attachment bearing points guides and stops for wear and damage grease and clean these components t 6 C...

Page 229: ...ent Issued on 20 11 2012 16 52 11 Chassis and Superstructure W A B C 1 Check that optional equipment such as mirrors storage compartments grips windscreen wipers and washing systems etc are working correctly and check for damage t ...

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