Powertrain:
Engine (LPG), ignition system, LPG fuel system, traction motor, generator
Hydraulics:
Lift mast hydraulics, auxiliary hydraulics, hydraulic circuit diagrams (standard and proportional), hydraulic system maintenance
Electrical:
Electrical system overview, circuit diagrams, fuse assignment, electrical system cleaning, working on electrical equipment, traction motor and generator brush maintenance
Chassis And Body:
Driver's compartment (single pedal, dual pedal, joystick), steering system, chassis components, front and rear covers, floor plate
Braking System:
Service brake operation, parking brake operation and adjustment, brake fluid level, brake system checks
Operator Controls And Displays:
Control console layout, joystick operation, single-lever operation, pedal operation, display elements, fault displays, driver's seat adjustment, steering column adjustment
Attachments And Accessories:
Attachment overview, accessory overview, assembling attachments, controlling attachments (multi-lever, joystick, single-lever), operation of additional equipment (lighting, hazard warning, indicators, wipers)
Safety Equipment:
Restraining belt, safety inspections, safety regulations, hazard identification and countermeasures, residual risks
Pre Operation Checks:
Visual inspections, coolant level, motor oil level, tire condition, LPG valve operation, fuel tank shut-off valve operation
Start Up And Operation:
Key switch operation, engine starting, horn operation, brake system check, steering system check, emergency stop function check, traction program settings, driving procedures (various control types), lifting, load handling, trailer operation
Maintenance Scheduling:
Scheduled maintenance intervals (50, 500, 1000, 3000, 9000, 10-year), break-in period maintenance
Routine Maintenance Tasks:
Carbon brush checks, filter cleaning and replacement (air, LPG), lubrication of joints and controls, fluid level checks (coolant, oil, brake fluid), tire and wheel servicing, battery servicing, fuse replacement, mast bearing lubrication, fork arm checks
Major Maintenance Tasks:
Engine oil and filter change, spark plug replacement, ribbed V-belt and toothed belt checks/replacement, LPG system overhaul, hydraulic oil and filter change, transmission oil change, wheel bearing checks, coolant change
Troubleshooting And Diagnostics:
Fault displays and messages (e.g., SAFETY BELT, AIR FILTER, OIL PRESSURE), emergency shutdown, procedure if truck tips over, emergency lowering
Refueling And Battery Handling:
LPG cylinder change, LPG tank filling, battery acid handling, consumable disposal
Storage And Decommissioning:
Parking securely, measures for prolonged shutdown, start-up after shutdown
Depth:
Comprehensive, covering operation, daily checks, scheduled maintenance, and technical specifications with detailed diagrams.
Diagrams Quality:
High quality illustrated diagrams including circuit diagrams for hydraulics and electrics.
Diagnostic Level:
Includes guidance on interpreting fault displays and basic troubleshooting for common issues.
Repair Scope:
Covers procedures for component removal, installation, cleaning, lubrication, adjustment, and replacement of wear parts.
Ec Conformity:
EC Declaration of Conformity and EC Mark of Conformity are mentioned in the Foreword.
Operational Safety:
Essentials for safe operation, safety regulations for driving, lifting, load handling, and attachments.
Emergency Systems:
Emergency stop function, emergency shutdown procedure, procedure if truck tips over, emergency lowering.
Operator Protection:
Restraining belt, driver's seat, operator compartment design, handling of hazardous substances (battery acid, coolant).
Inspection Requirements:
Periodic safety inspection of the industrial truck, regular checks of fuel gas system, exhaust emissions, and insulation testing.
Risk Assessment:
Overview of hazards and countermeasures, residual risks, special risks when using forklift and attachments.
Initial Service:
Maintenance after first 50 operating hours (break-in period).
Frequent Intervals:
500-hour / semi-annual maintenance, 1000-hour / annual maintenance.
Long Term Intervals:
3000-hour / two-year maintenance, 9000-hour / five-year maintenance, 10-year maintenance.
Engine Oil:
Specific grade and capacity detailed in Technical Data and Maintenance sections; requires API classification suitable for LPG engines. Exact spec needs reference to manual's tables.
Hydraulic Fluid:
Specific type (e.g., ISO VG) and capacity required, detailed in Technical Data and Maintenance. Must be compatible with seals and operating temperatures.
Coolant:
Recommended mixture of antifreeze and water, with specific concentration requirements mentioned for optimal protection against freezing and corrosion.
Brake Fluid:
DOT 3 or DOT 4 (typical for industrial equipment), specific requirement to be confirmed in Technical Data section.
Transmission Oil:
Specific type and capacity for hydrostatic or electric drive system, as detailed in Technical Data.
Common Wear Items:
Traction motor carbon brushes, air filters, LPG filters, hydraulic filters, wear on mast bearings and load chains are typically addressed by the scheduled maintenance.
Troubleshooting Areas:
The manual covers fault displays for common issues like low oil pressure, coolant temperature/level, and motor brush wear, providing initial diagnostic steps.
