Linde H 25 - 04, H 30 - 04 Operating Instructions

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Page 1

With Deutz Engine

351 807 1301 GB

Linde Fork Lift Truck

H 25 - 04 / H 30 - 04

Operating Instructions

0407

Page 2

Linde - Your Partner

Linde AG

Linde Material Handling Division

Linde, an enterprise operating

worldwide in the investment

and service sector, is one of

the large industrial enterpris-

es in the EC with its three

business segments and six

divisions.

The Linde Material Handling

division is a leading manufac-

turer of industrial trucks and

hydraulics. It includes eight

manufacturing plants in the

Federal Republic of Germany,

France and Great Britain, as

well as subsidiaries and bran-

ches in all economically im-

portant countries.

Linde industrial trucks enjoy a

worldwide reputation - thanks

to their high quality in engin-

eering, performance and serv-

ice.

Werk II, Aschaffenburg-Nilkheim

Werk I, Aschaffenburg

Lansing Linde Ltd., Basingstoke

Fenwick-Linde, Ch鈚ellerault

Werk III, Kahl am Main

Linde Heavy Truck Division Ltd., Merthyr Tydfil

Page 3

Foreword

Your Linde lift trucks

offer the best in economy, safety and driving convenience. Therefore it is mainly in the hands of the operator to preserve the qualities of the trucks for a long and profitable service life and to make full use of their benefits on the job.

These operating instructions tell you all you need to know about starting, operation, running, and servicing the truck.

For maintenance and repair work not described in these operating instructions special technical skill and knowledge, measuring equipment and special worshop tools are often required. Please contact your authorised Linde dealer for this service.

Only qualified persons authorised by Linde are allowed to service the trucks.

For some attachments, the own operating instructions supplied with them are applicable.

Follow all hints for operating the lift truck and carry out the maintenance and care prescribed in the inspection and maintenance schedule regularly, on time and with the specified lubricants.

Keep a record of all maintenance services, otherwise your warranty may become void.

The terms "front" "rear" "left" and "right" "refer to the position in which the item concerned is installed in the truck, looking forward in the travel direction.

Approved applications

Linde lift trucks are designed for transporting and lifting the loads stated in the load capacity diagram.

In particular, we refer to the attached rules for the normal and proper use of industrial trucks (VDMA) , the regulations of your employer's liability insurance the traffic regulations.

The safety rules for the use of industrial trucks must be followed under all circumstances by the responsible persons, especially by the operator and service personnel.

The user, and not Linde, is responsible for any danger arising from applications not authorised by the manufacturer.

If you desire to use the truck for applications not mentioned in the manual and convert or supplement it for this purpose, please first contact your authorised Linde dealer.

No changes, especially conversions or modifications, may be made on your fork truck without the prior permission of the manufacturer.

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Foreword

Technical note

These operating instructions or excerpts thereof may only be copied, translated or transmitted to third parties after prior written approval by the manufacturer.

Linde pursues a policy of continuous progress in the design and construction of its products. As a result, the illustrations and technical details referring to design, fittings and engineering of lift trucks are subject to change if progress warrants it.

Therefore, the manufacturer will not accept any claims based on the specifications, illustrations and descriptions contained in this operating manual.

Please submit all enquiries concerning your fork truck and all orders for spare parts to your authorised distributor, making sure to state your correct shipping address.

For repairs, use only genuine Linde spare parts to ensure that your Linde fork truck will maintain its original technical standard.

When ordering spare parts, it is important to specify the part numbers and to include the following truck data:

Lift truck model:________________________________ Serial number/Year built: _________________________

351 807 1301 0407

Handing-over date: _____________________________

Truck takeover

Every fork truck undergoes careful inspection before leaving the factory in order to make sure that it will be in satisfactory condition and fully equipped as ordered when delivered to the customer. Authorised distributors are under obligation to re-inspect the truck before delivery and to hand it over in good order.

In order to avoid later complaints and inconvenience to customers, you are requested to ascertain that the truck is in satisfactory condition and fully equipped at the time of delivery and to acknowledge orderly handing/taking over of the truck in the manufacturer's certificate of conformity. The following technical manuals are supplied with each fork truck:

1 Operating manual 1 EC certificate of conformity

(The manufacturer certifies that the industrial truck conforms to EC directives for machines)

1 Rules for the normal and proper use of industrial trucks

(VDMA)

Additionally specify the production no. of engine, mast, hydraulic pump and compact axle when ordering parts for these assemblies.

Engine number:________________________________ Mast number: _________________________________ Mast lift height: _____________________________ mm Hydraulic pump number: _________________________ Compact axle number: __________________________

When taking over the fork lift truck, transfer the data from the assembly type plates into this manual.

Wishing you satisfactory operation,

Linde AG Linde Material Handling Division Aschaffenburg

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1254378

Type plates Description

1 Lift truck type plate 2 Manufacturer 3 CE symbol

(The symbol certifies that EC directives for machines

and all applicable guidelines are fulfilled.) 4 Serial no./year 5 Unladen mass 6 Battery voltage 7 Rated load capacity 8 Type 9 Chassis no. (stamped on side) 10 Mast no. (glued) 11 Hydraulic pump type plate 12 Compact axle type plate 13 Right hub differential type plate 14 Engine type plate

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Fork lift truck H 25 / H 30 with Deutz engine Description

The latest technology, simple and ergonomic operation, energy saving, environment-conscious and minimal maintenance, simple and ergonomic operation, solid manufacture and for availability of your lift truck nearly all parts of our own manufacture! The success of a company with about 9600 employees in eight manufacturing sites.

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Driver's position and operating features are according to the latest findings of ergonomics. Each control is designed in regard to positioning and operation for the driver's convenience to guarantee effortless and therefore safe operation.

Of course, this also includes the easy hydrostatic power steering with a kick-back safety, the service-proved doublepedal travel control system: forward travel with the right foot, reversing with the left, and only one main control lever for all mast functions.

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Page

Table of contents Description

Foreword ............................................................2

Approved applications .............................................................. 2

Technical note ............................................................................ 3

Truck takeover ............................................................................ 3

Description............................................................................ 5

Type plates .................................................................................. 5

Technical data ..........................................................................10

Noise emission value ............................................................12

Technical description .............................................................13

Engine ....................................................................................13

Hydraulic system ..................................................................13

Operation ...............................................................................13

Brakes ....................................................................................13

Steering..................................................................................13

Electrical system ..................................................................13

General view .............................................................................14

Controls and indicators ..........................................................15

Composite instrument ...........................................................17

Beginning operation......................................................18

Safety rules ...............................................................................18

Important safety information .................................................18

Handling fuels and lubricants ..............................................18

Accident prevention check .....................................................19

Operation of industrial trucks in the plant area.................19

Diesel engine emissions ......................................................19

Soot particulate filter inspection ...........................................19

Running-in instructions ..........................................................19

Experts .......................................................................................19

Checks and services before initial operation....................19

Daily checks ..............................................................................19

Daily checks and servicing before operation ....................20

Opening the engine cover......................................................20

Closing the engine cover .......................................................20

Checking the fuel level ...........................................................20

Filling fuel ..................................................................................21

Checking the engine oil level................................................21

Checking the tyre pressure ...................................................22

Applying, opening the seat belt ............................................23

Adjusting the operator seat ...................................................23

Starting the engine ..................................................................24

Cold start ...................................................................................25

Stopping the engine................................................................25

Malfunctions during operation ..............................................25

Operation..............................................................................26

Driving ........................................................................................26

Forward travel .......................................................................26

Reverse travel .......................................................................26

Changing the travel direction ............................................26

Stopping.................................................................................26

Single-pedal model ................................................................27

Steering system .......................................................................30

Steering..................................................................................30

Braking system ........................................................................30

Service brake ........................................................................30

Parking brake........................................................................30

Applying the parking brake.................................................30

Releasing the parking brake .............................................30

Central-lever control of lifting device and attachments ...31

Tilting the mast forward ......................................................31

Tilting the mast back ...........................................................31

Lifting the fork carriage .......................................................31

Lowering the fork carriage .................................................31

Operating the attachments ................................................31

Operating the sideshift .......................................................31

Operating the clamp ............................................................ 31

Single-lever control of lifting device and attachments .....32

Installation of additional equipment....................................33

Switching on the front working lights ...................................33

Switching on the rear working lights ...................................33

Switching on the lighting ........................................................33

Switching on the hazard warning light ................................33

Turning on the front windscreen wiper ...............................33

Turning on the rear windscreen wiper ................................33

Switching on the directional indicators ...............................33

Water heater .............................................................................34

Controls .................................................................................34

Fan motor fuse .....................................................................34

Operating the horn ..................................................................34

Data Logger ..............................................................................34

Fuses .........................................................................................35

Check the fuses, replace if necessary............................35

Fuses, soot particulate filter system ................................36

Before lifting a load .................................................................37

Adjusting the fork spread .......................................................38

Loading......................................................................................38

Travel with a load.....................................................................39

Unloading..................................................................................39

Parking the lift truck .................................................................39

Transport ...................................................................................40

Transport with lorry or low-bed semi-trailer.......................40

Hoisting the truck.....................................................................40

Hoisting the truck with a crane..........................................40

Hoisting the truck with the eyebolts .................................40

Changing wheels ....................................................................41

Trailer coupling ........................................................................41

Mast removal ............................................................................41

Towing instructions .................................................................42

Towing ....................................................................................42

Towing procedure ................................................................42

Releasing the multiple disc brake ...................................42

Opening the hydraulic by-pass valve ...............................42

After towing ............................................................................42

Re-establishing braking power ........................................42

Emergency exit for trucks with rear windscreen ...............43

Taking the truck out of operation ..........................................44

Measures before taking the truck out of operation .......44

Putting the truck back into operation................................44

Maintenance .......................................................................44

General information ................................................................44

Mast types .................................................................................45

Work on the mast and on the front part of the truck .........45

Securing the mast against tilting back ...............................45

Standard mast..........................................................................45

Securing the raised standard mast.....................................45

Duplex mast..............................................................................45

Securing the raised duplex mast.........................................46

Triplex mast ..............................................................................46

Securing the raised triplex mast ..........................................46

Checks and services after the first 50 service hours ......46

Inspection and maintenance schedule ..............................47

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Page

Table of contents Description

Inspection and maintenance as required.........49

Clean the lift truck ....................................................................49

Cleaning and spraying the mast chain...............................49

Cleaning the air filter...............................................................50

Cleaning with compressed air .........................................50

Renewing the safety element ...............................................51

Checking the dust discharge valve ......................................51

Cleaning the prefilter ..............................................................51

Regenerate the soot particulate filter (variant I)................52

Remove the soot particulate filter.....................................52

Clean the soot particulate filter .........................................52

Regenerate the soot particulate filter (variant II)...............53

Clean and check the radiator and hydraulic oil cooler

for leaks .................................................................................54

Drain the fuel system water preseparator .........................55

Tighten the wheel fasteners ..................................................56

Check the tyres for damage and foreign objects ..............56

Lubricate the steer axle, mast and tilt cylinder bearings 56

Check seat belt for condition and proper operation ........57

500-hour inspection and maintenance ..............58

Change the engine oil ............................................................58

Drain the engine oil.................................................................58

Top up engine oil.....................................................................58

351 807 1301 0407

Renew the engine oil filter cartridge....................................59

Clean the radiator and hydraulic oil cooler ........................59

Check and oil the pedals, travel control

and engine control linkages ..............................................59

Cleaning the air filter...............................................................60

Cleaning with compressed air .............................................60

Check the hydraulic system oil level ...................................61

Renew the fuel filter (every 12 months minimum) ...........61

Drain the fuel system water preseparator .........................62

Bleed the fuel system .............................................................62

Check and adjust valve clearance .......................................62

Battery: Check condition, electrolyte level and specific

gravity......................................................................................65

Check and oil other pivots and joints ..................................65

Clean and grease the steering axle ....................................66

Grease the mast and tilt cylinder bearings ........................66

Clean and lubricate the sideshift, check the fasteners ...67

Check the forks and fork quick-releases ...........................68

Check the pre-tension of double hoses

if attachments are fitted ......................................................68

Check the mast, lift chains and stops for condition,

mounting and operation .....................................................69

Adjust the lift chain length ......................................................69

Lubricate with chain spray.....................................................69

Renew the air filter element, check the vacuum switch ..69 Check the engine mounting for condition and tightness 69

1000-hour inspection and maintenance ...........70

Renew the air filter element,

check the vacuum switch ...................................................70

Check the engine mounting

for condition and tightness ................................................70

Check the air intake and exhaust pipes for leaks ............71

Check the hydraulic system, compact axle, pumps,

valves and lines for leaks ...................................................71

Hydraulic system: Renew the pressure, suction,

and breather filters ..............................................................72

Renew the pressure filter...................................................72

Renew the suction filter ......................................................72

Renew the breather filter ....................................................73

Check the soot particulate filter system (variant II) ..........73

Check the parking brake ........................................................73

Clean strainer of fuel pump...................................................74

Check the V-belt.......................................................................74

Tighten the V-belt.....................................................................75

Check and adjust the time belt and tension pulley..........75

Renew the hydraulic oil ..........................................................77

Filling/adding hydraulic oil.....................................................77

6000-hour inspection and maintenance ...........78

Renew the injection nozzles ..................................................78

Renew the mounting of the engine .....................................78

Inspection and maintenance data .......................................79

Fuel and oil recommendations ............................................80

Engine oils ............................................................................80

Oil grades ..............................................................................80

Oil viscosity............................................................................80

Diesel fuel .............................................................................81

Hydraulic oil...........................................................................81

Lubricating grease ..............................................................81

Battery grease.......................................................................81

Chain spray...........................................................................81

Troubleshooting guide (Diesel engine) .............................82

Troubleshooting guide (hydraulic system)........................84

Wiring diagram .........................................................................85

Wiring diagram (options).......................................................87

Hydraulic circuit diagram .......................................................90

Check the mounting of the compact axle at the engine ..63 Check the mounting of the engine, counterweight,

overhead guard, steering axle, tilt cylinder

and wheel drives for tightness..........................................63

Checking the soot particulate filter system (variant I)......64

Check electric cables, cable connectors

and connections for condition and tightness ................64

3000-hour inspection and maintenance ...........76

Check crankcase pressure vent valve ................................76

Check the injection nozzles ...................................................76

Renew the V-belt......................................................................76

Renew the time belt and tension pulley.............................77

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Technical data Description

VDI 2198

DFG

Forklift Trucks

Data Sheet for Material Handling Equipment

Apral 2007

1.1 Manufacturer (see page 1)

1.2 Model designation

1.3 Power unit: battery, diesel, petrol, LP gas, mains power

1.4 Operation: manual, pedestrian, stand-on, seated, order picker

1.5 Load capacity Q [t]

1.6 Load centre c [mm]

CharacteristicsWeightWheels and TyresDimensionsPerformance

1.8 Axle centre to fork face x [mm]

1.9 Wheelbase y [mm]

2.1 Service weight [kg]

2.2 Axle load with load, front/rear [kg]

2.3 Axle load without load, front/rear [kg]

3.1 Tyres, front/rear (SE = CS superelastic, P = pneumatic)

3.2 Tyre size, front

3.3 Tyre size, rear

3.5 Wheels, number front/rear (x = driven)

3.6 Track width, front b10 [mm]

3.7 Track width, rear b11 [mm]

4.1 Mast/fork carriage tilt, forward/backward degree

4.2 Height of mast, lowered h1 [mm

4.3 Free lift h2 [mm]

4.4 Lift h3 [mm]

4.5 Height of mast, extended h4 [mm]

4.7 Height of overhead guard (cabin) h6 [mm]

4.8 Height of seat/stand-on platform h7 [mm]

4.20 Length to fork face l2 [mm]

4.21 Overall width b1/b2 [mm]

4.22 Fork dimensions s/e/l [mm]

4.23 Fork carriage to DIN 15173, class/form A, B

4.24 Width of fork carriage b3 [mm]

4.31 Ground clearance, mast m1 [mm]

4.32 Ground clearance, centre of wheel base m2 [mm]

4.33 Aisle width with pallets 1000x1200 across forks Ast [mm]

4.34 Aisle width with pallets 800x1200 along forks Ast [mm]

4.35 Turning radius Wa [mm]

4.36 Minimum distance between the centres of rotation b13 [mm]

5.1 Travel speed, with/without load km/h

5.2 Lifting speed, with/without load m/s

5.3 Lowering speed, with/without load m/s

5.5 Tractive force, with/without load, 60 minute rating N

5.7 Climbing ability with/without load, 30 minute rating % 6)

5.9 Acceleration time with/without load (first 10 m) s

5.10 Service brake

7.1 Manufacturer of engine/type

7.2 Engine rated power to ISO 1585 kW

7.3 Rated rpm min

7.4 Number of cylinders / cc n/cm

IC engineOthers

7.5 Fuel consumption to VDI 2198 l/h kg/h

8.1 Type of drive control

8.2 Working pressure for attachments bar

8.4 Mean noise level at driver's ear to EN 12053 dB (A)

8.5 Towing coupling, design/type DIN, no.

-1

Linde

H 25

Diesel seated

2,5

500

512.5 1715 4336

6160 / 676

2120 / 2216

7.00 - 12 / 16PR

6.50 - 10 / 10PR 2 (4) x / 2

3) 4)

990 (1220)

942

5 / 9, 5 / 9, 5 / 6

2405 (2110 / 2110)

150 3050 (2750 / 4025) 3885 (3535 / 4810) 2250 (2070 or 2550) 1135 (1064 or 1435)

2650

10)

1164

45 x 100 x 1000

2 A

10)

1150

130

160

4003 4203 2290

580

22 / 23

0.52 / 0.56

0.52 / 0.45

18800 / 14000

21 / 31

6.0 / 5.0

hydrostatic

Deutz D2011L04

36.9

2100

4 / 3108

12 )

2,5l / h

hydrostatic / stepless

170 (185)

80.2

11)

6) 7)

Linde

H 30

Diesel seated

3,0

500

517.5 1785 4835

7056 / 779

2301 / 2534

27 x 10 - 12 / 14PR

23 x 9 - 10 / 14PR

2 (4) x / 2

932

150

2731.5

1300

3 A

1300

140

160 4078 4278 2360

580

22 / 23

0.52 / 0.57

0.52 / 0.45

23 / 29

6.2 / 5.2

hydrostatic

36.9

2100

4 / 3108

2.62l / h

200 (215)

80.2

3) 4)

10)

12 )

11)

1053 (1220)

5 / 9, 5 / 9, 5 / 6

2405 (2110 / 2110)

3050 (2750 / 4025) 3885 (3535 / 4810) 2250 (2070 or 2550) 1135 (1064 or 1435)

45 x 122 x 1000

18200 / 16900

Deutz D2011L04

hydrostatic / stepless

Notes:

1) Optional: SE Type 27x10-12/14PR.7.00-12/16PR

twin type

2) Optional: SE Type 6.5-10, 23x9-10

3) Figure in brackets refer to twin tyres

4) 27x10-12 type, 1053mm, 28x9-15 type 975mm

6) 7)

5) Standard , Dupiex, Triplex mast

6) Standard mast with 150mm free lift

7) Figure in brackets refer to Duplex mast / Triplex mast

8) Figure in brackets refer to Duplex mast / Triplex mast

9) Figure in brackets refer to optional equipment

10) Different type vs different figures

11) Figure in brackets refer to Triplex mast

12) Test by 45 cycles of norm VDI 2198

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Technical data Description

Load capacity diagrams for standard, duplex masts and triplex mast with standard fork carriage:

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Standard lift mast (in mm) H25/30

Lift h3 3050 4050 4650 5150 5650 Mast lowered with specified free lift h1 2360 2860 3160 3410 3610 Mast lowered with 150mm free lift h1* 2405 2905 3205 3455 3655 Mast extended h4 3855 4855 5455 5955 6355 Free lift h2 150 150 150 150 150

H25 Choese SE type if list height > 4750mm H30 Choese SE type if list height > 5050mm

Duplex lift mast (in mm) H25/30

Lift h3 2750 Mast lowered with specified free lift h1 2110 Mast extended h4 3535 Free lift h2 1475

Triplex lift mast (in mm) H25/30

Lift h3 4025 5075 6275 Mast lowered with specified free lift h1 2110 2460 2860 Mast extended h4 4810 5860 7060 Free lift h2 1475 1825 2225

Choese SE type if list height > 4975mm Other lifting heights and values for triplex mast on request.

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Technical data Description

Noise emission levels

Determined in a test cycle in accordance with EN 12053 from the weighted values in the operating modes DRIVING, LIFTING, IDLING.

Noise level at driver's station

H 25 - H 30 L Uncertainty KPA= 4 dB (A)

Sound level at driver's place

Llifting with rated load LPa=81.8 dB (A) Lower idling LPb=67.8dB (A) 80% rated speed LPc=78.4dB (A) Uncertainty KPA= 4 dB (A

Guaranteed acoustic power level

Acc. to directive 2000/14/EC LWA=101 dB (A)

The directive legally requires this information. This value has been calculated from the acoustic power levels for "Lifting" and "Driving" and is only be used as a comparable value for different trucks. For the determination of the real environmental noise stress this value is less appropriate, as it is not representative of normal truck operation, which includes "Idling".

=80.2dB (A)

PAZ

351 807 1301.0407

NOTE Higher or lower noise emissions can exist during operation of the truck, for example due to type of operation, environmental influences and additional noise emission sources.

Page 14

Technical description Description

The series 351 fork trucks are designed for handling loads weighing up to 2.5 tonnes with model H 25, 3 tonnes with model H 30 .

The compact design and a small turning radius make the trucks especially suitable for close passages and narrow aisles.

Engine

The truck is equipped with a 4-cylinder four-stroke IC engine. It drives the hydraulic pumps at load-dependent speed.

The engine is cooled by a closed-loop oil circuit with the oil pump in the oil sump.

The lubrication system is a forced-feed type lubrication with the oil pump in the oil sump.

A dry air filter with a paper cartridge cleans the combustion air.

Hydraulic system

The traction drive consists of a variable-displacement pump and two fixed-displacement motors installed as a unit in the compact axle, and a tandem pump (fixed displacement) for

351 807 1301.0407

the working hydraulics and power steering system. Travel direction and speed are controlled by accelerator

pedals via the variable-displacement pump. The fixed-displacement motors in the drive axle are supplied

with oil by the variable-displacement pump, and they each power a drive wheel via a two-stage reduction gearbox.

Operation

The variable-displacement hydraulic pump and travel speed are simultaneously controlled by one pedal each for forward and reverse travel. With the hydrostatic drive truck speed can be regulated from a standstill up to maximum speed with infinitely variable control in both directions. The double pedal control permits easy as well as safe and quick handling of the lift truck.

Both hands are always free for steering and control of the work movements. The result is quick reversing and efficient stacking.

There is only one control lever (main control lever) for controlling the work motions lifting, lowering and tilting. For the operation of additional attachments, further control levers are installed.

Brakes

The hydrostatic transmission is used as service brake. The two disc brakes integrated in the compact axle are utilized as parking brake.

When the engine is stopped, the disc brakes are applied = automatic braking.

The brake pedal is also designed as parking brake so that it must be locked mechanically when the truck is shut down.

Steering

The steering system consists of a hydrostatic steering system, which operates the rear wheels by the steering wheel via the steering cylinder.

The steering system can also be operated when the engine is stopped but a greater effort is required to turn the steering wheel.

Electrical system

The electrical system is supplied by a three-phase current generator with 12 VDC. A 12 V battery is installed for starting the engine.

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General view Description

1 Counterweight 2 Engine cover 3 Battery compartment 4 Rear silencer 5 Overhead guard 6 Driver抯 seat 7 Instrument panel 8 Lift cylinder (not shown) 9 Mast 10 Lift chain 11 Fork quick-releases 12 Fork carriage 13 Forks 14 Wheel drive 15 Chassis 16 Steering axle

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Controls and indicators Description

1 Parking brake lever 2 Ignition switch with switch key 3 Steering wheel/power steering 4 Horn button 5 Composite instrument 5a Rrain the fuel system water pre-separator

warning light 6 Toggle switch for auxiliary hydraulics* 7 Control lever for auxiliary hydraulics

(attachments)* 8 Symbol label for auxiliary hydraulics (attachments)* 9 Notice plate 10 Load capacity plate (attachment)* 11 Load capacity diagram

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12 Symbol label for working hydraulics

13 Control lever for working hydraulics 14 Forward accelerator pedal 15 Brake pedal 16 Reverse accelerator pedal 17 Fuses (in lower part of control console)

* Option

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Composite instrument Description

* Option

The composite instrument contains the following control and indicator elements:

1 Hour meter 2 Hour meter on light 3 Cooling oil temperature warning light 4 Soot particulate filter warning light 5 Oil temperature warning light for hydraulic system 6 Engine oil pressure warning light 7 Preheat indicator light 8 Flasher warning light 9 Discharge indicator light 10 Fuel level warning light 11 Air filter warning light

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Indicator element Function Possible fault(s)

Hour meter (1). The left digits (13) indicates lift truck service NOTE indicate full service hours, the hours. The meter indicates the Record elapsed service hours

right digit (12) 1/10th of an hour. elapsed service hours of the when replacing a defective hour-

truck and the required meter. Record data on durable inspection and maintenance tape and affix next to the hour

services. meter. "ON" light for hour meter (2) indicates operation of meter Cooling oil temperature warning light (3) indicates coolant temperature is - fan V-belt slack

too high - radiator dirty

- leak in cooling circuit

- low ing oil level

Soot particulate filter warning light* (4) indicates that the soot particle filter - regenerate the soot particulate

must be regenerated filter

Oil temperature warning light monitors the oil temperature of - oil level in hydraulic system is (5) for hydraulic system the hydraulic system too low

- oil not as specified

- oil filter clogged

- dirt on oil cooler

Engine oil pressure warning indicates low oil pressure of - low oil level in crankcase light (6) engine lubrication - engine is overheated

- oil not as specified

- internal leakage in lubricating system

Preheat indicator light* (7) indicates cold start* function Flasher warning light* (8) indicates function of flasher

unit when flasher is turned on

Discharge indicator light (9) indicates malfunctions in the - V-belt broken or slipping

electrical system - cables faulty

- alternator faulty

- regulator or charger switch faulty

Fuel level warning light (10) indicates a fuel reserve of

approx. 5.5 litres.

Air filter warning light (11) indicates restriced air filter element - air filter element restricted

Page 19

Safety rules Beginning operation

The responsible persons, particularly the truck operator and servicing personnel, must be instructed in the safety guidelines for the normal and proper use of industrial trucks included with these operating instructions. The employer must ensure that the operator has understood all safety informations.

Please observe the guidelines and safety rules therein for example:

- information on the operation of industrial trucks

- rules for roadways and work areas

- rights, duties and safety rules for the operator

- operation in special areas

- information related to starting, driving and braking

- service and repair information

- recurrent inspections, accident prevention check

- disposal of greases, oil and batteries

- remaining risks. The operator (employer) or the responsible person must

ensure that all the guidelines and safety rules applicable for your truck are observed.

When instructing a trained operator, acquaint him with the

- special features of the lift truck (double-pedal control, main control lever, brake pedal)

- optional attachments

- special operating and working area characteristics,

by training and practicing driving, shifting and steering operations until they are completely mastered.

Only then start to practice shelf-stacking. The stability of the truck in the work area is ensured if

employed properly. Should the truck tip over during an unauthorised application or due to incorrect operation, always follow the instructions depicted below.

Important safety information

The precautions WARNING, CAUTION, ATTENTION and NOTE in this manual are provided to indicate special dangers or unusual information requiring special identification:

WARNING indicates hazards that may result in personal injury or death and/or substantial damage to the

product.

CAUTION indicates hazards that may result in personal injury and/or substantial damage to the product.

ATTENTION indicates hazards that may result in damage to or destruction of the product.

This note is found on various positions of the truck where special attention is required. Read the appropriate section of your operating instructions.

Further warning notices are also used for your safety. Please observe the various symbols.

NOTE identifies technical information requiring special attention because the connection may not even be obvious to skilled personnel.

Handling fuels and lubricants

Always handle fuels and lubricants as required and

as specified by the manufacturer. Only store fuels and lubricants in approved containers at

specified storage places. As they could be inflammable, do not contact them with hot objects or a naked flame.

Only use clean containers when replenishing fuels and lubricants.

Follow the manufacturer's safety and disposal instructions when using fuels and lubricants and cleaning compounds.

Avoid spilling fuels and lubricants. Remove any spillage immediately with a suitable binding agent and dispose of as specified.

Also dispose of used or contaminated fuels and lubricants as specified.

Follow laws and regulations. Clean the area surrounding the part in question before

lubrication, filter renewal or repairs in the hydraulic system. Discard parts in a way friendly to the environment.

CAUTION Do not allow hydraulic oil under pressure, for example at a leak, to penetrate the skin. Medical

aid is required if such an injury occurs.

CAUTION Improper handling of coolants and coolant additives puts your health and the environment at risk.

351 807 1301.0407

Page 20

Safety rules Beginning operation

Accident prevention check

The accident prevention rules in some countries prescribe that the forklift truck must be checked at least once a year for proper working condition by trained personnel. Please contact your authorised dealer in this regard.

Operation of industrial trucks in the plant area

ATTENTION Many plant areas are so-called limited public

traffic areas. We advise you to check if your company liability insurance covers any damages occurring with your fork truck against third parties on so-called limited public traffic areas.

Diesel engine emissions

In Germany, fork trucks equipped with diesel engines must conform to TRGS 554. According to this regulation, diesel emissions are carcinogenic and they should, if at all possible, not permeate the air of workplaces. If trucks equipped with diesel engines are used in totally or partially enclosed spaces, the labour protection authority must first be notified. Appropriate notices must be posted in

351 807 1301.0407

the work areas (refer to TRGS 554 for an example).

Soot particulate filter inspection

(option) The responsible authorities specify that soot particulate

filters must be inspected and serviced every six months by an expert. The results of the inspection must be recorded in a Diesel Engine Emissions Inspection Certificateand attached to the log book (e.g. the truck Accident Prevention Inspection booklet).

Running-in instructions

The lift truck can be operated at full speed directly. Avoid sustained high loads on the working hydraulic system and the travel drive in the first 50 hours of operation.

Tighten wheel nuts daily before each shift until they are seated firmly, i.e. until no further tightening is possible.

Tighten opposite wheel fasteners to a torque of:

front: ..................................................................................195 Nm

rear:...................................................................................400 Nm

NOTE Observe the tightening instructions on the tag attached to the steering column.

Experts

Experts are specially skilled persons who have thorough knowledge and experience in servicing and testing industrial trucks and being furthermore sufficiently familiar with the national industrial safety and accident prevention regulations and all further general technical rules and guidelines (DIN and ISO standards, technical rules arising from EC directives or EEA agreements), so that they can give a qualified judgement upon the safe operating conditions of the truck.

Checks and services before initial operation

- Engine oil level

- Coolant level in the reservoir

- Fill fuel

- Battery: check condition, electolyte level and specific gravity

- Tyre pressure

- Tighten wheel fasteners

- Hydraulic oil level

- Function of braking system

- Function of steering system

- Lifting device and attachments

- Regenerate the soot particle filter (option)

Daily checks

- Engine oil level

- Fuel level

- Tyre pressure

* A description of the service can be found in the index.

Page 21

Daily checks and servicing before operation Beginning operation

Opening the engine cover

- Push up the lever (9) and fold the backrest (2) forward.

- Pull the lever (4) and slide the seat fully forward.

- Release the engine cover lock (1) by inserting the key (5) and turning it anti-clockwise as far as possible.

- Lift up the rotary lever (6) and turn anti-clockwise as far as possible.

- Unhook the tongue (7) from the bracket (8) and lift it.

- Open the engine cover with the grip (3).

NOTE

The engine cover is held in place by a gas-filled strut.

Closing the engine cover

- Close the engine cover with the grip (3).

- Hook the tongue (7) of engine cover lock (4) into the bracket (8).

- Turn the rotary lever (6) clockwise as far as possible.

- Turn the key (5) clockwise as far as possible and remove it.

Checking the fuel level

A warning light in the instrument panel lights to indicate a fuel level of 5.5 litres.

Fill fuel when the light comes on.

351 807 1301.0407

Page 22

Daily checks and servicing before operation Beginning operation

Filling fuel

CAUTION Stop the engine before filling fuel. No smoking or

naked light when filling fuel. Avoid spilling fuel and do not allow fuel to contact hot components. Follow the precautions for handling diesel fuel.

- Open the filler cap (1) on fuel tank and fill clean diesel fuel.

Max. capacity...................................................................... 45.0 L

ATTENTION Never drive fuel tank empty in order to prevent malfunction by air in the fuel injection system.

- Install and tighten the tank cap.

351 807 1301.0407

Checking the engine oil level

ATTENTION Follow the precautions for handling fuels and lubricants.

- Open the engine cover.

- Pull out the oil dipstick (2) at the engine on the left side.

- Clean the dipstick with a clean cloth.

- Reinsert the dipstick completely and pull it out again.

- The oil level should be between both markings.

- If necessary, add oil through the filler opening as far as the upper marking.

- For this, remove the filler cap (1).

- Refit and tighten the filler cap.

- Close the engine cover.

Page 23

Daily checks and servicing before operation Beginning operation

Checking the tyre pressure

ATTENTION Low inflation pressure reduces tyre service life and truck stability.

- Check the tyres for specified pressure.

- If necessary, inflate or deflate at the filler valves.

Inflate or deflate the tyres to the pressure specified on the sticker on the inside of the overhead guard.

Drive axle Single tyre

H 25 7.00-12/16PR............10 bar

H 25, H 30 27x10-12/14PR........... 7 bar

Twin tyre

H 25, H 30 7.00-12/16PR.............. 7 bar

Steering axle Single tyre

H 25 6.50-10/10PR.............. 8 bar

H 25, H 30 23x9-10/14PR ............. 7 bar

Example Tyre pressure sticker Drive axle

- Single tyre ....................................................................10 bar

- Twin tyre ......................................................................... 7 bar

Steering axle

- Single tyre ...................................................................... 8 bar

351 807 1301.0407

Page 24

Daily checks and servicing before operation Beginning operation

Applying the seat belt

WARNING The seat belt must always be applied during the operation of the truck! The seat belt is only for

securing one person. Drivercabs with closed, solid doors or bar-type doors comply with the safety requirements for driver retaining systems. We recommend the additional use of the seat belt. The seat belt must be used if the truck is operated with the doors open or removed.

PVC doors are not considered to be a driver restraint system.

NOTE The automatic lock blocks the belt when the truck is tilting heavily. The belt can then not be pulled out of the retractor. To unlock the automatic lock, carefully drive the truck off the side slope.

- Pull the seat belt (1) out of the retractor with a smooth

movement.

- Place the seat belt over the loin area, not over the belly.

- Engage the tongue (2) in the lock (4).

- Check seat belt tension. The belt should be snug on the

body.

351 807 1301.0407

CAUTION The webbing should not be twisted, stuck or

knotted. Protect the lock (4) and retractor (3) against foreign particles, damage and dirt.

NOTE During operation of the truck (e.g. driving, lifting, etc.) the operator should sit as far back as possible so that the back contacts the backrest.

The automatic lock of the retractor allows sufficient freedom of movement on the seat during normal operation of the truck.

Opening the seat belt

- Press the red button (5) on the belt buckle (4) to disen-

gage the belt.

- Return the tongue (2) back to the roller (3) by hand.

NOTE A belt which returns too fast can trigger the automatic lock when the tongue hits the enclosure. The belt can then not be pulled out with the usual force.

Adjusting the operator seat

- Release the backrest adjuster (11).

- Pull out the knob on the adjusting handwheel (10) and turn the handwheel to set the cushioning to the weight of the driver. The adjustment range from 50 kg to 130 kg is visible at the weight range indicator (9). To increase the weight, turn handwheel clockwise. To reduce the weight, turn handwheel anti-clockwise.

- To adjust the backrest upholstery* (6), move button (7) until a comfortable sitting position is reached. Turning the knob anti-clockwise makes the backrest upholstery arch out. Turning the knob clockwise returns the backrest upholstery to its original position.

NOTE Long sitting puts excessive strain on the spinal column. Prevent strain with regular, light exercising.

* Option

- For a horizontal adjustment of the seat, pull the adjustment lever (8) out.

- Slide the seat in the guide rails either forward or back until the optimum position in relation to the steering wheel, accelerator pedals and control levers is obtained.

- Re-engage the lever.

- The adjustment of the backrest is by means of the backrest adjuster (11).

- Push up and hold the backrest adjuster (11).

- Tilt the backrest forward or back until the position is comfortable for the driver.

Page 25

Starting the engine operation

Starting the engine

NOTE It the lift truck has been out of service for a long period in an enclosed space, first ventilate well before operating the electrical system.

NOTE All control levers must be in neutral.

NOTE On certain Linde fork trucks (eg with container overhead guard, swivel seat) the torso clearance is reduced. Therefore only persons with a headroom of 30 mm between the head and overhead guard should operate this truck.

- Sit down on the driver's seat.

- Apply the seat belt.

- Place both feet on the accelerator pedals (4) without

depressing them (brake pedal (5) locked; engine will start only with brake pedal locked).

- Insert the switch key (1) into the ignition switch and turn

from the zero position to position I. The electrical system is turned on.

NOTE When buzzer* buzzes (fault in soot particulate filter system, version II), conduct a lamp test (see Troubleshooting Guide (Diesel engine), Possible Cause, Correction). If the buzzer continues to buzz contact your Linde dealer.

- The engine oil pressure warning light (7)and discharge

indicator light (9) are illuminated red. The preheat indicator* (8) and soot particulate filter warning light* (6) are illuminated yellow.

- Turn the ignition key to position II. Release the key when

the engine has started.

- If engine does not start, discontinue the starting proce-

dure and repeat after a break in the same manner.

Wait at least 1 minute between starting attempts to spare the battery. If the engine does not start after the third attempt, refer to: Engine Troubleshooting Guide.

- The discharge indicator, engine oil pressure and soot

particulate filter* warning lights must extinguish when the engine is running.

Engine speed is governed automatically, depending on the load.

NOTE Refer to regenerating the soot particulate filter if one of the warning lights (2) illuminates with the variant I soot particulate filter* or if warning light (6) illuminates with the variant II soot particulate filter*.

WARNING Do not let the engine run in unventilated enclosed spaces. Risk of carbon monoxide poisoning!

NOTE Do not warm up the engine at idle speed. The engine will reach operating temperature after running briefly with a moderate load and at various speeds.

351 807 1301.0407

* Option

Page 26

Stopping the engine, malfunctions during operation operation

* Option

Cold start

- Hold the switch key about 15 sec in position I, then turn it to position II. Release the key when the engine has started. The yellow preheat indicator (1) will extinguish.

- For further procedures refer to: Starting the engine.

* Option

351 807 1301.0407

Stopping the engine

NOTE

Do not stop the engine with a full load.

- Release the accelerator pedals (3).

- Turn switch key (2) to the zero position.

NOTE

The brake engages when the engine is stopped.

- Push up parking brake lever (1).

- Push down stop pedal (4). The stop pedal engages in this position.

- Remove the switch key when leaving the truck unattended.

Malfunctions during operation

CAUTION If one of the following indicator lamps illuminates

during operation, the engine must be stopped immediately and the malfunction eliminated. (see: Diesel Engine Troubleshooting Guide)

- Coolant temperature warning light (1)

- Hydraulic oil temperature warning light (2)

- Engine oil pressure warning light (3)

- Discharge indicator light (5)

NOTE The air filter must be serviced if the air filter warning light (6) comes on during operation. If the yellow indicator light (7) illuminates with the variant I soot particulate filter*, the regeneration must be performed within the next hour. Regenerate the soot particulate filter if the soot particulate filter warning light (4) illuminates with the variant II soot particulate filter*.

Page 27

* Option

Driving Operation

CAUTION Travel on long slopes over 15 % is not allowed as

a rule due to the prescribed minimum brake applications and truck stability characteristics. Before driving on steeper slopes, you should consult your authorized dealer. The climbing ability rates given in the data sheet were derived from the tractive force of the truck and they apply only for crossing obstacles and for short differences in level. Always accommodate your driving style to suit the conditions of the roadway (rough surfaces, etc.), especially hazardous work areas and the load.

CAUTION

When using rear view mirrors it should be noted

that the latter are only provided to monitor the rear traffic area and that reversing is only allowed with a direct view in the reverse direction of travel.

NOTE When the soot particulate filter warning light* (2) with the variant I soot particulate filter*, or warning light* (7) with the variant II soot particulate filter* refer to regenerating the soot particulate filter.

- Start the engine.

- Elevate the forks slightly and tilt the mast back.

- Push the parking brake lever (1) forward. The stop pedal (5) disengages.

Forward travel

- Depress the right accelerator pedal (4) smoothly. Truck speed will increase with the pedal stroke.

NOTE Quick flooring of the accelerator pedal is not recommended as the maximum acceleration rate is regulated automatically.

Reverse travel

- Depress the left accelerator pedal (6). The truck will

reverse at a speed depending on the position of the accelerator pedal.

Changing the travel direction

- Release the actuated accelerator pedal. The hydrostatic drive will act as service brake.

- Depress the accelerator pedal for the opposite direction of travel. The truck will now be accelerated in the selected direction.

- During travel, keep both feet on the accelerator pedals in order to be able to control all movements of the truck easily.

- The accelerator pedals can be operated from forward to reverse travel directly. The hydrostatic drive will brake the truck to a standstill and then accelerate it in the opposite direction.

Stopping

- Slowly release the depressed accelerator pedal. The hydrostatic travel drive will act as service brake.

- When stopping on gradients during upgrade travel, leave both feet on the pedals and equalise any drive slippage due to technical reasons by depressing the pedal slightly, or

351 807 1301.0407

- depress the brake pedal for a long stop.

- When dismounting from the truck with the engine running, for example, in order to briefly perform some action in close vicinity to the truck (opening a gate, unhitching a trailer, etc.), the brake pedal must be depressed and locked. Open the seat belt. Shut down the engine if making a long stop. When leaving the truck unattended, remove the ignition key.

Page 28

Single-pedal model Operation

Starting the engine

NOTE It the lift truck has been out of service for a long period in an enclosed space, first ventilate well before operating the electrical system.

NOTE The travel direction control lever (2) on the left-hand side of the steering wheel and all other control levers must be in the neutral position.

- Sit down on the driver's seat.

- Apply the seat belt.

- Stop pedal (5) is locked (engine will start only with the

brake pedal locked).

- Insert the switch key (1) into the ignition switch and turn

from the zero position to position I. The electrical system is now switched on.

351 807 1301.0407

NOTE When buzzer* buzzes (fault in soon particulate filter system, version II), conduct a lamp test (see Troubleshooting Guide (Diesel engine), Possible Cause, Correction). If the buzzer continues to buzz contact your Linde dealer.

- The engine oil pressure warning light (7), discharge

indicator light (9) and the variant II are illuminated red. The preheat indicator* (8) and the variant II soot particulate filter warning light* (6) are illuminated yellow.

- Turn the switch key to position II. Release the key when

the engine has started.

- If engine does not start, discontinue the starting proce-

dure and repeat after a break in the same manner.

Wait at least 1 minute between starting attempts to spare the battery. If the engine does not start after the third attempt, refer to: Engine Troubleshooting Guide.

- The discharge indicator, engine oil pressure and soot

particulate* warning lights must extinguish when the engine is running.

Engine speed is governed automatically, depending on the

load.

NOTE Refer to regenerating the soot particulate filter if one of the warning lights (4) illuminates with the variant I soot particulate filter* or if warning light (6) illuminates with the variant II soot particulate filter*.

WARNING

Do not let the engine run in unventilated enclosed spaces. Risk of carbon monoxide poisoning!

NOTE Do not warm up the engine in idle. The engine will attain its running temperature after running briefly with a moderate load and at various speeds.

* Option

Page 29

Single-pedal model Operation

Cold start

- Hold the switch key about 15 sec in position I, then turn it to position II. Release the key when the engine has started. The yellow preheat indicator (1) will extinguish.

- For further procedures refer to: Starting the engine.

* Option

Stopping the engine

NOTE

Do not stop the engine with a full load.

- Release the accelerator pedal (4).

- Place the travel direction control lever (3) in the neutral position.

- Turn the switch key (2) to the zero position.

NOTE

The brake engages when the engine stops.

- Set the parking brake lever (1) to the vertical position.

- Depress the stop pedal (5). The pedal will engage in this position.

- Remove the switch key when leaving the truck unattended.

Malfunctions during operation

ATTENTION If one of the following indicator lamps illuminates

during operation, the engine must be stopped immediately and the malfunction eliminated. (see: Diesel Engine Troubleshooting Guide)

- Coolant temperature warning light (1)

- Hydraulic oil temperature warning light (2)

- Engine oil pressure warning light (3)

- Discharge indicator light (5)

NOTE The air filter must be serviced if the air filter warning light (6) comes on during operation. If the yellow indicator light (7) illuminates with the variant I soot particulate filter*, the regeneration must be performed within the next hour. Regenerate the soot particulate filter if the particle filter warning light (4) illuminates with the variant II soot particulate filter*.

* Option

351 807 1301.0407

Page 30

Single-pedal model Operation

Travel

CAUTION Travel on long slopes over 15 % is not allowed as

a rule due to the prescribed minimum brake applications and truck stability characteristics. Before driving on steeper slopes, you should consult your authorized dealer. The climbing ability rates given in the data sheet were derived from the tractive force of the truck and they apply only for crossing ob-stacles and for short differences in level. Always accommodate your driving style to suit the conditions of the roadway (rough surfaces, etc.), especially hazardous work areas and the load.

CAUTION

When using rear view mirrors it should be noted

that the latter are only provided to monitor the rear traffic area and that reversing is only allowed with a direct view in the reverse direction of travel.

* Option

351 807 1301.0407

NOTE Refer to regenerating the soot particulate filter if one of the warning light (4) illuminates with the variant I soot particulate filter* or if warning light (7) illuminates with the variant II soot particulate filter*.

- Start the engine.

- Slightly raise the forks and tilt the mast backward.

- Push the parking brake lever (1) forward to release the

stop pedal (6).

Forward travel

- Shift the travel direction lever (2) forward.

- Depress the accelerator pedal (5) gently. Truck speed

depends on how for the pedal is depressed.

NOTE Quick flooring of the accelerator pedal is not recommended as the maximum acceleration rate is regulated automatically.

Reverse travel

- Pull back the travel direction control lever (2).

- Depress the accelerator pedal (5) gently. Truck speed depends on how far the pedal is pushed.

Changing the travel direction

- Release the depressed accelerator pedal (5). The hydrostatic drive will act as service brake.

- Shift the travel direction control lever (2) to the opposite travel direction.

- Depress the accelerator pedal (5). The lift truck will be accelerated in the new direction of travel.

- The travel direction control lever (2) can be shifted from forward travel directly to reverse travel. The hydrostatic drive will brake the lift truck to a standstill and then accelerate the truck in the opposite travel direction.

Stopping

- Slowly release the depressed accelerator pedal. The hydrostatic travel drive will act as service brake.

- When stopping on gradients during upgrade travel, leave the foot on the accelerator pedal, set the directional lever (2) to the uphillposition and equalise any drive slippage due to technical reasons by depressing the pedal slightly, or

- depress the brake pedal for a long stop.

- When dismounting from the truck with the engine running, for example, in order to briefly perform some action in close vicinity to the truck (opening a gate, unhitching a trailer, etc.), the brake pedal must be depressed and locked, open the seat belt. Shut down the engine if making a long stop. When leaving the truck unattended, remove the ignition key.

Page 31

Steering system, braking system Operation

Steering

Due to the hydrostatic power steering, very little effort is required to turn the steering wheel. This is especially advantageous when stacking in narrow aisles.

- Start the engine and drive the truck.

- Turn the steering wheel from left to right full lock and vice versa.

WARNING Contact your distributor if steering becomes hard or if there is excessive play in the steering wheel.

Do not drive the lift truck with a faulty steering system.

Turning radius

- H 25.........................................................................2290 mm

- H 30 .........................................................................2360 mm

Service brake

- Allow the accelerator pedals to return to the neutral position. The hydrostatic drive will act as a service brake. Braking can be controlled from soft to hard braking with sensitivity by releasing the accelerator pedals slowly or quickly.

ATTENTION For emergency braking depress the STOP pedal located between the accelerator pedals.

NOTE It is recommended that the operator acquaint himself with the function and effect of these brakes without a load being on the truck. Drive on a roadway without traffic at a slow speed.

Parking brake

The multiple disc brakes are used as a parking brake.

Applying the parking brake:

- Set the parking brake lever (2) to the vertical position.

- Depress the stop pedal (1). The stop pedal will lock in this position.

Releasing the parking brake:

NOTE The multiple disc brakes will only be released when the engine is running.

- Push the parking brake lever (2) forward to disengage the

stop pedal.

WARNING Contact your authorized distributor if faults or

signs of wear become evident in the braking system. Do not drive the truck with a faulty braking system.

351 807 1301.0407

Page 32

Central-lever control of lifting device and attachments Operation

ATTENTION Use the lifting device and attachments only for

authorised applications. The operator must be instructed in the handling of the lifting device and attachments. Observe the maximum height of lift. Do not put your hands into or step into the mast or in area between the mast and truck.

Always operate the control levers smoothly and without jerking. The lifting, lowering and tilting speed is determined by how far the control levers are moved. The control levers return to their neutral position automatically when released.

NOTE

Note the operating symbols with direction arrows.

Tilting the mast forward

- Push the control lever (1) forward.

Tilting the mast back

- Pull the control lever (1) back.

351 807 1301.0407

Lifting the fork carriage

WARNING Do not step on raised forks. Increased danger of falling and being squeezed.

- Push the control lever (1) to the right.

Lowering the fork carriage

- Push the control lever (1) to the left.

CAUTION The mast and fork carriage can be lowered even when the engine is shut off.

Operating the attachments

Attachments can be installed as options (e.g. sideshift, clamp, etc.). Note the working pressure and operating instructions of the attachments. One or two additional control levers are fitted for their operation.

NOTE For each attachment, affix a load capacity plate and a symbol label on the bonnet and a symbol label behind the appropriate control lever.

Operating the sideshift

- To move the sideshift to the left, push the control lever (2) forward.

- To move the sideshift to the right, pull the control lever (2) back.

Operating the clamp

- To open the clamp, push the control lever (3) forward.

- To close the clamp, pull the control lever (3) back.

CAUTION Attachments not supplied with the truck may only

be employed if your authorised dealer ascertains that they will not reduce the load capacity and stability of the truck.

Page 33

Single-lever control of lifting device and attachments Operation

ATTENTION Use the lifting device and attachments only for

Always operate the control levers smoothly and without jerking. The lifting, lowering and tilting speed is determined by how far the control levers are moved.

The control lever returns to its initial position automatically when released.

NOTE

Note the operating symbols with direction arrows.

Lifting the fork carriage

WARNING Do not step on raised forks. Increased danger of falling and being squeezed.

- Pull the control lever (1) back.

Lowering the fork carriage

- Push the control lever (1) forward.

CAUTION The mast and fork carriage can be lowered even when the engine is shut off.

Tilting the mast forward

- Push the control lever (2) forward.

Tilting mast back

- Pull control lever (2) back.

Operating the attachments

Additional equipment can be installed as option (e.g. sideshift, clamp, etc.). Observe the working pressure and operating instructions of the attachments. One or two additional control levers are fitted for their operation.

NOTE For each attachment affix a load capacity plate on the engine cover and a symbol label depicting the attachment

behind the appropriate control lever.

Operating the sideshift

- To move the sideshift to the left, push the control lever (3)

forward.

- To move the sideshift to the right, pull control lever (3)

back.

Operating the clamp

- To open the clamp, push the control lever (4) forward.

- To close the clamp, pull the control lever (4) back.

CAUTION Attachments not supplied with the truck may only

be employed if your authorised dealer ascertains that a safe operation is assured in respect to load capacity and stability.

351 807 1301.0407

Page 34

Windscreen wipers*, lighting*, working lights*, directional indicators

* Option

Operation

Installation of additional equipment

ATTENTION Electrical additional equipment (lights, seat heat-

er etc.) should be connected to the free connectors of the cable loom provided for this purpose. Further connections beyond this anticipated range are only permitted after contacting Linde. Only qualified skilled persons who observe the applicable rules and use appropriate material should carry out these activities.

NOTE

The switches on the console can be arranged in a different order, depending on the model. Please note the switch symbols.

Switching on the front working lights

The working lights are turned on and off with toggle switch (1).

Switching on the rear working lights

The working lights are turned on and off with toggle switch (2).

351 807 1301.0407

Switching on the lighting (7)

- Depress the light switch (3) to the intermediate position to switch on the side marker lights and license plate light.

- Depress the light switch to switch on low beam.

Switching on the hazard warning light

- Depress the hazard warning light switch (4).

Turning on the front windscreen wiper

- Depress switch (5) to the intermediate position to operate the front wiper intermittently.

- Depress switch (5) fully to operate the front wiper continuously.

Turning on the rear windscreen wiper

- Depress switch (6) to the intermediate position to operate the rear wiper intermittently.

- Depress switch (6) fully to operate the rear wiper continuously.

Switching on the directional indicators

- Move the directional indicator switch (9) on the steering column forward or back to operate the directional indicators (8) on the left or right.

Page 35

Water heater

, horn, data logger* Operation

Controls

The fan is turned on with the fan switch (1); the air flow can be regulated in three stages.

Shift lever (3) for temperature control

- up for less heat,

- down for more heat.

Shift lever (4) for air intake

- down for air intake through opening (10) in the cabin,

- up for air intake from outside. The swivelling air outlets (5, 6 and 7) and the distributor (2) can be opened separately. Depending upon the position of lever (3), either warmed or non-warmed air flows out of all outlets and the distributor.

NOTE When lever (3) is in the topmost and lever (4) in the bottommost position, fresh air from outside flows in through

the outlets and distributor. If you want to prevent outside air from entering, shift lever (4) up.

All controls (except the fan switch) can be set to any intermediate position.

Fan motor fuse

- Screw the retainer (9) out of the housing and remove along with the fuse (8) (8 A).

Operating the horn

When operating at blind corners and junctions, a horn serves as warning signal.

- Press the horn button on the steering wheel to sound the horn.

Data Logger*

The Data Logger has a key panel with 12 buttons. By allocating a 5-digit PIN number to the driver it is assured that only authorised personnel may operate the fork truck. The truck is started by entering this PIN number.

Start the truck:

- Turn the switch (1) clockwise to switch position I. The two indicator lights (2) come on.

- Enter the 5-digit PIN number at the key panel (3).

- Confirm by pressing the "ENT" button (4).

- Turn the switch (1) fully clockwise to start the truck.

NOTE

If the truck does not start at first, the starting procedure can be repeated until the switch is returned to the zero position and the PIN number is no longer stored.

Stop the truck:

- Press the CLR button (5) in the key panel (3).

- Turn the switch (1) counterclockwise as far as possible. The engine is shut off. The two green indicator lights (2) extinguish again.

NOTE

If the driver's seat is left for a longer period (about 3 min), the truck shuts off automatically. To resume operations, restart the truck.

* Option

351 807 1301.0407

Page 36

Fuses Operation

* Option

Check the fuses, replace if necessary

NOTE

For the protection of the electrical system, up to 3 fuse boxes can be installed in the console, depending on the model. The fuse boxes can be accessed by lowering the cover on the underside of the console (arrow) after first removing 4 screws.

- Remove the cover of the appropriate fuse box. The version B fuses (8 A) protect the following circuits: 1 Composite instrument

2 Horn 3 Directional control, single-pedal model* 4 Wiper motor* 5 Front working light* 6 Front working light* 7 Front working light* 8 Rear working light* 9 Front dip beam, left* 10 Front dip beam, right* 11 Front and rear left position light, tail light* 12 Front and rear right position light, tail light* 13 Directional indicators* 14 Hazard warning flasher*

351 807 1301.0407

The version A fuses protect the following circuits: Note the numbers or letters on the fuse boxes and in the cover (1 = A left).

Fuse box I: standard equipment

1 Starter relay (F2) ...............................................................5 A

2 Composite instrument (F3)............................................5 A

3 Electronic ignition, fuel shutoff valve (F4)..................30 A

4 Horn and aux. relay, seat heater*, fine filter*,

terminal 15 (F5) ..............................................................10 A

5 Single-pedal model, reversing signal (F6).................5 A

6 Oil pump (F7) ....................................................................5 A

Fuse box* II: lighting

1 Left dip beam (5F5) .......................................................10 A

2 Right dip beam (5F6) ....................................................10 A

3 Left side marker light (5F7)............................................5 A

4 Right side marker light (5F8).........................................5 A

5 Main lighting fuse, terminal 15 (5F9) .........................20 A

6 Main lighting fuse, terminal 30 (5F10).......................15 A

Fuse box* III: windscreen wiper, working lights, heater 2 Working light, revolving light,

flashing light (9F13)......................................................15 A

3 Working light (9F12) ......................................................15 A

4 Working light (9F11) ......................................................15 A

5 Rear screen wiper (9F5)...............................................10 A

6 Front screen wiper (9F4) ..............................................10 A

Another MTA fuse in the engine compartment protects the following electric circuits:

- Open the bonnet, remove the covers (15).

Main fuse (F1) (16) for complete electrical system .......50 A

Heater (9F14) ........................................................................50 A

ATTENTION Only use genuine Linde fuses.

Page 37

Fuses, soot particulate filter system

* Option

The fuses for the variant II soot particulate filter system* are located in the fuse box behind the battery compartment cover.

- Remove the battery compartment cover.

- Remove the mounting screws (19) and take off the cover (18).

15 Metering pump solenoid valve (7F15) .........................5 A

16 Fan motor (7F17)............................................................20 A

17 Main fuse (7F16).............................................................30 A

Operation

351 807 1301.0407

Page 38

Before lifting a load Operation

Before lifting a load, check the capacity diagram (1) on the engine cover.

WARNING When attachments are fitted, check the capacity

plate (2) for that equipment. Figures stated in the capacity diagram or plate apply to compact and regular loads and must not be exceeded, as this will reduce the stability of the fork truck and the strength of the forks and mast.

The maximum capacity is determined by the height of lift and the load centre distance.

NOTE Check the load capacity limits and contact your authorized distributor before transporting

- off-centre or swinging loads,

- loads with the mast tilted forward or the load not near the

ground,

- loads beyond the centre of gravity,

- before operating attachments,

- loads at wind force 6 and higher.

351 807 1301.0407

Example

Load centre distance .................................................. 600 mm

Height of lift .................................................................6000 mm

- Follow the vertical line for a load distance of 600 mm to where it intersects the line for a height of lift of 6000 mm.

- Read to the left of the point of intersection of the horizontal line for max. permitted load.

- Max. weight here is ...............................................1900 kg.

Proceed accordingly for other lift heights and load centre distances. Values ascertained apply to even distribution of the load on the forks.

1 Max. weight of loads in kg 2 Height of lift in mm 3 Fork truck type with rated capacity 4 Distance of load centre from fork-face in mm

Page 39

Loading Operation

Adjusting the fork spread

- Raise the fork quick-release levers (1).

- Move the forks further apart or closer together depending to the size of the load to be lifted. Make sure that both forks are equally distant from the truck centre.

- Allow the quick-release levers to engage in a notch on the fork carriage.

NOTE

The load centre should be in the centre between the forks.

NOTE

The loads must be picked up so that they do not project beyond the loading area of the truck, and will not fall over or off.

- Approach the load to be lifted carefully and as accurately as possible.

- Put the mast to the vertical position.

- Lift or lower the fork carriage to the required height.

- Carefully drive the truck forward under the centre of the load until the load contacts the fork-face, if possible, while taking care not to dislodge adjacent loads.

- Lift the fork carriage until the load is clear of the ground.

- Reverse the lift truck until the load is clear.

- Tilt the mast back.

WARNING Do not stand under an elevated load. Drive the fork lift truck only with the load lowered and the mast

tilted back.

351 807 1301.0407

Page 40

Travel with a load, unloading Operation

Travel with a load

NOTE

When sending goods by freight, the consignor must load and fasten, if necessary, the transported goods safely. Pay attention to proper stacking and make sure that the packaging, pallets, etc. are not damaged. The freight carrier is responsible for the safe handling.

- Do not drive with the load shifted to the side (e.g. with sideshift).

- Transport the load near the ground.

- Always travel with the load facing uphill on inclines, never travel or turn across the slope.

- If visibility is reduced, work with a guide.

- Operate the lift truck only in reverse if the load being transported is stacked so high as to obstruct visibility in the direction of travel.

351 807 1301.0407

Unloading

- Carefully approach the racking receiving the load.

- Lift the fork carriage to the required height.

- Put the mast into vertical position (load horizontal).

- Carefully drive into the racking.

- Carefully lower the load onto the racking.

- Reverse the lift truck

WARNING Never park the truck and leave it unattended with the load raised.

Parking the lift truck

- Deposit the load or lower the fork carriage.

- Tilt the mast slightly forward so that the forks touch the ground.

- Set the parking brake lever (1) to the vertical position.

- Depress the stop pedal (3). The stop pedal will lock in this position.

- Stop the engine.

- Remove the switch key (2).

Page 41

Transport, hoisting the truck Operation

* Option

Transport with lorry or low-bed semi-trailer

- Lower the mast.

- Operate the parking brake.

- Chock the truck.

- Lash the truck down.

Hoisting the truck with a crane

DANGER When loading the truck by crane

make sure no persons are within the working range of the crane! Do not step under the elevated load!

CAUTION Only use lifting slings and crane of sufficient capacity. See the manufacturer's plate for the

truck weight.

NOTE To hoist with a crane, attach the lifting slings at the points provided. The lifting points on your truck are not labelled

extra.

- Attach the lifting sling (2) (3000 kg carrying capacity

minimum) to the tow bolt.

- Lock the tow bolt.

- Attach the lifting sling (3) (3000 kg carrying capacity

minimum) to the cross member on the outer upright of the mast.

Use edge protections on sharp edges.

- Attach all the ends to the crane hook (1).

CAUTION After inserting the slings into the crane hook, the

safety lock (4) must close. When the truck is hoisted, the slings must not rub against the sides of the overhead guard and any attachments fitted.

Hoisting the truck with the eyebolts

CAUTION Only use a slifting sling and acrane with a suffi-

cient capacity. See the manufacturer's plae for the truck.

ATTENTION The truck may be hoisted with the eyebolts (1)

only if the appropriate lifting equipment (3) is used with which the chains (2, 6) lead straight up from the eyebolts (1).

- Hook the chains (6) (minimum capacity 3000 kg) into the

eyebolts (1) on the counterweight.

- Hook the chains (2) (minimum capacity 3000 kg) into the

eyebolts (1) on the frame.

ATTENTION

After attaching the lifting slings to the crane

hook (4), the hook safety (5) must close.

The lifting gear must not touch the overhead guard and any attachments fitted.

351 807 1301.0407

Page 42

Changing wheels, trailer coupling, mast removal Operation

Changing wheels

CAUTION Only use a jack with a sufficient lifting capacity. The minimum capacity should be 3600 kg.

- Loosen the fasteners of the wheel to be changed.

- Locate the jack.

NOTE

Locate the jack only at the front corner of the frame (2) and under the counterweight (1).

CAUTION The truck may only be raised at these locations on the left and right side.

- Raise the truck with the jack until the wheels are clear.

- Secure the truck with wooden blocks under the frame or counterweight.

- Remove the wheel fasteners and change the wheel.

- Install the wheel fasteners and tighten them by hand.

- Lower the truck.

- Tighten all wheel fasteners to a torque of:

front.............................................................................195 Nm

rear..............................................................................400 Nm

351 807 1301.0407

Trailer coupling

NOTE

The trailer coupling should only be used to tow light trailers inside the plant area (Observe the applicable accident prevention guidelines and VDI 3973.)

- Turn the lever 90o degrees to the rear and then raise the tow bolt.

- Place the towbar in the coupling sleeve.

- Press down the tow bolt against spring pressure, turn 90degrees and let engage in the safety.

Mast removal

ATTENTION Attach the lifting sling to the top cross member (1) of the outer upright of the mast.

CAUTION Do not step under the elevated load.

The mast may only be dismantled by your distributor's skilled staff.

Page 43

Towing instructions Operation

Towing

Should it become necessary to tow the truck, with the by-pass

device it is possible

- to by-pass the hydraulic oil circuit (7), and

- to release the disc brakes in the compact axle (1).

CAUTION The truck cannot be braked now.

The tractor used to tow the fork truck must have sufficient tractive and braking power for the unbraked towed load.

Towing the truck is only allowed with a rigid connection (tow bar).

Towing procedure

- Lower the load so far that the forks do not scrape on the

ground during towing.

- Deposit the load.

- Secure the tractor (observe sufficient tractive and braking power) with tow bar to towing pin of lift truck.

- Place chocks (wedges) behind the wheels on the slope side.

Releasing the multiple disc brake

- Open the bonnet.

- Remove the floor plate.

- Unscrew the cap nut (2) in the centre under the pedal console and remove the seal ring (4).

- Screw in the threaded pin (6) as for as possible and tighten to 10 Nm.

- Lock the threaded pin with nut (3). Tighten the nut to 25 Nm.

- Apply about 4 shots of grease with a grease gun through the lubricating nipple (5) until the brake is clear.

Opening the hydraulic by-pass valve

- Remove the front cover on the truck.

- Loosen the locknut (9) (18 or 19 mm) on the housing by turning it anti-clockwise with a socket.

- Loosen the setscrew (8) with 10 mm socket by 3 turns.

- Lock the setscrew with the locknut (9). Torque the nut to 60 Nm.

After towing

- Chock the wheels on the slope side.

- Loosen locknut (9).

- Screw in setscrew (8) (10 mm) and torque to 20+5 Nm.

- Lock setscrew by tightening the locknut (9) to 60 Nm.

- Install the front cover on the truck.

Re-establishing braking power

- Loosen locknut (3).

- Loosen threaded pin (6).

- Lock threaded pin with nut (3), torque to 25 Nm.

- Fit the sealing ring (4).

- Screw on cap nut (2) and tighten to 30 Nm.

- Install the floot plate and close the bonnet.

Check brake function after completing repairs.

351 807 1301.0407

Page 44

Emergency exit for trucks with rear windscreen Operation

Emergency exit for trucks with rear windscreen

NOTE If the truck is fitted with a front and rear windscreen, it may not be possible to dismount at the side if the truck breaks

down in a narrow aisle. In case of acute danger, the driver can leave the truck through the rear window. To do so, the driver must destroy the window with an emergency hammer.

- Pull the cotter pin (1) out of the mounting (2) at the right

rear support of the overhead guard.

- Take the hammer (3) out of the mounting and cautiously

break the window pane.

- Remove any pane remnants

CAUTION Risk of injury.

- Carefully dismount from the truck through the rear win-

dow.

351 807 1301.0407

Page 45

Taking the truck out of operation Maintenance

If the truck is taken out of operation for over 2 months, it must be parked in a well ventilated, frost-free, clean and dry room and the following measures must be carried out.

Measures before taking the truck out of operation

- Thoroughly clean the truck.

- Fully elevate the fork carriage several times, tilt the mast forward and back and, if fitted, operate the attachment several times.

- Lower the forks on a support until the chains are slack.

- Check the hydraulic oil level and add oil, if needed.

- Add diesel fuel.

- Apply a thin film of oil or grease on all unpainted mechanical parts.

- Lubricate the truck.

- Check the condition and electrolyte level of the battery. Coat the battery terminals with non-acidic grease. (Follow the instructions of the battery manufacturer.)

- Spray all open electrical contacts with a suitable contact spray.

ATTENTION Block up the truck so that all wheels are clear of the ground. This will prevent tyre deformation.

Putting the truck back into operation

- Thoroughly clean the truck.

- Lubricate the truck.

- Coat the battery terminals with non-acidic grease.

- Check the condition and electrolyte level of the battery.

- Check the engine oil for condensation water and change the oil, if necessary.

- Check the hydraulic oil for condensation water and change the oil, if necessary.

- Perform the same services as for commissioning.

- Take the truck into service.

General information

Your truck will remain operational only if the maintenance and checks are carried out regularly and according to the information and instructions in the operating manual. The maintenance may only be performed by qualified authorized personnel. This work can be carried out by your authorized distributor under a service contract.

If you wish to do the work yourself, we recommend that the first three customer service checks be carried out by your distributor's mechanic in the presence of the responsible mechanic in your workshop, so that your staff can receive the appropriate instruction.

For all servicing, the truck must be placed on a level surface and the wheels secured.

Stop the engine and remove the switch key. When working on the truck with the fork carriage and mast

elevated, secure them against inadvertent lowering. For work on the front end of the truck, secure the mast against

tilting back. No changes, particulary no modifications and additions, may

be made to the truck without the approval of the manufacturer.

ATTENTION Missing or damaged plates and/or adhesives must be replaced. For location and oder no. refer to

Parts catalogue.

Perform a functional check and trial run after every servicing.

351 807 1301.0407

NOTE Do not use plastic foil as this enhances the formation and collection of condensation water.

NOTE If the vehicle is to be taken out of operation for over 6 months, contact your authorized dealer for further measu-

res.

NOTE

When operating the truck under extreme conditions (i.e. extreme heat or cold, intensive dust concentration, etc.), the intervals given in the maintenance schedule should be reduced accordingly.

ATTENTION Follow the precautions for handling fuels and lubricants.

Page 46

Mast types Maintenance

Work on the mast and on the front part of the truck

WARNING Before attempting to carry out repairs or adjust-

ments on the raised mast and fork carriage, ensure that the following safety procedures are carried out! These safety measures are only sufficient for general maintenance on your truck (tests and lubrication). For repairs (e.g. replacement of chains or lift jack), further additional safety measures must be applied. Please contact your authorized distributor.

Securing the mast against tilting back

To prevent the lift mast from tilting back accidentally, insert a 800 mm long 120 x 120 mm hardwood block (1).

351 807 1301.0407

Standard mast

FUNCTION When the inner mast is lifted, the chain idler wheel is also moved upward thereby raising the fork carriage at a 2 : 1 speed ratio.

Securing the raised standard mast

WARNING Use a suitable chain for the particular lifting mast. Do not exceed the maximum height of lift.

- Raise the mast.

- Fasten the chain around the cross member of the outer upright (1) and the cross member of the inner mast (2).

- Lower the inner mast until it is held by the chain.

Duplex mast

NOTE

The advantage of this mast version is that the special free lift height can be used even in spaces with a low ceiling (cellars, wagons, ships).

FUNCTION The fork carriage is raised to the special free lift height by the centre lift cylinder via the chain guide roller. It moves at twice the rate of the centre cylinder. The inner mast and the fork carriage is then raised together by both the secondary exterior lift cylinders. The centre cylinder is mounted within the extendible inner mast.

Page 47

Mast types Maintenance

Securing the raised duplex mast

WARNING Use a suitable chain for the particular lifting mast. Do not exceed the maximum height of lift.

- Lift the mast.

- Fasten chain around the cross member of outer upright (1) and the cross member of inner mast (2).

- Lower the inner mast until it is held by the chain.

- Fully lower the fork carriage.

Triplex mast

FUNCTION The fork carriage is raised to the special free lift height by the centre cylinder via the chain guide roller. Then the two lift cylinders raise the inner mast. When the inner mast is fully extended, two further lift cylinders raise the centre mast, which is raised together with the inner mast and fork carriage. The centre cylinder is mounted on the extendible centre mast.

Securing the raised triplex mast

WARNING Use a suitable chain for the particular lifting mast.

Do not exceed the maximum height of lift.

- Raise the mast.

- Fasten the chain around the cross member outer mast (1) and the intermediate mast (2).

- Lower the mast until it is held by the chain.

- Fully lower the fork carriage.

Checks and services after the first 50 service hours

NOTE

A description of the services can be located in the index.

- Replace the engine oil

- Replace the engine oil filter

- Check the tension and condition of alternator and fan Vbelt

- Check and adjust valve clearance

- Check the air intake and exhaust pipes for leaks

- Check parking brake

- Tighten wheel fasteners

- Check tyres for damage and foreign objects

- Check tyre inflation pressure

- Check hydraulic system, compact axle, pumps, valves, and lines for leaks

- Renew the pressure, suction and breather filters in the hydraulic system

- Check battery condition, electrolyte level and specific gravity

- Check engine mounting for condition and tightness

- Check mounting of engine, overhead guard, steering axle and wheel drive for tightness

- Clean and grease the steering axle

- Grease the mast and tilt cylinder pivots

- Check the mast, lift chains and stops for condition, mounting and operation

- Check the pre-tension of double hoses if attachments are fitted

- Clean, adjust the lift chains and spray with chain spray

- Check electric cables, cable connectors and connections for condition and tightness

- Drain the fuel system water pre-separator

- Clean the air filter

- Check engine monitoring system, warning system

351 807 1301.0407

Page 48

Inspection and maintenance schedule Maintenance

Service (A description of the service can be located in the index)

See page 19 for the services ........................................................................................................... l

See page 46 for the services .................................................................................................................................................. l

Checking the engine oil level........................................................................................................................................................................................ l

Checking the fuel level ................................................................................................................................................................................................... l

Checking the tyre pressure ........................................................................................................................................................................................... l

Clean the lift truck .................................................................................................................................................................................................................................................. l

Cleaning and spraying the mast chain............................................................................................................................................................................................................. l

Cleaning the air filter............................................................................................................................................................................................................................................. l

Renewing the safety element ............................................................................................................................................................................................................................. l

Checking the dust discharge valve .................................................................................................................................................................................................................... l

351 807 1301.0407

Cleaning the prefilter ............................................................................................................................................................................................................................................ l

Regenerate the soot particulate filter................................................................................................................................................................................................................ l

Prior to first

operation

After the first

50 service hours

Daily checks

Inspection

as required

Clean and check the radiator and hydraulic oil cooler for leaks ................................................................................................................................................................. l

Drain the fuel system water preseparator ....................................................................................................................................................................................................... l

Tighten the wheel fasteners (at least every 100 hours)................................................................................................................................................................................ l

Check the tyres for damage and foreign objects ............................................................................................................................................................................................ l

Lubricate the steer axle, mast and tilt cylinder bearings .............................................................................................................................................................................. l

Check seat belt for condition and proper operation ...................................................................................................................................................................................... l

Page 49

Inspection and maintenance schedule Maintenance

Service (A description of the service can be located in the index)

Renew the engine oil..................................................................................................................................................l

Renew the oil filter cartridge ......................................................................................................................................l

Clean the radiator and hydraulic oil cooler .............................................................................................................l

Check and oil the pedals, travel control and engine control linkages ..............................................................l

Check and clean the air filter .....................................................................................................................................l

Check the hydraulic system oil level ........................................................................................................................l

Renew the fuel filter cartridge ...................................................................................................................................l

Renew the fuel system water pre-separator ..........................................................................................................l

Bleed the fuel system ..................................................................................................................................................l

Check and adjust valve clearance ............................................................................................................................l

Check the mounting of the compact axle at the engine .......................................................................................l

Check the mounting of the engine, counterweight, overhead guard, steering axle, tilt cylinder

and wheel drives for tightness ..............................................................................................................................l

Checking the soot particulate filter system .............................................................................................................l

Check electric cables, cable connectors and connections for condition and tightness ..............................l

Battery: Check condition, electrolyte level and specific gravity

(even with a maintenance-free battery) ...............................................................................................................l

Check and oil other pivots and joints .......................................................................................................................l

Clean and grease the steering axle .........................................................................................................................l

Grease the mast and tilt cylinder bearings .............................................................................................................l

Clean and lubricate the sideshift, check the fasteners ........................................................................................l

Check the forks and fork quick-releases ................................................................................................................l

Check the pre-tension of double hoses if attachments are fitted......................................................................l

Check the mast, lift chains and stops for condition, mounting and operation ...............................................l

Adjust the lift chain length, lubricate with chain spray..........................................................................................l

Every

500 hours

or 12 months

Every

1000 hours

or 2 years

Every

3000 hours

Every

6000 hours

351 807 1301.0407

Renew the air filter element, check the vacuum switch

(every 1 years minimum or after 5 cleanings).....................................................................................................................................l

Check the engine mounting for condition and tightness......................................................................................................................l

Check the air intake and exhaust pipes for leaks ..................................................................................................................................l

Check the hydraulic system, compact axle, pumps, valves and lines for leaks ..............................................................................l

Hydraulic system: Renew the pressure, suction, and breather filters ...............................................................................................l

Check the soot particulate filter system (part 2) .....................................................................................................................................l

Check the parking brake ..............................................................................................................................................................................l

Clean strainer of fuel pump.........................................................................................................................................................................l

Change fule leakage line.............................................................................................................................................................................l

Check and adjust V-belt...............................................................................................................................................................................l

Check and adjust the time belt and tension pulley...............................................................................................................................l

Check crankcase pressure vent valve .......................................................................................................................................................................................l

Check the injection nozzles ..........................................................................................................................................................................................................l

Renew the V-belt.............................................................................................................................................................................................................................l

Renew the time belt and tension pulley....................................................................................................................................................................................l

Renew the hydraulic oil .................................................................................................................................................................................................................l

Renew injection valve nozzles ..................................................................................................................................................................................................................................... l

Renew the mounting of the engine (if damaged).................................................................................................................................................................................................... l

Page 50

Inspection and maintenance as required Maintenance

Clean the lift truck

NOTE

The necessity of cleaning depends on the use of the truck. If used with aggressive media such as salt water, fertilizer, chemicals, cement, etc., clean the truck thoroughly after every application. Hot steam or intensive degreasing solution should be used with the utmost care! If not, the grease in the lubricated-forlife bearings will dissolve and leak out. As regreasing is not possible, damage to the bearings will result. Do not wash the truck when the engine is hot.

ATTENTION When cleaning with a water jet (high pressure or steam jet cleaning device, etc.) do not directly

expose the electrical or electronic components as well as the connectors to the jet. If this cannot be avoided, cover them first.

Regularly remove inflammable debris especially on or in the area of parts with a high temperature such as exhaust pipes.

351 807 1301.0407

When cleaning with compressed air, remove sticking dirt with a cold cleaner. Clean the oil filler openings, surrounding areas and grease nipples before lubrication.

Cleaning and spraying the mast chain

NOTE

The mast chain must be cleaned if the dust on the chain prevents penetration of the lubricant.

- Place a container under the mast.

- Clean the chain with paraffin derivatives such as washing petrol (observe manufacturer's notes on safety).

- When using a steam jet, clean without additives.

- After cleaning, blow dry the chain at once to remove any water in the chain links and on the surface. Move the chain several times during this procedure.

- Immediately spray Linde chain spray on the chain, while also moving it.

ATTENTION Lifting chains are safety components. The use of

cold cleaners, chemical cleaning agents and caustic or acidic and chlorinated fluids can be a direct cause of damage to the chain.

Page 51

Inspection and maintenance as required Maintenance

Cleaning the air filter

NOTE

Cleaning the air filter element is necessary only when the air filter restriction indicator in the composite instrument illuminates. A restricted air filter results in loss of power and increased engine wear. Therefore careful and regular servicing of the air filter is essential to engine life and performance. Carry out all services on the air intake system with the engine stationary. Do not start engine when the filter element is removed.

- Open the engine cover.

- Screw off the wing nut (2) and remove the air filter cover (1).

- Screw out the nut (3) and pull out the air filter element (4).

Cleaning with compressed air

ATTENTION Do not clean the filter casing with compressed air, wipe it with a clean cloth.

- To clean the filter element (4), blow dry compressed air at max. 5 bar pressure from the inside to the outside until the filter is free of dust.

- Before installing the cleaned air filter element, examine it for damage eg at paper of filter element, rubber seals, for dents or bulges on the metal frame

- Using an inspection lamp, examine the paper part of the filter element for cracks and holes.

- Renew a damaged filter element.

NOTE Mark every servicing on the filter element. Discard the filter element if it has been cleaned 5 times, if

damaged, after 1000 service hours, or at least every 12 months.

- Re-install the filter element into the filter casing. Make

sure that the filter element is not damaged and that the seal on the filter casing fits properly.

- Note the arrow symbol on the dust bowl indicating the top.

- Refit the air filter cover.

351 807 1301.0407

Page 52

Inspection and maintenance as required Maintenance

Renewing the safety element

NOTE

The safety element is only installed if a prefilter* is fitted to the air filter.

Changing the safety element (5) is required:

- After cleaning the main element (4) five times.

- The number of services (renewal or cleaning) must be recorded on the appropriate marks of the safety element.

- After 2 years of operation maximum. If, after servicing the main element, the air filter warning light responds again.

- When the main element is damaged:

- Remove the air filter cover and the main element.

- Unscrew the hexagonal nut (6) and pull out the

safety element (5).

- Install the new safety element and fasten with the

hexagonal nut (6), filter element (4) and refit the air filter cover.

ATTENTION Safety elements may neither be cleaned nor reused.

* Option

351 807 1301.0407

Checking the dust discharge valve

NOTE

The dust discharge valve (7) is largely maintenance-free.

- If required, squeeze the valve and remove the remaining dust.

Replace the valve if damaged.

- Close the engine cover.

Cleaning the prefilter

NOTE

The dust bowl (3) should never be more than half filled (2) with dust. Daily servicing may be necessary under excessive dust conditions.

- Loosen clips (1) and remove dust bowl (3). Clean the dust bowl.

- Refit the dust bowl and secure with the clips.

* Option

Page 53

Inspection and maintenance as required Maintenance

* Option

Regenerate the soot particulate filter* (variant I)

NOTE

The soot particulate filter must be regenerated at least every 6 hours. The warning lamp (1) (yellow) illuminates after 5 hours as visual indicator. A maximum of 1 hour remains until regeneration is required. The on-going work should be completed and a filter change scheduled. After the 6 hours are up, the second warning light (2) (red) illuminates, accompanied by an acoustic signal. The truck must now be shut down at once and the filter either regenerated or renewed, otherwise the filter will be destroyed.

ATTENTION When the power fails (e.g. battery disconnected),

the installed hour meter is automatically reset to zero. For safety reasons, the soot particulate filter should be regenerated at once. Otherwise the exhaustion time and filter capacity will be exceeded.

Remove the soot particulate filter

- Drive to the regeneration station.

- Stop the engine.

- Open the clip (4) and swing the guard (5) away.

CAUTION Risk of burning! Use gloves.

- Remove the quick-disconnect coupling (6) by turning it anti-clockwise.

- Remove the soot particle filter (3) without jolting it.

NOTE

When the filter is removed, the built-in hour meter is automatically reset to zero by a limit switch.

Clean the soot particulate filter

- Remove the guard (16) at the regeneration station.

- Connect the soot particulate filter stress-free to the regenerator (8) with the quick-disconnect coupling (13).

- Close the insulation (15) and secure the clip (14).

- Hook the guard (16) into the pin (7).

- Turn the EMERGENCY OFF switch (10) clockwise until it disengages and pops up.

- Start the regenerator by depressing the pushbutton (9).

When starting the regenerator, check its load condition at the pressure gauge (11):

Gauge indication: green = filter new or regenerated black = regular filter load red = filter overload

Contact your authorised distributor.

NOTE

Regeneration time.........................................approx. 40 min.

Cooling time ....................................................approx. 30 min.

NOTE The air heater and fan motor stop automatically.

351 807 1301.0407

CAUTION Risk of burning! Regenerate the filter only with the guard in place. The filter surface temperature

can reach 700 oC. Observe the notice label (12).

Depress the EMERGENCY OFF switch (10) in case of danger.

- Take the soot particulate filter out of the regenerator.

- Re-install the soot particulate filter in the truck.

Page 54

* Option

Inspection and maintenance as required Maintenance

Regenerate the soot particulate filter* (variant II)

NOTE

The switches can either be mounted in the console or in a separate box on the console.

WARNING Do not fuel the truck during filter regeneration.

NOTE The soot particulate filter must be regenerated at least every 8.5 engine service hours. The yellow soot warning lamp (1) lights as visual indicator after 7.5 hours. The filter must be regenerated within the next 30 min. If this period

is exceeded, the buzzer will sound (intermittently for half an hour, then continuously). In this case shut the engine off as soon as possible and regenerate the filter.

NOTE

A regeneration can also be started before the maximum exhaustion time is reached.

351 807 1301.0407

CAUTION Perform regeneration only in the open with the engine at operating temperature and not in the vicinity of inflammable goods. The exhaust gases must not be conducted into an

air evacuation system for fire safety reasons. The exhaust gases must not be conducted into an air evacuation system for fire safety reasons.

ATTENTION The filter can be regenerated only when the engine is switched off (ignition off).

- Thoroughly clean the exhaust duct.

- If over 30 min have elapsed after stopping the engine,

briefly turn the preheating switch to position I and then back to the zero position (turn ignition on briefly and off again). The soot filter control remains active for another 30 minutes. During this period regeneration can be started.

- Unlock switch (3) by depressing the lock (4), and press

the switch for approx. 6 seconds until the built-in yellow switch light (ON indicator) illuminates. The lamp will stay on until the end of the regeneration cycle, which lasts approx. 23 minutes.

Regeneration proceeds automatically, i. e. preheating approx. 60 seconds, burning approx. 10 minutes and afterventilation approx. 5 minutes. After a successful regeneration, the switch lamp (ON indicator) will extinguish and the truck can be operated again.

area, or the regeneration must be stopped for safety reasons,

- Unlock and operate EMERGENCY-OFF- switch (2). The regeneration procedure will be stopped immediately and the truck can be started. (Only operate in an emergency, as the system can be damaged.)

If a soot alarm was signalled before the interrupted regeneration procedure, the alarm will continue. In this case a complete regeneration must be carried out.

buzzer buzzes. Start regeneration again. If a fault occurs again, shut down the truck and contact your authorised dealer.

NOTE

ATTENTION The engine cannot be started during regeneration. If the truck must be removed from a security

ATTENTION The soot particulate filter is not regenerated if the regeneration procedure is interrupted!

ATTENTION If a fault occurs during regeneration the red warning lamp in the emergency OFF (2) blinks and a

NOTE

To shut off the buzzer in the emergency OFF (2), unlock and operate. If the buzzer continues to buzz, please contact your authorised dealer.

NOTE During operation the regeneration system glow plug is cleaned every 1.75 hours by means of intermediate glow-

ing.

Page 55

Inspection and maintenance as required Maintenance

Clean and check the radiator and hydraulic oil cooler for leaks

NOTE

Only clean the radiator and hydraulic oil cooler when the engine is stopped and cool.

- Open the engine cover.

- Remove screws (1) and take off the radiator cover (2).

Cleaning with compressed air

- Clean the radiator (3) with compressed air from the engine side.

- Flush any loosened dirt off with a water jet.

Cleaning with a cold cleaner

- Clean the radiator (3) with a commercial cold cleaner and allow it to soak in for approx. 10 minutes.

- Clean the radiator with a strong water jet from the engine side.

ATTENTION Protect the alternator against the direct water jet.

- Let the engine run warm to evaporate any residual water and prevent rust formation.

- Check connectors, coolant hoses and pipes at the radiator and hydraulic oil cooler for leaks.

- Renew porous hoses, retighten loose clamps, if necessary.

- Refit the cover (2).

351 807 1301.0407

Page 56

Drain the fuel system water preseparator

ATTENTION Drain the fule system water is necessary only when water restriction indicat(A) illuminates. Follow the precautions for handling fuels and lubri-

cants.

- Press the drain pump (1) by hand, and drain off any water collected inside.

- Retighten the drain plug.

- Open the engine cover.

- Make a visual inspection for any water in the preseparator and drain it, if necessary.

- Loosen the drain plug (2) and turn out about 3-5 turn.

- Connecting a drain hose (4) to drain connector (3) , and another of drain hose (4) connecting to a suitable container .

351 807 1301.0407

- Close the engine cover.

Page 57

Inspection and maintenance as required Maintenance

Tighten the wheel fasteners

CAUTION At least every 100 hours.

- Tighten opposite wheel fasteners to a torque of:

front:............................................................................195 Nm

rear: ............................................................................400 Nm

Check the tyres for damage and foreign objects

- Secure the truck against rolling (apply parking brake).

- Chock a wheel that is not to be jacked up.

- Raise the truck with a jack until the wheels are clear of the ground.

- Secure the truck with squared timbers.

- Check the wheels for ease of rotation and remove anything hindering their free movement.

- Replace worn or damaged tyres.

Lubricate the steer axle, mast and tilt cylinder bearings

If used in clean and dry areas, truck servicing every 500 service hours is sufficient as a rule. For mixed use inside and outside, it is recommended that the lubrication interval be halved.

In an environment with dust, dirt, water and possibly de-icing salt or chemicals, weekly lubrication will extend the service life of the bearings substantially.

NOTE

Preferably lubricate the bearings with less grease more often than a lot of grease less frequently.

351 807 1301.0407

Page 58

Inspection and maintenance as required Maintenance

Check seat belt for condition and proper operation

NOTE

For safety reasons the condition and proper operation of the retention system should be inspected regularly (monthly). Under extreme operating conditions this check is required daily before taking the truck into operation.

- Pull the belt (1) out fully and inspect for fraying.

- Check the lock (3) for correct operation and the retractor for proper return of the belt.

- Check covers for damage.

- Check the automatic lock.

- Park the truck on level ground.

- Pull out the belt with a jerk.

The automatic lock should prevent the belt from

unrolling from the retractor (2).

- Slide the seat fully forward.

351 807 1301.0407

NOTE When opening the bonnet, watch out for a possibly installed rear windscreen*.

- Open the bonnet (4) about 30o. The automatic lock should prevent the belt from

unrolling from the retractor (2).

CAUTION Do not operate the truck with a faulty seat belt. Have a defective seat belt replaced immediately

by your authorised dealer.

* Option

CAUTION To prevent back injury, the weight setting should

be set to the individual weight of the driver. To prevent injuries, do not store any objects in the tilting range of the seat. To prevent accidents, check that all adjustments are properly engaged before operating the truck. Do not operate the seat adjusting devices while operating the truck. Seat belts must be applied before operation of the truck. After an accident, the seat belt must be renewed. In the case of seat belts attached to the operator seat, the seat and mounting of the seat must also be inspected by qualified personnel. Nuts and bolts should be checked regularly for tightness. A wobbling of the seat can indicate loose bolts or other faults. If malfunctions in the operation of the seat are detected (e.g. seat cushioning), contact your authorised dealer immediately to eliminate the cause. In case of nonobservance, you put your health in danger and there is a higher risk of accidents.

Page 59

500-hour inspection and maintenance Maintenance

Renew the engine oil (every 12 months minimum) Drain the engine oil

ATTENTION Follow the precautions for handling fuels and lubricants.

CAUTION Risk of scalding when draining hot engine oil.

NOTE

Change oil only when the engine is at operating temperature.

- Drive truck over a repair pit.

- Place a suitable container under the frame.

- Open the engine cover.

- Start the engine and bring it up to operating temperature (approx.80oC).

- Stop the engine.

- Remove the cap (1) from the filler opening to vent the engine crankcase and allow the engine oil to drain more easily.

- Push up the rubber mat over the opening in the floor.

- Remove the engine oil drain plug (2) on the engine sump from below.

- Allow the oil to drain completely into the container.

- After all oil has been drained from the engine. refit the drain plug .

Torque to ............................................................................ 55Nm

- Lower the rubber mat back in place.

Top up engine oil

- Remove the cap (1) on the filler opening.

- Fill new engine oil through the filler opening. Filling capacity

- with filter renewal ................................................... max. 9 L

- After refilling, check the engine oil level with the dipstick and add oil to the maximum mark, if necessary.

- Install and tighten the engine oil cap (1).

NOTE During the trial run after the oil change and filter renewal, observe the oil pressure warning light and watch for leakage at the oil drain plug and oil filter. An accurate check of the oil level, particularly after renewing the oil filter, requires stopping the engine again and rechecking the oil level after about one minute.

351 807 1301.0407

Page 60

500-hour inspection and maintenance Maintenance

Renew the engine oil filter cartridge

CAUTION Risk of scalding when draining hot engine oil.

- Stop the engine.

- Loosen the engine oil filter cover (1) using a filter spanner and remove by hand.

- Carefully loosen paper filter cartridge (3) upwards from guide (4).

- Catch any escaping oil and replace paper filter cartridge (3).

- Clean any dirt from sealing surface of filter carrier and lube oil filter cover (1) and from guide (4).

- Replace and lightly oil rubber gasket (2).

- Carefully insert new paper filter cartridge (3) into guide (4).

- Screw in the oil filter cover (1) by hand until the seal is seated, then tighten an additional 3/4 of a turn using the filter spanner.

351 807 1301.0407

Clean the radiator and hydraulic oil cooler

NOTE Only clean the radiator and hydraulic oil cooler when the

engine is stopped and cool.

- Remove the radiator cover (1). Cleaning with compressed air

- Clean the radiator with compressed air from the engine side.

- Flush any loosened dirt off with a water jet.

Cleaning with a cold cleaner

- Clean with a commercial cold cleaner and allow to soak in for approx. 10 minutes.

- Clean the radiator with a strong water jet from the engine side.

ATTENTION Protect the alternator against the direct water jet.

- Let the engine run warm to evaporate any residual water and prevent rust formation.

Check and oil the pedals, travel control and engine control linkages

ATTENTION The following work must be carried out by qualified service staff. Please contact your authorised

dealer.

- Check pedals for ease of operation.

- Check the pin and pivot circlips for tight seating.

- If necessary, slightly oil lever pivots and clevises.

Page 61

500-hour inspection and maintenance Maintenance

Cleaning the air filter

NOTE

A restricted air filter results in loss of power and increased engine wear. Therefore careful and regular servicing of the air filter is essential to engine life and performance. Carry out all services on the air intake system with the engine stationary. Do not start engine when the filter element is removed.

- Open the engine cover.

- Screw off the wing nut (2) and remove the air filter cover (1).

- Screw out the nut (3) and pull out the air filter element (4).

Cleaning with compressed air

ATTENTION Do not clean the filter casing with compressed air, wipe it with a clean cloth.

- To clean the filter element (4), blow dry compressed air at max. 5 bar pressure from the inside to the outside until the filter is free of dust.

- Before installing the cleaned air filter element, examine it for damage eg at paper of filter element, rubber seals, for dents or bulges on the metal frame

- Using an inspection lamp, examine the paper part of the filter element for cracks and holes.

- Renew a damaged filter element.

NOTE Mark every servicing on the filter element. Discard the filter element if it has been cleaned 5 times, if

damaged, after 1000 service hours, or at least every 12 months.

- Re-install the filter element into the filter casing. Make

sure that the filter element is not damaged and that the seal on the filter casing fits properly.

- Note the arrow symbol on the dust bowl indicating the top.

- Refit the air filter cover.

351 807 1301.0407

Page 62

500-hour inspection and maintenance Maintenance

Check the hydraulic system oil level

ATTENTION Follow the precautions for handling fuels and lubricants.

NOTE For the oil level check, the fork carriage of the mast must be lowered completely.

- Screw out the breather filter (1) with oil dipstick on the right

side of the truck.

NOTE The tank is slightly pressurised. Some air will escape.

351 807 1301.0407

- Wipe the oil dipstick with a clean cloth.

- Screw in the breather filter with oil dipstick fully and screw out again.

- Oil level should be between both markings on the dipstick.

- If necessary, add hydraulic oil up to the upper mark.

Capacity between max. and min. marks ........ approx. 2.0 L

Renew the fuel filter (every 12 months minimum)

ATTENTION Follow the precautions for handling fuels and lubricants. The fuel system must be bled.

- Place a suitable container beneath the fuel filter.

- Clean the exterior of the filter.

- Remove the fuel filter (1) using a filter wrench.When removing the filter , hold the bottom of the fule filter with a piece of rag to prevent the fuel oil from dropping. If you spill fuel, wipe such spillage carefully.

- Clean the sealing surface of the filter head and bowl.

- Coat the rubber gasket of a new filter with fuel.

- install the new fuel filter manually turing it clockwise until it comes into contact with the mountingsurface, and tighten it further to 1/2 turn using a filter wrench.

Page 63

500-hour inspection and maintenance Maintenance

234111132

414

Renew the fuel system water pre-separator

ATTENTION Follow the precautions for handling fuels and lubricants.

- Open the engine cover.

- Place a suitable container beneath the water separator..

- Clean the exterior of the water separator..

- Remove the fuel filter (1) using a filter wrench.When removing the separator, hold the bottom of the fule filter with a piece of rag to prevent the fuel oil from dropping. If you spill fuel, wipe such spillage carefully.

- Clean the sealing surface of the separator head and bowl.

- Coat the rubber gasket of a new filter with fuel.

- Remove the drain plug (2) from separator and fix to new separator.

- install the new separator with drain plug (2) manually turing it clockwise until it comes into contact with the mounting surface, and tighten it further to 1/2 turn using a filter wrench.

- Close the engine cover.

Bleed the fuel system

NOTE

This is required if the truck has been driven until the fuel tank is empty, the fuel pump was cleaned, or the fuel filter was changed.

- Loosen the air bleeding bolt (1) on the oil/water separator by turning 2 - 3 times to the counter-clockwise.

- Turn the starter switch to the ON position and hold it in the position for 10-15 seconds to operate the fuel feeding pump.

- When the fuel coming out is clear and not mixed with any bubbles, tighten the air bleeding bolt (1) .

Check and adjust valve clearance

Proper adjustment is necessary to maintain the correct timing for opening and closing the valves. Improper adjustment will cause the engine to run noisily, resulting in poor engine performance and engine damage.

NOTE The adjustment of the valve clearance requires special tools and skills. Please contact your authorised dealer.

- Stop the engine.

- Befor adjusting valve clearance, allow engine to cool down for at least 30 minutes. Oil temperature shold be below 80oC.

- Remove the cylinder head cover.

351 807 1301.0407

- Position crankshaft.

Page 64

500-hour inspection and maintenance Maintenance

- Check valve clearance( 1) between roker arm/tappet contactface( 2 )and valve stem (3 )with feeler gauge (there should be only slight resistance when feeler blade is inserted).

- Permissble valve clearace with cold engine: Inlet 0.3 exhaust 0.5

...................................................................................................................................................

- Adjust valve clearance if necessary: Release locknut (4). Use Allan Key (7) to turn setscrew (5) so that correct clearance to attained after locknut (4) has been tightened.

- Chek and adjust valve clearance on all cylinders.

- Reinstall cylinder head cover, with new gasket if necessary.

351 807 1301.0407

+0.1 +0.1

mm mm

Check the mounting of the compact axle at the engine

- Remove the floor plate.

- Tighten any loose bolts.

- Hexagonal bolts (4)

Torque .................................................................................64 Nm

NOTE The intermediate housing is mounted on the engine with M12bolts.

Torque .................................................................................32 Nm

Check the mounting of the engine, counterweight, overhead guard, steering axle, tilt cylinder and wheel drives for tightness

- Check the mounting of the engine, steering axle, drive axle, counterweight and overhead guard for tightness of fasteners and for wear.

- Tighten any loose nuts and bolts.

- Replace damaged parts.

- If necessary, touch up the paint coat.

- Tighten the tilt cylinder mounting bolts (1) at the frame to a torque of 275 Nm.

Page 65

500-hour inspection and maintenance Maintenance

Checking the soot particulate filter system

- Check the electric contacts for tightness, corrosion and damage.

- Check the combustion air hose for damage, leaks and security.

- Check fuel-conducting lines and parts for damage, leaks and security.

- Check the system for correct operation (soot warning, acoustic alarm, regeneration, diagnostic lamp).

- Check the burner mounting for leaks, security and deformation.

- Clean the corrugated hose and elbow (fan to burner).

Please contact your authorized distributor for the servicing.

Check electric cables, cable connectors and connections for condition and tightness

- Check cable connections for tightness and oxidation.

- Check earth lead for tightness.

- Check electric wiring for chafe marks and tightness.

NOTE Oxidized terminals and cracked cables result in loss of voltage, thus leading to starting difficulties.

- Remove oxidation remains and replace any cracked

cables.

351 807 1301.0407

* Option

Page 66

500-hour inspection and maintenance Maintenance

Battery: Check condition, electrolyte level and specific gravity

ATTENTION Even a so-called maintenance-free battery must be checked for proper condition, electrolyte level

and specific gravity.

ATTENTION Battery electrolyte is very caustic. Avoid any contact with battery electrolyte. If clothing, skin or eyes nevertheless come in contact with electrolyte, flush the areas respective immediately

with water. If electrolyte comes into contact with the eyes, seek medical aid immediately! Neutralise spilled electrolyte at once.

- Pull the battery compartment cover out of the lock at the

bottom and remove upward.

- Check the battery to see whether tray is cracked, plates

are lifted or acid has drained.

351 807 1301.0407

- Unscrew caps and check the electrolyte level. On batteries with check tubes, the liquid should be at the bottom of the tubes. On batteries without tubes, the liquid should be 10 to 15 mm above the plates.

- If the electrolyte level is low, top up with distilled water only.

- Remove any oxidation at the battery poles and grease with non-acidic grease.

- Retighten the pole clamps firmly.

- Check electrolyte specific gravity with a hydrometer. The specific gravity should be between 1.24 and 1.28.

- Engage the battery compartment cover at the top and push down into the lock at the bottom.

Check and oil other pivots and joints

Inspect and oil the pivots and mountings of:

- Seat guide, engine cover mounting pivot pin

- Windscreen wipers*

- Cab* door hinges and locks

- Check and grease the engine lock mounting and pretension.

* Option

Page 67

500-hour inspection and maintenance Maintenance

Clean and grease the steering axle

- Thoroughly clean the steering axle with water or cold cleaner.

NOTE

Lubricate with grease.

- Lubricate the track rods and stub axles with lubricating grease at the grease nipples (see arrows).

- Grease with a grease gun unti fresh grease is visible at the bearings.

Grease the mast and tilt cylinder bearings

- Lubricate the nipples of the tilt cylinder bearings at the frame with grease.

- Lubricate the nipple of the mast bearing on the left and right side of the frame with lubricating grease.

- Lubricate the nipple of the tilt cylinder bearing on the left and right side of the mast from the front lubricating grease with lubricating grease.

- Lubricate with a grease gun until fresh grease emerges at the bearings.

- Install the floor plate, close the bonnet.

351 807 1301.0407

Page 68

500-hour inspection and maintenance Maintenance

Clean and lubricate the sideshift*, check the fasteners

NOTE

Use lubricating grease for lubrication.

- Clean the sideshift with a steam jet.

- Inspect the hydraulic lines for chafing, replace if required.

- Inspect the hydraulic lines and fasteners for security and wear; tighten or renew as required.

- Lubricate the grease nipples depending on version A, B or C at the fork carriage with lubricating grease until fresh grease emerges at the side.

NOTE The sideshift must be greased every time the truck is washed.

* Option

351 807 1301.0407

Page 69

500-hour inspection and maintenance Maintenance

Check the forks and fork quick-releases

- Inspect the forks for visible distortion, wear and damage.

- Check the bolts fork stops and fork quick-releases for correct seating and damage.

- Replace any damaged parts.

Check the pre-tension of double hoses if attachments are fitted

- The pre-tension of double hoses should be 5 - 10 mm per metre referred to initial length.

- Adjust the pre-tension to the specified tension by shifting the hoses in the clamps.

351 807 1301.0407

Page 70

500-hour inspection and maintenance

Maintenance

Check the mast, lift chains and stops for condition, mounting and operation

- Clean the mast channels and chains.

- Inspect the chains for condition and wear, especially in the pulley area.

- Check the chain security at the chain anchor.

- Replace any damaged chains.

NOTE

Damaged or missing plastic links do not reduce the function and service life of the chain.

- Check mast, channels and rollers for condition and security.

- Check the mast pivot bracket bolts for tightness.

- Check the condition, mounting and operation of the stops.

351 807 1301.0407

Adjust the lift chain length

NOTE

As lift chains stretch with use, they must be adjusted, on the left and right hand side.

- Completely lower the mast.

- Loosen the locknut (1).

- Adjust chain length with the adjusting nut (2) at the chain anchor. The lower guide pulley on the fork carriage can project max. 25 mm from the inner mast channel.

- Tighten the locknut (1).

- Also adjust the second chain.

Lubricate with chain spray

- Spray channel surfaces, pulleys and chains with Linde chain spray.

NOTE Trucks in service in the food industry must be lubricated with a special oil instead of chain spray.

* Standard mast only

Adjust the mast chain length

NOTE

As mast chains stretch with use, they must be adjusted.

- Completely lower the mast and fork carriage.

- Loosen the locknut (1).

- Adjust chain length with the adjusting nut (2) at the chain anchor. The lower guide pulley on the fork carriage can project max. 25 mm from the inner mast channel.

- Tighten the locknut (1).

Lubricate with chain spray

- Spray channel surfaces, pulleys and chains with Linde chain spray.

NOTE Trucks in service in the food industry must be lubricated with a special oil instead of chain spray.

* Duplex and triplex mast only

Page 71

1000-hour inspection and maintenance Maintenance

Renew the air filter element, check the vacuum switch

(Every 12 months minimum or after 5 cleanings)

NOTE

The safety element* in the air filter must be changed after 5 cleanings.

- Open the engine cover.

- Unscrew the wing nut (2) and remove the air filter cover (1).

- Unscrew nut (3) and remove the air filter element (4).

* Option

ATTENTION Thoroughly clean the inside of the air filter casing. Do not clean with compressed air, but wipe with

a clean cloth.

- Take care not to damage the element during installation, and be sure that the correct end is in.

- Fasten element with nut (3) and mount the filter cover.

- Remove the hose (5) from the air inlet.

- With the engine running, slowly close the air filter intake opening (eg with a cardboard or metal plate) until the air filter restricted warning light in the composite instrument lights up. To prevent damage, do not close the opening further after the warning light illuminates.

NOTE If the air filter restriction indicator light is not illuminated, please contact your authorised distributor.

- Refit the hose (5).

Check the engine mounting for condition and tightness

The flexible engine mountings are subject to great stresses. Depending on the operating conditions, their service life is limited.

- Check the rubber mounts for cracks and replace, if necessary.

NOTE

Please contact your authorised distributor.

351 807 1301.0407

Page 72

1000-hour inspection and maintenance Maintenance

Check the air intake and exhaust pipes for leaks

- Check the combustion air hoses on the air filter for condition and tightness. If necessary, re-tighten hose clamps and replace any porous hoses.

- Examine the air intake and exhaust manifolds at the cylinder head. If they prove not to be tight, retighten the fastening bolts or replace the gaskets.

- Inspect the exhaust pipe for leaks at the manifold and tighten the fastening screws or renew the gasket, if necessary.

351 807 1301.0407

- Remove the cover (1) at the counterweight.

- Check the mounting, connections and air tightness of the exhaust pipe in the counterweight, tightening the mounting screws if necessary.

- Install the counterweight cover.

Check the hydraulic system, compact axle, pumps, valves and lines for leaks

- Remove the floor plate.

- Examine all connections between the oil reservoir, compact axle, pumps and control valves for leaks. Tighten any loose connections.

- Inspect the lift, tilt and steering cylinders for leaks.

- Replace any porous hoses.

- Examine pipes and hoses for chafe marks and replace, if necessary.

Page 73

1000-hour inspection and maintenance Maintenance

Hydraulic system: Renew the pressure, suction, and breather filters Renew the pressure filter

ATTENTION Follow the precautions for handling fuels and lubricants.

- Lower the front cover.

- Lower the mast

- Loosen filter housing (1) with a filter spanner.

- Remove the filter with the hand.

NOTE Place a clean cloth beneath the filter to collect any hydraulic oil flowing out.

- Fill the new filter with oil and coat the seal with oil.

- Install the filter and tighten the filter approx. 3/4 of a turn

after the seal contacts the filter housing. Use a strap-type spanner.

- Check the filter flange for leaks in a trial run.

Renew the suction filter

- Remove the front cover.

- Loosen and remove the filter cover (2).

- Draw out the filter element (4) slowly so that the oil can flow back into the tank.

- Then draw out the filter completely.

- Carefully insert a new filter element into the filter bowl.

- Clean the seal (3) on the filter cover (2) and coat it with oil.

- Refit the filter cover (2).

- The hydraulic system is bled automatically when the engine is running.

- Check for leaks at the filter cover in a trial run.

- Install the front cover.

351 807 1301.0407

Page 74

1000-hour inspection and maintenance Maintenance

Renew the breather filter

- Screw the hydraulic oil tank breather filter from the filler neck.

- Unscrew the dipstick (2) from the breather filter (1) and mount onto the new filter.

NOTE

In a dusty atmosphere it may become necessary to renew the filter earlier.

- Install the floor plate.

- Close the engine cover.

351 807 1301.0407

Check the soot particulate filter system* (variant II)

- Inspect the filter mounts for security.

- Check the parts conducting exhaust gases for leaks.

- Clean the air intake tube at the burner (for this loosen the olive fitting and remove any soot with a round wire brush).

- Check the screws on the filter casing and parts conducting exhaust gases for tightness.

Please contact your authorised distributor for these services.

* Option

Check the parking brake

Drive the lift truck with the maximum load onto a 15 % slope.

- Depress the brake pedal (1).

- Place the parking brake lever (2) in the up position. The brake pedal will lock. The truck must not move.

- Release the parking brake lever (2). The brake pedal will return to its initial position.

- Stop the engine. The lift truck must not move.

NOTE

If the parking brake is not operating correctly, contact your authorised distributor.

Page 75

1000-hour inspection and maintenance Maintenance

Clean strainer of fuel pump

- Stop the engine.

- Open the engine cover.

- Loosen ang unscrew hexagonal nut (1).

- Remove fuel strainer cover (2) (cover and strainer, one unit).

- Clean fuel strainer (2) with diesel fuel. Replace if necessary

- Place seal (3) in position.

- mount fuel strainer cover (2).

- Tighten hexagonal screw (1)

- Check for leaks.

ATTENTION Keep naked flames away when working on the fuel system. Do not smoke!

Check the V-belt

- Open the engine cover.

- Visually inspect entire V-belt for damage.

- Replace damaged V-belts.

- After installing new belts, run engine for 15 minutes, then check belt tension.

NOTE

Chek, tension and change belts only with engine off. Refit

belt guard, if provided.

- To check tension of V-belt, use tension gauge.

- Position guide (3) on V- belt (2), midway between pulleys, with stop against edge of belt.

- Push slowly on black pad (4) at right angles to V-belt (2) unit spring is heard or felt to trigger.

- Carefully remove gauge without altering position of indicator arm (1).

- Read off value where black indicator arm (1) inter acts scale (5 arrow) . Tension: Pretension 450N Retension (after engine has been runing under load 15 minutes) 350N

- If necessary, retension belt and measure again.

351 807 1301.0407

Page 76

1000-hour inspection and maintenance Maintenance

351 807 1301.0407

Tighten the V-belt

- Open the engine cover.

- Slacken of bolt (1) (2) and (3).

- Adjust alternator (4) in directon of arrow by tuning bolt (3) until correct belt tension is achieved. Tension:

Pretension 450N Retension (after engine has been runing under load 15 minutes) 350N

- Retighten bolt (1) (2) and (3).

- Close the engine cover.

NOTE

Chek, tension and change belts only with engine off. Refit

belt guard, if provided.

Check and adjust the time belt and tension pulley

NOTE

Chek, tension and change belts only with engine off.

- Open the engine cover.

- Check the time belt (1) for excessive wear, broken -out flanks,breks and traces of oil.

- Adjust tension pulley (3) until the proper time belt tension is achieved.

- Close the engine cover.

NOTE As this maintenance requires special tools and skills. Please contact your authorised dealer.

Page 77

3000-hour inspection and maintenance Maintenance

Check crankcase pressure vent valve

－ Open the engine cover. － Remove the M10 bolt (1). － Remove the ctrankcase pressure vent valve (3)

and seal (2).

－ Clean the ctrankcase pressure vent valve (3)

and seal (2) use cleaning diesel oil.

－ Dry the ctrankcase pressure vent valve (3)

and seal (2).

－ Install the seal (2) on the ctrankcase pressure vent

valve (3).

－ Install the the ctrankcase pressure vent

valve (3) with seal (2) , and screw the M10 bolt (1).

- Close the engine cover.

Check the injection nozzles

Open the engine cover.

- Remove the injection valve.

- Inset injection valve in holder.

- Unscrew nozzles clamping nut with long socket.

- Check the njection nozzles as belower.

- Renew any damaged njection nozzles.

- Close the engine cover.

NOTE

Do not touch the nozzle needle with your fingers.

NOTE As this maintenance requires special tools and skills. Please contact your authorised dealer.

Renew the V - belt

- Open the engine cover.

- Slacken of bolt (1) (2) and (3).

- Adjust alternator (4) in directon of arrow by tuning bolt (3) to slacken belt.

- Remove and replace belt.

- Adjust alternator (4) iagainst directon of arrow by tuning bolt (3), until correct belt tension is achieved.

- Retighten bolt (1) (2) and (3).

- Close the engine cover.

NOTE

Chek, tension and change belts only with engine off. Refit

belt guard, if provided.

351 807 1301.0407

Page 78

3000-hour inspection and maintenance Maintenance

Renew the time bell and tension pulley

NOTE As this maintenance requires special tools and skills. Please contact your authorised dealer.

351 807 1301.0407

Renew the hydraulic oil

Draining the hydraulic oil

NOTE

The fork carriage must be lowered completely.

ATTENTION Follow the precautions for handling fuels and lubricants.

- Drive the truck over a repair pit.

- Put a container under the lift truck at the right side.

- Open the engine cover.

- Remove the breather filter with the oil dipstick (2).

- Remove the hydraulic oil drain plug (1) at the hydraulic oil tank.

- Allow the oil to drain completely.

- Clean the area around the oil drain thoroughly.

- Re-install the drain plug.

Torque .................................................................................25 Nm

Filling/adding hydraulic oil

Capacity

- without draining the hydraulic unit............approx. 38.5 L

Total capacity:

- incl. filling of hydraulic unit.........................approx. 47.0 L

- Fill hydraulic oil at the filler opening.

- Check the oil level with the dipstick (2) and fill oil until the upper mark on the dipstick is reached.

- Run the engine briefly and repeat the check.

NOTE The hydraulic system is bled automatically when the engine is running.

Page 79

6000-hour inspection and maintenance Maintenance

Renew the injection nozzles

Open the engine cover.

- Remove the injection valve.

- Inset injection valve in holder.

- Unscrew nozzles lock nut (6) with long socket.

- Renew the njection nozzles (5).

- Complete the injection valve and install on engine

- Close the engine cover.

NOTE

Do not touch the nozzle needle with your fingers.

NOTE As this maintenance requires special tools and skills. Please contact your authorised dealer.

Renew the mounting of the engine

The flexible engine mountings are subject to great stresses. Depending on the operating conditions, their service life is limited.

- Remove the engine and renew the mounting of the engine .

NOTE

Please contact your authorised distributor.

351 807 1301.0407

Page 80

Inspection and maintenance data Maintenance

No. Assembly Aids/Oils and lubricants Filling capacity/Settings

1 Engine Engine oil 9 L 2 Valve clearance Intake valve 0.30 mm

(with engine warm or cold) Exhaust valve 0.50 mm

3 Fuel tank Diesel fuel 45.0 L

4 Hydraulic system Hydraulic oil without filling hydraulic unit approx. 38.5 L

with filling hydraulic unit approx. 47.0 L 5 Battery Distilled water As required 6 Tyres Air See information on label on inside of

overhead guard

7 Wheel fasteners tighten front: 195 Nm

rear: 400 Nm 8 Mast and tilt cylinder pivots Lubricating grease As required 9 Lift chains, mast channels Linde chain spray As required

351 807 1301.0407

10 Fuel injection nozzle Diesel Operating pressure 210 bar 11 V-belt tension

- Fan - Alternator See page 75 See page 75

Page 81

Fuel and oil recommendations

Engine oil

Lube oils are differentiated by Deatz according to their performance and quality class.

Oils of other, comparable specifications can be used.

Oil grades

Trucks equipped with a soot particulate filter should only be operated with ash-free oils. Residues from the combustion of additives (ash) cannot be regenerated and they will eventually clog the monolith in the long run. During engine operation, part of the oil serving as a lubricant for the piston is combusted ("onsumed"). The products of combustion and the high temperatures combined lead to "wear", particularly of the chemical oil additives. For this reason the oil must be changed at certain intervals.

Since this oil wear depends on the operating conditions and the quality of the oil (oil performance) and fuel used, oil change intervals of different lengths result. The longest possible oil change interval for lubricating oil in the engine is one year. This means that the oil must be renewed at least once every year, regardless of the oil change intervals.

Oil viscosity

SAE viscosity 20W-20 (Standards of Society of Automotive Engineering).

There are no limits to using oils with higher specifications. Since the viscosity of lubricants varies with temperature, the

ambient temperature at the site determines the viscosity class (SAE class) of the engine oil (see diagram). If the ambient temperature occasionally falls below the temperature limit (e.g. using SAE 15 W-40 at -15oC/5oF), the cold start capability of the engine can be reduced, but no damage to the engine will result.

If the viscosity of the oil is too high, the engine will experience starting problems. Therefore the ambient temperature when the engine is started determines the grade of oil to be used in winter. Seasonal oil changes can be avoided by using multigrade oils. The specified oil change intervals also apply to multigrade oils.

NOTE Oil additives of any kind must not be added to any of the above-mentioned engine oils! Their use will void the engine

warranty! The mixing of different types of oil should be avoided. Since the temperature ranges of adjacent SAE classifications overlap, the oil does not need to be changed when short-term temperature fluctuations occur.

NOTE For problem-free cold starts it is important to select the

viscosity of the engine oil (SAE grade) on the basis of the ambient temperature when starting the engine. At temperatures below -10 oC, SAE grade 5 W-30 engine oil is recommended.

351 807 1301.0407

CAUTION The used oil must be kept out of the reach of

children until disposed of in accordance with laws and regulations. Do not allow the oil to get into the sewage system or seep into the ground.

Due to the disposal problem, the necessary special tools and special knowledge, have your authorised distributor renew the engine oil and filter.

Page 82

Fuel and oil recommendations

Diesel fuel

Use only Diesel fuel to EN 590 with a cetane number not lower than 45.

The following fuel specifications / standards are approved:

- DIN EN 590

- BS 2869

- ASTM D 975-96, 1-D and 2-D

- NATO code F-54 / F-34 / F-44 and X F 63 The sulphur content should not exceed 0.5 %. If the sulphur

content is 0.5 to 1 %, the oil change intervals must be halved. If the values are higher, contact the manufacturer of the lift

truck or the supplier of the lubricant.

NOTE

As the ambient temperature decreases, so does the viscosity of Diesel fuel due to the precipitation of paraffin. If "summer grade" diesel fuel is used, malfunctions can result. For this reason, "winter grade" diesel fuel that functions reliably at temperatures down to about

-22 oC is available in the cold season of the year.

In winter, fill only winter diesel fuel to prevent any clogging caused by paraffin precipitation. At very low temperatures you

351 807 1301.0407

must reckon with disturbing precipitations even if winter diesel fuel is used. Please first contact your authorised dealer.

CAUTION For the use of plant diesel fuel (RME acc. to

DIN 51606 / preliminary norm) some important items have to be observed. Please first contact your authorised dealer.

Winter - grade fuel

At temperature below -15oC to - 20oC, kerosene should be added to the diesel fuel. The relevant percentages are given in the adjacent diagram.

If summer-grade diesel fuel must be used at temperatures below 0oC, up to 60% kerosene canbe added ( see diagram).

Lubricating grease

Linde heavy duty grease with additives EP and MOS2. Designation acc. to DIN 51825-KPF 2N-20 (see the Parts

Catalogue for the order number). Any mixing with grease types other than lithium-based greas-

es is not allowed.

Hydraulic oil

Recommendation for normal duty: Hydraulic oil ISO - L - HM 68 to ISO 6743 - 4 or HLP ISO VG 68

to DIN 51524, T.2 (factory filling), average continuous oil temperature 60 oC - 80 oC.

Hydraulic oil recommendation for heavy duty: Hydraulic oil ISO - L - HM 100 to ISO 6743 - 4 or HLP ISO VG 100

to DIN 51524 T.2 for heavy duty and multi-shift operation, operation in extreme climate zones or high ambient temperatures, average continuous oil temperature over 80 oC.

For normal and heavy duty: Hydraulic oil ISO - L - HV 68 to ISO 6743 - 4 or HVLP ISO VG 68

to DIN 51524 T.3 (multigrade oil).

NOTE

The choice of the correct oil is determined by the oil temperature in the hydrostatic transmission.

The above-mentioned recommendations are only approximate values.

Bio hydraulic oil

Biologically fast-degradable pressure fluid

Aral Forbex SE 46

ATTENTION Do not mix bio-oils with mineral oils. Other fluids from other manufactures cannot be recommended.

NOTE

If in doubt, contact your authorised distributor. Recommendations of representatives of the oil industry

should also be checked with your authorised distributor. Only the above-mentioned oils are approved by the manu-

facturer. If other hydraulic oils are used or mixed, costly damage can result.

Battery grease

Non-acidic grease (pole grease).

Chain spray

Linde chain spray (see the Parts Catalogue for the order

Page 83

Troubleshooting guide (Diesel engine)

Trouble Possible Cause Correction See Page

Engine will not start Fuel tank empty.

Fuel filter clogged, in winter by paraffin deposit. Water in fuel system water preseparator. Fuel solenoid fails to open.

Fuel line leaking. Charging indicator light not illuminated

although lamp is okay. Fuel pump defective.

Injection nozzles defective. Injection pump defective. Engine idling speed incorrect.

Engine starting performance Battery power is too low. Battery terminal

is poor loose or oxidized, causing the starter to turn only slowly.

Fuel supply insufficient. Restriction or air in fuel system due to paraffin deposits in winter.

Particularly in winter: Engine oil viscosity too high.

Refill fuel. Renew the filter, bleed the fuel system, use winter fuel. Drain the water preseparator. Check for electric current with test lamp. If there is no current, check fuse F1 and switch.

Check all pipe connections for leaks and tighten fittings. Tighten connecting clamps at battery, check cable connections.

These faults should always be checked and corrected by skilled staff.

Please contact your authorised distributor.

Check battery, clean battery terminals, tighten clamps and cover with non-acidic grease.

Renew the fuel filter, bleed the fuel system. Check the fuel line connections for leaks and tighten fittings. Use winter fuel in the cold season.

Use engine oil appropriate for the ambient temperature.

21 61, 81 62

64, 65

351 807 1301.0407

62 81

Buzzer buzzes and the fault warning lamp blinks after switching on the ignition switch

Fault exist in the switch lighting of the start or emergency OFF, when no illumination for the soot particulate filter system exist

Fault in soot particulate filter system

Conducting a lamp test Switch on the ignition switch. Both warning lamps illuminate 1x short, if this is not the case, replace the warning lamps. (Regeneration is possible, after the lamp fault has been corrected, by pressing the fault warning button to acknowledge)

Please contact your authorised dealer.

25, 52

Page 84

Troubleshooting guide (Diesel engine)

Trouble Possible Cause Correction See Page

Engine running unevenly with poor performance

Exhaust smokes excessively Poor compression due to burned-in or broken pis-

Idle running trouble Fuel system not in order.

351 807 1301.0407

composite instrument illuminated. Stop the engine immediately.

ATTENTION Engine overheating, red warning light in

Fuel supply insufficient. Restriction or air in fuel system due to paraffin deposits in winter.

Injection pump overflow valve not functioning correctly.

Valve clearance not as specified. Injection nozzles defextive. Engine oil level too high.

ton rings or incorrect valve clearance.

Speed setting incorrect.

Oil level low.

Fan V-belt either slack or broken. Radiator fins restricted due to dirt or foreign

objects.

Renew the fuel filter, bleed the fuel system. Check the fuel line connections for leaks and tighten fittings. Use winter fuel in the cold season.

Contact your authorised distributor.

Adjust valve clearance. Contact your authorised distributor. Drain oil to the top mark on the dipstick.

Adjust valve clearance. Contact your authorised distributor.

Drain water preseparator and renew fuel filter. Check fuel lines and injection lines for leaks, bleed the fuel system.

Should only be adjusted by skilled staff. Contact your authorised distributor.

Check oil system for leaks, seal if necessary. Add oil.

Tighten or renew the V-belt. Clean the radiator.

62 81

62 21

62, 71

21, 58

75 54

ATTENTION Engine oil pressure too low.

Stop the engine immediately.

Charging indicator light illuminated during operation

Injection system setting incorrect.

Leaks in the lubricating system. Oil level too low.

Alternator RPM too low. Alternator not charging the battery because alter-

nator or relay defective.

Contact your authorised distributor.

Contact your authorised distributor. Add lubricating oil.

Contact your authorised distributor.

21, 58

75Check V-belt tension.

Page 85

Troubleshooting guide (hydraulic system)

Trouble Possible Cause Correction See Page

Abnormal noise Suction filter restricted.

Suction hoses leaking, oil foaming. Hydraulic pump or motor failure, seals defective, causing air intake. Incorrect oil viscosity, low oil level in tank or in hydraulic pump.

No or too low pressure in system

Oil pressure fluctuates

No oil flow or low oil flow Filter restricted (if accompanied by noise).

Pump suction defective, noise. Pump failure, leakages, pressure valves do not close, valve seat damage. Pipe broken or leaky. Oil of low viscosity, causing high leakage losses. Oil temperature warning lamp illuminated.

Cause as under abnormal noise. Pressure limiting valves or boost pressure valves sticking. Lift and tilt cylinders have tight spots. Mast does not extend completely or retracts slightly after being extended.

Pump failure, leakages, pressure limiting valves do not close, valve seat damaged. Pipe broken or leaky. Valves restricted. Hydraulic system overheating.

Renew the filter. Tighten lines. Check oil level, top up if necessary. Have hydraulic unit inspected by your authorised distributor. Change oil, be sure to use the correct viscosity, top up oil.

Change oil, top up oil. Contact your authorised distributor.

Replace or tighten line, Change oil, be sure to use oil of correct viscosity. Check oil level, clean oil cooler.

See abnormal noise. Contact your authorised distributor.

Contact your authorised distributor. Top up hydraulic oil.

Clean or replace filter. Contact your authorised distributor.

Replace or tighten line. Contact your authorised dealer. Check oil level, use specified oil, clean oil cooler, if needed.

72 71

77, 81

61, 77, 81

71 60, 77, 81 54, 61

351 807 1301.0407

71 54, 61, 81

Hydraulic oil temperature too high

Pump failure, valves leaky. Oil level too low or oil cooler defective.

Contact your authorised distributor. Check oil level, if necessary top up oil. Clean cooler and check for leaks. If defective, contact your authorised distributor.

54, 61

Page 86

Wiring diagram

1A1 Pre-heating controler F1 Fuse, MTA Maxifuse 50 A

F2 Fuse 5 A F3 Fuse 5 A F4 Fuse 5 A F5 Fuse 10 A F7 Fuse, 5 A F8 Fuse, MTA Maxifuse 50 A

G1 Alternator with regulator G2 Battery 12 V

H1 Battery charging lamp, 2 W H2 Warning, electr. control H3 Engine oil temperature warning lamp, 1.2 W H4 Hydraulic oil temperature

warning lamp, 1.2 W H5 Engine oil pressure warning lamp, 1.2 W H6 Air filter restriction warning lamp, 1.2 W H12 Flasher indicator lamp, 1.2 W* H13 Low fuel level warning lamp, 1.2 W H24 Cooling fan H25 Preheating 1.2 W H26 Soot filter warning lamp 1.2 W* 4H1 Horn 48 W

351 807 1301.0407

9H9 Control lamp, water separator 9H10 Control lamp, water separator

K2 Starter relay K3 Aux. relay terminal 15

R2 Glow plug S1 Ignition switch

S2 Engine temperature switch S3 Hydraulic oil temperature switch S4 Engine oil pressure switch S5 Air filter vacuum switch S6 Fuel level warning light switch S14 Brake pedal switch (start inhibit) 1S1 Travel direction switch*

(single-pedal model only)

4S8 Horn button V1/V3 Decoupling diode X1 Connector 16 pins

X2 Power connector 1 pin X3 Connector 3 pins 7X7 Connector 2 pins, soot filter* connection

1Y3 Fuel shutoff solenoid

(a) Soot filter* (b) Wiring diagram for optional turn signal indicator

Colour code

BU blue BN brown YE yellow GN green GY grey RD red BK black WH white VT violet OG orange

The number before the cable colour indicates the cross section of the cable.

Cables without indication of the cross section = 0.75 mm

M1 Starter 3 kW P1 Hour meter

6P3 Composite instrument

Page 87

Wiring diagram

Ｄｉｅｓ　ｉｓｔ　ｅｉｎ　Ｈｉｌｆｓｍｉｔｔｅｌ

351 807 1301.0407

Page 88

Wiring diagram (options)

5E2 Dip beam, left 55 W 5E3 Dip beam, right 55 W 5E4 Side light, front left 5 W 5E5 Side light, front right 5 W 5E6 Side light, rear left 5 W 5E7 Side light, rear right 5 W 5E8 License plate light 5 W 9E21-26 Working lights 55 W

5F5 Fuse 10 A 5F6 Fuse 10 A 5F7 Fuse 5 A 5F8 Fuse 5 A 5F9 Fuse 15 A 5F10 Fuse 15 A 9F4 Fuse 10 A 9F5 Fuse 10 A 9F11 Fuse 15 A 9F12 Fuse 15 A 9F13 Fuse 15 A

5H8 Turn signal light, front left 21 W 5H9 Turn signal light, rear left 21 W 5H10 Turn signal light, front right 21 W 5H11 Turn signal light, rear right 21 W 5H18 Switch illumination 1.2 W

351 807 1301.0407

5H19 Switch illumination 1.2 W 9H3 Switch illumination 1.2 W 9H4 Switch illumination 1.2 W 9H16 Switch illumination 1.2 W 9H17 Switch illumination 1.2 W

5K1 Flasher unit 9K5 Wiper relay, front 9K6 Wiper relay, rear

9M1 Wiper motor, front 30 W 9M2 Wiper motor, rear 30 W

5X1 Connector, 8 pins 5X2 Connector, 6 pins 9X1 Connector, 6 pins 9X2 Connector, 3 pins 9X2a Connector, 3 pins 9X7 Connector, 6 pins 9X8 Connector, 6 pins

(I) Working lights (II) Lighting (III) Directional indicator and hazard warning system (a) Wiring diagram, standard equipment (IV) Wiper, front (V) Wiper, rear

Cable colours

BU blue BN brown YE yellow GN green GY grey RD red BK black WH white VT violet OG orange

The number before the cable colour indicates the cross section of the cable.

Cables without indication of the cross section = 0.75 mm

5S11 Light switch 5S12 Hazard warning light switch 5S13 Turn signal switch 9S1 Front working light switch 9S2 Rear working light switch 9S3 Wiper switch, front 9S4 Wiper switch, rear

Page 89

Wiring diagram (options)

351 807 1301.0407

Page 90

351 807 1301.0407

Page 91

Hydraulic circuit diagram

A Service hydraulics

1 Working cylinder (auxiliary hydraulics) 2 Working cylinder (auxiliary hydraulics) 3 Tilt cylinder 4 Slow lowering valve 5 Standard mast 6 Duplex mast 7 Triplex mast 8 Control valve block assy. comprising: 9 Directional control valve - auxiliary hydraulics 10 Directional control valve - auxiliary hydraulics 11 Pressure holding valve (pilot controlled) 12 Directional control valve - tilting 13 Directional control valve - lifting 14 Pressure reducing valve 15 2/2-way valve (pressure balance) 16 Pressure relief valve

Standard Duplex Triplex H 25 175 +5 bar 175 +5 bar 185 +5 bar H 30 200 +5 bar 200 +5 bar 205 +5 bar

17 Check valve 18 Shuttle valve

B Shuttle valve C Check valve 1 bar D Oil cooler E Steering control valve comprising:

19 Maximum pressure valve 120 +5 bar H 20 - 30 20 Steering control valve 21 Suction valve 22 Hose safety valve 180

+20

bar H 25 - 30

G Compact axle AK 30-02 assembly com-

prising:

23 Directional control valve, selection of direction (sin-

gle-pedal model)* 24 Bypass valve (towing device) 25 Pressure reducing valve 4 - 10 bar 26 4/3-way valve travel direction 27 Pressure relief valve 11 bar 28 2/2- way valve 12 bar 29 3/2- way valve - speed control signal 30 5/3- way valve - brakes 31 2/2- way valve 5 bar (lock-out logic) 32 Slave piston 33 3/2- way valve (lock-out logic) 34 Boost pressure valve 17.5 bar 35 Pilot valve 36 Control piston 37 Variable-displacement pump 38 Hand pump - release of multiple disc brake 39 Fixed-displacement hydraulic motor 40 Maximum pressure valve 41 Multiple disc brake

L Tandem pump assembly comprising:

42 Check valve 43 Priority valve 21 l/min 44 2/2-way valve 45 Gear pump 46 Gear pump

H Oil filter, 9 μm rating

J Control piston speed control 5-14 bar K Engine

n = 800 ... 2100 rpm (H 20 - 30)

M Suction filter 0.25 bar, 15 μm N Oil tank with:

47 Breather filter with suction and pressurising valve

0.35

+0,15

bar

351 807 1301.0407

F Steering axle

* Option

Page 92

Hydraulic circuit diagram

351 807 1301.0407

３５１　８０２　０２５２ｂ

Page 93

Linde (China) Forklift Truck Com.Ltd

No. 89 JInshang Road, Xiamen 361009 P.R .China

Tel +86 -592- 5533800 Fax +86 -592- 5533381

351 807 1301 0407

351 807 1301.0407