387 801 1501 EN – 04/2012

With over 100,000 fork lift trucks and ware- Your local Linde partner can offer you a
house machines sold annually, Linde is one of complete package from a single source;
the world’s leading manufacturers of material ranging from expert advice on all aspects
handling equipment. There are many reasons of sales and service through, of course, to
for this success: Linde products are renowned appropriate finance options. Our leasing, hire
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ating costs, which are up to 40 per cent lower your individual business requirements.
than those of their competitors.
Linde Material Handling GmbH
The high quality of Linde products is also Carl-von-Linde-Platz
matched by the quality of our service. With ten 63743 Aschaffenburg
production plants worldwide and an extensive Telephone +49 (0) 6021 99-0
network of sales partners, we are at your Fax +49 (0) 6021 99-1570
service round the clock and around the world. Mail: info@linde-mh.com
Web: http://www.linde-mh.com

Operating Instructions – 387 801 1501 EN – 04/2012 I

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Operating Instructions – 387 801 1501 EN – 04/2012 III

 ..................................... ............ 33
Entering and exiting the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 33
Adjusting the driver’s seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 35
Adjusting the steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 38
Setting the time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 39
Seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 40
Switching the truck on and off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 42
Driving (dual-pedal operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 44
Driving (single-pedal operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 47
Steering system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 50
Brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 51
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 56
Joystick —Central-lever operation . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 57
Joystick — Single-lever operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 63
Emergency off switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 70
................................................... 70
Adjusting the driver’s seat equipped with air suspension . . . . . . . . . . . . . . . . . . . . . . . 70
Adjusting the driver’s seat with rotating device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Lift mast positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Steering angle display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Lift height restriction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Driving speed reduction via a switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Lifting system and attachments (single-lever operation with 3rd auxiliary hy-
draulics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Depressurisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Windscreen wipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Window heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Linde Forklift Data Management (LFM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Integrated charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
......... . . . . . . . ............. . . . . . . . .. .......... . . 111
Before load pick up . . . . . . . . . . . . . . . . . ............. . . . . . . . .. .......... . . 112
Adjust fork arm distance . . . . . . . . . . . . . ............. . . . . . . . .. .......... . . 112
Load pick up . . . . . . . . . . . . . . . . . . . . . ............. . . . . . . . .. .......... . . 114
Driving under load . . . . . . . . . . . . . . . . . ............. . . . . . . . .. .......... . . 114
Setting down loads . . . . . . . . . . . . . . . . . ............. . . . . . . . .. .......... . . 116
Towing device . . . . . . . . . . . . . . . . . . . . ............. . . . . . . . .. .......... . . 117

IV Operating Instructions – 387 801 1501 EN – 04/2012

 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
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Dismantling the lift mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Driving without lift mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Crane loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Transportation by lorry or low loading trucks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

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.... . . . . . . . ........... . . . . . . . . . . . . . . 128
Service plan after 50 hours . . . . . . . . . . ... . . . . . . . ........... . . . . . . . . . . . . . . 128
One-off service plan after 1000 hours . . . . . . . . . . . . ........... . . . . . . . . . . . . . . 130
1000 h service plan . . . . . . . . . . . . . . . . . . . . . . . . . ........... . . . . . . . . . . . . . . 132
3000 h service plan . . . . . . . . . . . . . . . . . . . . . . . . . ........... . . . . . . . . . . . . . . 134
6000 h service plan . . . . . . . . . . . . . . . . . . . . . . . . . ........... . . . . . . . . . . . . . . 137
........................... ............................... 140
Checking the planetary transmission oil level ............................... 140
Checking the planetary transmission for leaks. .............................. 142
Changing the oil in the planetary transmission ............................... 143
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Checking the mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............. . . .. 146
Cleaning the industrial truck . . . . . . . . . . . . . . . . . . . . . . . . . . . ............. . . .. 147
Opening and closing the battery hood . . . . . . . . . . . . . . . . . . . . ............. . . .. 148
Checking the condition and correct function of the seat belt . . . . ............. . . .. 150
Check the tilt cylinder bearings for wear . . . . . . . . . . . . . . . . . . ............. . . .. 151
Check and oil other bearings and joints . . . . . . . . . . . . . . . . . . . ............. . . .. 153
Other cleaning and greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . ............. . . .. 153
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Checking the tyres(Air pressure, size, rims) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Wheel change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Tightening the wheel fastenings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Checking the condition of the antistatic belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Cleaning and lubricating the combined axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Checking the drive axle heat sinks for contamination, cleaning if necessary . . . . . . . . . 162
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Checking the brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

Operating Instructions – 387 801 1501 EN – 04/2012 V

 Check bellows on joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Checking and oiling the pedal group and linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
................................................. 168
Checking the battery charge status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Charging the battery using an external battery charger . . . . . . . . . . . . . . . . . . . . . . . . 171
Active charging ventilation unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Battery replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Checking the main contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Adjusting the accelerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Checking the fans for function and contamination, and cleaning if necessary . . . . . . . . 185
Checking the condition and secure positioning of electric cables, cable connectors and
connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
......................................................... 190
Checking the oil level of the hydraulic system (hydraulic tank) . . . . . . . . . . . . . . . . . . . 190
Checking the hydraulic system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Changing the hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Checking the breather filter for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Changing the breather filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Checking the control unit for correct function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Replacing the high-pressure filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Changing the suction filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Check the tension of double hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
..................................................... 201
Working on the lift mast and at the front of the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Tightening the lift mast fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Cleaning the lift mast chain and spraying with chain spray . . . . . . . . . . . . . . . . . . . . . . 206
Adjust lift mast chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Checking the mounting, condition and correct function of lift mast, lift mast chains, lift
cylinders and end stops. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Check fork arms and arm safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
................................................... 210
Filling up the washer system / water tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Cleaning and lubricating the sideshift (special equipment), checking the fastening . . . . 210
Cleaning and lubricating the fork prong positioner (special equipment), checking the
mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Check fork arm adjustment device (special equipment) for wear and tear . . . . . . . . . . . 213
Checking the slide guides on the sideshift (special equipment) for wear . . . . . . . . . . . . 213
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Malfunctions during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Fuses - Basic equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

VI Operating Instructions – 387 801 1501 EN – 04/2012

 Fuses -Special equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . 217
Diagnostic connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . 222
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . 223
Shutdown of forklift truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . 227
Disposal of old trucks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . 228

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272

Operating Instructions – 387 801 1501 EN – 04/2012 VII

offers optimum economic efficiency, safety With orders for parts, please specify the
and driving comfort. It is primarily down to following along with the parts numbers:
you to maintain these characteristics for a
long time and take advantage of the resulting Industrial truck
benefits. model:
Production number /
During manufacture: year of manufacture:
• all safety requirements of the relevant EC Handover date:
directives were observed
• all conformity assessment procedures The production number should also be speci-
stipulated in the applicable directives were fied for parts from the following units: lift mast,
carried out drive axle and steering axle.

This is attested by the CE mark shown on the Lift mast number:

nameplate.
Lift mast lift:
These operating instructions contain every-
thing you need to know about commissioning, Drive axle number:
driving and maintenance. Steering axle
number
A number of items of special equipment have
their own operating instructions, which are When you receive the industrial truck, this data
supplied along with these devices. should be copied from the identification plates
of the units into these operating instructions.
Please observe the operation information that
corresponds to your industrial truck version
and carry out the specified work regularly,
at the due times and using the consumables In the event of repairs, only use genuine spare
envisaged for this purpose in accordance with parts from the manufacturer. This is the only
the inspection and maintenance overview. way to guarantee that your industrial truck
Please make sure you record the work per- remains in the same technical condition as at
formed in the registration document for the the time of reception.
industrial truck; this is essential for any war- Please address all queries and orders for
ranty claims. spare parts relating to your industrial truck
The designations used in the text: front - rear only to your authorised dealer, stating your
- left - right - always refer to the installation mailing address.
position of the parts described, with forwards The company, i.e. the manufacturer, is con-
as the drive direction (fork arms forwards) for stantly engaged in the further development of
the industrial truck. its products. We ask for your understanding
Servicing work not described here will require that figures and technical data are subject to
specialist knowledge, measuring devices and technical modification in terms of form, equip-
frequently also special tools. ment and expertise in the interest of progress.

Please ask your authorised dealer to carry out For this reason, no claims can be asserted
this work. on the basis of the following data, figures and
descriptions in these operating instructions.
Servicing should only be carried out by quali-
fied personnel approved by the manufacturer These operating instructions must not be
(specialists). reproduced, translated or made accessible to
third parties—including as excerpts—except

2 Operating Instructions – 387 801 1501 EN – 04/2012

with the express written approval of the
manufacturer.

The industrial truck may only be used as ponents developed especially for this purpose
permitted. must be used.
The industrial truck is used for moving and
lifting the loads indicated on the capacity rating
plate. Driving routes shall be sufficiently paved,
level and free of objects. Drain channels and
railways crossings, etc., shall be levelled and,
if necessary, covered with ramps in such a way
Damages and other defects to industrial trucks
that they can be driven over without bumps as
or to attachments must be reported to the
far as possible.
Supervisor immediately. Industrial trucks and
attachments which are not safe to operate Industrial trucks shall only be used on routes
may not be used until they have been properly without sharp curves, excessive slopes and
repaired. gates which are too narrow or too low.
Safety installations and switches may not be Inclines used by industrial trucks shall not ex-
removed or rendered unusable. Specified set- ceed the limits specified by the manufacturer
tings may only be changed with the approval and must have an adequately rough surface.
of the manufacturer. Level and smooth transitions at the upper and
lower end shall prevent the load from touching
the floor or causing damages to the chassis.

Danger areas are those areas in which The admissible area and point load of driving
persons are in danger as a result of the lanes or routes may not be exceeded. There
movements of industrial trucks, their operating shall be an adequate clearance between the
equipment, their load carrying devices (e.g. highest parts of industrial trucks or the load
their attachments) or the loaded goods. This and the fixed parts of the surrounding areas.
also includes the area which can be reached The EU Directive 89/654/EEC (Minimum
by falling goods or lowering or falling operating Regulations for Health and Safety at Work)
equipment and devices. shall be observed. The respective national
No other persons may stand in the danger regulations apply for non-EU countries.
area of an industrial truck. Danger points on driving lanes or routes shall
be secured or marked by the customary road
traffic signs and by additional warning signs, if
necessary.
Only the areas approved by the operator or his
representative may be used for transportation When driving on public roads, the correspond-
purposes. Loads may only be deposited or ing regulations must be observed, as well as
stored at the intended places. country-specific restrictions for winter road
conditions.
In operating areas with magnetic fields that
have a magnetic flux density greater than 5
mT, unintentional truck and lift mast move-
ments cannot be entirely excluded under un- The operator is responsible for adequate
favourable circumstances. In this case com- fire protection in the vicinity of the industrial

Operating Instructions – 387 801 1501 EN – 04/2012 3

truck. Depending on the form of use, he is the specifications of the manufacturer. The
responsible for additional fire protection on the proper functioning of the attachments shall be
industrial truck. Enquiries should be directed checked after each installation before initial
to the responsible supervisory authority in use.
case of doubt.
The permissible carrying capacity of the
attachments and the permitted load of the
industrial truck (carrying capacity and load
Attachments shall only be used as permitted. moment) combined with the attachments shall
The driver shall be instructed in the handling not be exceeded., refer to additional capacity
of attachments. rating plate.

The attachment operating instructions are en- Modifications, in particular attachments or

closed for trucks that are delivered from the conversions, are not permitted to be made to
factory with an attachment. Before commis- the industrial truck without the manufacturer’s
sioning a truck with an attachment, you must approval.
check that loads are handled securely. De-
pending on the type of attachment, it may be
necessary to make adjustments, e.g. pres-
Industrial trucks may only be used to tow trail-
sure settings or adjusting stops and operating
ers if they are intended for this purpose by the
speeds. See the attachment operating in-
manufacturer and if they are fitted with the
structions for the corresponding instructions.
appropriate trailer coupling. The maximum
If attachments are not supplied with the indus- towed load specified in the operating instruc-
trial truck, the specifications of the industrial tions for unbraked or braked trailers must not
truck manufacturer and the attachment manu- be exceeded.
facturer must be observed.
The towing industrial truck must be operated
The attachments and the connection of power in such away that safe driving and braking
supplies for powered attachments may only of the towed vehicle is ensured for all driving
be made by specialists in accordance with movements.

It is not permitted:
• To use the truck to transport people (if the
Avoid impermissible use.
truck is not designed for this purpose)
• in areas where there is a risk of fire of
The operating company or driver, and not the explosion
manufacturer, is liable if the truck is used in a • for stacking/unstacking operations on
manner that is not permitted. slopes
The following list is exemplary and is not • To stand on the fork arms when raised
intended to be exhaustive. • To exceed the truck’s maximum load
capacity
• To increase the truck’s load capacity, e.g.
by attaching an additional weight.

4 Operating Instructions – 387 801 1501 EN – 04/2012

• Indoor and outdoor use
• Ambient temperature in tropical and Nordic • Ambient temperature in tropical regions to
regions ranging from -10 °C to 40 °C 40 °C
• Use at up to 2000 metres above sea level. • Cold store version to -32 °C

The terms DANGER, WARNING, CAUTION,

NOTE and ENVIRONMENT NOTE are used
in these operating instructions for notes on Means that particular attention is drawn to
particular hazards or for unusual information combinations of technical factors which may
that needs to be highlighted: not be evident even to a specialist.

The instructions listed here must be complied

with as otherwise environmental damage may
result.

Means that failure to comply can cause risk of

serious injury and/or major damage to property. This label is found on the truck in
the areas where particular care and
attention are required.
You should refer to the appropriate
section in these operating instructi-
Means that failure to comply can cause risk of ons.
material damage or destruction.

For your safety, additional symbols are also

used. Please heed the various symbols.

Operating Instructions – 387 801 1501 EN – 04/2012 5

Electric forklift trucks in the 387 series are Thanks to the dual pedal system, continuously
designed to handle loading and palletising variable control of forwards and reverse travel
operations for loads up to 2.0 t with the E 20, is possible via the digital controller.
2.5 t with the E 25, 3.0 t with the E 30 and 3.5 t
with the E 35.

Kickback-free steering of the truck, which is

sensitive and virtually free of play, is carried
Please refer to each load capacity diagram for out manually using the small steering wheel
the load centre of gravity data. of the hydrostatic steering on the steering
A driver’s compartment with the most up-to- cylinder of the steering axle.
date ergonomic design and the energy-saving
digital controller (LDC) included as standard
ensure that this industrial truck is a valuable
piece of equipment. The hydraulic system consists of an electric
motor with a hydraulic pump for the steering
It is characterised by a compact design, and for the lift and tilt cylinders of the lift mast,
good visibility, maximum stability against a hydraulic oil tank with a breather filter and
overturning and cornering stability. an oil dipstick, as well as a suction filter and
There is an electric forklift truck in this version: pressure filter.

With one accelerator pedal each for forwards

travel and reverse travel, the traction motors
If you require further information on the differ- are controlled steplessly from a standstill to
ent versions, please contact your authorised maximum speed in both drive directions.
dealer.
The driver always has both hands free for
The combined axle ensures a large movement steering and controlling operational move-
range for the steering axle, good ground ments.
contact and reliable handling for both inside
and outside operations, even when used on This results in fast reversing and efficient
inferior road surfaces. stacking.

The truck has an electric drive unit and an A joystick is used to control the lifting, lowering
electric motor with a hydraulic pump for the and tilting operational movements.
steering and working hydraulics. There is also another joystick for operating the
additional attachments.
If desired, all operational movements (lifting,
Front-wheel drive via two electric traction lowering and tilting) can also be controlled with
motors combined in one compact axle with single lever operation.
automatic corner shift, which drive the right
and left-hand drive wheel via the respective
wheel gear.
The truck is equipped with three independent
The power required is supplied by the battery brake systems that act on the front axle:
installed in the truck.

6 Operating Instructions – 387 801 1501 EN – 04/2012

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

Operating Instructions – 387 801 1501 EN – 04/2012 7

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

8 Operating Instructions – 387 801 1501 EN – 04/2012

 Linde Material Handling GmbH
Carl-von-Linde-Platz
D-63743 Aschaffenburg, Germany

We declare that the machine

Industrial truck
Model

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

Personnel authorised to compile the technical documents:

see EC declaration of conformity

Linde Material Handling GmbH

shown explains the conformity with the re-

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

Operating Instructions – 387 801 1501 EN – 04/2012 9

10 Operating Instructions – 387 801 1501 EN – 04/2012
It is essential that operating personnel and
repair personnel observe the rules for the
proper use of industrial trucks enclosed with
these operating instructions.
Examples of those listed are:
For magnetic fields with magnetic flux densities
• Operating industrial trucks greater than 5 mT, components developed espe-
• Driving licence, cially for this purpose must be used.
Contact your authorised dealer.
• Driveways and working areas
• Rights, duties and rules of behaviour for the
driver,
• Special operating areas
• Information regarding setting off, driving
and braking, Safety systems must never be disabled, regardless
• Information for maintenance and repair, of the kind.

• Regular tests
• Disposal of greases, oils and batteries
The operating company or the person it has
commissioned must ensure that the driver
understands all safety information and that
all guidelines and safety regulations are
Industrial trucks may only be retrofitted with a 3rd
observed. auxiliary hydraulic system with the approval of the
truck manufacturer.
During training, the driver must familiarise
himself with the following:
• The operating conditions of the working
area
• The specific technical characteristics of the
industrial truck
• The operation of attachments It is therefore strictly prohibited to drill holes in the
overhead guard or to weld to it.
Practise driving, control and steering oper-
ations with an unloaded truck until they are
completely mastered. Only then may a loaded
industrial truck be used for practice. Risk of overloading the battery female connector.
This means that only the embedded battery female
connector (MRC socket) that has been approved
by the manufacturer may be used.
Make sure that the correct battery female connector
is connected, especially after changing the battery.
Contact your authorised dealer.

Only trained persons and those authorised for

operation may have access to the industrial truck.

12 Operating Instructions – 387 801 1501 EN – 04/2012

Welding operations on other parts of the truck can The industrial truck working area must be adequa-
cause damage to the electronics. tely lit.
Therefore, always disconnect the battery and all If it is not sufficiently lit, working spotlights must be
connections to the electronic controls beforehand. installed to ensure that the driver can see properly.

Different functions are supported by gas springs. Various pieces of special equipment are connected
Gas springs are under a high internal pressure of to the speed reduction special function. This is
up to 300 bar. simply an assistance function, and the driver must
They must only be removed when not under com- not rely solely on this function during operation.
pression and must never be opened without instruc- The driver is always responsible for safe operation.
tions. Any kind of damage, lateral forces, buckling,
temperatures in excess of 80°C and heavy conta-
mination must be avoided under all circumstances.
Damaged or defective gas springs must be repla-
ced immediately. If the driver has active medical equipment, e. g.
pace makers or hearing aids, these may be impai-
Contact your authorised dealer. red.
Check with a doctor or the medical equipment
manufacturer whether the equipment is sufficiently
protected against electromagnetic interference.
In trucks with an accumulator, serious injuries may
occur if the accumulator is not properly handled.
Before starting work on the accumulator, it must be
depressurised. If your truck is equipped with a fire extinguis-
Contact your authorised dealer. her, make sure that you familiarise yourself
with it in case of an emergency. Handling in-
formation is provided on the fire extinguisher.

Depending on the duration of use

and the operating time, components
carrying exhaust air may become
hot.
Therefore wear protective equip-
ment.

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

Operating Instructions – 387 801 1501 EN – 04/2012 13

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

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

• Stay buckled up The stability of your industrial truck is ensured

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

14 Operating Instructions – 387 801 1501 EN – 04/2012

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

• Observe the manufacturer’s instructions

relating to safety and disposal.
Consumables must be handled properly • Avoid spilling.
and in accordance with the manufacturer’s • Remove any spilled fluid immediately with a
instructions. suitable binder and dispose of it according
• Consumables should only be stored in to applicable regulations.
containers complying with applicable • Old and contaminated operating materials
regulations and at the locations stipulated. should be disposed of according to the
• Do not bring flammable consumables into regulations.
contact with hot objects or a naked flame. • Comply with the statutory provisions.
• When topping up consumables, use only • Before performing greasing, filter changes
clean containers. or any work on the hydraulic system,

Operating Instructions – 387 801 1501 EN – 04/2012 15

 carefully clean the area around the part
involved.
The improper handling of coolant and coolant addi-
• Dispose of used spare parts in an environ- tives presents a risk to health and the environment.
mentally friendly manner. Observe the manufacturer’s instructions without
fail.

The penetration of pressurised hydraulic fluid into

the skin, e.g. due to leakage, is hazardous. If an
injury of this type occurs, always consult a doctor.
Protective equipment must be worn.

A competent person is a specialist in the field The competent person is able to assess the
of industrial trucks who has: condition of industrial trucks in terms of health
• Successfully completed training, as at least and safety.
a service engineer for industrial trucks
• Many years of professional experience with
industrial trucks
• Knowledge of the accident prevention
regulations
• Knowledge of the relevant national techni-
cal regulations

Periodic safety inspections are required in

order to maintain the function and security of
the industrial truck.
Comply with the national regulations for your
country.
In Europe, the national laws are based
on the directives 95/63/EC, 99/92/EC and
2001/45/EC. These stipulate that periodic
safety inspections of the industrial truck must
be carried out by competent personnel, in or-
der to ensure proper condition.

16 Operating Instructions – 387 801 1501 EN – 04/2012

There is a recommendation setting out the
scope of the periodic safety inspection —FEM
4.004 of the European Industrial Truck Asso-
ciation— which defines a test log to document
the current safety inspection and an inspection
sticker for the next safety inspection. The next
safety inspection date is shown by the year
number (3) on an adhesive label (2), which
changes colour every year and is found on a
label (1).
The scope of the safety inspections is added
by the manufacturer in accordance with
the specific truck type. Please ask your
authorised dealer to carry out this work.

To depressurise the oil in the lines

fitting an attachment, the hydraulic system
Improper handling of the accumulator may lead to
for the auxiliary hydraulics can be connected serious injuries.
using an accumulator (Special equipment)
Before starting work on the accumulator, it must be
depressurised depressurised. Contact your authorised dealer.
See the section entitled Depressurisation .

Operating Instructions – 387 801 1501 EN – 04/2012 17

The control valve is equipped with an emer-
gency lowering screw (1) for manual lowering
of the fork carriage.
This may be necessary if a malfunction occurs
in the hydraulic system.
The control valve block (3), located under-
neath the bottom plate on the right-hand side
of the truck, is equipped with an emergency
lowering screw (1). This is secured and sealed
with a self locking nut (2).

1 Emergency lowering screw

2 Self locking nut
People must not stand near the fork 3 Control valve block
arms when they are being lowered.
During lowering, leave the socket
wrench on the screw (1) on the valve
block (3) to enable lowering to be
interrupted at any time.

Ø Remove the rubber mat from the bottom

plate.

Ø Remove the bottom plate.

Slowly turn the emergency lowering screw (1)
about 3 turns anti-clockwise using an SW 8
socket wrench until the fork carriage has been
completely lowered.

After emergency lowering has been perfor-

med three times, a new emergency lowering
screw with self locking nut must be used.
Ø After lowering, reinsert the emergency
lowering screw (1) in a clockwise direction
(tightening torque 10 Nm). Otherwise it will
not be possible to operate the fork carriage
lift function using the joystick.
Ø Tighten the self-locking nut (2). Tightening
torque 9.5 Nm.
Ø Refit the bottom plate.
Ø Place the rubber mat on the bottom plate.

18 Operating Instructions – 387 801 1501 EN – 04/2012

1 Identification plate

20 Operating Instructions – 387 801 1501 EN – 04/2012

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

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

Operating Instructions – 387 801 1501 EN – 04/2012 21

1 Lift mast 13 Counterweight
2 Tilt cylinder 14 Step
3 Overhead guard 15 Pedals / reverse accelerator pedal
4 Display unit 16 Left wheel gear
5 Rear-view mirror 17 Fork carriage
6 Load capacity diagram 18 Sideshift
7 Switch panel / toggle switch for special 19 Fork arms
equipment 20 Lift mast chain
8 Rotating beacon 21 Front left working spotlight
9 Driver’s seat with armrest and operating 22 Steering column adjusting knob
console 23 Steering column
10 Rear flap 24 Flasher unit / windscreen wiper switch
11 Left tail light (LED) 25 Steering wheel
12 Towing pin 26 Handhold

22 Operating Instructions – 387 801 1501 EN – 04/2012

1 Steering column adjusting knob 8 Horn signal button
2 Steering wheel 9 Armrest
3 Parking brake switch 10 Forward travel accelerator pedal
4 Key switch 11 Stop pedal
5 Emergency off switch 12 Reverse travel accelerator pedal
6 Joystick for working hydraulics 13 Driver’s seat with seat switch
7 Joystick for attachments (special equip-
ment)

The switches for lighting, windscreen wipers

and the heating system (special equipment)
are located in the top right-hand area of the
overhead guard at the same level as the
display unit.

Operating Instructions – 387 801 1501 EN – 04/2012 23

24 Operating Instructions – 387 801 1501 EN – 04/2012
1 Display unit 19 Remaining travel time display for electric
2 Direction indicator light (green) forklift trucks active
3 Engine temperature at upper limit (red) 20 No function
4 Neutral warning light (red)/no function 21 Speed display (km/h / mph)
5 Error in electrical controller or integrated 22 Function key
battery charger (red) 23 Reset button
6 Drive direction forwards for single-pedal 24 Clock/remaining travel time/speed display
trucks (green) 25 No function
7 Lift height restriction special equipment 26 Parking brake activated
(green/red) 27 Operating hours until next service
Electronic joystick locked (red) 28 Seat belt not fastened
8 Speed reduction activated (green) 29 Text field for error code
9 Assist (red) 30 Lift mast positioning activated (special
10 Drive direction backwards for single-pedal equipment)
trucks (green) 31 LCD display with backlight (orange)
11 Refer to truck documentation (yellow) 32 Neutral warning light (yellow)
12 Battery discharge indicator (green/red) 33 Rear cover monitoring
13 No function 34 Prewarning: engine temperature increasing
14 Steering position display active (yellow)
15 Operating hours display 35 Battery charging via integrated charger
16 Hour meter active finished — green (special equipment)
17 Service interval exceeded 36 Integrated charger in charging mode —
18 Clock display (am/pm) yellow (special equipment)

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

- The green direction indicator

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

Operating Instructions – 387 801 1501 EN – 04/2012 25

 The function can be pro-
- The red indicator light
(4) Neutral warning light grammed via the truck diag-
provides optional information
(red), no function nostics.
about necessary servicing
Contact your authorised dealer.
- Lights up if errors occur in the
(5)Indicator light (red), error electrical controllers or during
in the electronic control unit battery charger operation. Contact your authorised dealer.
or integrated charger Error code is displayed in the
text field (29).
- Lights up if the forwards
(6) Indicator light (green),
direction is selected via the
drive direction forwards Contact your authorised dealer.
drive direction selector in
(single-pedal version)
single-pedal trucks.
- Lights up (green) when the Faulty sensor system.
(7) Indicator light (green/red),
specified lift height is reached
lift height restriction Faulty joystick.
- Lights up (red) if an error
function/error
occurs in the sensor system
Indicator light goes out when
Electronically locked
joystick is locked. Contact your authorised dealer.
joystick , green (special
Display lights up when joystick
equipment)
is unlocked.
- The green indicator light
(8) Indicator light (green),
signals that the speed has
speed reduction activated
been reduced via an optional
(special equipment)
switch
(9) Indicator light (red) - The red indicator light
Assist provides optional information Contact your authorised dealer.
(special equipment) about servicing.
- Lights up if the reverse
(10)Indicator light (green),
direction is selected via the
reverse drive direction in
drive direction selector in
single-pedal trucks
single-pedal trucks
Seat switch or FDE unit not
activated and accelerator pedal
actuated
- When the yellow indicator
Battery charger connected to
light lights up, this may be
system voltage and accelerator
(11)Indicator light (yellow), due to an operating error or
pedal actuated
refer to the truck documenta- malfunction An error code
tion is usually shown in the text Tilt angle sensor alignment
display (29) in conjunction with process active
this indicator light. New truck control unit sensor
system not yet aligned.
Contact your authorised dealer.

26 Operating Instructions – 387 801 1501 EN – 04/2012

 - Shows the current charge
status of the battery The
battery discharge status is
shown by an LED bar display
in the display unit.
- The 7 green LEDs go out
one after another as the
(12)Battery discharge
battery becomes increasingly
indicator — LED bar display
discharged
(green/red)
- Once the battery is 80
discharged, the red LED with
the battery symbol lights up.
When the battery has
discharged even further
(residual battery capacity <
20 ), the red LED flashes.
(13) Symbol for particle
- No function
filter
- The steering angle is shown
on the second line of the text
(14) Steering position display display
symbol display activated - If the steering angle display is
switched on, the symbol (14)
lights up in the display unit.
If a faulty display unit is
replaced, the operating hours
that have been incurred up to
that point must be recorded.
- Shows the operating hours of
Affix the information to an
the truck This display is used
embossed strip near the display
to show the truck’s operating
(15) Operating hours display unit.
time and when performing
There is also the option of
inspection and maintenance
updating the new display unit
work.
at a later time.
The display can only be reset
using the diagnostic program.
Contact your authorised dealer.
- The hour meter symbol
flashes and the operating
(16) Operating hours active
hours are counted when the
symbol
truck is switched on and the
seat switch is activated
Implement the corresponding
(17) Service interval Signals that the service interval
service interval.
exceeded symbol has been exceeded.
Contact your authorised dealer.

Operating Instructions – 387 801 1501 EN – 04/2012 27

 The diagnostic program can be
For 12-hour format:
(18)Clock display symbol used to reset the display to a
am = morning
(am/pm) 12-hour clock.
pm = afternoon
Contact your authorised dealer.
(19)Display for electric forklift
truck remaining travel time
active
(20) Symbol has no function
(21)Speed display (km/h /
mph)
- Setting the time
(22) Function key - Scrolling through error
messages
- Setting the time
- Scrolling through error
(23) Reset button
messages
- Turning off the warning sound
The diagnostic program can be
- 24-hour clock display Can be
(24) Time /remaining travel used to reset the display to a
adjusted via the (22) and (23)
time/speed display 12-hour clock.
push buttons.
Contact your authorised dealer.
(25) Do not start the engine
- No function in electric trucks
symbol
- Lights up when the parking
brake is activated
(26) Parking brake symbol
-Goes out when the parking
brake is deactivated.
- Once the key switch has been
switched on, the display field
(17) shows the operating hours
until the next service (counting
down)
(27) Operating hours until Symbol (27) lights up. After
the next service symbol 5 seconds, the symbol (27)
goes out and the display (17)
switches automatically to the
truck’s operating hours — the
operating hours symbol (16)
flashes.
(28) Symbol for Seat belt not
- Lights up if seat belt has not
fastened Fasten the seat belt.
been fastened
(special equipment)
- Display line 1: lift height
(29) Text field, error code display error code
display - Display line 2: steering
position display error code

28 Operating Instructions – 387 801 1501 EN – 04/2012

 - Lights up when the Lift
(30) Lift mast positioning
mast positioning function is
symbol (special equipment)
activated
(31) LCD display with - Illuminated display field for
backlight various functions
- The neutral yellow indicator
light flashes and provides
(32) Indicator light (yellow),
information on whether all
depressurisation of working
conditions for depressurisation
hydraulics
of the working hydraulics have
been met
- The yellow indicator light
illuminates if the truck’s rear
flap is opened
(33) Indicator light (yellow), - For trucks with an integrated
Close the rear flap.
rear cover open charger, this is monitored to
prevent the truck from being
driven if the charging cable is
still connected to the truck
- The yellow indicator light
illuminates when the truck
battery is being charged
(34)Indicator light (yellow), - The yellow indicator light is
charging via integrated activated by the integrated
charger (special equipment) charger when the truck battery
is being charged
- The indicator light flashes
during the equalising charge
- The green indicator light is
activated by the integrated
charger when battery charging
has finished
(35) Indicator light (green),
- The indicator light flashes
battery charging via
during the maintenance
integrated charger finished.
charge
- The indicator light is activated
directly by the integrated
charger
- The yellow indicator light is
activated by the integrated
(36)Indicator light (yellow),
charger when the truck battery
charging via integrated Contact your authorised dealer.
is being charged
charger (special equipment)
- The indicator light flashes
during the equalising charge
.

Operating Instructions – 387 801 1501 EN – 04/2012 29

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

The configuration of the switch panel and

arrangement of individual switches may vary
depending on the version. Please note the
switch symbols.

30 Operating Instructions – 387 801 1501 EN – 04/2012

Check wheel fastenings and tighten.
Test the brake system (service and parking brake).
Check the steering system.

Battery: Check charge state, acid level and acid density.

Check the electrical system (e.g. lighting, warning units and any additional special
equipment).
Check traction functions (forwards and reverse travel).
Check the emergency stop switch.

Hydraulic system: Check the oil level.

Perform a test drive and functional test.

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

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

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

32 Operating Instructions – 387 801 1501 EN – 04/2012

Check the condition and function of the driver’s seat and seat belt.

Check the tyres

Check brake system and parking brake.

Check the charge status of the battery.

Check the electrical system (e.g. lighting, horn, lift functions and attachments).
Check the condition of the antistatic belt (special equipment) (when using tyres that
are not antistatic)
Check the function of the integrated charger (special equipment).

Check oil level of working and steering hydraulics.

Check truck for leak tightness (visual inspection).

Carry out functional test and test drive.

Entering and exiting the truck can result in injuries

to the feet or back.
Always face the truck when you enter or exit the
truck.

Do not use the steering wheel or the joysticks

as an aid to get in or out of the cab.

Operating Instructions – 387 801 1501 EN – 04/2012 33

Ø Use the handle (1) or the vertical bar (2) and
step (3).

34 Operating Instructions – 387 801 1501 EN – 04/2012

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

There is a risk of crushing if the lever is grasped

fully.
Only grasp the lever by the trough provided for this
purpose.

Ø Pull lever (1) upwards.

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

Operating Instructions – 387 801 1501 EN – 04/2012 35

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

Sitting for lengthy periods places a major

burden on the spine. Try to compensate for
this by performing regular simple gymnastic
movements.

Ø Pull lever (4) up and hold.

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

36 Operating Instructions – 387 801 1501 EN – 04/2012

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

Take note of the symbol label affixed to the

rear of the seat backrest.

Ø Operating this switch (7) activates the seat

heater for the driver’s seat.

Operating Instructions – 387 801 1501 EN – 04/2012 37

Only adjust the steering column when the vehicle is
stationary.

Ø Undo the adjusting knob (see arrow) by

turning anticlockwise.
Ø Move the steering wheel into the required
position.
Ø Tighten the adjusting knob again by turning
clockwise.

38 Operating Instructions – 387 801 1501 EN – 04/2012

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

The hours or minutes can be adjusted gradu-

ally by pressing push button (2) or quickly by
holding down the push button.
Ø Press push button (2) to set the hours.
Ø Press push button (3) to confirm the hours
setting.
Now the minutes display will flash.
Ø Press push button (2) to set the minutes.
Ø Press push button (3) to confirm the minutes
setting.

Operating Instructions – 387 801 1501 EN – 04/2012 39

 For this reason, the seat belt must
always be worn when operating the
truck
The seat belt should only be worn by
one person.

The seat belt must function perfectly.

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

Driver’s cabs with fixed closed doors or

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

40 Operating Instructions – 387 801 1501 EN – 04/2012

Ø Pull the seat belt (3) smoothly out of the belt
retractor (1) to the left.
Ø Position belt over the lap, not over the
stomach.
Ø Allow the latch plate (2) to snap into place in
the buckle (4).
Ø Check seat belt tension.
The belt must fit close to the body.

Ø Push the red button (5) on the buckle (4).

Ø Manually return the buckle guide (2) to the
belt retractor (1).

The automatic blocking mechanism may be

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

Operating Instructions – 387 801 1501 EN – 04/2012 41

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

Joysticks or single-levers must be in the

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

After the key switch has been switched on,

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

The joysticks and/or accelerator pedals must

not be used until all indicator lights apart from
(10) have gone out. Otherwise the truck will
not function. To restart: switch the key switch
off and on again.

42 Operating Instructions – 387 801 1501 EN – 04/2012

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

The braking effect of the automatic brake

holds the truck with a lowered load and/or
lowered lifting accessory on a clean floor
covering at a gradient of up to 10 .

Operating Instructions – 387 801 1501 EN – 04/2012 43

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

Rear-view mirrors should not be used for reverse

travel.
Reverse travel is therefore only permitted when
looking directly behind you.

Certain Linde forklift trucks (e.g. those with

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

Any side doors attached must be protected from

damage when driving.
Please therefore ensure that both side doors are
closed and locked before setting off.

The truck can only be driven with the driver’s

seat under load.

All actuating levers and accelerators pedals

must be in the neutral position before the truck
is switched on.

44 Operating Instructions – 387 801 1501 EN – 04/2012

Ø Sit down on the driver’s seat (5) (only then
is the seat switch under the driver’s seat
activated).
Ø Fasten the seat belt.
Ø Pull the emergency off switch (3).

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

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

The actuating levers (joystick) and/or acce-

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

Operating Instructions – 387 801 1501 EN – 04/2012 45

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

Pressing down the accelerator pedal hard is

to no advantage as the maximum acceleration
rate is controlled automatically.

Ø Carefully operate the left accelerator pedal

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

Ø Release the actuated accelerator pedal.

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

46 Operating Instructions – 387 801 1501 EN – 04/2012

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

Rear-view mirrors should not be used for reverse

travel.
Reverse travel is therefore only permitted when
looking directly behind you.

Certain Linde forklift trucks (e.g. those with

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

Any side doors attached must be protected from

damage when driving.
Please therefore ensure that both side doors are
closed and locked before setting off.

The truck can only be driven with the driver’s

seat under load.

Operating Instructions – 387 801 1501 EN – 04/2012 47

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

The battery discharge indicator (10) and all

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

If the red light in the brake switch lights up,

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

48 Operating Instructions – 387 801 1501 EN – 04/2012

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

Pressing down the accelerator pedal hard is

to no advantage as the maximum acceleration
rate is controlled automatically.

Ø Move direction selection lever (4) back-

wards.
Ø Press the accelerator pedal (5) gently.
Indicator light (9) in the display unit lights up.
The parking brake is released and the truck is
ready for operation.
The truck will reverse slowly or quickly de-
pending on the accelerator pedal position.

Ø Release accelerator pedal.

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

Operating Instructions – 387 801 1501 EN – 04/2012 49

The hydrostatic steering system means that The steering wheel can be moved beyond
very little effort is required for the steering the stop if sufficient force is applied, without
wheel turning movement. the position of the wheels changing on the
steering axle.
This is particularly advantageous when
palletising in narrow aisles.
Ø Start up and drive the industrial truck.
Ø Turn the steering wheel to the left and right
If the steering is stiff or has too much play, contact
to the stop.
your authorised dealer.

50 Operating Instructions – 387 801 1501 EN – 04/2012

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

Therefore, only use the oil prescribed by the manu-

facturer (see Recommendations for consumables).
Contact your authorised dealer.

The stop pedal (2) is positioned between the

accelerator pedals and is used for hydraulic
operation of the multi-disc brake.

It is recommended that drivers familiarise

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

Operating Instructions – 387 801 1501 EN – 04/2012 51

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

If required, this function can be adjusted via a

diagnostic program so that the effect is greater
or less. Contact your authorised dealer.

The regenerative brake increases the braking

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

When the emergency off switch is actuated,

the truck is braked (not braked fully).

Always use stop pedal (2) for emergency braking.

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

52 Operating Instructions – 387 801 1501 EN – 04/2012

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

The parking brake can be applied manually

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

A manually activated parking brake must also

be switched off manually before driving the
truck again.

Operating Instructions – 387 801 1501 EN – 04/2012 53

Actuate brake switch (1) by pressing the
P symbol (3) (red LED (2) in the switch
illuminates).

The brake symbol (see arrow) in the display

unit lights up permanently. The truck is
braked.

Do not actuate brake switch (1) during travel.

Under some circumstances, the load can slip from
the fork arms if the parking brake is applied too
sharply.
Only actuate the brake switch (1) during travel
if emergency braking with the stop pedal is not
sufficient.

54 Operating Instructions – 387 801 1501 EN – 04/2012

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

When starting up the truck on a gradient, the

truck is held electrically once the parking brake
has been released, in order to prevent it from
rolling backwards.

In safety-critical situations (e.g. when a worker

is in a raised workshop hoist), the parking
brake must be actuated manually using the
brake switch (1). This will result in all of the
drive functions being blocked.

Operating Instructions – 387 801 1501 EN – 04/2012 55

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

56 Operating Instructions – 387 801 1501 EN – 04/2012

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

On the version with central lever operation,

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

The lifting system and attachments only

function when the truck is switched on and
the driver’s seat is occupied (seat switch is
actuated).

Operating Instructions – 387 801 1501 EN – 04/2012 57

For this reason, it is not permitted to step onto the
raised fork arms.

Ø Push joystick (1) to the right.

Ø Push joystick (1) to the left.

Ø Push the joystick (1) forwards.

Ø Pull the joystick (1) backwards.

Attachments can be fitted to the truck as

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

Before fitting an attachment, depressurisation

(special equipment) can be performed to
depressurise the hydraulic system for the
auxiliary hydraulics so that the connection
on the attachment can be connected to
the connection on the fork carriage (see
Depressurisation under special equipment).

58 Operating Instructions – 387 801 1501 EN – 04/2012

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

The methods of attachment operation descri-

bed here are examples. The configuration
of the joystick may vary depending on your
truck’s equipment.
Ø Take note of the switching symbols with
arrows.

For every attachment, a label stating the load

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

In order to prevent damage, do not activate

the sideshift when the fork arms are on the
ground.
Ø Push joystick (2) to the left.
Sideshift moves to the left.
Ø Push joystick (2) to the right.
Sideshift moves to the right.

Operating Instructions – 387 801 1501 EN – 04/2012 59

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

For attachments that perform a clamping function

(e.g. a bale clamp), a lockable joystick must be
used.
If your truck is not fitted with this equipment, please
contact your authorised dealer.

Ø Take note of the switching symbols with

arrows.

60 Operating Instructions – 387 801 1501 EN – 04/2012

Ø Push joystick (2) forwards by at least 40
and then move to the zero position.

Joystick is unlocked for approx. one second

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

If the joystick is not moved forwards within this

time period, it is locked again.
Ø Push the joystick (2) forwards.
Clamp opens.
Once the joystick has been released, it is
locked again within one second.
Ø Pull the joystick (2) backwards.
Clamp closes.

The joystick (single lever) is recognisable by

the somewhat wider design of the bellows.

Operating Instructions – 387 801 1501 EN – 04/2012 61

Ø Take note of the switching symbols with
arrows.

Ø Unlock the joystick (4) (depending on the

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

62 Operating Instructions – 387 801 1501 EN – 04/2012

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

Ø Take note of the switching symbols with

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

The lifting system and attachments only

function when the truck is switched on and
the driver’s seat is occupied (seat switch is
actuated).

Operating Instructions – 387 801 1501 EN – 04/2012 63

For this reason, it is not permitted to step onto the
raised fork arms.

Ø Pull the joystick (1) backwards.

Ø Push the joystick (1) forwards.

Ø Push the joystick (2) forwards.

Ø Pull the joystick (2) backwards.

64 Operating Instructions – 387 801 1501 EN – 04/2012

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

Before fitting an attachment, depressurisation

(special equipment) can be performed to
depressurise the hydraulic system for the
auxiliary hydraulics so that the connection
on the attachment can be connected to
the connection on the fork carriage (see
Depressurisation under special equipment).

Attachments alter the load capacity and stability of

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

The methods of attachment operation descri-

bed here are examples. The configuration
of the joystick may vary depending on your
truck’s equipment.
Ø Take note of the switching symbols with
arrows.

For every attachment, a label stating the load

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

Operating Instructions – 387 801 1501 EN – 04/2012 65

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

In order to prevent damage, do not activate

the fork prong positioner with a load, or with
the fork arms on the ground. Do not use the
fork prong positioner as a clamp.
Ø Push the joystick (4) forwards.
Fork arms move outwards.
Ø Pull the joystick (4) backwards.
Fork arms move inwards.

For attachments that perform a clamping function

(e.g. a bale clamp), a lockable joystick must be
used.
If your truck is not fitted with this equipment, please
contact your authorised dealer.

66 Operating Instructions – 387 801 1501 EN – 04/2012

Ø Take note of the switching symbols with
arrows.

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

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

Operating Instructions – 387 801 1501 EN – 04/2012 67

Joystick is unlocked for approx. one second
and the display (6) lights up in the display unit.

If the joystick is not moved forwards within this

time period, it is locked again.
Ø Push the joystick (5) forwards.
Clamp opens.
Once the joystick has been released, it is
locked again within one second.
Ø Pull the joystick (5) backwards.
Clamp closes.

The joystick is recognisable by the somewhat

wider design of the bellows.
Ø Take note of the switching symbols with
arrows.

68 Operating Instructions – 387 801 1501 EN – 04/2012

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

Operating Instructions – 387 801 1501 EN – 04/2012 69

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

Ø Pull the emergency off switch (1).

The emergency off switch is unlocked and the
electrical system is switched on. The truck is
ready for use.

Ø Push the emergency off switch (1).

Only the lift and drive functions of the truck are
deactivated by pressing the emergency off
switch.

The battery voltage on the input side of the main

contactor remains connected when the emergency
off switch is actuated.
In order to de-energise the truck completely (e.g. for
maintenance work), the battery female connector
must be removed from the battery male connector.

Incorrect seat adjustment may cause injury to the

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

Ø Sit on the driver’s seat.

70 Operating Instructions – 387 801 1501 EN – 04/2012

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

There is a risk of crushing if the lever is grasped

fully.
Only grasp the lever by the trough provided for this
purpose.

Ø Lift lever (1) upwards.

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

Ø Lift lever 2 and hold it there.

The seat surface is moved to the desired
position by applying pressure to the seat
surface or removing pressure from it.

Ø Lift lever 1 and hold it there.

The seat surface can be moved to the desired
position by sliding the seat surface forward or
to the rear.

The maximum temperature is pre-set.

Operating Instructions – 387 801 1501 EN – 04/2012 71

Ø Switch (1) turns the seat heater ON and
OFF.
• 0 = seat heater OFF
• I = seat heater ON

The lumbar support enables optimum config-

uration of the seat back contour to the driver’s
body.
Ø Turn the handwheel (2) upwards.
The convexity of the upper part of the backrest
can be adjusted individually.
Ø Turn the handwheel (2) downwards.
The convexity of the lower part of the backrest
can be adjusted individually.

Ø Lift lever (2) and hold it there.

Ø Move the seat backrest forwards and
backwards to find a comfortable seat
position for the driver.
Ø Release lever (2).

Ø Push backrest extension (1) in or pull it out

for individual adjustment.

72 Operating Instructions – 387 801 1501 EN – 04/2012

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

The driver’s seat with rotating device offers

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

Operating Instructions – 387 801 1501 EN – 04/2012 73

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

The tilt angle sensor system allows a specific

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

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

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

74 Operating Instructions – 387 801 1501 EN – 04/2012

Resetting the truck control unit parameters
(working hydraulics) to the factory setting
deactivates the lift mast positioning; it must be
switched on again. When the truck is switched
off, the lift mast position currently stored is lost.

The lift mast positioning function is designed to

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

For safety reasons, tilting is permitted only in

the direction of the stored tilt angle, and must
be reactivated with each lift mast positioning.
When the stored lift mast position has been
reached, the lift mast remains stationary and
an acoustic signal sounds in the display unit.
Ø Release the joystick (1) or push the button
(2) again briefly.
The light (3) in the push button goes out and
the lift mast positioning is switched off.
The lift mast can now be operated normally
using the joystick (1).
Ø Briefly push the push button (2) again.
Lift mast position identification is switched on
again.

Operating Instructions – 387 801 1501 EN – 04/2012 75

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

The lift height restriction function enables the

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

76 Operating Instructions – 387 801 1501 EN – 04/2012

The guaranteed speed can be exceeded on a
descent depending on the function.
The driver can reduce the driving speed by
braking.
The speed can also be reduced using the
switch (1):
• This is designed to aid the driver and is
purely a comfort feature.
• The responsibility and control for maintain-
ing the required speed always lie with the
driver.
The switch for speed reduction, indicated by a
tortoise symbol, is integrated into the switch
panel above in the overhead guard.
When the speed reduction is activated via
the switch (1), the green indicator lamp (3) is
illuminated on the display unit (2).

Operating Instructions – 387 801 1501 EN – 04/2012 77

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

Ø Take note of the switching symbols with

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

The lifting system and attachments only

function with the truck switched on and the
driver’s seat occupied.

78 Operating Instructions – 387 801 1501 EN – 04/2012

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

Ø Pull the joystick (1) backwards.

Ø Push the joystick (1) forwards.

Ø Take note of the switching symbol with
directional arrows.

Operating Instructions – 387 801 1501 EN – 04/2012 79

Ø Push the joystick (2) forwards.

Ø Pull the joystick (2) backwards.

Ø Take note of the switching symbol with

directional arrows.

80 Operating Instructions – 387 801 1501 EN – 04/2012

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

For attachments that perform a clamping function

(e.g. a bale clamp), a locked joystick must be used.
The joystick is recognizable by the somewhat wider
design of the bellows.
If your truck is not fitted with this equipment, please
contact your authorised dealer.

Before fitting an attachment, depressurisation

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

When the auxiliary hydraulics is operated, it

is necessary to wait a few seconds before it
can be depressurised again via the switches.

Operating Instructions – 387 801 1501 EN – 04/2012 81

Otherwise an error will occur and the lift mast
will no longer be able to be actuated. In this
case, switch the switch lock off and on again.

Depressurisation can also be performed using

the diagnostics software. Please contact your
authorised dealer.
Take note of the switching symbols with
arrows.

For every attachment, a label stating the load

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

Attachments affect the load capacity and stability of

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

This operation of attachments described

here are examples. The configuration of the
actuating levers may vary depending on your
truck’s equipment.
Ø Take note of the switching symbols with
arrows.

82 Operating Instructions – 387 801 1501 EN – 04/2012

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

Ø Take note of the switching symbol with

directional arrows.

Operating Instructions – 387 801 1501 EN – 04/2012 83

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

Ø Take note of the switching symbol with

directional arrows.

84 Operating Instructions – 387 801 1501 EN – 04/2012

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

Ø Take note of the switching symbol with

directional arrows.

Operating Instructions – 387 801 1501 EN – 04/2012 85

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

86 Operating Instructions – 387 801 1501 EN – 04/2012

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

Operating Instructions – 387 801 1501 EN – 04/2012 87

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

Ø Move the toggle switch (1) to the centre

position (setting 1).

Ø Press the toggle switch (1) to the end

position (setting 2).

The clipboard light remains in switch setting 2

and is also switched on.

The side lights, dipped beams and the di-

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

Ø Activate the toggle switch (3).

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

88 Operating Instructions – 387 801 1501 EN – 04/2012

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

Ø Press the toggle switch (6) to the end

position (setting 2).
The rear working spotlights are switched on.

Ø Move the toggle switch (6) to the centre

position (setting 1).
For reverse travel, the rear working spotlights
will turn on.

Ø Activate the toggle switch (10).

Depending on the equipment there are three

different versions.
Version 1
Ø Activate the toggle switch (10).
The rotating beacon is always in operation.
Version 2
Ø Switch on the key switch.
The rotating beacon is in operation.
Version 3
Ø Switch on the key switch and press the
reverse pedal.
The rotating beacon is in operation for reverse
travel only.

Operating Instructions – 387 801 1501 EN – 04/2012 89

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

Ø Switch flasher unit (1) on the steering wheel

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

90 Operating Instructions – 387 801 1501 EN – 04/2012

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

1 Left reflector (red)

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

Operating Instructions – 387 801 1501 EN – 04/2012 91

Ø Move the multifunction lever (1) on the
steering wheel downwards to activate the
windscreen wipers.
Depending on the position of the
and the drive direction, the following modes
of operation are possible:
Drive direction forwards:

Intermittent
Setting 0 Off
mode
Continuous Intermittent
Setting 1
mode mode
Continuous Continuous
Setting 2
mode mode
Drive direction backwards:

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

Pulling the multifunction lever (1) upwards

activates the selected mode of operation for
as long as the multifunction lever is pulled up.

92 Operating Instructions – 387 801 1501 EN – 04/2012

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

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

Ø Push in multifunction lever (1) as far as it will

go.
Activates wash-wipe mode for the front
windscreen wiper and rear window wiper while
the multifunction lever is pressed in.

Ø Press push button (1).

Dummy (2) test.
Ø Dummy (1) test.
The rear window heating is switched off.
Ø Dummy (1) test.
The rear window heating is in operation for a
further 15 minutes.

Operating Instructions – 387 801 1501 EN – 04/2012 93

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

• Turning knob (3) for setting vent positions

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

Ø Turn switch (2) to switch setting 1 .

The blower is switched on.
The air flow can be switched to three different
settings.

For maximum windscreen defrosting:

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

94 Operating Instructions – 387 801 1501 EN – 04/2012

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

Ø Actuate the switch (7).

Operating Instructions – 387 801 1501 EN – 04/2012 95

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

The PIN number can be extended from 5 to

8 digits. Before entering the PIN number,
please contact your fleet manager to check
the number of digits in the PIN number and
find out about the truck settings.

The code provides information on the status of

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

96 Operating Instructions – 387 801 1501 EN – 04/2012

contact your fleet manager to find out the
definition of these status messages.

If you notice one of these states (such as a

problem with driving) only after you have input
the status code 0 (truck OK), you have to log
off.
Ø Log in again with the status message 3
(problem with driving).

• In the standard setting, the PIN and status

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

Operating Instructions – 387 801 1501 EN – 04/2012 97

Ø Press any button on the keypad to start the
input device.
The green LED (2) flashes.
Ø Enter your PIN number (factory setting = 0
0 0 0 0 ) and status code.

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

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

The status code is not required with the special

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

The red LED (1) lights up when a code is

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

If the truck does not start properly the first time,

the starting procedure can be repeated until
the turning knob (5) is returned to the zero
position and the PIN is discarded after expiry
of the delay time.

If the green (2) and red (1) LEDs both light up

as steady lights, the data must be read out.
Please inform your fleet manager at once.
Ø Close cover of the armrest (4) again.

98 Operating Instructions – 387 801 1501 EN – 04/2012

Ø Release parking brake either by pressing
the brake switch (see arrow) or by actuating
the accelerator pedal.
The truck is now ready for use.

Ø Press button.
or
Ø Leave driver’s seat — this actuates the seat
switch.
After a delay time (factory setting = 10 sec-
onds) the red LED (1) lights up briefly, and the
green (2) and red (1) LEDs then flash for ap-
prox. 3 seconds.
During this period, the truck can be started at
any time. Afterwards, the LEDs go out. The
PIN is discarded and the truck is automatically
turned off.

The delay time can be set to between 10 se-

conds and 10 minutes using the diagnostic
program. Please contact your authorised dea-
ler.

Ø Turn knob switch anticlockwise to the zero

position.
The truck is turned off immediately without a
delay time.

The truck data acquisition (FDE) input device

is integrated in the armrest console.
The input device has a corresponding field
(3) on which the RFID chip or a magnetic strip
card must be placed so that the truck data can
be read in and the truck can be started.

Ø Pull the emergency off switch.

Ø Turn the knob switch (instead of the key
switch) on the right of the steering column
clockwise as far as the stop.

Operating Instructions – 387 801 1501 EN – 04/2012 99

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

The red LED (1) lights up when a code is

entered incorrectly.
Possible causes of errors:
• Read errors
• Incorrect or defective RFID chip or magnetic
strip card.

If the green (2) and red (1) LEDs both light up

as steady lights, the data must be read out.
Please inform your fleet manager at once.

Ø Press button.
or
Ø Leave driver’s seat — this actuates the seat
switch.
After a delay time (factory setting = 10 sec-
onds) the red LED (1) lights up briefly, and the
green (2) and red (1) LEDs then flash for ap-
prox. 3 seconds.
During this period, the truck can be started at
any time. Afterwards, the LEDs go out. The
PIN is discarded and the truck is automatically
turned off.

100 Operating Instructions – 387 801 1501 EN – 04/2012

The delay time can be set to between 10 se-
conds and 10 minutes using the diagnostic
program. Please contact your authorised dea-
ler.

Ø Turn knob switch anticlockwise to the zero

position.
The truck is turned off immediately without a
delay time.

Operating Instructions – 387 801 1501 EN – 04/2012 101

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

The battery charger LPS-80/75 (80 V/75 A) is

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

102 Operating Instructions – 387 801 1501 EN – 04/2012

The battery charger always has a 400 V / 16 A
CEE plug (1).

A helix cable with a CEE 400 V/16 A socket

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

The fan (2) starts to operate as soon as the

emergency off switch is pressed. If the truck is
not used for a longer period of time, the battery
male connector must be removed in order to
prevent an unnecessary battery discharge.

Operating Instructions – 387 801 1501 EN – 04/2012 103

The truck control unit has a sensor (3) on the
hinge (2) of the rear cover (1), to determine
whether or not the cover is fitted to the truck. If
the sensor is deactivated during the charging
process (rear cover removed or folded up),
all drive functions and hydraulic functions are
interrupted.

The battery charger is also able to control an

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

A filter is integrated into the air pump for the

electrolyte circulation; this must be cleaned or
replaced in accordance with the maintenance
intervals.
All parameters (charging procedure, battery
type etc.) can be set using the diagnostic
program.
Contact your authorised dealer.

104 Operating Instructions – 387 801 1501 EN – 04/2012

The integrated charger is connected via a
mains line (helix cable) to a mains socket
(CEE socket 16 A / 400 V) for power supply
and to start the charging process.
Insert the mains line (helix cable) connection
to the mains socket.

The mains socket must be protected in accordance

with regulations. This applies especially to the use
of extension cords. Observe the notes for correct
protection of mains sockets. Contact an authorised
technician.

Only use mains cables in good condition that have

been tested by an authorised technician.

With a new battery, the battery charger must

be set accordingly prior to its first commissi-
oning using the diagnostic program (charging
characteristic curve setting). Contact your au-
thorised dealer.

During charging, ensure sufficient ventilation

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

Operating Instructions – 387 801 1501 EN – 04/2012 105

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

If the rear cover is removed, the sensor

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

The yellow plug symbol indicator light

lights up and the charging process begins
automatically.

The charging process only begins automati-

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

106 Operating Instructions – 387 801 1501 EN – 04/2012

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

Once the charging process is complete, the

rear flap must be closed again correctly.
Otherwise the truck is not ready for operation
(rear sensor not actuated).

The battery charger should not be interrupted

during the charging process.
However, external factors may make an inter-
ruption of the charging process necessary.

The charging process is systematically inter-

rupted if, for example, the fan is blocked or if
the minimum number of revolutions for the fan
is not achieved as a result of contamination
being too heavy.

To end the charging process, always press push

button (3) (deep discharge start / charging interrup-
tion) first and then remove the mains plug.

Charging will restart as soon as the mains

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

During normal operation, the charging pro-

cess should not be terminated before it is

Operating Instructions – 387 801 1501 EN – 04/2012 107

automatically switched off. Early switch-off
during charging results in an insufficiently
charged battery. This diminishes the battery’s
capacity.

If the mains plug remains in the socket, the

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

The status of the integrated charger is shown

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

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

108 Operating Instructions – 387 801 1501 EN – 04/2012

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

Operating Instructions – 387 801 1501 EN – 04/2012 109

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

5 The battery charger output module has Battery charger faulty. Contact your
C150 failed. authorised dealer.
5
Fault on the CAN bus. Contact your authorised dealer.
C152

110 Operating Instructions – 387 801 1501 EN – 04/2012

 5 Replace the battery charger. Contact
Wrong battery charger installed in truck.
C153 your authorised dealer.
5T553 The battery charger has system voltage Disconnect the mains plug before
D170 and the truck is switched on. switching on the truck.
.

Before picking up a load, check the load

capacity diagram (see arrow). It is attached to
the top left-hand side of the overhead guard.

If the event of conversions, the new residual load

capacity of the truck must be determined and
the load capacity diagram must be changed as
necessary. Please contact your authorised dealer.

The maximum permissible load is determined

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

When using attachments, observe the capacity

rating plate for each attachment.

Observe the load restriction and consult your

authorised dealer.
• Before transporting off-centre or swinging 1 Maximum weight of permissible loads in kg
loads 2 Lift height in mm

Operating Instructions – 387 801 1501 EN – 04/2012 111

 3 Series designation with truck model and lift
• Before transporting loads with the lift mast mast series
tilted forward or the load not close to the 4 Distance between load centre of gravity and
ground fork back in mm
• Loads involving a large centre of gravity
distance
• Before transporting loads in a wind force of
6 and upwards.

Load centre of gravity distance: 600 mm

Load height to be lifted: 6000 mm
Ø Trace a vertical line from a load distance of
600 mm to its point of intersection with the
line for a lift height of 6000 mm.
Ø Read off the maximum permissible load to
the left of the point of intersection with the
horizontal line.
The maximum load in this example is 600 kg
Use the same procedure for other lift heights
and centre of gravity distances. The deter-
mined values refer to both fork arms and
evenly distributed loads.

The centre of gravity of the load should be

positioned between the fork arms in the
middle.

112 Operating Instructions – 387 801 1501 EN – 04/2012

Ø Lift the stopping lever (1).
Ø Adjust the fork arms inwards or outwards
according to the load to be lifted .
Ensure a uniform distance to the centre of the
forklift truck.
Ø Allow the stopping lever to snap into place
in a groove on the fork carriage.

d3921429

Operating Instructions – 387 801 1501 EN – 04/2012 113

 Never allow people to be lifted on Adhere to the permitted load weight based on the
either the forks, or on a pallet placed load capacity diagram.
on the forks.
If the truck is to be used for lifting
people then it must be fitted with
a purposely designed working
platform. Ensure that the platform,
platform securing method and
platform interlocks have been Always drive the industrial truck with the load
approved for the truck. lowered and the lift mast tilted to the rear.
Please contact your local distributor.
Ø Approach the load to be taken up carefully
and as accurately as possible.
Ø Set the lift mast to vertical.
Ø Lift or lower the fork carriage to the neces-
sary height.
During stacking and de-stacking Ø Carefully steer the truck forks beneath the
operations do not allow people to centre of the load to be taken up, where
stand or walk in the working area of
the truck.
possible so the load touches the fork back,
taking account of adjacent loads.
Trucks should only be driven with the
load lowered and tilted back. Look Ø Lift fork carriage until the load is no longer in
out for people. contact with the supporting surface.
Ø Reverse the industrial truck to release the
load.
Ø Tilt the lift mast backwards.

Loads must be arranged so that they do not pro-

trude beyond the truck loading area and cannot
slip, topple over or fall off. If necessary, use a load
backrest (special equipment).

Ø Do not transport loads if they have slipped

to the side ( e. g. with sideshift).
When transporting cargo, the dispatcher must
Ø Transport loads close to the floor.
ensure that the goods are safely loaded for
transportation and secured as necessary. Ø On ascents/descents, always transport
Please therefore make sure that goods are loads facing uphill; never travel across the
properly stacked and there is no damage slope or turn around.
to packaging, pallets etc. The carrier must
Ø If visibility is poor, instructions should be
ensure safe loading.
provided by a second person.

114 Operating Instructions – 387 801 1501 EN – 04/2012

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

Operating Instructions – 387 801 1501 EN – 04/2012 115

 Ø Position the lift mast vertically (load hori-
zontal).
Carefully lower the fork carriage until the fork arms Ø Carefully move the load over the load
touch the ground. storage area.
Never park the truck and leave it with a raised load.
Ø Carefully lower the load until the fork arms
are clear.
Ø Carefully drive the industrial truck up to the
load storage area. Ø Back up the truck.
Ø Lift the fork carriage to the necessary height.

116 Operating Instructions – 387 801 1501 EN – 04/2012

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

Operating Instructions – 387 801 1501 EN – 04/2012 117

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

The manually actuated parking brake holds

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

This work should only be performed by

specialist staff working for your authorised
dealer.

118 Operating Instructions – 387 801 1501 EN – 04/2012

Operating the truck without a lift mast is
permissible only for transfer purposes and
the speed must be adjusted as appropriate.
Ø Switch off the truck
Ø Push the emergency off button.
Ø Remove lift mast.

When driving without the lift mast, the speed of

the industrial truck must be also reduced for safety
reasons.
For this reason, before the lift mast is removed, two
additional stop screws should be fitted under the
forwards and backwards accelerator pedals (dual
pedal operation) or a stop screw should be fitted
under the forwards accelerator pedal (single pedal
operation) in order to reduce the speed.

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

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

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

Operating Instructions – 387 801 1501 EN – 04/2012 119

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

Crane loading may cause damage to the tilt cylin-

ders and the cover sheet on the counterweight.
Retract the lift mast, retract the tilt cylinders as far
as the stop and lift the truck in such a way that it
hangs at an angle towards the front.

Ø Attach round slings to the lifting points.

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

During lifting, the lifting gear should not touch

the overhead guard, the cover sheet on the
counterweight and any additional equipment
attached.

120 Operating Instructions – 387 801 1501 EN – 04/2012

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

Ø Attach chains (6) (min. load capac-

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

During lifting, the lifting gear should not touch

the overhead guard, the cover sheet on the
counterweight and any additional equipment
attached.

Ø Lower the lift mast completely. Ø Place wedges underneath.

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

Operating Instructions – 387 801 1501 EN – 04/2012 121

122 Operating Instructions – 387 801 1501 EN – 04/2012
Your industrial truck will only remain in a state All servicing work should be followed by a
ready for use at all times if you perform a small function check and a test run performed on the
number of maintenance and inspection tasks industrial truck.
according to the information in the registration
document for the industrial truck and the data
or instructions in the operating instructions at Any side doors fitted could fall shut during mainten-
regular intervals. ance work and trap staff.
For this reason, both doors should be opened and
Servicing should be carried out only by secured in place during servicing.
qualified staff authorised by Linde.
You can agree to have this work performed on
the basis of a maintenance contract concluded
with your authorised Linde dealer. The industrial truck must always be properly label-
led.
If you wish to perform this work yourself, we Missing or damaged identification plates and/or ad-
recommend at least having the first 3 customer hesive labels must be replaced. For the warehouse
service checks carried out by the dealer’s or order number, please consult the spare parts
service technician in the presence of your catalogue.
workshop representative, so that your own
workshop staff can be instructed accordingly.
Whenever performing maintenance work, Observe information about working with
the industrial truck should be parked on a level
consumables.
surface and secured so that it cannot roll away.
The industrial truck must be switched off com-
pletely and the switch key must be removed.
When using industrial trucks under extreme
Ø Disconnect the battery male connector. conditions (e.g. extreme heat or cold, high
levels of dust etc.), the time periods given in
When working with the fork carriage and/or
the maintenance overview should be reduced
lift mast raised, make sure they are secured
accordingly.
against unintentionally dropping.
Whenever work is carried out at the front of the
industrial truck, the lift mast must be secured
to prevent it from tilting backwards. The inspection and maintenance intervals
depend on the operating and application
No modifications, in particular attachments or conditions of the industrial truck.
conversions, should be made to your industrial
truck without the manufacturer’s approval. For more difficult conditions we recommend
shorter intervals.
Please contact your authorised dealer.

124 Operating Instructions – 387 801 1501 EN – 04/2012

 Distilled water As required
1 Battery
Acid-free grease As required
Electric motors:
2 Traction motor Electric cleaner
Hydraulic motor
Electrical system: - -
Right- and left-hand traction motor Fuse (1F1) 1 x 355 A
Pump motor Fuse (2F1) 1 x 355 A
Discharge indicator Fuse (F3) 1 x 10 A
3 Fan 9M1, 9M4, 9M5 Fuse (1F8) 1x5A
Fan 9M2, 9M3 Fuse (2F6) 1x5A
Control current Fuse (F2) 1 x 15 A
Horn Fuse (4F1) 1 x 10 A
Voltage transformer (secondary) Fuse (F4) 1x5A
4 Hydraulic system Filter insert for suction filter Efficiency =15 µm
Filter insert for pressure Efficiency = 6 µm
filter
Hydraulic system Hydraulic oil Maximum 25 litres
Standard, duplex — all lift heights -
Triplex — lift height up to 5161 mm 18 litres
Triplex — lift height up to 7955 mm 24 litres
Drive wheel Torque value 425 Nm
5 Wheels
Rear wheel Torque value 210 Nm
6 Wheel gear Gearbox oil Oil change 0.55 litres
7 Steering axle Grease As required
8 Lift mast and chain guide Linde chain spray As required
.

Operating Instructions – 387 801 1501 EN – 04/2012 125

 Preferably SAE 80W-90 API GL4
also suitable: SAE 80W-90 API GL5
Damage to the hydraulic system due to unapproved
hydraulic oil. Recommendation:
Use only approved hydraulic oils. Only the oils ARAL EP Plus SAE80W90 GL4 or GL5
listed below have the manufacturer’s approval. Do
not mix hydraulic oils. If in doubt, please contact
your authorised dealer. Recommendations made
by representatives from the mineral oil industry Used oil must be kept away from children until
should also be agreed with your authorised dealer. disposed of according to the regulations. Un-
der no circumstances should oil be allowed to
penetrate the mains drainage or the ground.
Due to disposal problems and the specialist
ISO-L-HM 46 as per ISO 6743-4 knowledge required, the gearbox oil change
or ISO VG46-HLP as per DIN 51524-2 should ideally be carried out by your authori-
sed dealer.

ISO-L-HM 68 as per ISO 6743-4

or ISO VG68-HLP as per DIN 51524-2 Linde lithium-saponified lubricating grease
KPF2K as per DIN 51825
Linde spare part no., see spare parts
catalogue
ISO-L-HM 32 as per ISO 6743-4 Linde heavy-duty grease, lithium-saponi-
or ISO VG32-HLP as per DIN 51524-2 fied with EP agents and MOS 2
KPF2N-20 as per DIN 51825
Linde spare part no., see spare parts
catalogue

All the above applications can be covered

by a hydraulic oil with a high viscosity index
(multigrade oils). Mixing with soap-based lubricating grease
types other than lithium-saponified is not
ISO-L-HV 46 as per ISO 6743-4 permitted.
or ISO VG46-HVLP as per DIN 51524-3

Castrol Carelube HFS 46 highly biodegrad- Acid-free lubricating grease (battery

able hydraulic fluid grease)

Damage to the hydraulic system due to mixing

bio-hydraulic oil with mineral oil. Linde standard chain spray
Only use approved, pure bio-hydraulic oil. Linde spare part no., see spare parts
catalogue

126 Operating Instructions – 387 801 1501 EN – 04/2012

 Contact your authorised dealer.

Operating Instructions – 387 801 1501 EN – 04/2012 127

(As required) Clean the truck.
Read out the error memory and delete.
Check and adjust the date and time of the display unit.
Adjust the accelerator and joysticks.
Enter the next maintenance interval.

Visually check the planetary transmission for leaks.

Planetary transmission: change the oil.

Check the mountings on the chassis, counterweight, overhead guard, drive axle,
steering axle, tilt cylinder and tilt cylinder supports (visual inspection).
Check the tilt cylinder mountings on the tilt cylinder supports and lift mast.
Check other bearings and joints and lubricate as required.

Check the brake system for correct function.

Check wheel fastenings and tighten as required.
Check the release of the multi-disc brake for the towing procedure: push the brake
lever at the brake valve several times.
Clean and grease the combined axle.

Check that the power module connections are mounted correctly.

Check the condition and secure positioning of electric cables, plug connectors and
cable connections.
Check the horn for correct function.

Hydraulic tank: check the oil level.

Hydraulic system: Check for leaks.

128 Operating Instructions – 387 801 1501 EN – 04/2012

Check the lift mast, lift mast chain, lift cylinder and end stops for condition, secure
mounting and function.
Check the lift mast mounting at the axle and tighten as required.
Clean and adjust the lift mast chain and apply chain spray.

Clean and lubricate the sideshift and attachments and check for correct function
(refer to the manufacturer’s operating instructions).

Carry out functional test and test drive.

Attach maintenance sticker.

Operating Instructions – 387 801 1501 EN – 04/2012 129

See the recommendation for consumables.

(As required) Clean the truck.

Read out the error memory and delete.
Check and adjust the date and time of the display unit.
Adjust the accelerator and joysticks.
Enter the next maintenance interval.

Drive axle and planetary transmission: Check the mounting.

Visually check the planetary transmission for leaks.
Check the shaft seal between the motor and planetary transmission for leaks by
using the checking screw.

Check the mountings on the chassis, counterweight, overhead guard, drive axle,
steering axle, tilt cylinder and tilt cylinder supports (visual inspection).
(As required) Check and lubricate other bearings and joints.
Check and tighten the lift mast mounting at the axle (special tool required).
Check the axle bearing mounting, tighten if applicable.

Check the brake system for correct function.

Check wheel fastenings and tighten as required.
Check the condition of the antistatic belt when using non-antistatic tyres (light-
coloured tyres).
Check the release of the multi-disc brake for the towing procedure: push the brake
lever at the brake valve several times.
Clean and grease the combined axle.

Check the pedal group for ease of movement and oil joints as required.
Check the horn for correct function.
Check the bellows on the joystick.

130 Operating Instructions – 387 801 1501 EN – 04/2012

Check that the power module connections are mounted correctly.
Test fan for correct function and contamination, and clean as required.
Check the drive unit and pump motor power modules for contamination, and clean
as required.
Clean the contactor carrier with compressed air.
Check the condition and secure positioning of electric cables, plug connectors and
cable connections.
Test battery in accordance with the manufacturer’s specifications.
Test rear cover sensor for correct function.
Clean the oil cooler using the fan and clean the sensor using compressed air and/or
cold cleaner.

Hydraulic tank: check the oil level.

Hydraulic system: check for leaks.

Check the lift mast, lift mast chain, lift cylinder and end stops for condition, secure
mounting and function.
Lift mast chain: adjust length, clean and apply chain spray.
Check fork arms and arm safety devices.
Check and grease the mast fixation.

Check the electrolyte circulation pump filter, and clean as required.

Clean and lubricate the sideshift and attachments and check for correct function
(refer to the manufacturer’s operating instructions).
Check the pre-load of the auxiliary hydraulics double hoses.

Carry out functional test and test drive.

Attach maintenance sticker.

Operating Instructions – 387 801 1501 EN – 04/2012 131

Dependent on the consumables used, driving style and operating conditions, but
at least after 2, 4, 5, 7, 8, 10, 11, 13, 14, 16, 17, 19 and 20 years of operating time.
Refer also to the recommendation for consumables.

(As required) Clean the truck.

Read out the error memory and delete.
Check and adjust the date and time of the display unit.
Adjust the accelerator and joysticks.
Enter the next maintenance interval.

Drive axle and planetary transmission: check the mounting.

Visually check the planetary transmission for leaks.
Check the shaft seal between the motor and planetary transmission for leaks using
the checking screw.

(As required) Check and lubricate other bearings and joints.

Check the brake system for correct function.

Check wheel fastenings and tighten as required.
Check the release of the multi-disc brake for the towing procedure: push the brake
lever at the brake valve several times.
Clean and grease the combined axle.

Check the pedal group for ease of movement and oil joints as required.
Check that the horn is working correctly.

Test battery in accordance with the manufacturer’s specifications.

Clean the contactor carrier with compressed air.

132 Operating Instructions – 387 801 1501 EN – 04/2012

Clean the oil cooler using the fan and clean the sensor using compressed air and/or
cold cleaner.

Lift mast chain: adjust length, clean and apply chain spray.
Check and grease the mast fixation.

Integrated charger: Clean the heat sink and fan.

Carry out a functional check of the active charging ventilation unit.
Check the electrolyte circulation pump filter and clean as required.
Clean and lubricate the sideshift and attachments and carry out a function check
(refer to the manufacturer’s operating instructions).
Check the rear cover sensor (in special equipment with integrated charger).
Check the pre-load of the auxiliary hydraulics double hoses.

Carry out functional test and test drive.

Attach maintenance sticker.

Operating Instructions – 387 801 1501 EN – 04/2012 133

Dependent on the consumables used, driving style and application conditions, but
at least after 3, 9 and 15 years of operating time. Refer also to the recommendation
for consumables.

(As required) Clean the truck.

Read out the error memory and delete.
Check and adjust the date and time of the display unit.
Adjust the accelerator and joysticks.
Enter the next maintenance interval.

Drive axle and planetary transmission: Check the mounting.

Visually check the planetary transmission for leaks.
Planetary transmission: change the oil.
Check the shaft seal between the motor and planetary transmission for leaks by
using the checking screw.

Visually check the mountings on the chassis, counterweight, overhead guard, drive
axle, steering axle, tilt cylinder and tilt cylinder supports.
(As required) Check and lubricate other bearings and joints.
Check the tilt cylinder mountings on the tilt cylinder supports and lift mast.
Check the tilt cylinder bearing for wear, and replace as required.
Check the battery hood interlock, and adjust as required.
Check the axle bearing mounting, tighten as required.
Check the axle bearings for wear, replace as required.

Check the brake system for correct function.

Check wheel fastenings and tighten as required.
Check the condition of the antistatic belt when using non-antistatic tyres (light-
coloured tyres).
Check the release of the multi-disc brake for the towing procedure: push the brake
lever at the brake valve several times.

134 Operating Instructions – 387 801 1501 EN – 04/2012

Clean and grease the combined axle.

Check the pedal group for ease of movement and oil joints as required.
Check the horn for correct function.
Check the bellows on the joystick.

Check that the power module connections are mounted correctly.

Test fan for correct function and contamination, and clean as required.
Check the drive unit and pump motor power modules for contamination, and clean
as required.
Clean the contactor carrier with compressed air.
Check the condition and secure positioning of electric cables, plug connectors and
cable connections.
Test battery in accordance with the manufacturer’s specifications.
Clean the oil cooler using the fan and clean the sensor using compressed air and/or
cold cleaner.

Hydraulic tank: check the oil level.

Hydraulic system: check for leaks.
Hydraulic system: change breather filter, pressure filter and suction filter.

Check the lift mast, lift mast chain, lift cylinder and end stops for condition, secure
mounting and function.
Lift mast chain: adjust length, clean and apply chain spray.
Check the lift mast mounting at the axle, and tighten if required.
Check fork arms and arm safety devices.
Visually check the tilt cylinder bearing for wear, and clean or replace as required.
Check and grease the mast fixation.

Integrated charger: Clean the heat sink and fan.

Check the electrolyte circulation pump filter, and clean as required.
Clean and lubricate the sideshift and attachments and check for correct function
(refer to the manufacturer’s operating instructions).

Operating Instructions – 387 801 1501 EN – 04/2012 135

Check the pre-load of the auxiliary hydraulics double hoses.
Check the rear cover sensor (in special equipment with integrated charger).
Check slide guides on sideshift for wear.

Carry out functional test and test drive.

Attach maintenance sticker.

136 Operating Instructions – 387 801 1501 EN – 04/2012

Dependent on the consumables used, driving style and application conditions, but
at least after 6, 12 and 18 years of operating time. Refer also to the recommendation
for consumables.

(As required) Clean the truck.

Read out the error memory and delete.
Check and adjust the date and time of the display unit.
Adjust the accelerator and joysticks.
Enter the next maintenance interval.

Drive axle and planetary transmission: Check the mounting.

Visually check the planetary transmission for leaks.
Planetary transmission: change the oil.
Check the shaft seal between the motor and planetary transmission for leaks by
using the checking screw.

Visually check the mountings on the chassis, counterweight, overhead guard, drive
axle, steering axle, tilt cylinder and tilt cylinder supports.
(As required) Check and lubricate other bearings and joints.
Check the tilt cylinder mountings on the tilt cylinder supports and lift mast.
Check the tilt cylinder bearing for wear, and replace as required.
Check the battery hood interlock, and adjust as required.
Check the axle bearing mounting, tighten as required.
Check the axle bearings for wear, replace as required.

Check the brake system for correct function.

Check wheel fastenings and tighten as required.
Check the condition of the antistatic belt when using non-antistatic tyres (light-
coloured tyres).
Check the release of the multi-disc brake for the towing procedure: push the brake
lever at the brake valve several times.

Operating Instructions – 387 801 1501 EN – 04/2012 137

Clean and grease the combined axle.

Check the pedal group for ease of movement and oil joints as required.
Check the horn for correct function.
Check the bellows on the joystick.

Check that the power module connections are mounted correctly.

Test fan for correct function and contamination, and clean as required.
Check the drive unit and pump motor power modules for contamination, and clean
as required.
Clean the contactor carrier with compressed air.
Check the condition and secure positioning of electric cables, plug connectors and
cable connections.
Test battery in accordance with the manufacturer’s specifications.
Clean the oil cooler using the fan and clean the sensor using compressed air and/or
cold cleaner.

Hydraulic tank: check the oil level.

Hydraulic system: Check for leaks.
Hydraulic system: change breather filter, pressure filter and suction filter.
Change the hydraulic oil.

Check the lift mast, lift mast chain, lift cylinder and end stops for condition, secure
mounting and function.
Lift mast chain: adjust length, clean and apply chain spray.
Check the lift mast mounting at the axle and tighten as required.
Check fork arms and arm safety devices.
Visually check the tilt cylinder bearing for wear, and clean or replace as required.
Check and grease lift mast bearings.

Integrated charger: Clean the heat sink and fan.

Check the electrolyte circulation pump filter, and clean as required.

138 Operating Instructions – 387 801 1501 EN – 04/2012

Clean and lubricate the sideshift and attachments and check for correct function
(refer to the manufacturer’s operating instructions).
Check the pre-load of the auxiliary hydraulics double hoses.
Check the rear cover sensor (in special equipment with integrated charger).
Check slide guides on sideshift for wear.

Carry out functional test and test drive.

Attach maintenance sticker.

Operating Instructions – 387 801 1501 EN – 04/2012 139

Ø Park the truck so that checking screw (1) is
between the 5 and 6 o’clock positions.
Ø Switch off the truck.

Ø Unscrew the screw (3).

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

Drain off excess oil via the checking screw (1)

into a collection container.
Ø Unscrew checking screw(1) (tightening
torque 20 Nm).

Observe information regarding working with

consumables. See the recommendations for
consumables.
Ø Check the oil level again.

140 Operating Instructions – 387 801 1501 EN – 04/2012

Ø Screw in the filler plug (3) and tighten
(tightening torque 70 Nm).

Operating Instructions – 387 801 1501 EN – 04/2012 141

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

If leaks occur at the planetary transmission,

please contact your authorised dealer.

142 Operating Instructions – 387 801 1501 EN – 04/2012

Observe information regarding working with
consumables. See recommendations for
consumables

Change the oild after the first 50 operating

hours, with further oil changes every 3000
hours thereafter.
The oil may also be changed when the drive
wheels are attached.

When carrying out an oil change, it should be

ensured that the drive axle is horizontal.
Ø Warm up the planetary transmission.
Ø Park the truck so that checking screw (1) is
between the 5 and 6 o’clock positions.
Ø Switch off the truck.
Ø Raise the truck using jacks on the left and
the right and secure.
Ø Carefully lower the jacks until the drive axle
is horizontal.

Operating Instructions – 387 801 1501 EN – 04/2012 143

Ø Clean the area around the filler plug (1) and
drain plug (3).
Ø Unscrew the filler plug (1) (tightening
torque 70 Nm).
Ø Place a collection container under the drain
plug (3).

The drain plug is not located on the planetary

transmission, but on the bottom of the axle
housing.
Ø Unscrew the drain plug with the magnetic
plug and allow all of the gearbox oil to drain
off.

Dispose of used gearbox oil in an environmen-

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

Drain off excess oil via the checking screw (4)

(tightening torque 20 Nm).
Ø Check the oil level again.

144 Operating Instructions – 387 801 1501 EN – 04/2012

Ø Screw in the checking screw (4) and tighten
(tightening torque 20 Nm).
Ø Lower the truck.

Operating Instructions – 387 801 1501 EN – 04/2012 145

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

Note the corresponding tightening torques.

Ø Change damaged parts.
Ø Touch up paintwork if necessary.

146 Operating Instructions – 387 801 1501 EN – 04/2012

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

Operating Instructions – 387 801 1501 EN – 04/2012 147

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

Risk of crushing fingers and hands.

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

Ø Open the rear window bolts (special equip-

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

Before doing this, be sure to remove any loose

items from the battery hood or from under the
driver’s seat.
Ø Operate the locking lever (1).
Ø Slowly swivel the battery hood with the
driver’s seat to the rear.

148 Operating Instructions – 387 801 1501 EN – 04/2012

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

Battery hood fastener (2)

When closing the battery hood, check also

that the side battery door is correctly locked.

Operating Instructions – 387 801 1501 EN – 04/2012 149

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

For safety reasons, the condition and correct

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

150 Operating Instructions – 387 801 1501 EN – 04/2012

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

When opening the battery hood, remember

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

The tilt cylinders are attached on both sides in

spring elements.

Operating Instructions – 387 801 1501 EN – 04/2012 151

Ø Undo screw (1) and remove it together with
washer (2).
Ø Visually check the spring elements for
cracks.
The rubber must not exhibit any cracks.
Ø Check the spring elements for each tilt
cylinder at the front and rear.
If the rubber bearings are worn or damaged,
renew them. Please advise your authorised
dealer.
Ø Refit the screw and washer.
Ø Tighten the screw to 275 Nm.

152 Operating Instructions – 387 801 1501 EN – 04/2012

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

When used indoors in clean dry conditions, it

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

Operating Instructions – 387 801 1501 EN – 04/2012 153

Under certain circumstances the truck may
become electrostatically charged. The char-
ging level depends on a number of factors
such as type of tyre, air humidity, floor cove-
ring etc.
• Excessive electrostatic charging is noticed
when the electrostatic charge is discharged
to the ground via the body of a person who
touches the truck (electric shock) or when
a spark passes from the truck to an earthed
part (e.g. a metal shelf).
• With standard types of tyre (black pneuma-
tic or solid rubber tyres), the high graphite
content means that electrostatic charging is
relatively rare. However, if non-scrubbing
tyres (light-coloured tyres) are used and the
truck is driven into an area with a sealed
floor, the electrostatic charging effect oc-
curs very often.
• Non-scrubbing tyres are identified by
the safety information on the tyre wall
(arrowed).

The truck must always be earthed with an antistatic

belt.
The antistatic belt must be permanently in contact
with the ground.

Electrostatic charging is prevented by means

of an antistatic belt, which is attached to the
chassis under trucks with light-coloured tyres,
and its free end trails along the ground.
The antistatic belt is made of a synthetic
conductive material.
It is fitted as standard to trucks with light-
coloured tyres.
Ø Apply the parking brake.

154 Operating Instructions – 387 801 1501 EN – 04/2012

The industrial truck must be secured against
rolling away.
Ø Place a wheel chock under a wheel that is
not to be lifted.
Ø Lift the industrial truck with the hydraulic
jack until the wheels are off the ground.
Ø Place square timbers underneath.
Ø Check for free movement of wheels and
remove anything hindering their movement.
Ø Change worn or damaged tyres.

Pneumatic tyres are considered special

equipment.

If the air pressure is too low, the tyres’ service life

will be reduced and the stability of the truck will be
impaired.
The prescribed air pressure should always be
checked regularly.

Ø Check that the tyres have the prescribed air

pressure.
Ø If necessary, adjust tyre pressure according
to data.

E 20/500 Front: 23x9—10 10 bar

E 20/600 Rear: 18x7—8 10 bar

E 25/500 Front: 23x9—10 10 bar

E 25/500L
E 25/600H Rear: 180/60—10 10 bar
E 25/600HL

E 30/500 Front: 23x9—10 10 bar

E 30/500L
E 30/600 Rear: 200/50—10 10 bar
E 30/600HL

Operating Instructions – 387 801 1501 EN – 04/2012 155

 E 35/500L Front:
10 bar
E 35/500HL 315/45—12
Rear: 200/50—10 10 bar
.

The trucks are generally equipped with

tyres made of solid material, referred to as
superelastic tyres (SE).

The individual tyre types and sizes can also be

found in the type sheets (Chapter 6 Technical
data).

Front: 23x9—10 SE
E 20/500
E 20/600 Rear: 18x7—8 SE

E 25/500 Front: 23x9—10 SE

E 25/500L
E 25/600H Rear: 180/60—10 SE
E 25/600HL

E 30/500 Front: 23x9—10 SE

E 30/500L
E 30/600H Rear: 200/50—10 SE
E 30/600HL

E 35/500 Front: 315/45—12 SE

E 35/500HL
Rear: 200/50—10 SE
.

Tyre size Rim size

18x7—8 4.33R—8

156 Operating Instructions – 387 801 1501 EN – 04/2012

23x9—10 6.50F—10
23x10—12 8.00G—12
200/50—10 6.50F—10
315/45—12 10.00G—12

Only rims that have been approved by the

manufacturer may be used. Please contact
your authorised dealer.
The correct rim sizes for your industrial truck
and other information can be found in the
spare parts catalogue.

Operating Instructions – 387 801 1501 EN – 04/2012 157

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

When using wheels that are not antistatic, consider

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

Ø Extend lift mast to first level and secure.

Ø Loosen all wheel fastenings (1) of the wheel
in question.
Ø Position the hydraulic jack under the
right-hand lift mast profile and lift the truck
until the right-hand wheel moves freely.
Ø Support the chassis securely from below
using square timber supports.
Ø Position the hydraulic jack (2) under the
left-hand lift mast profile and lift the truck
until the left-hand wheel moves freely.
Ø Support the chassis securely from below
using square timber supports.
Ø Unscrew wheel fastenings and change
wheel.

Ensure correct positioning of the hydraulic jack.

The industrial truck should only be lifted at the lifting
points at the front.

Ø Position wheel fastenings and hand-tighten.

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

158 Operating Instructions – 387 801 1501 EN – 04/2012

Ø Loosen all wheel fastenings of the wheel in
question.
Ø Position the hydraulic jack (1) only at
the lifting point in the centre under the
counterweight (2) and lift the truck until
the wheel is free.

Ensure correct positioning of the hydraulic jack.

The industrial truck should only be raised at these
lifting points at the rear.

Ø Support the chassis securely from below

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

The wheel fastenings should be tightened

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

Front 425 Nm
Rear 210 Nm

Operating Instructions – 387 801 1501 EN – 04/2012 159

 driven into an area with a sealed floor, the
electrostatic charging effect occurs very
Under certain circumstances the truck may often.
become electrostatically charged. • Non-scrubbing tyres are identified by the
• The charging level depends on a number safety information on the tyre wall.
of factors such as type of tyre, air humidity, For this case, an antistatic belt is fitted to the
floor covering etc. underside of the truck and is connected to the
• Excessive electrostatic charging is noticed truck chassis.
when the electrostatic charge is discharged
to the ground via the body of a person who Ø
touches the truck (electric shock) or when
a spark passes from the truck to an earthed
part (e.g. a metal shelf). Ø
• With standard types of tyre (black pneuma-
tic or solid rubber tyres), the high graphite
content means that electrostatic charging is
relatively rare.
• However, if non-scrubbing tyres (light-
coloured tyres) are used and the truck is

160 Operating Instructions – 387 801 1501 EN – 04/2012

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

Ø Fully lower the fork carriage.

Ø Push the emergency off switch.
Ø Clean the combined axle with water or
cleaner solvent.

After cleaning with a steam jet, lubrication is

always recommended.

Observe information regarding working with

consumables.

Lubricating grease should be used for lubri-

cation (see Recommendations for consuma-
bles ).
Ø Apply lubricating grease to lubricating
nipples (arrowed) on the left and right tie
rods.
Ø Lubricate with a grease gun until fresh
lubricating grease escapes at the bearings.

It is better to apply a little grease to the

bearings frequently than a lot of grease
infrequently.

Operating Instructions – 387 801 1501 EN – 04/2012 161

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

2
d3921482

Ø Lift up the panelling and check heat sink

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

If the contamination is very heavy, remove the

covering in the engine compartment. Please
contact your authorised dealer.

Observe information regarding working with

consumables.
e3861315

162 Operating Instructions – 387 801 1501 EN – 04/2012

Check that the truck’s braking function is in perfect
condition prior to each commissioning. In the case
of defects in the brake system, the truck must be
taken out of operation at once. The truck may only
be restarted once the brake system is in perfect
condition again. Please contact your authorised
dealer immediately.

Therefore, only use the oil prescribed by the manu-

facturer (see Recommendations for consumables).
Please contact your authorised dealer.

Ø Press stop pedal (3) with your foot.

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

To ensure maximum braking force when the

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

Operating Instructions – 387 801 1501 EN – 04/2012 163

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

If required, this function can be adjusted via a

diagnostic program so that the effect is greater
or less. Contact your authorised dealer.

In the quiescent state, the truck is braked using

the automatic brake. To check this, the brake
symbol (see arrow) appears in the display unit.

When the truck is standing on a clean floor

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

164 Operating Instructions – 387 801 1501 EN – 04/2012

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

The brake symbol (see arrow) in the display

unit goes out.

Operating Instructions – 387 801 1501 EN – 04/2012 165

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

166 Operating Instructions – 387 801 1501 EN – 04/2012

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

Operating Instructions – 387 801 1501 EN – 04/2012 167

The battery’s discharge status is shown by an
LED bar display (2) in the display unit (1).
The 7 green LEDs go out one after another as
the battery discharges
When the battery is 75 discharged, the red
LED (3) with the battery symbol lights up.
At a discharge level of 80 (20 residual
capacity), the lifting speed of the truck will be
reduced.
As the battery discharges further (residual
battery capacity < 20 ), the red LED (3)
flashes and the buzzer sounds.

Repeated deep discharging of the battery can

cause irreparable damage.
When the red LED flashes, the battery must be
charged immediately.

Ø Pull out the emergency off switch (5).

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

168 Operating Instructions – 387 801 1501 EN – 04/2012

The battery must only be charged at the charging
stations and locations provided for this purpose and
in accordance with regulations.
They must fulfil certain criteria, such as ensuring
sufficient ventilation during the charging process.

The
in section should
be followed without fail. The following instruc-
tions must be observed for the operation and
maintenance of batteries.

Charging, maintenance and servicing of the

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

Repeated deep discharges of the battery may not

only shorten the service life but also damage the
battery irreparably.
Batteries can be discharged to an acid density of
1.13 kg/l.
The battery must then be recharged.

Storage of discharged batteries over lengthy peri-

ods will result in lasting damage.
Discharged batteries should be recharged at once.

It is recommended to recharge the battery

when all green LEDs of the discharge indicator

Operating Instructions – 387 801 1501 EN – 04/2012 169

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

You can also charge the battery using an

integrated charger. Please contact your
authorised dealer.

170 Operating Instructions – 387 801 1501 EN – 04/2012

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

Battery chargers with a charging current over 250 A

are not permitted and cause damage to the battery
male connector.
The battery charger used to recharge the battery
must not exceed a charging current of 250 A.
If the charger available exceeds this charging
current, contact your authorised dealer.

Ø Fully lower the fork carriage.

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

Risk of crushing fingers and hands.

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

Ø Open the battery hood and fold it back.

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

Operating Instructions – 387 801 1501 EN – 04/2012 171

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

Ø Fully lower the fork carriage.

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

The fan (2) is activated when the emergency

off switch is pressed.
Ø Open the rear flap and fold it upwards.
Ø Connect the battery charger connector plug
to the battery female connector (1).
Ø Switch on the charger.

If the truck will not be used for a prolonged

period of time, either press the emergency off
switch or unplug the battery male connector
from the truck battery after the charging
process has ended, in order to prevent
unnecessary battery discharge.

172 Operating Instructions – 387 801 1501 EN – 04/2012

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

The battery must only be charged in sufficiently

ventilated areas.

The active charging ventilation unit is part

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

The contactor is supplied with battery voltage

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

The fan (2) runs until the emergency off switch

is deactivated.

After the charging process, the emergency off

switch must not be pressed and held down,
as the battery is discharged during prolonged
downtimes.

Operating Instructions – 387 801 1501 EN – 04/2012 173

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

The plug on the battery side of the external

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

After the charging process, the emergency off

switch must not be pressed and held down,
as the battery is discharged during prolonged
downtimes.

174 Operating Instructions – 387 801 1501 EN – 04/2012

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

Ø Park the truck safely.

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

Risk of crushing fingers and hands.

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

Ø Move the driver’s seat and armrest back-

wards.

Operating Instructions – 387 801 1501 EN – 04/2012 175

Ø Release the battery hood using lever (1)
and swing all the way backwards along with
the driver’s seat.
Ø For safety reasons, take appropriate
measures to ensure that the battery hood
does not lower from the uppermost position.

If the driver’s cab with rear window special

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

Ø Pull out the battery male connector (1)

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

If the battery slips, this can result in damage to the

battery and battery tray.
The new battery must correspond to the standard
model in terms of size and weight. Any variation in
weight must be offset using ballast weights.
Contact your authorised dealer.

176 Operating Instructions – 387 801 1501 EN – 04/2012

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

When picking up the C hook (3), ensure that

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

Risk of accident
Only trucks and battery removal tools with sufficient
load capacity may be used.

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

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

Operating Instructions – 387 801 1501 EN – 04/2012 177

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

The truck floor may be damaged if the fork arms are

not correctly positioned on the covers provided.
Adjust the fork arm distance correspondingly.

The underside of the battery support has four

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

The truck floor in the battery compartment may

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

Ø Drive the truck slowly until the fork arms are

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

178 Operating Instructions – 387 801 1501 EN – 04/2012

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

When the push button is actuated, the locking

cylinder initially extends, which blocks the
steering axle. The battery then extends.

Ø Move the steering axle to the straight-ahead

position.
The hydraulic power unit is actuated via a push
button (1) in the battery compartment.
Ø Press push button (1) on the left-hand side
(see arrow).
The locking cylinder extends and blocks the
steering axle. The battery then slowly extends
(by approx. 60 ).
Ø Disconnect the battery male connector from
the battery female connector.
Ø Insert suitable lifting gear into the openings
provided in the battery tray.
Ø Carefully lift the battery and put down safely
in a suitable place.

Operating Instructions – 387 801 1501 EN – 04/2012 179

Risk of crushing and risk of accident when retracting
the battery into the battery compartment.
When retracting the battery, ensure that no one is
in the area surrounding the battery compartment.

Ø Carefully insert the new battery into the

reach carriage (2), ensuring that it is posi-
tioned correctly.
Ø Remove the lifting gear.
Ø Plug the battery male connector into the
battery female connector.
Ø Press push button (1) on the right-hand side
(see arrow).
Battery retracts slowly. After the battery
retracts, the locking cylinder releases the
steering axle.
Ø Close the side battery door, ensuring that it
is fastened correctly.
Ø Close the battery hood.

Observe information regarding working with

consumables

Only check the oil level when the battery is

retracted.

Risk of crushing fingers and hands.

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

Ø Open the battery hood.

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

180 Operating Instructions – 387 801 1501 EN – 04/2012

Ø Unscrew the cap screw and top up with hy-
draulic oil (standard oil, see Recommenda-
tions for consumables) to the corresponding
oil level marking, as required.
Ø Screw the cap screw back onto the tank.
Ø Close the battery hood.

• Pump motor power rating 1.2 kW

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

Operating Instructions – 387 801 1501 EN – 04/2012 181

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

Risk of crushing fingers and hands.

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

Ø Open the battery hood and fold it back.

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

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

side.

182 Operating Instructions – 387 801 1501 EN – 04/2012

Fan (1) for heat extraction from the control
compartment

As a precaution, pull out the plug connector

(see arrow) for the fan (1).

Ø Check the main contactor (3) for burns and

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

Operating Instructions – 387 801 1501 EN – 04/2012 183

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

184 Operating Instructions – 387 801 1501 EN – 04/2012

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

In the left-hand area of the control compart-

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

Operating Instructions – 387 801 1501 EN – 04/2012 185

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

The best medium for cleaning the fans is

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

186 Operating Instructions – 387 801 1501 EN – 04/2012

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

To clean the fan (1) located on the right side

of the truck, the panelling (2) must first be
removed.
Ø Remove the side panelling (2), pull out the
fan plug (see arrow) and place the panelling
to one side.

Operating Instructions – 387 801 1501 EN – 04/2012 187

Ø Disassemble the fan (1) from the panelling
(2).
Ø Clean fans with compressed air and/or
cleaner solvent.

Observe information regarding working with

consumables.

If there is too much contamination, remove or

replace the fans in the control compartment.
Please contact your authorised dealer.

In the charging the battery using an external

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

All fans must be checked for correct function

during inspection and maintenance work.

The fans may only be tested using an appro-

priate diagnostic program (Pathfinder).

Defective fans or those exhibiting faults must

be changed immediately. Please contact your
authorised dealer.

188 Operating Instructions – 387 801 1501 EN – 04/2012

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

Operating Instructions – 387 801 1501 EN – 04/2012 189

Observe information regarding working with
consumables.

Observe the oil level, oil volume, specifications.

When checking the hydraulic oil level, always have
the lift mast vertical and the fork carriage lowered.
Observe the recommendations for consumables.

Ø Fully lower the fork carriage.

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

Marking Filling quantity Standard mast Duplex mast Triplex mast

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

The maximum permissible oil filling quantity is

25.0 litres.
Ø Top up hydraulic oil to the appropriate oil
level marking (1) or (2) as required.
Ø Reinsert the oil dipstick and screw in in a
clockwise direction.

190 Operating Instructions – 387 801 1501 EN – 04/2012

Ø Place the rubber mat back on the bottom
plate.

Operating Instructions – 387 801 1501 EN – 04/2012 191

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

192 Operating Instructions – 387 801 1501 EN – 04/2012

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

Observe information regarding working with

consumables. See the recommendation for
consumables.

Hydraulic oil can only be extracted with a hand

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

Dispose of used oil in an environmentally

friendly manner.
Ø Add new hydraulic oil to hydraulic oil tank.

The filling quantity depends on the lift height.

Operating Instructions – 387 801 1501 EN – 04/2012 193

The oil dipstick (4) has two markings for the
different mast types.

Marking Filling quantity Standard mast Duplex mast Triplex mast

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

The maximum permissible oil filling quantity is

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

The oil level marking (2) must not be exceeded

under any circumstances.
Ø Clean the seal of the fuel tank cap and wet
with oil.
Ø Refit the fuel tank cap (5) and turn it in a
clockwise direction.
Ø Tighten the fuel tank cap to 25 Nm.
Ø Screw breather filter (3) back on.
Ø Check the tightness of the fuel tank cap
during the test run.

194 Operating Instructions – 387 801 1501 EN – 04/2012

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

Dispose of the old breather filter in an environ-

mentally friendly manner.

If there is heavy dust accumulation, it may be

necessary to change the filter earlier.
Ø Remove the rubber mat from the bottom
plate.
Ø Unscrew the breather filter (3) with oil
dipstick (4) from the tank cap in an anti-
clockwise direction.
Ø Pull the breather filter (3) off the oil dipstick
(4).
Ø Connect the new breather filter to the oil
dipstick.
Ø Screw the breather filter (3) together with oil
dipstick (4) onto the tank cap in a clockwise
direction.
Ø Place the rubber mat back on the bottom
plate.

Operating Instructions – 387 801 1501 EN – 04/2012 195

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

196 Operating Instructions – 387 801 1501 EN – 04/2012

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

Observe information regarding working with

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

Operating Instructions – 387 801 1501 EN – 04/2012 197

Ø Unscrew the cover (4) of the filter housing
(1) using a socket wrench or box-end
wrench.
Ø Slowly remove the filter insert (3) with dirt
trap (2) from the filter housing (1).
Ø Remove and clean the dirt trap (2) from the
filter insert (3).
Ø Collect oil drips in a container.

Dispose of old filter insert and oil in an environ-

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

198 Operating Instructions – 387 801 1501 EN – 04/2012

Observe information regarding working with
consumables.
Ø Fully lower the fork carriage.
Ø Push the emergency off button and pull the
key switch out of the switch lock.
Ø Remove the rubber mat from the bottom
plate.
Ø Remove the bottom plate.
Ø Unscrew the breather filter (1) in an anti-
clockwise direction.

As long as the tank container is under internal

pressure, the head of the suction filter is generally
full with hydraulic oil. Due to the diagonally installed
suction filter housing, a quantity of approx. 0.3 litres
hydraulic oil can flow out into the truck when the fuel
tank cap is opened and the suction filter is taken
out.
To avoid this, make sure that the breather filter (1) is
unscrewed before opening the suction filter cover.
This allows the air to escape so that the oil will not
overflow when the filter cartridge is taken out.

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

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

Dispose of old filter insert and oil in an environ-

mentally friendly manner.
Ø Clean the seal (5) of the filter cover and wet
with oil.
Ø Carefully insert new filter cartridge in
hydraulic tank.
Ensure that it is correctly centred in the base
of the tank.

Operating Instructions – 387 801 1501 EN – 04/2012 199

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

The tension of the double hoses should be

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

d3921519

200 Operating Instructions – 387 801 1501 EN – 04/2012

When the lift mast or fork carriage is lifted, no work
should be performed on the lift mast and at the front
of the truck without the following safety measures
These safety precautions are sufficient only for
general maintenance on the truck (inspection and
greasing).
For repairs (such as changing chains, dismantling
lift cylinders), additional safety precautions must be
taken.
Please contact your authorised dealer.

The lift mast must be secured from tilting back

unintentionally (see arrow).
Ø Tilt lift mast right back.
Ø Push the emergency off switch.
Ø Pull the switch key out from the key switch.
Ø Disconnect the battery male connector.
The truck must be switched off completely.
Ø Apply the parking brake.

FUNCTION: When lifting the inner mast,

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

Operating Instructions – 387 801 1501 EN – 04/2012 201

 1

Select a safety chain with sufficient load bearing

capacity for the lift mast. Take the maximum lift
height into account.

Ø Extend lift mast.

Ø Connect the chain over the cross beam of
the outer mast (1) and under the cross beam
of the inner mast (2).
Ø Watch out for the hose lines on the cross
beam of the outer mast. 2
Ø Lower the inner mast until it reaches the d3921482
chain.

The benefit of this equipment version is that

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

202 Operating Instructions – 387 801 1501 EN – 04/2012

 1

Select a safety chain with sufficient load bearing

capacity for the lift mast. Take the maximum lift
height into account.

Ø Extend lift mast.

Ø Connect the chain over the cross beam of
the outer mast (1) and under the cross beam
of the inner mast (2).
Ø Watch out for the hose lines on the cross
beam of the outer mast.
Ø Lower the lift mast until it reaches the chain. 2 d3921483

Ø Lower fork carriage as far as it will go.

FUNCTION: The fork carriage is lifted to the

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

Operating Instructions – 387 801 1501 EN – 04/2012 203

 1

Select a safety chain with sufficient load bearing

capacity for the lift mast. Take the maximum lift
height into account.

Ø Extend lift mast.

Ø Connect the chain over the cross beam of
the outer mast (1) and under the cross beam
of the middle mast (2).
Ø Watch out for the hose lines on the cross
beam of the outer mast.
2
Ø Lower the lift mast until it reaches the chain. d3921484

Ø Lower fork carriage as far as it will go.

204 Operating Instructions – 387 801 1501 EN – 04/2012

To access the lift mast mounting screws, the
lift mast be tilted forwards to the mechanical
stop. An appropriate level of specialist knowledge is
required for this task.
To do this, a special tool and the correspond-
ing diagnostic program are required. Please contact your authorised dealer.

Operating Instructions – 387 801 1501 EN – 04/2012 205

Do not use cleaner solvent, chemical cleaners or
fluids that are corrosive or contain acid or chlorine.

If the lift mast chain is so dusty that penetration

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

The lift mast chain stretches over time during

operation and therefore has to be readjusted
on the right and left.
Ø Lower the lift mast completely.

206 Operating Instructions – 387 801 1501 EN – 04/2012

Ø Release counter nut (2).
Ø Adjust chain at adjusting nut (1) of chain
anchor.
The lower guide roller of the fork carriage
should only protrude max. 25 mm from the
guide rail of the internal lift mast.
Ø Tighten counter nut (2) securely.
Ø Also adjust second chain.

When extended, the lift mast should not touch the

end stops.
Fully extend lift mast and check clearance to end
stops.

In the case of forklift trucks which are used in

the food production sector chain spray should
not be used but a low-viscosity oil licensed for
use in the food industry.
Ø Apply Linde chain spray to guide surfaces
and chain.

The lift mast chain stretches over time during

operation and therefore has to be readjusted.
Ø Lower the lift mast and fork carriage com-
pletely.

Operating Instructions – 387 801 1501 EN – 04/2012 207

Ø Release counter nut (4). Adjust chain at
adjusting nut (3) of chain anchor.
The lower guide roller of the fork carriage
should only protrude max. 25 mm from the
guide rail of the internal lift mast.
Ø Tighten counter nut (4) securely.

When extended, the lift mast should not touch the

end stops.
Fully extend lift mast and check clearance to end
stops.
3

4 d3921486

In the case of forklift trucks which are used in

the food production sector chain spray should
not be used but a low-viscosity oil licensed for
use in the food industry.
Ø Apply Linde chain spray to guide surfaces
and chain.

208 Operating Instructions – 387 801 1501 EN – 04/2012

Ø Clean lift mast guides and chain.
Ø Check chain for condition and wear, espe-
cially at guide pulleys.
Ø Check the mounting of the chain to chain
anchor.
Ø Replace damaged chains.

Individual plastic links that are damaged or

missing do not impair function or service life.
Ø Check the condition and mounting of the lift
mast, guide surfaces and rollers.
Ø Check the condition, mounting and correct
function of the end stops.
Ø Check the mounting of the lift cylinders.
Ø Check that the locking ring of the piston
rod mounting to the top of the lift mast is
securely positioned.

Ø Check fork arms for visible deformation, 1

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

3
E336/085

Operating Instructions – 387 801 1501 EN – 04/2012 209

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

The rear flap (4) is monitored by a sensor (3).

If the rear flap is not closed properly, the truck
is not ready for operation. Therefore, make
sure that the rear flap is closed properly.

Observe information regarding working with

consumables.

The sideshift should be greased whenever

the truck is washed. Use lubricating grease
complying with the recommendations for
working materials.
Ø Clean sideshift with steam jet.
Ø Check hydraulic lines for scuffing and
replace if necessary.
Ø Check hydraulic connections and fastening
elements for secure positioning and wear
and tighten/replace if necessary.

210 Operating Instructions – 387 801 1501 EN – 04/2012

Ø Check cylinders for leaks.
Ø Check piston rods for damage.
Ø Move fork arms so that the 4 lubricating
nipples (1) are accessible.
Ø Let down sideshift until fork arms touch the
ground.
Ø Apply lubricating grease to the lubricating
nipples (1) of the support rollers on the fork
carriage until grease escapes at the side.
Ø Apply lubricating grease to the lubricating
nipples (2) of the slide guides on the fork
carriage until grease escapes at the side.

Ø Clean the fork prong positioner using a

steam jet.
Ø Check condition of fork prong positioner
and check for leaks.
Ø Check hydraulic lines for chafing and
replace if necessary.
Ø Check hydraulic connections for tightness,
replace if necessary.
Ø Check cylinders for leaks.
Ø Check piston rods for damage.

Operating Instructions – 387 801 1501 EN – 04/2012 211

Ø Tighten mounting screws (1) to 106 Nm.
Ø Screw in the screws (2) to the fork arm stop,
tighten lock nut to 50 Nm.
Ø Tighten mounting screws (3) to 120 Nm.

Ø Tighten mounting screws (7) to 145 Nm.

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

212 Operating Instructions – 387 801 1501 EN – 04/2012

The fork arm adjustment device must only be
dismantled by a specialist using special tools.
Please contact your authorised dealer.

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

Operating Instructions – 387 801 1501 EN – 04/2012 213

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

Each error is indicated by a numerical code

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

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

Error in electrical controllers or battery charger

Please contact your authorised dealer.
operation

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

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

Traction motors and/or pump motors have

Allow motors to cool down as soon as possible.
almost reached the temperature limit
.

214 Operating Instructions – 387 801 1501 EN – 04/2012

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

1 10 A fuse 4F1 for alarm horn

2 15 A control current fuse F2

3 10 A fuse for discharge indicator F3

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

Operating Instructions – 387 801 1501 EN – 04/2012 215

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

Ø Change the defective fuse.

The 2 main current fuses (safety fuses) for

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

The fuse elements must be correctly fitted.

The assembly sequence of the individual
components must be observed. Please
contact your authorised dealer.
Ø Change the defective fuse.

216 Operating Instructions – 387 801 1501 EN – 04/2012

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

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

When the rear flap is open, the sensor (4)

is deactivated and all traction functions and
hydraulic functions are switched off.

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

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

Use only genuine Linde spare fuses with a

high voltage rating (32V). Please contact your
authorised dealer.

Operating Instructions – 387 801 1501 EN – 04/2012 217

218 Operating Instructions – 387 801 1501 EN – 04/2012
5F40 1.1 15 A/32 V Working spotlight pos. 1 + 2
5F41 1.2 15 A/32 V Working spotlight pos. 3 + 4
5F42 1.3 * Working spotlight pos. 5 + 6 or cross beam

5F43 1.4 * Working spotlight pos. 7 + 8

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

9F81 2.2 10 A/32 V Wash pumps

9F82 2.3 10 A/32 V Front windscreen wiper

9F83 2.4 10 A/32 V Rear window and roof panel wipers
9F98 3.1 7.5 A/32 V Battery carrier
3.2 Not assigned
9F73 3.3 15 A/32 V Seat heater
9F93 3.4 15 A/32 V 12 V socket
9F94 8.1 1 A/32 V 70 A relay coil for relay 9K90
9F99 8.2 10 A/32 V 80/24 V voltage transformer
8.3 Not assigned
8.4 Not assigned
5F20 9.1 15 A/32 V Lighting
5F21 9.2 10 A/32 V Hazard warning system
Hazard warning system for reverse travel with stop light
5F27 9.2 5 A/32 V
and without lighting
5F26 9.3 5 A/32 V Brake light lighting
5F22 9.4 7.5 A/32 V Left dipped beam
5F23 10.1 7.5 A/32 V Right dipped beam
5F24 10.2 5 A/32 V Left-hand sidelights
5F25 10.3 5 A/32 V Right-hand sidelights
5F28 10.4 2 A/32 V Interior lighting/terminal board light
6F60 15.1 2 A/32 V Linde Forklift Data Management
15.2 Not assigned

15.3 Not assigned

15.4 Not assigned

Operating Instructions – 387 801 1501 EN – 04/2012 219

 16.1 Not assigned
16.2 Not assigned
16.3 Not assigned
16.4 Not assigned

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

9 fuse holders, each with 4 slots, are provided

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

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

5 A/80 V Light brown

7.5 A/32 V Brown

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

220 Operating Instructions – 387 801 1501 EN – 04/2012

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

To protect the special equipment, up to four

maxi fuses can be found at the contactor
carrier.
9F92 voltage transformer fuse,
1
pos. 1/2
9F90 voltage transformer fuse,
2
pos. 3
3 9F70 heating system fuse
4 9F97 battery carrier fuse
.

Operating Instructions – 387 801 1501 EN – 04/2012 221

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

After completing the diagnostics, the lid (1)

must be screwed back onto the diagnostic
connector (2) to prevent moisture from ente-
ring.
Please contact your authorised dealer.

222 Operating Instructions – 387 801 1501 EN – 04/2012

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

Braking no longer takes place.

Do not exceed the towing speed.

Power-assisted steering does not function

once the emergency off button has been
pressed.
Ø Lower the load, but not so far that the
fork arms scrape along the ground during
towing.
Ø Remove the load.

Operating Instructions – 387 801 1501 EN – 04/2012 223

Ø Attach the towing vehicle to the towing pin
(1) using a tow bar.

Ø Unscrew and remove bottom plate.

Ø Tighten screw (1) clockwise to the stop.

224 Operating Instructions – 387 801 1501 EN – 04/2012

Ø Disassemble the flat iron (see arrow) from
the bottom plate.

Insert the flat iron in the opening provided and

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

To release the multi-disc brake in the wheel

gears, an accumulator is also used for supply
of the brake valve.

Before starting repair work on the accumulator

or on any pressurised hydraulic pipework, the
accumulator must be depressurised.
Appropriate specialist knowledge is required to do
this. Contact your authorised dealer.

Ø A driver must steer the truck while it is being

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

Operating Instructions – 387 801 1501 EN – 04/2012 225

Directly after the towing procedure, the screw
(1) must be removed again in an anti-clockwise
direction.

226 Operating Instructions – 387 801 1501 EN – 04/2012

 Ø Jack up the vehicle so all wheels are off the
ground.
If the vehicle is shut down for more than
2 months e.g. for operational reasons, it This will prevent permanent deformation of the
should only be left in a well ventilated, clean tyres.
and dry room free of frost, and the following
measures undertaken beforehand.
Ø Clean forklift truck thoroughly. Do not cover with plastic foil or this will encou-
Ø Raise fork carriage several times to the rage the formation and collection of conden-
end stop, move lift mast backwards and sed water.
forwards a few times and operate any
attachments several times.
Ø Lower the fork carriage to a supporting If the vehicle is to be shut down for more than
surface until the chains are relieved of load. 6 months, further measures should be agreed
with your authorised dealer.
Ø Check the hydraulic oil level and top up if
necessary.
Ø All unpainted mechanical components
should be coated with a thin film of oil or Ø Clean forklift truck thoroughly and grease.
grease. Ø Clean the battery and lubricate battery
Ø Grease vehicle. terminals with acid-free grease

Ø Check battery condition and density of acid. Ø Check battery condition and density of acid
and recharge if necessary.
Ø Lubricate battery terminals with acid-free
grease. (Follow instructions of battery Ø Check hydraulic oil for condensed water
manufacturer .) and change if necessary.

Ø Apply a suitable contact spray to all exposed Ø Perform maintenance as before initial
electrical contacts . commissioning.
Ø Put forklift truck into service.

Operating Instructions – 387 801 1501 EN – 04/2012 227

The disposal of old trucks is regulated in available for disassembled and partially
directive 2000/53/EC from the European oil-smeared parts, as well as for tyres
Parliament and Council. including fire protection measures. Suitable
storage tanks for fluids such as fuel, engine
We therefore recommend having this work
oil, hydraulic oil, coolant and fluids from
carried out in an approved recycling plant. If
air conditioning systems must also be
you would like to carry out this work yourself,
provided.
you must obtain approval from the relevant
authorities as per articles 9, 10 and 11 of • In order to dispose of harmful substances
directive 75/442/EEC. from the old trucks, the batteries and LPG
container must be removed. The following
The following minimum requirements must must also be removed, collected and
also be observed: stored separately: fuel, engine oil, coolant,
• The locations in which old trucks are stored hydraulic oil and fluids from air conditioning
before treatment must be areas suited to systems
this task with impervious surfaces. These • The following parts are to be collected sep-
areas are also to be equipped with collection arately and recycled: catalytic converters,
devices and separators for leaking fluids metal components containing copper and
and degreasing cleaning materials aluminium, tyres, large plastic components
• The locations for treatment must be areas (consoles, fluid containers) and glass
suited to this task with impervious surfaces.
These areas are also to be equipped with
collection devices and separators for
The operating company is responsible for ad-
leaking fluids and degreasing cleaning
herence to the directives as well as additional
materials. Suitable storage areas must be
country-specific regulations.

228 Operating Instructions – 387 801 1501 EN – 04/2012

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

2.1 Net weight kg 42101

2.2 Axle load with front/rear load kg 5615/595
2.3 Axle load without front/rear load kg 2450/1760 2

Tyres: solid rubber, superelastic, pneumatic,

3.1 SE
polyurethane
3.2 Tyre size, front 23x9—10
3.3 Tyre size, rear 180/70–8 (18x7-8)
3.5 Number of wheels, front/rear (x = driven) 2x/2
3.6 Front track width b10 [mm] 942
3.7 Rear track width b11 [mm] 900

4.1 Lift mast/fork carriage tilt, forwards/backwards α/β (°) 5.0/8.0

4.2 Height with lift mast retracted h1 [mm] 2247
4.3 Free lift h2 [mm] 150
4.4 Lift h3 [mm] 3150
4.5 Height with lift mast extended h4 [mm] 3813
4.7 Height above overhead guard (cab) h6 [mm] 2080

1 Including battery, line 6.4/6.5

2 Including battery, line 6.4/6.5

230 Operating Instructions – 387 801 1501 EN – 04/2012

4.8 Seat height/standing height h7 [mm] 1002
4.12 Coupling height h10 [mm] 621
4.19 Total length l1 [mm] 3318
4.20 Length including fork back l2 [mm] 2318
4.21 Total width b1/b2 [mm] 1150/1148
4.22 Fork arm dimensions s/e/l [mm] 45 x 100 x 1000
4.23 ISO 2328 fork carriage, class/model A, B 2A
4.24 Fork carriage width b3 [mm] 1080
4.31 Ground clearance with load under lift mast m1 [mm] 130
4.32 Ground clearance at centre of wheelbase m2 [mm] 120
4.33 Aisle width for pallet 1000 x 1200 crosswise Ast [mm] 36383
4.34 Aisle width for pallet 800 x 1200 longitudinal A st [mm] 37664
4.35 Turning radius Wa [mm] 1873
4.36 Smallest pivot point distance b13 [mm] 0

5.1 Driving speed with/without load km/h 20/20

5.2 Lifting speed with/without load m/s 0.45/0.56
5.3 Lowering speed with/without load m/s 0.54/0.54
5.5 Pulling force with/without load N 4600/4600
5.6 Maximum pulling force with/without load N 15,000/15,000
5.7 Climbing capability with/without load 7.6/11.2
5.8 Maximum climbing capability with/without load 25.4/39.0
5.9 Acceleration time with/without load s on request
Hydraulic/me-
5.10 Service brake
chanical

6.1 Traction motor, power rating S2 60 min kW 2x9

6.2 Lift motor, power rating at S3 15 kW 22
Battery in accordance with DIN 43531/35/36 A, B, C,
6.3 43536/A
no

3 Including a = 200 mm safety distance

4 Including a = 200 mm safety distance

Operating Instructions – 387 801 1501 EN – 04/2012 231

 6.4 Battery voltage, nominal capacity K5 V/Ah 80 V/460–500
6.5 Battery weight (±5 ) kg 1210
Energy consumption in accordance with standardised
6.6 kWh/h 6.4
VDI cycle

Digital con-
8.1 Traction controller type troller/continu-
ously variable
8.2 Working pressure for attachments bar 170
8.3 Oil volume for attachments l/min 50
.

232 Operating Instructions – 387 801 1501 EN – 04/2012

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

2.1 Net weight kg 48255

2.2 Axle load with front/rear load kg 5886/939
2.3 Axle load without front/rear load kg 2620/22056

Tyres: solid rubber, superelastic, pneumatic,

3.1 SE
polyurethane
3.2 Tyre size, front 23x9—10
3.3 Tyre size, rear 180/70–8 (18x7-8)
3.5 Number of wheels, front/rear (x = driven) 2 x/2
3.6 Front track width b10 [mm] 942
3.7 Rear track width b11 [mm] 900

4.1 Lift mast/fork carriage tilt, forwards/backwards α/β (°) 5.0/8.0

4.2 Height with lift mast retracted h1 [mm] 2397
4.3 Free lift h2 [mm] 150
4.4 Lift h3 [mm] 3450
4.5 Height with lift mast extended h4 [mm] 4113
4.7 Height above overhead guard (cab) h6 [mm] 2237

5 Including battery, line 6.4/6.5

6 Including battery, line 6.4/6.5

Operating Instructions – 387 801 1501 EN – 04/2012 233

4.8 Seat height/standing height h7 [mm] 1160
4.12 Coupling height h10 [mm] 656
4.19 Total length l1 [mm] 3352
4.20 Length including fork back l2 [mm] 2352
4.21 Total width b1/b2 [mm] 1150/1146
4.22 Fork arm dimensions s/e/l [mm] 45 x 100 x 1000
4.23 ISO 2328 fork carriage, class/model A, B 2A
4.24 Fork carriage width b3 [mm] 1080
4.31 Ground clearance with load under lift mast m1 [mm] 130
4.32 Ground clearance at centre of wheelbase m2 [mm] 120
4.33 Aisle width for pallet 1000 x 1200 crosswise Ast [mm] 36727
4.34 Aisle width for pallet 800 x 1200 longitudinal Ast [mm] 38008
4.35 Turning radius Wa [mm] 1907
4.36 Smallest pivot point distance b13 [mm] 0

5.1 Driving speed with/without load km/h 20/20

5.2 Lifting speed with/without load m/s 0.45/0.56
5.3 Lowering speed with/without load m/s 0.54/0.54
5.5 Pulling force with/without load N 4600/4600
5.6 Maximum pulling force with/without load N 15,000/15,000
5.7 Climbing capability with/without load 6.9/9.8
5.8 Maximum climbing capability with/without load 23.0/33.4
5.9 Acceleration time with/without load s on request
Hydraulic/me-
5.10 Service brake
chanical

6.1 Traction motor, power rating S2 60 min kW 2x9

6.2 Lift motor, power rating at S3 15 kW 22
Battery in accordance with DIN 43531/35/36 A, B, C,
6.3 43536 A
no

7 Including a = 200 mm safety distance

8 Including a = 200 mm safety distance

234 Operating Instructions – 387 801 1501 EN – 04/2012

 6.4 Battery voltage, nominal capacity K5 V/Ah 80 V/560–620
6.5 Battery weight (+/- 5 ) kg 1 558
Energy consumption in accordance with standardised
6.6 kWh/h 7
VDI cycle

Digital con-
8.1 Traction controller type troller/continu-
ously variable
8.2 Working pressure for attachments bar 170
8.3 Oil volume for attachments l/min 50
.

Operating Instructions – 387 801 1501 EN – 04/2012 235

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

2.1 Net weight kg 46549

2.2 Axle load with front/rear load kg 6401/753
2.3 Axle load without front/rear load kg 2444/2210 10

Tyres: solid rubber, superelastic, pneumatic,

3.1 SE
polyurethane
3.2 Front tyre size 23x9-10
3.3 Rear tyre size 180/60–10
3.5 Number of wheels, front/rear (x = driven) 2x/2
3.6 Front track width b10 [mm] 942
3.7 Rear track width b11 [mm] 900

4.1 Lift mast/fork carriage tilt, forwards/backwards α/β (°) 5.0/8.0

4.2 Height with lift mast retracted h1 [mm] 2247
4.3 Free lift h2 [mm] 150
4.4 Lift h3 [mm] 3150
4.5 Height with lift mast extended h4 [mm] 3813
4.7 Height above overhead guard (cab) h6 [mm] 2080

9 Including battery, line 6.4/6.5

10 Including battery, line 6.4/6.5

236 Operating Instructions – 387 801 1501 EN – 04/2012

4.8 Seat height/standing height h7 [mm] 1002
4.12 Coupling height h10 [mm] 621
4.19 Total length l1 [mm] 3318
4.20 Length including fork back l2 [mm] 2318
4.21 Total width b1/b2 [mm] 1150/1148
4.22 Fork arm dimensions s/e/l [mm] 45 x 100 x 1000
4.23 ISO 2328 fork carriage, class/model A, B 2A
4.24 Fork carriage width b3 [mm] 1080
4.31 Ground clearance with load under lift mast m1 [mm] 129
4.32 Ground clearance at centre of wheelbase m2 [mm] 120
4.33 Aisle width for pallet 1000 x 1200 crosswise Ast [mm] 363811
4.34 Aisle width for pallet 800 x 1200 longitudinal A st [mm] 376612
4.35 Turning radius Wa [mm] 1873
4.36 Smallest pivot point distance b13 [mm] 0

5.1 Driving speed with/without load km/h 20/20

5.2 Lifting speed with/without load m/s 0.45/0.56
5.3 Lowering speed with/without load m/s 0.54/0.54
5.5 Pulling force with/without load N 4600/4600
5.6 Maximum pulling force with/without load N 15,000/15,000
5.7 Climbing capability with/without load 6.5/10.0
5.8 Maximum climbing capability with/without load 21.6/34.1
5.9 Acceleration time with/without load s on request
Hydraulic/me-
5.10 Service brake
chanical

6.1 Traction motor, power rating S2 60 min kW 2x9

6.2 Lift motor, power rating at S3 15 kW 22
Battery in accordance with DIN 43531/35/36 A, B, C,
6.3 43536 A
no

11 Including a = 200 mm safety distance

12 Including a = 200 mm safety distance

Operating Instructions – 387 801 1501 EN – 04/2012 237

 6.4 Battery voltage, nominal capacity K5 V/Ah 80 V/460–500
6.5 Battery weight (±5 ) kg 1210
Energy consumption in accordance with standardised
6.6 kWh/h 7.5
VDI cycle

Digital con-
8.1 Traction controller type troller/continu-
ously variable
8.2 Working pressure for attachments bar 170
8.3 Oil volume for attachments l/min 50
.

238 Operating Instructions – 387 801 1501 EN – 04/2012

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

2.1 Net weight kg 543013

2.2 Axle load with front/rear load kg 7082/848
2.3 Axle load without front/rear load kg 2965/246514

Tyres: solid rubber, superelastic, pneumatic,

3.1 SE
polyurethane
3.2 Front tyre size 23x9-10
3.3 Rear tyre size 180/60–10
3.5 Number of wheels, front/rear (x = driven) 2x/2
3.6 Front track width b10 [mm] 942
3.7 Rear track width b11 [mm] 900

4.1 Lift mast/fork carriage tilt, forwards/backwards α/β (°) 5.0/8.0

4.2 Height with lift mast retracted h1 [mm] 2297
4.3 Free lift h2 [mm] 150
4.4 Lift h3 [mm] 3200
4.5 Height with lift mast extended h4 [mm] 3975
4.7 Height above overhead guard (cab) h6 [mm] 2237

13 Including battery, line 6.4/6.5

14 Including battery, line 6.4/6.5

Operating Instructions – 387 801 1501 EN – 04/2012 239

4.8 Seat height/standing height h7 [mm] 1160
4.12 Coupling height h10 [mm] 658
4.19 Total length l1 [mm] 3375
4.20 Length including fork back l2 [mm] 2375
4.21 Total width b1/b2 [mm] 1150/1146
4.22 Fork arm dimensions s/e/l [mm] 45 x 100 x 1000
4.23 ISO 2328 fork carriage, class/model A, B 2A
4.24 Fork carriage width b3 [mm] 1150
4.31 Ground clearance with load under lift mast m1 [mm] 127
4.32 Ground clearance at centre of wheelbase m2 [mm] 120
4.33 Aisle width for pallet 1000 x 1200 crosswise Ast [mm] 369315
4.34 Aisle width for pallet 800 x 1200 longitudinal Ast [mm] 382216
4.35 Turning radius Wa [mm] 1907
4.36 Smallest pivot point distance b13 [mm] 0

5.1 Driving speed with/without load km/h 20/20

5.2 Lifting speed with/without load m/s 0.44/0.53
5.3 Lowering speed with/without load m/s 0.56/0.56
5.5 Pulling force with/without load N 4600/4600
5.6 Maximum pulling force with/without load N 15,000/15,000
5.7 Climbing capability with/without load 5.9/8.7
5.8 Maximum climbing capability with/without load 19.7/29.3
5.9 Acceleration time with/without load s on request
Hydraulic/me-
5.10 Service brake
chanical

6.1 Traction motor, power rating S2 60 min kW 2x9

6.2 Lift motor, power rating at S3 15 kW 22
Battery in accordance with DIN 43531/35/36 A, B, C,
6.3 43536 A
no

15 Including a = 200 mm safety distance

16 Including a = 200 mm safety distance

240 Operating Instructions – 387 801 1501 EN – 04/2012

 6.4 Battery voltage, nominal capacity K5 V/Ah 80 V/560–620
6.5 Battery weight (±5 ) kg 1 558
Energy consumption in accordance with standardised
6.6 kWh/h 7.9
VDI cycle

Digital con-
8.1 Traction controller type troller/continu-
ously variable
8.2 Working pressure for attachments bar 170
8.3 Oil volume for attachments l/min 50
.

Operating Instructions – 387 801 1501 EN – 04/2012 241

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

2.1 Net weight kg 458517

2.2 Axle load with front/rear load kg 6412/673
2.3 Axle load without front/rear load kg 2575/2010 18

Tyres: solid rubber, superelastic, pneumatic,

3.1 SE
polyurethane
3.2 Front tyre size 23x9-10
3.3 Rear tyre size 180/60–10
3.5 Number of wheels, front/rear (x = driven) 2x/2
3.6 Front track width b10 [mm] 942
3.7 Rear track width b11 [mm] 900

4.1 Lift mast/fork carriage tilt, forwards/backwards α/β (°) 5.0/8.0

4.2 Height with lift mast retracted h1 [mm] 2247
4.3 Free lift h2 [mm] 150
4.4 Lift h3 [mm] 3150
4.5 Height with lift mast extended h4 [mm] 3813
4.7 Height above overhead guard (cab) h6 [mm] 2080

17 Including battery, line 6.4/6.5

18 Including battery, line 6.4/6.5

242 Operating Instructions – 387 801 1501 EN – 04/2012

4.8 Seat height/standing height h7 [mm] 1002
4.12 Coupling height h10 [mm] 624
4.19 Total length l1 [mm] 3463
4.20 Length including fork back l2 [mm] 2463
4.21 Total width b1/b2 [mm] 1150/1148
4.22 Fork arm dimensions s/e/l [mm] 45 x 100 x 1000
4.23 ISO 2328 fork carriage, class/model A, B 2A
4.24 Fork carriage width b3 [mm] 1080
4.31 Ground clearance with load under lift mast m1 [mm] 130
4.32 Ground clearance at centre of wheelbase m2 [mm] 120
4.33 Aisle width for pallet 1000 x 1200 crosswise Ast [mm] 378319
4.34 Aisle width for pallet 800 x 1200 longitudinal A st [mm] 391120
4.35 Turning radius Wa [mm] 2018
4.36 Smallest pivot point distance b13 [mm] 0

5.1 Driving speed with/without load km/h 20/20

5.2 Lifting speed with/without load m/s 0.45/0.56
5.3 Lowering speed with/without load m/s 0.54/0.54
5.5 Pulling force with/without load N 4600/4600
5.6 Maximum pulling force with/without load N 15,000/15,000
5.7 Climbing capability with/without load 6.6/10.3
5.8 Maximum climbing capability with/without load 22.1/35.4
5.9 Acceleration time with/without load s on request
Hydraulic/me-
5.10 Service brake
chanical

6.1 Traction motor, power rating S2 60 min kW 2x9

6.2 Lift motor, power rating at S3 15 kW 22
Battery in accordance with DIN 43531/35/36 A, B, C,
6.3 43536 A
no

19 Including a = 200 mm safety distance

20 Including a = 200 mm safety distance

Operating Instructions – 387 801 1501 EN – 04/2012 243

 6.4 Battery voltage, nominal capacity K5 V/Ah 80 V/575–625
6.5 Battery weight (±5 ) kg 1458
Energy consumption in accordance with standardised
6.6 kWh/h 7.3
VDI cycle

Digital con-
8.1 Traction controller type troller/continu-
ously variable
8.2 Working pressure for attachments bar 170
8.3 Oil volume for attachments l/min 50
.

244 Operating Instructions – 387 801 1501 EN – 04/2012

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

2.1 Net weight kg 544521

2.2 Axle load with front/rear load kg 7057/888
2.3 Axle load without front/rear load kg 3070/237522

Tyres: solid rubber, superelastic, pneumatic,

3.1 SE
polyurethane
3.2 Front tyre size 23x9-10
3.3 Rear tyre size 180/60–10
3.5 Number of wheels, front/rear (x = driven) 2x/2
3.6 Front track width b10 [mm] 942
3.7 Rear track width b11 [mm] 900

4.1 Lift mast/fork carriage tilt, forwards/backwards α/β (°) 5.0/8.0

4.2 Height with lift mast retracted h1 [mm] 2297
4.3 Free lift h2 [mm] 150
4.4 Lift h3 [mm] 3200
4.5 Height with lift mast extended h4 [mm] 3975
4.7 Height above overhead guard (cab) h6 [mm] 2237

21 Including battery, line 6.4/6.5

22 Including battery, line 6.4/6.5

Operating Instructions – 387 801 1501 EN – 04/2012 245

4.8 Seat height/standing height h7 [mm] 1160
4.12 Coupling height h10 [mm] 659
4.19 Total length l1 [mm] 3520
4.20 Length including fork back l2 [mm] 2520
4.21 Total width b1/b2 [mm] 1150/1146
4.22 Fork arm dimensions s/e/l [mm] 45 x 100 x 1000
4.23 ISO 2328 fork carriage, class/model A, B 2A
4.24 Fork carriage width b3 [mm] 1150
4.31 Ground clearance with load under lift mast m1 [mm] 127
4.32 Ground clearance at centre of wheelbase m2 [mm] 120
4.33 Aisle width for pallet 1000 x 1200 crosswise Ast [mm] 383823
4.34 Aisle width for pallet 800 x 1200 longitudinal Ast [mm] 396724
4.35 Turning radius Wa [mm] 2052
4.36 Smallest pivot point distance b13 [mm] 0

5.1 Driving speed with/without load km/h 20/20

5.2 Lifting speed with/without load m/s 0.44/0.53
5.3 Lowering speed with/without load m/s 0.56/0.56
5.5 Pulling force with/without load N 4600/4600
5.6 Maximum pulling force with/without load N 15,000/15,000
5.7 Climbing capability with/without load 5.9/8.6
5.8 Maximum climbing capability with/without load 19.6/29.3
5.9 Acceleration time with/without load s on request
Hydraulic/me-
5.10 Service brake
chanical

6.1 Traction motor, power rating S2 60 min kW 2x9

6.2 Lift motor, power rating at S3 15 kW 22
Battery in accordance with DIN 43531/35/36 A, B, C,
6.3 43536 A
no

23 Including a = 200 mm safety distance

24 Including a = 200 mm safety distance

246 Operating Instructions – 387 801 1501 EN – 04/2012

 6.4 Battery voltage, nominal capacity K5 V/Ah 80 V/700–775
6.5 Battery weight (±5 ) kg 1863
Energy consumption in accordance with standardised
6.6 kWh/h 7.9
VDI cycle

Digital con-
8.1 Traction controller type troller/continu-
ously variable
8.2 Working pressure for attachments bar 170
8.3 Oil volume for attachments l/min 50
.

Operating Instructions – 387 801 1501 EN – 04/2012 247

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

2.1 Net weight kg 532525

2.2 Axle load with front/rear load kg 7560/765
2.3 Axle load without front/rear load kg 2810/2515 26

Tyres: solid rubber, superelastic, pneumatic,

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

4.1 Lift mast/fork carriage tilt, forwards/backwards α/β (°) 5.0/8.0

4.2 Height with lift mast retracted h1 [mm] 2223
4.3 Free lift h2 [mm] 150
4.4 Lift h3 [mm] 3050
4.5 Height with lift mast extended h4 [mm] 3826
4.7 Height above overhead guard (cab) h6 [mm] 2080

25 Including battery, line 6.4/6.5

26 Including battery, line 6.4/6.5

248 Operating Instructions – 387 801 1501 EN – 04/2012

4.8 Seat height/standing height h7 [mm] 1002
4.12 Coupling height h10 [mm] 623
4.19 Total length l1 [mm] 3444
4.20 Length including fork back l2 [mm] 2444
4.21 Total width b1/b2 [mm] 1150/1178
4.22 Fork arm dimensions s/e/l [mm] 45 x 100 x 1000
4.23 ISO 2328 fork carriage, class/model A, B 3A
4.24 Fork carriage width b3 [mm] 1150
4.31 Ground clearance with load under lift mast m1 [mm] 136
4.32 Ground clearance at centre of wheelbase m2 [mm] 120
4.33 Aisle width for pallet 1000 x 1200 crosswise Ast [mm] 376227
4.34 Aisle width for pallet 800 x 1200 longitudinal A st [mm] 389128
4.35 Turning radius Wa [mm] 1973
4.36 Smallest pivot point distance b13 [mm] 0

5.1 Driving speed with/without load km/h 20/20

5.2 Lifting speed with/without load m/s 0.42/0.51
5.3 Lowering speed with/without load m/s 0.56/0.56
5.5 Pulling force with/without load N 4600/4600
5.6 Maximum pulling force with/without load N 15,000/15,000
5.7 Climbing capability with/without load 5.6/8.8
5.8 Maximum climbing capability with/without load 18.7/30.0
5.9 Acceleration time with/without load s on request
Hydraulic/me-
5.10 Service brake
chanical

6.1 Traction motor, power rating S2 60 min kW 2x9

6.2 Lift motor, power rating at S3 15 kW 22
Battery in accordance with DIN 43531/35/36 A, B, C,
6.3 43536 A
no

27 Including a = 200 mm safety distance

28 Including a = 200 mm safety distance

Operating Instructions – 387 801 1501 EN – 04/2012 249

 6.4 Battery voltage, nominal capacity K5 V/Ah 80 V/460–500
6.5 Battery weight (+/- 5 ) kg 1210
Energy consumption in accordance with standardised
6.6 kWh/h 8.6
VDI cycle

Digital con-
8.1 Traction controller type troller/continu-
ously variable
8.2 Working pressure for attachments bar 170
8.3 Oil volume for attachments l/min 50
.

250 Operating Instructions – 387 801 1501 EN – 04/2012

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

2.1 Net weight kg 536529

2.2 Axle load with front/rear load kg 7564/801
2.3 Axle load without front/rear load kg 2915/245030

Tyres: solid rubber, superelastic, pneumatic,

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

4.1 Lift mast/fork carriage tilt, forwards/backwards α/β (°) 5.0/8.0

4.2 Height with lift mast retracted h1 [mm] 2222
4.3 Free lift h2 [mm] 150
4.4 Lift h3 [mm] 3050
4.5 Height with lift mast extended h4 [mm] 3825
4.7 Height above overhead guard (cab) h6 [mm] 2080

29 Including battery, line 6.4/6.5

30 Including battery, line 6.4/6.5

Operating Instructions – 387 801 1501 EN – 04/2012 251

4.8 Seat height/standing height h7 [mm] 1002
4.12 Coupling height h10 [mm] 622
4.19 Total length l1 [mm] 3539
4.20 Length including fork back l2 [mm] 2539
4.21 Total width b1/b2 [mm] 1150/1148
4.22 Fork arm dimensions s/e/l [mm] 45 x 100 x 1000
4.23 ISO 2328 fork carriage, class/model A, B 3A
4.24 Fork carriage width b3 [mm] 1150
4.31 Ground clearance with load under lift mast m1 [mm] 136
4.32 Ground clearance at centre of wheelbase m2 [mm] 120
4.33 Aisle width for pallet 1000x1200 crosswise Ast [mm] 385731
4.34 Aisle width for pallet 800x1200 longitudinal Ast [mm] 398632
4.35 Turning radius Wa [mm] 2068
4.36 Smallest pivot point distance b13 [mm] 0

5.1 Driving speed with/without load km/h 20/20

5.2 Lifting speed with/without load m/s 0.42/0.51
5.3 Lowering speed with/without load m/s 0.56/0.56
5.5 Pulling force with/without load N 4600/4600
5.6 Maximum pulling force with/without load N 15,000/15,000
5.7 Climbing capability with/without load 5.6/8.8
5.8 Maximum climbing capability with/without load 18.6/29.7
5.9 Acceleration time with/without load s on request
Hydraulic/me-
5.10 Service brake
chanical

6.1 Traction motor, power rating S2 60 min kW 2x9

6.2 Lift motor, power rating at S3 15 kW 22
Battery in accordance with DIN 43531/35/36 A, B, C,
6.3 43536 A
no

31 Including a = 200 mm safety distance

32 Including a = 200 mm safety distance

252 Operating Instructions – 387 801 1501 EN – 04/2012

 6.4 Battery voltage, nominal capacity K5 V/Ah 80 V/575–625
6.5 Battery weight (±5 ) kg 1458
Energy consumption in accordance with standardised
6.6 kWh/h 8.6
VDI cycle

Digital con-
8.1 Traction controller type troller/continu-
ously variable
8.2 Working pressure for attachments bar 170
8.3 Oil volume for attachments l/min 50
.

Operating Instructions – 387 801 1501 EN – 04/2012 253

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

1.5 Load capacity/load Q [kg] 3000

1.6 Load centre of gravity c [mm] 600

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

2.1 Net weight kg 587033

2.2 Axle load with front/rear load kg 8000/870
2.3 Axle load without front/rear load kg 3045/2825 34

Tyres: solid rubber, superelastic, pneumatic,

3.1 SE
polyurethane
3.2 Tyre size, front 23x10—12
3.3 Tyre size, rear 200/50-10
3.5 Number of wheels, front/rear (x = driven) 2 x/2
3.6 Front track width b10 [mm] 980
3.7 Rear track width b11 [mm] 886

4.1 Mast/fork carriage tilt, forward/backward α/β (°) 5.0/8.0

4.2 Height with lift mast retracted h1 [mm] 2300
4.3 Free lift h2 [mm] 150
4.4 Lift h3 [mm] 3200
4.5 Height with lift mast extended h4 [mm] 3978
4.7 Height above overhead guard (cab) h6 [mm] 2237

33 Including battery, line 6.4/6.5

34 Including battery, line 6.4/6.5

254 Operating Instructions – 387 801 1501 EN – 04/2012

4.8 Seat height/standing height h7 [mm] 1160
4.12 Coupling height h10 [mm] 656
4.19 Total length l1 [mm] 3383
4.20 Length including fork back l2 [mm] 2383
4.21 Total width b1/b2 [mm] 1228/1146
4.22 Fork arm dimensions s/e/l [mm] 50 x 120 x 1000
4.23 ISO 2328 fork carriage, class/model A, B 3A
4.24 Fork carriage width b3 [mm] 1150
4.31 Ground clearance with load under lift mast m1 [mm] 136
4.32 Ground clearance at centre of wheelbase m2 [mm] 120
4.33 Aisle width for pallet 1000 x 1200 crosswise Ast [mm] 370035
4.34 Aisle width for pallet 800 x 1200 longitudinal A st [mm] 383036
4.35 Turning radius Wa [mm] 1907
4.36 Smallest pivot point distance b13 [mm] 0

5.1 Driving speed with/without load km/h 20/20

5.2 Lifting speed with/without load m/s 0.42/0.51
5.3 Lowering speed with/without load m/s 0.56/0.56
5.5 Pulling force with/without load N 4600/4600
5.6 Maximum pulling force with/without load N 15,000/15,000
5.7 Climbing capability with/without load 5.3/8.0
5.8 Maximum climbing capability with/without load 17.5/27.0
5.9 Acceleration time with/without load s on request
Hydraulic/me-
5.10 Service brake
chanical

6.1 Traction motor, power rating S2 60 min kW 2x9

6.2 Lift motor, power rating at S3 15 kW 22
Battery in accordance with DIN 43531/35/36 A, B, C,
6.3 43536 A
no

35 Including a = 200 mm safety distance

36 Including a = 200 mm safety distance

Operating Instructions – 387 801 1501 EN – 04/2012 255

 6.4 Battery voltage, nominal capacity K5 V/Ah 80 V/560–620
6.5 Battery weight (±5 ) kg 1 558
Energy consumption in accordance with standardised
6.6 kWh/h 8.7
VDI cycle

Digital con-
8.1 Traction controller type troller/continu-
ously variable
8.2 Working pressure for attachments bar 170
8.3 Oil volume for attachments l/min 50
.

256 Operating Instructions – 387 801 1501 EN – 04/2012

1.1 Manufacturer (code designation) Linde
1.2 Manufacturer’s type designation E 30/600 HL
1.3 Drive Electric
1.4 Operation Seated
1.5 Load capacity/load Q [kg] 3000
1.6 Load centre of gravity c [mm] 600
1.8 Load distance x [mm] 476
1.9 Wheelbase y [mm] 1796

2.1 Net weight kg 583037

2.2 Axle load with front/rear load kg 7937/893
2.3 Axle load without front/rear load kg 3140/269038

Tyres: solid rubber, superelastic, pneumatic,

3.1 SE
polyurethane
3.2 Tyre size, front 23x10—12
3.3 Tyre size, rear 200/50-10
3.5 Number of wheels, front/rear (x = driven) 2 x/2
3.6 Front track width b10 [mm] 980
3.7 Rear track width b11 [mm] 886

4.1 Lift mast/fork carriage tilt, forwards/backwards α/β (°) 5.0/8.0

4.2 Height with lift mast retracted h1 [mm] 2299
4.3 Free lift h2 [mm] 150
4.4 Lift h3 [mm] 3200
4.5 Height with lift mast extended h4 [mm] 3977
4.7 Height above overhead guard (cab) h6 [mm] 2237

37 Including battery, line 6.4/6.5

38 Including battery, line 6.4/6.5

Operating Instructions – 387 801 1501 EN – 04/2012 257

4.8 Seat height/standing height h7 [mm] 1160
4.12 Coupling height h10 [mm] 661
4.19 Total length l1 [mm] 3528
4.20 Length including fork back l2 [mm] 2528
4.21 Total width b1/b2 [mm] 1228/1146
4.22 Fork arm dimensions s/e/l [mm] 50 x 120 x 1000
4.23 ISO 2328 fork carriage, class/model A, B 3A
4.24 Fork carriage width b3 [mm] 1150
4.31 Ground clearance with load under lift mast m1 [mm] 136
4.32 Ground clearance at centre of wheelbase m2 [mm] 120
4.33 Aisle width for pallet 1000x1200 crosswise Ast [mm] 384539
4.34 Aisle width for pallet 800x1200 longitudinal Ast [mm] 397540
4.35 Turning radius Wa [mm] 2052
4.36 Smallest pivot point distance b13 [mm] 0

5.1 Driving speed with/without load km/h 20/20

5.2 Lifting speed with/without load m/s 0.42/0.51
5.3 Lowering speed with/without load m/s 0.56/0.56
5.5 Pulling force with/without load N 4600/4600
5.6 Maximum pulling force with/without load N 15,000/15,000
5.7 Climbing capability with/without load 5.3/8.1
5.8 Maximum climbing capability with/without load 17.6/27.2
5.9 Acceleration time with/without load s on request
Hydraulic/me-
5.10 Service brake
chanical

6.1 Traction motor, power rating S2 60 min kW 2x9

6.2 Lift motor, power rating at S3 15 kW 22
Battery in accordance with DIN 43531/35/36 A, B, C,
6.3 43536 A
no

39 Including a = 200 mm safety distance

40 Including a = 200 mm safety distance

258 Operating Instructions – 387 801 1501 EN – 04/2012

 6.4 Battery voltage, nominal capacity K5 V/Ah 80 V/700–775
6.5 Battery weight (+/- 5 ) kg 1863
Energy consumption in accordance with standardised
6.6 kWh / h 8.7
VDI cycle

Digital con-
8.1 Traction controller type troller/continu-
ously variable
8.2 Working pressure for attachments bar 170
8.3 Oil volume for attachments l/min 50
.

Operating Instructions – 387 801 1501 EN – 04/2012 259

1.1 Manufacturer (code designation) Linde
1.2 Manufacturer’s type designation E 35/500 L
1.3 Drive Electric
1.4 Operation Seated
1.5 Load capacity/load Q [kg] 3500
1.6 Load centre of gravity c [mm] 500
1.8 Load distance x [mm] 476
1.9 Wheelbase y [mm] 1810

2.1 Net weight kg 570541

2.2 Axle load with front/rear load kg 8422/783
2.3 Axle load without front/rear load kg 3035/2670 42

Tyres: solid rubber, superelastic, pneumatic,

3.1 SE
polyurethane
3.2 Tyre size, front 315/45-12
3.3 Tyre size, rear 200/50-10
3.5 Number of wheels, front/rear (x = driven) 2 x/2
3.6 Front track width b10 [mm] 1028
3.7 Rear track width b11 [mm] 886

4.1 Lift mast/fork carriage tilt, forwards/backwards α/β (°) 5.0/8.0

4.2 Height with lift mast retracted h1 [mm] 2220
4.3 Free lift h2 [mm] 150
4.4 Lift h3 [mm] 3050
4.5 Height with lift mast extended h4 [mm] 3823
4.7 Height above overhead guard (cab) h6 [mm] 2237

41 Including battery, line 6.4/6.5

42 Including battery, line 6.4/6.5

260 Operating Instructions – 387 801 1501 EN – 04/2012

4.8 Seat height/standing height h7 [mm] 1002
4.12 Coupling height h10 [mm] 626
4.19 Total length l1 [mm] 3594
4.20 Length including fork back l2 [mm] 2594
4.21 Total width b1/b2 [mm] 1322/1178
4.22 Fork arm dimensions s/e/l [mm] 50 x 120 x 1000
4.23 ISO 2328 fork carriage, class/model A, B 3A
4.24 Fork carriage width b3 [mm] 1150
4.31 Ground clearance with load under lift mast m1 [mm] 129
4.32 Ground clearance at centre of wheelbase m2 [mm] 120
4.33 Aisle width for pallet 1000 x 1200 crosswise Ast [mm] 391143
4.34 Aisle width for pallet 800 x 1200 longitudinal A st [mm] 404144
4.35 Turning radius Wa [mm] 2118
4.36 Smallest pivot point distance b13 [mm] 0

5.1 Driving speed with/without load km/h 20/20

5.2 Lifting speed with/without load m/s 0.39/0.51
5.3 Lowering speed with/without load m/s 0.56/0.56
5.5 Pulling force with/without load N 4600/4600
5.6 Maximum pulling force with/without load N 15,000/15,000
5.7 Climbing capability with/without load 5.1/8.2
5.8 Maximum climbing capability with/without load 16.8/27.8
5.9 Acceleration time with/without load s on request
Hydraulic/me-
5.10 Service brake
chanical

6.1 Traction motor, power rating S2 60 min kW 2 x 9.0

6.2 Lift motor, power rating at S3 15 kW 22
Battery in accordance with DIN 43531/35/36 A, B, C,
6.3 43536 A
no

43 Including a = 200 mm safety distance

44 Including a = 200 mm safety distance

Operating Instructions – 387 801 1501 EN – 04/2012 261

 6.4 Battery voltage, nominal capacity K5 V/Ah 80 V/575–625
6.5 Battery weight (+/- 5 ) kg 1458
Energy consumption in accordance with standardised
6.6 kWh/h 9.5
VDI cycle

Digital con-
8.1 Traction controller type troller/continu-
ously variable
8.2 Working pressure for attachments bar 170
8.3 Oil volume for attachments l/min 50
.

262 Operating Instructions – 387 801 1501 EN – 04/2012

1.1 Manufacturer (code designation) Linde
1.2 Manufacturer’s type designation E 35/500 HL
1.3 Drive Electric
1.4 Operation Seated
1.5 Load capacity/load Q [kg] 3500
1.6 Load centre of gravity c [mm] 500
1.8 Load distance x [mm] 476
1.9 Wheelbase y [mm] 1796

2.1 Net weight kg 598545

2.2 Axle load with front/rear load kg 8547/938
2.3 Axle load without front/rear load kg 3145/284046

Tyres: solid rubber, superelastic, pneumatic,

3.1 SE
polyurethane
3.2 Tyre size, front 315/45-12
3.3 Tyre size, rear 200/50-10
3.5 Number of wheels, front/rear (x = driven) 2 x/2
3.6 Front track width b10 [mm] 1028
3.7 Rear track width b11 [mm] 886

4.1 Lift mast/fork carriage tilt, forwards/backwards α/β (°) 5.0/8.0

4.2 Height with lift mast retracted h1 [mm] 2295
4.3 Free lift h2 [mm] 150
4.4 Lift h3 [mm] 3200
4.5 Height with lift mast extended h4 [mm] 3973
4.7 Height above overhead guard (cab) h6 [mm] 2237

45 Including battery, line 6.4/6.5

46 Including battery, line 6.4/6.5

Operating Instructions – 387 801 1501 EN – 04/2012 263

4.8 Seat height/standing height h7 [mm] 1160
4.12 Coupling height h10 [mm] 659
4.19 Total length l1 [mm] 3528
4.20 Length including fork back l2 [mm] 2528
4.21 Total width b1/b2 [mm] 1322/1146
4.22 Fork arm dimensions s/e/l [mm] 50 x 120 x 1000
4.23 ISO 2328 fork carriage, class/model A, B 3A
4.24 Fork carriage width b3 [mm] 1150
4.31 Ground clearance with load under lift mast m1 [mm] 129
4.32 Ground clearance at centre of wheelbase m2 [mm] 120
4.33 Aisle width for pallet 1000 x 1200 crosswise Ast [mm] 384547
4.34 Aisle width for pallet 800 x 1200 longitudinal Ast [mm] 397548
4.35 Turning radius Wa [mm] 2052
4.36 Smallest pivot point distance b13 [mm] 0

5.1 Driving speed with/without load km/h 20/20

5.2 Lifting speed with/without load m/s 0.39/0.51
5.3 Lowering speed with/without load m/s 0.56/0.56
5.5 Pulling force with/without load N 4600/4600
5.6 Maximum pulling force with/without load N 15,000/15,000
5.7 Climbing capability with/without load 4.9/7.9
5.8 Maximum climbing capability with/without load 16.3/26.4
5.9 Acceleration time with/without load s on request
Hydraulic/me-
5.10 Service brake
chanical

6.1 Traction motor, power rating S2 60 min kW 2x9

6.2 Lift motor, power rating at S3 15 kW 22
Battery in accordance with DIN 43531/35/36 A, B, C,
6.3 43536 A
no

47 Including a = 200 mm safety distance

48 Including a = 200 mm safety distance

264 Operating Instructions – 387 801 1501 EN – 04/2012

 6.4 Battery voltage, nominal capacity K5 V/Ah 80 V/700–775
6.5 Battery weight (±5 ) kg 1863
Energy consumption in accordance with standardised
6.6 kWh / h 9.8
VDI cycle

Digital con-
8.1 Traction controller type troller/continu-
ously variable
8.2 Working pressure for attachments bar 170
8.3 Oil volume for attachments l/min 50
.

Operating Instructions – 387 801 1501 EN – 04/2012 265

If attachments and conversions are required,
please contact your authorised dealer. A new
truck configuration sign must then be created
and attached to the truck by the authorised
dealer.

1 Frame number
2 Lift mast number or
identification: CO
3 Capacity rating plate number
4 Maximum permissible forwards/backwards tilt angle
5 Attachment:
GTR/FC/PF means fork carriage
ISS/ISS/TI means integrated sideshift
IZVG/IFP/IPF means integrated fork prong positioner
CO/CO/CO means customer-specific option (without attachment)
6 Lift mast series/version:
St means standard lift mast
Du means duplex lift mast
Tr means triplex lift mast
CO
7 Lift height in mm or
identification: CO
8 Front tyres:
SE/SE/SE means solid rubber tyres
SE Zw./SE tw./SE jum. means solid rubber dual tyres
Luft/Pneu./Gonf. means pneumatic tyres
Luft Zw./Pneu. tw./Gonf. jum. means pneumatic dual tyres
Bandage/Cushion/Bandage means bandage tyres
9 Placeholder for data-matrix code
CO means customer-specific option (without lift mast or with released non-original lift mast)
.

266 Operating Instructions – 387 801 1501 EN – 04/2012

Operating Instructions – 387 801 1501 EN – 04/2012 267
268 Operating Instructions – 387 801 1501 EN – 04/2012
 h
Lift 3150 3450 3750 4050 4550 3050 3200 3650 4050 4450 4950
3
Lift mast h
2247 2397 2547 2697 2947 2225 2300 2524 2724 2924 3174
retracted 1
Lift mast h
3813 4113 4413 4713 5213 3828 3978 4428 4828 5228 5728
extended 4
Free lift h
150 150 150 150 150 150 150 150 150 150 150
2

h
Lift 3170 3770 2925 3215 3765 4065
3
Lift mast h
2174 2474 2081 2226 2501 2651
retracted 1
Lift mast h
3832 4432 3652 3942 4442 4742
extended 4
Free lift h
1511 1811 1274 1424 1674 1824
2

Lift h 3 4715 4865 5165 5515 5965 6465 4350 4780 5355 5955 6455
Lift mast
h 1 2174 2224 2324 2474 2624 2824 2074 2224 2449 2649 2849
retracted
Lift mast h4
5378 5528 5828 6178 6628 7128 5125 5555 6130 6730 7230
extended
Free lift h 2 1511 1561 1661 1811 1961 2161 1299 1449 1674 1874 2074
.

Operating Instructions – 387 801 1501 EN – 04/2012 269

If the label is missing or if the information about
the truck equipment, attachments, load data etc.
is not accurate, please contact your authorised
dealer, who will calculate the data using a program
authorised by Linde.

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

Example for reading the load capacity:

• a = 3930 kg at load centre of gravity b =
900 mm to lift height c = 7200 mm.

270 Operating Instructions – 387 801 1501 EN – 04/2012

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

Example for reading the load capacity:

• a = 4340 kg at load centre of gravity b =
650 mm to lift height c = 6800 mm.

The values were determined according equipment according to the type sheet (driving
to EN 13059 using trucks with standard over test course with humps).

Operating Instructions – 387 801 1501 EN – 04/2012 271

Measured The vibration characteristic for bodily vibrati-
vibration aW,ZS = < 0.5 m/s2 ons cannot be used to determine the actual
characteristic vibration load during operation. This depends
on the application conditions (state of road-
way, method of operation etc.) and should
therefore be determined on site where appro-
Vibration characteristic < 2.5 m/s2 priate. It is mandatory to specify the hand-arm
vibrations even where the values do not indi-
cate any hazard, as in this case.

Calculated in the test cycle in accordance

with EN 12053 from the weighted values for
the TRACTION, LIFT and IDLING operating Lower or higher noise emission values may
states. occur when using industrial trucks, e.g. due
to the method of operation, factors in the
surrounding area and other sources of noise.

E 20 - E 35 LPAZ = 66 dB (A)
Insecurity KPA = 4 dB (A)

272 Operating Instructions – 387 801 1501 EN – 04/2012

 Before load pick up . . . . . . . . . . . . . . . . 112
Brake system . . . . . . . . . . . . . . . . . . . . . 51
Accumulator . . . . . . . . . . . . . . . . . . . . . 17
Checking . . . . . . . . . . . . . . . . . . . . 163
Active charging ventilation unit
Brakes . . . . . . . . . . . . . . . . . . . . ....... 6
with an integrated battery charger . . 173
without an integrated battery
charger . . . . . . . . . . . . . . . . . . . 174
Actuating the fork arm positioner Changing the breather filter . . . . . . . . . 195
Single lever operation . . . . . . . . . . . . 84 Changing the drive direction . . . . . . . 46, 49
Additional capacity rating plate for Changing the hydraulic oil . . . . . . . . . . 193
attachments . . . . . . . . . . . . . . . . 270 Changing the oil in the planetary
with loads that are fixed or clamped . 271 transmission . . . . . . . . . . . . . . . 143
with loads that are not clamped . . . . 270 Changing the suction filter . . . . . . . . . . 199
Adjust fork arm distance . . . . . . . . . . . . 112 Charging interruption . . . . . . . . . . . . . . 107
Adjust lift mast chain Charging the battery . . . . . . . . . . . . . . . 169
Duplex or triplex lift mast . . . . . . . . . 207 Charging the battery using an external
battery charger . . . . . . . . . . . . . . 171
Standard lift mast . . . . . . . . . . . . . . 206
Check and oil other bearings and joints . 153
Adjust the seat angle . . . . . . . . . . . . . . . 71
Check bellows on joystick . . . . . . . . . . . 166
Adjust the seat back . . . . . . . . . . . . . . . . 72
Check fork arm safety devices . . . . . . . 209
Adjust the seat height . . . . . . . . . . . . . . . 71
Check fork arms . . . . . . . . . . . . . . . . . . 209
Adjusting the backrest extension . . . . . . 72
Check the tension of double hoses . . . . 200
Adjusting the driver’s seat . . . . . . . . . . . . 35
Check the tilt cylinder bearings for wear . 151
Adjusting the driver’s seat equipped
with air suspension . . . . . . . . . . . . 70 Checking and oiling the pedal group
and linkage . . . . . . . . . . . . . . . . 167
Adjusting the driver’s seat with rotating
device . . . . . . . . . . . . . . . . . . . . . 73 Checking slide guides on sideshift for
wear . . . . . . . . . . . . . . . . . . . . . 213
Adjusting the lumbar support . . . . . . 37, 72
Checking the battery charge status . . . . 168
Adjusting the seat backrest . . . . . . . . . . . 36
Checking the breather filter for leaks . . . 195
Adjusting the steering column . . . . . . . . . 38
Checking the condition and secure po-
Applying the parking brake manually . . . . 53
sitioning of electric cables, cable
Attachments connectors and connections . . . . 189
Instructions for fitting . . . . . . . . . . . . . 17 Checking the condition of the antistatic
Automatic brake belt . . . . . . . . . . . . . . . . . . . . . . 160
Checking . . . . . . . . . . . . . . . . . . . . 164 Checking the control unit for correct
function . . . . . . . . . . . . . . . . . . . 196
Checking the drive axle heat sinks
Battery charger for contamination, cleaning if
necessary . . . . . . . . . . . . . . . . . 162
Charge indicators . . . . . . . . . . . . . . 108
Checking the fans for function and
Mains supply . . . . . . . . . . . . . . . . . . 105
contamination, and cleaning if
Battery charger LPS-80/75 . . . . . . . . . . 102 necessary . . . . . . . . . . . . . . . . . 185
Battery grease . . . . . . . . . . . . . . . . . . . 126 Checking the hydraulic system for
Battery replacement . . . . . . . . . . . . . . . 175 leaks . . . . . . . . . . . . . . . . . . . . . 192
Before exiting the truck . . . . . . . . . . . . . 118 Checking the main contactor . . . . . . . . 182

Operating Instructions – 387 801 1501 EN – 04/2012 273

Checking the mounting, condition and Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
correct function of lift mast, lift Driving
mast chains, lift cylinders and
Dual-pedal operation . . . . . . . . . . . . . 44
end stops. . . . . . . . . . . . . . . . . . 209
Single-pedal operation . . . . . . . . . . . 47
Checking the mountings . . . . . . . . . . . . 146
under load . . . . . . . . . . . . . . . . . . . 114
Checking the oil level . . . . . . . . . . . . . . 190
without lift mast . . . . . . . . . . . . . . . . 119
Checking the oil level of the hydraulic
power unit . . . . . . . . . . . . . . . . . 180 Driving speed reduction
Checking the planetary transmission via a switch . . . . . . . . . . . . . . . . . . . . 77
for leaks. . . . . . . . . . . . . . . . . . . 142 Duplex lift mast . . . . . . . . . . . . . . . . . . 202
Checking the planetary transmission Securing the raised mast . . . . . . . . . 203
oil level . . . . . . . . . . . . . . . . . . . 140
Checking the tyres (air pressure, size,
rims) E 20/500 type sheet, as at 02/2011 . . . . 230
Checking the tyres for damage and E 20/600H type sheet, as at 02/2011 . . . 233
foreign objects . . . . . . . . . . . . . . 154
E 25/500 L type sheet, as at 02/2011 . . . 242
Checks
E 25/500 type sheet, as at 02/2011 . . . . 236
Before starting work . . . . . . . . . . . . . 33
E 25/600 H type sheet, as at 02/2011 . . 239
Cleaning . . . . . . . . . . . . . . . . . . . . . . . 161
E 25/600 HL type sheet, as at 02/2011 . 245
Fork prong positioner . . . . . . . . . . . 211
E 30/500 L type sheet, as at 02/2011 . . . 251
Sideshift . . . . . . . . . . . . . . . . . . . . . 210
E 30/500 type sheet, as at 02/2011 . . . . 248
Cleaning and lubricating the combined
E 30/600 H type sheet, as at 02/2011 . . 254
axle . . . . . . . . . . . . . . . . . . . . . . 161
E 30/600 HL type sheet, as at 02/2011 . 257
Cleaning and lubricating the sideshift
E 35/500 HL type sheet, as at 02/2011 . 263
Checking the fastening . . . . . . . . . . 210
E 35/500 L type sheet, as at 02/2011 . . . 260
Cleaning the fan for the battery-
charging function . . . . . . . . . . . . 188 EC declaration of conformity . . . . . . . . . . . 9
Cleaning the industrial truck . . . . . . . . . 147 Electric regenerative brake . . . . . . . . . . . 52
Cleaning the lift mast chain and Electrical system . . . . . . . . . . . . . . . . . . . 7
spraying with chain spray . . . . . . 206 Emergency exit with attached rear
Climatic conditions . . . . . . . . . . . . . . . . . . 5 window . . . . . . . . . . . . . . . . . . . . 15
Combined axle . . . . . . . . . . . . . . . . . . . 161 Emergency off switch . . . . . . . . . . . . . . . 70
Competent person . . . . . . . . . . . . . . . . . 16 End of charging . . . . . . . . . . . . . . . . . . 107
Consumables . . . . . . . . . . . . . . . . . . . . 15 Entering the truck . . . . . . . . . . . . . . . . . . 33
Crane loading with lifting eyes . . . . . . . . 121 Equalising and maintenance charges . . 108
Error messages . . . . . . . . . . . . . . . . . . 109
Exiting the truck . . . . . . . . . . . . . . . . . . . 33
Depressurisation . . . . . . . . . . . . . . . 17, 86 Extending the battery . . . . . . . . . . . . . . 179
Description of use . . . . . . . . . ......... 5
Diagnostic connector . . . . . . . . . . . . . . 222
Dismantling the lift mast . . . . . . . . . . . . 118 Fire extinguisher . . . . . . . . . . . . . . . . . . 13
Display unit . . . . . . . . . . . . . . . . . . . . . . 24 Fork arm adjustment device
Disposal of old trucks . . . . . . . . . . . . . . 228 Check wear and tear . . . . . . . . . . . . 213
Fork carriage emergency lowering . . . . . 18

274 Operating Instructions – 387 801 1501 EN – 04/2012

Fork prong positioner Lifting system and attachments
Cleaning and lubricating, checking Single lever operation with 3rd aux-
the mounting . . . . . . . . . . . . . . . 211 iliary hydraulics . . . . . . . . . . . . . . 78
Forklift Data Management . . . . . . . . . . . 96 Lifting the fork carriage
Forward travel . . . . . . . . . . . . . . . . . 46, 49 Central-lever operation . . . . . . . . . . . 58
Front wheel change . . . . . . . . . . . . . . . 158 Single lever operation . . . . . . . . . . . . 79
Fuses Single-lever operation . . . . . . . . . . . . 64
Basic equipment . . . . . . . . . . . . . . . 215 Lighting . . . . . . . . . . . . . . . . . . . . . . . . . 88
Main current fuses . . . . . . . . . . . . . . 216 Load capacity diagrams . . . . . . . . . . . . 267
Special equipment . . . . . . . . . . . . . 217 Load pick up . . . . . . . . . . . . . . . . . . . . 114
Lowering the fork carriage
Central-lever operation . . . . . . . . . . . 58
General . . . . . . . . . . . . . . . . . . . . . . . . 168 Single lever operation . . . . . . . . . . . . 79
General remarks . . . . . . . . . . . . . . . . . 124 Single-lever operation . . . . . . . . . . . . 64
Lubricating . . . . . . . . . . . . . . . . . . . . . . 161

Handling consumables . . . . . . . . . . . . . . 15
Heating system . . . . . . . . . . . . . . . . . . . 94 Maintenance data . . . . . . . . . . . . . . . . 125
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Maintenance intervals . . . . . . . . . . . . . 124
Hydraulic power unit technical data . . . . 181 Malfunctions during operation . . . . . . . . 214
Hydraulic system . . . . . . . . . . . . . . . . . .. 6 MAXI fuses . . . . . . . . . . . . . . . . . . . . . 221
Checking the oil level . . . . . . . . . . . . 190 Measures prior to shutdown . . . . . . . . . 227

Identification plate . . . . . . . . . . . . . . . . . 20 Noise emission values . . . . . . . . . . . . . 272

Impermissible use . . . . . . . . . . . . . . . . . . 4
Inspection data . . . . . . . . . . . . . . . . . . 125
Instructions for running-in . . . . . . . . . . . . 32 Opening and closing the battery hood . . 148
Integrated charger . . . . . . . . . . . . . . . . 102 Operating attachments
Intended use . . . . . . . . . . . . . . . . . . . . . . 3 Single lever operation . . . . . . . . . . . . 81
Operating devices . . . . . . . . . . . . . . . . . 23
Operating the attachments
Joystick Central-lever operation . . . . . . . . . . . 58
Central-lever operation . . . . . . . . . . . 57 Single-lever operation . . . . . . . . . . . . 65
Single-lever operation . . . . . . . . . . . . 63 Operating the clamp
Central-lever operation . . . . . . . . . . . 60
Single lever operation . . . . . . . . . . . . 85
Legal requirements for placing on the Single-lever operation . . . . . . . . . . . . 66
market . . . . . . . . . . . . . . . . . . . . . . 9 Operating the fork prong positioner
Lift height restriction . . . . . . . . . . . . . . . . 76 Central-lever operation . . . . . . . . . . . 60
Lift mast data . . . . . . . . . . . . . . . . . . . . 268 Single-lever operation . . . . . . . . . . . . 66
Lift mast positioning . . . . . . . . . . . . . . . . 74

Operating Instructions – 387 801 1501 EN – 04/2012 275

Operating the lift and tilt attachments Reverse travel . . . . . . . . . . . . . . . . . 46, 49
Single-lever operation . . . . . . . . . . . . 57 Rim sizes . . . . . . . . . . . . . . . . . . . . . . . 156
Operating the sideshift
Central-lever operation . . . . . . . . . . . 59
Single lever operation . . . . . . . . . . . . 83 Safety guidelines . . . . . . . . . . . . . . . . . . 12
Single-lever operation . . . . . . . . . . . . 66 Safety information . . . . . . . . . . . . . . . . . 12
Operation . . . . . . . . . . . . . . . . . . . . . . . . 6 active medical equipment . . . . . . . . . 13
Other cleaning and greasing . . . . . . . . . 153 Driver’s field of vision . . . . . . . . . . . . . 13
Gas springs . . . . . . . . . . . . . . . . . . . 13
Speed reduction . . . . . . . . . . . . . . . . 13
Parking brake Welding operations . . . . . . . . . . . . . . 12
Checking . . . . . . . . . . . . . . . . . . . . 165 Seat belt
Parking the truck securely . . . . . . . . . . 118 Checking the condition and correct
Periodic safety inspection . . . . . . . . . . . . 16 function . . . . . . . . . . . . . . . . . . . 150
Pneumatic tyres Fastening . . . . . . . . . . . . . . . . . . . . . 40
Checking the tyre pressures . . . . . . 155 Open . . . . . . . . . . . . . . . . . . . . . . . . 41
Seat heater . . . . . . . . . . . . . . . . . . . . . . 71
Securing the lift mast from tilting back . . 201
Rear lights . . . . . . . . . . . . . . . . . . . . . . . 91 Service brake
Rear wheel change . . . . . . . . . . . . . . . 159 Checking . . . . . . . . . . . . . . . . . . . . 163
Receiving the industrial truck . . . . . . . . . . 8 Service brake via the stop pedal . . . . . . . 51
Recommendations for consumables Service plan
Chain spray . . . . . . . . . . . . . . . . . . 126 1000 h . . . . . . . . . . . . . . . . . . . . . . 132
Electric cleaner . . . . . . . . . . . . . . . . 127 3000 h . . . . . . . . . . . . . . . . . . . . . . 134
Gearbox oil . . . . . . . . . . . . . . . . . . . 126 6000 h . . . . . . . . . . . . . . . . . . . . . . 137
Grease . . . . . . . . . . . . . . . . . . . . . . 126 after 50 hours . . . . . . . . . . . . . . . . . 128
Hydraulic oil . . . . . . . . . . . . . . . . . . 126 before initial commissioning . . . . . . . . 32
Regenerative brake Before starting work . . . . . . . . . . . . . 33
Checking . . . . . . . . . . . . . . . . . . . . 164 Once after 1000 hours . . . . . . . . . . . 130
Regulations . . . . . . . . . . . . . . . . . . . . . . 16 Setting down loads . . . . . . . . . . . . . . . . 116
Replacing a battery using a truck and a Setting the driver’s weight . . . . . . . . . 36, 70
battery removal tool . . . . . . . . . . 177 Shutdown of forklift truck . . . . . . . . . . . 227
Replacing the battery using a crane Stability . . . . . . . . . . . . . . . . . . . . . . . . . 14
and C hooks . . . . . . . . . . . . . . . . 177 Standard lift mast . . . . . . . . . . . . . . . . . 201
Replacing the battery using a lateral Securing the raised mast . . . . . . . . . 202
hydraulic battery carrier (special
Start of charging . . . . . . . . . . . . . . . . . . 106
equipment) . . . . . . . . . . . . . . . . 179
Start-up after shutdown . . . . . . . . . . . . 227
Replacing the battery with the truck
and a battery support (special Steering . . . . . . . . . . . . . . . . . . . . . . . . . . 6
equipment) . . . . . . . . . . . . . . . . 178 Steering angle display . . . . . . . . . . . . . . 76
Replacing the high-pressure filter . . . . . 197 Steering system . . . . . . . . . . . . . . . . . . . 50
Residual risks . . . . . . . . . . . . . . . . . . . . 13 Switch panel . . . . . . . . . . . . . . . . . . . . . 30
Retracting the battery . . . . . . . . . . . . . . 180 Switching on the clipboard light . . . . . . . . 88

276 Operating Instructions – 387 801 1501 EN – 04/2012

Switching on the direction indicators . . . . 90 Towing device . . . . . . . . . . . . . . . . . . . 117
Switching on the front working spotlights . 88 Transportation by lorry or low loading
Switching on the hazard warning system . 89 trucks . . . . . . . . . . . . . . . . . . . . 121
Switching on the interior lighting . . . . . . . 88 Triplex lift mast . . . . . . . . . . . . . . . . . . . 203
Switching on the rear window heating . . . 93 Securing the raised mast . . . . . . . . . 204
Switching on the rear working spotlights . 89 Truck
Switching on the rotating beacon / Switching off . . . . . . . . . . . . . . . . . . . 43
flashing beacon . . . . . . . . . . . . . . 89 Switching on . . . . . . . . . . . . . . . . . . . 42
Switching on the seat heater . . . . . . . 37, 95 Truck configuration sign . . . . . . . . . . . . 266
Switching on the side lights, dipped Truck data acquisition
beams and licence plate lamp . . . . 88 Logging off . . . . . . . . . . . . . . . . 99 – 100
Switching on the working spotlights for Logging on and starting . . . . . . . . 97, 99
reverse travel . . . . . . . . . . . . . . . . 89
PIN . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . 5
Status code . . . . . . . . . . . . . . . . . . . . 96
Switching off . . . . . . . . . . . . . . . 99, 101
via RFID chip or magnetic strip card . . 99
Technical description . . . . . . . . . . . . . ... 6
Via the keypad . . . . . . . . . . . . . . . . . 96
Tightening the lift mast fastening . . . . . . 205
Truck overview . . . . . . . . . . . . . . . . . . . 22
Tightening the wheel fastenings . . . . . . 159
Tyres made of solid material . . . . . . . . . 156
Tilt the lift mast forward.
Single lever operation . . . . . . . . . . . . 80
Tilting the lift mast back Ventilation
Central-lever operation . . . . . . . . . . . 58
Switching on . . . . . . . . . . . . . . . . . . . 94
Single-lever operation . . . . . . . . . . . . 64
Vibration characteristics . . . . . . . . . . . . 271
Tilting the lift mast backwards
Single lever operation . . . . . . . . . . . . 80
Tilting the lift mast forwards Warnings . . . . . . . . . . . . . . . . . . . . . . ... 5
Central-lever operation . . . . . . . . . . . 58 Washer system (special equipment)
Single-lever operation . . . . . . . . . . . . 64 Filling up the water tank . . . . . . . . . . 210
Time Wheel change . . . . . . . . . . . . . . . . . . . 158
Setting . . . . . . . . . . . . . . . . . . . . . . . 39 Working on the lift mast and at the front
Tip-over of the truck . . . . . . . . . . . . . . . . 14 of the truck . . . . . . . . . . . . . . . . . 201
Towing . . . . . . . . . . . . . . . . . . . . . . . . 223

Operating Instructions – 387 801 1501 EN – 04/2012 277

387 801 1501 EN – 04/2012