Operating Instructions

Linde Fork Lift Truck

Type 351
H 20 - 02 / H 25 - 02 / H 30 - 02
With Diesel Engine

351 804 3001 E

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.
For attachments, the proprietary 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.
This manual tells you all you need to know about star-
ting, running, servicing and maintaining your Linde lift
truck.
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 guidelines for the
normal and proper use of industrial trucks (VDMA) con-
cerning safe operation and accident prevention of fork
lift trucks, as well as to 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 person-
nel.
The user, and not Linde, is responsible for any danger
arising from applications not authorized by the manufac-
turer.
If you desire to use the truck for applications not mentio-
ned in the manual and convert or supplement it for this
purpose, please first contact your authorized Linde dea-
ler.
No changes, especially conversions or modifications,
may be made on your fork truck without the prior permis-
sion of the manufacturer.
Only qualified persons authorized by Linde are allowed
to service the trucks.
To keep your warranty valid, all maintenance services
must be performed by qualified persons authorized by
Linde.
2
Technical note Truck takeover
These operating instructions or excerpts thereof may Every fork truck undergoes careful inspection before
only be copied, translated or transmitted to third parties leaving the factory in order to make sure that it will be in
after prior written approval by the manufacturer. satisfactory condition and fully equipped as ordered
when delivered to the customer. Authorized distributors
Linde pursues a policy of continuous progress in the
are under obligation to re-inspect the truck before delive-
design and construction of its products. As a result, the
ry and to hand it over in good order.
illustrations and technical details referring to design,
fittings and engineering of lift trucks are subject to In order to avoid later complaints and inconvenience to
change if progress warrants it. customers, you are requested to ascertain that the truck
is in satisfactory condition and fully equipped at the time
Therefore, the manufacturer will not accept any claims
of delivery and to acknowledge orderly handing/taking
based on the specifications, illustrations and descrip-
over of the truck in the manufacturer’s certificate of
tions contained in this operating manual.
conformity.
Please submit all enquiries concerning your fork truck
The following technical manuals are supplied with each
and all orders for spare parts to your authorized distri-
fork truck:
butor, making sure to state your correct shipping ad-
dress.
1 Operating manual
For repairs, use only genuine Linde spare parts to ensure 1 EC certificate of conformity
that your Linde fork truck will maintain its original tech- (The manufacturer certifies that the industrial truck
nical standard. conforms to EC guidelines for machines)
1 Safety rules for the use of industrial trucks (VDMA)
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: __________________________
Handing-over date: _______________________________
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. We wish you satisfactory operation.
Linde AG
Werksgruppe Flurförderzeuge und Hydraulik
Aschaffenburg
TYPE PLATES
1 Lift truck type plate
2 Manufacturer
3 CE symbol 1 10 11
(The symbol certifies that EC guidelines for machines
and all applicable guidelines are fulfilled.)
4 Serial No./year
5 Unladen mass
6 Battery voltage
7 Battery mass
8 Rated capacity
9 Type
10 Serial number (stamped)
11 Mast number (stamped)
12 Compact axle type plate
13 Engine number type plate

13 12 351/02-01

3
FORK LIFT TRUCK TYPE 351 H 20 - 02 / H 25 - 02 / H 30 - 02 WITH DIESEL ENGINE
Most advanced technology,
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 8600 employees in seven plants.

351-02/02
Driver’s position and operating features are according to
the latest findings of ergonomics. Each control is de-
signed in regard to positioning and operation for the
driver’s convenience to guarantee effortless and therefo-
re safe operation.

Of course, this also includes the easy hydrostatic power

steering with a kick-back safety, the service-proved doub-
le-pedal travel control system: forward travel with the
right foot, reversing with the left, and only one main
control lever for all mast functions.

4
TABLE OF CONTENTS
Page Page Page

Description ............................................................... 2 Reverse travel ................................................................ 21 Towing procedure ...................................................... 36

Approved applications .................................................. 2 Changing the travel direction ....................................... 21 Releasing the wheel drive brake pressure .............. 36
Technical note ................................................................ 2 Single-pedal model ........................................................ 22 Opening the hydraulic by-pass valve ...................... 36
Truck takeover ............................................................... 2 Steering system, Braking system ................................ 25 After towing ................................................................ 36
Type plates ..................................................................... 3 Steering ....................................................................... 25 Re-establishing braking power ................................. 36
Technical data ................................................................ 7 Service brake .............................................................. 25 Taking the truck out of operation ................................ 37
Technical description .................................................... 8 Parking brake .............................................................. 25 Measures before taking the truck out
Engine .......................................................................... 8 Applying the parking brake ....................................... 25 of operation ................................................................. 37
Hydraulic system ....................................................... 8 Releasing the parking brake ..................................... 25 Putting the truck back into operation ...................... 37
Operation .................................................................... 8 Lifting device and attachments ................................... 26
Brakes .......................................................................... 8 Tilting the mast forward ............................................ 26 Maintenance ............................................................ 37
Steering ....................................................................... 8 Tilting the mast back ................................................. 26 General information ...................................................... 37
Electrical system ........................................................ 8 Lifting the fork carriage ............................................. 26 Work on the mast and on the front part
General view .................................................................. 9 Lowering the fork carriage ........................................ 26 of the truck .................................................................. 38
Controls and indicators ................................................ 10 Operating the attachments ....................................... 26 Securing the mast against tilting back ....................... 38
Composite instrument .................................................. 11 Operating the sideshift .............................................. 26 Standard mast ................................................................ 38
Operating the clamp .................................................. 26 Securing the raised standard mast ............................. 38
Single-lever operation of lifting device Duplex mast ................................................................... 38
Beginning operation .......................................... 12
and attachments ......................................................... 27
Safty rules ...................................................................... 12 Securing the raised duplex mast ................................. 39
Turning on the windscreen wipers .............................. 28 Triplex mast ................................................................... 39
Important safety information ....................................... 12 Switching on the lights ................................................. 28
Handling fuels and lubricants ...................................... 12 Securing the raised triplex mast .................................. 39
Switching on the hazard warning light ....................... 28 Checks and services after the first
Accident prevention check ........................................... 13 Turning on the ventilation ............................................ 28
Particle filter inspection ............................................... 13 50 service hours ......................................................... 39
Front working lights ...................................................... 28 Inspection and maintenance chart .............................. 40
Running-in instructions ................................................ 13 Rear working lights ....................................................... 28
Checks and services before initial operation ............ 13 Heater .............................................................................. 29
Daily checks ................................................................... 13 Heater controls ........................................................... 29
Inspection and maintenance
Daily pre-operational checks and services ................ 14 Fan motor fuse ........................................................... 29 as required ............................................................ 42
Opening the engine cover ............................................ 14 Operating the horn ........................................................ 30 Cleaning the lift truck .................................................... 42
Checking the engine oil level ....................................... 14 Fuses ............................................................................... 30 Cleaning and spraying the mast chain ....................... 42
Checking the fuel level ................................................. 14 Before lifting a load ....................................................... 31 Cleaning the air filter ..................................................... 42
Filling fuel ....................................................................... 15 Adjusting the fork spread ............................................. 32 Cleaning with compressed air .................................. 43
Hydraulic system: Checking the oil level ................... 15 Loading ........................................................................... 32 Wet cleaning ............................................................... 43
Checking the fluid level in coolant reservoir ............. 16 Travel with a load .......................................................... 33 Replacing the safety element ....................................... 43
Adjusting the driver’s seat ........................................... 17 Unloading ....................................................................... 33 Checking the dust discharge valve ............................. 44
Checking the typre pressure ........................................ 18 Before leaving the lift truck unattended ..................... 33 Cleaning the prefilter .................................................... 44
Starting the engine ........................................................ 19 Hoisting the truck with a crane .................................... 34 Checking the mounting of the steering cylinder
Cold start ........................................................................ 19 Hoisting the truck with a crane using and king pin at the steering axle .............................. 44
Stopping the engine ...................................................... 20 the lifting eyes ............................................................ 34 Regenerating the particle filter .................................... 45
Malfunctions during operation ..................................... 20 Jack locations when changing wheels ....................... 34 Cleaning and checking radiator and
Trailer coupling .............................................................. 35 hydraulic oil cooler for leaks .................................... 46
Operation .................................................................. 21 Mast removal .................................................................. 35 Drain the fuel system water preseparator .................. 46
Travel .............................................................................. 21 Towing instructions ...................................................... 36 Tightening the wheel nuts ............................................ 47
Forward travel ................................................................ 21 Towing ......................................................................... 36 Check the tyres for damage and foreign objects ...... 47

5
TABLE OF CONTENTS
Page Page Page

250-hour inspection and maintenance .. 48 1000-hour inspection and maintenance 58 3000-hour inspection and maintenance 65
Clean and grease the steering axle ............................. 48 Renew the air filter element, check the Renew the hydraulic oil ................................................ 65
Grease the mast and tilt cylinder pivots ..................... 48 vacuum switch ........................................................... 58 Check the mounting of the compact
Check electric cables, cable connectors and con- Check the engine mounting for condition axle on engine ............................................................ 65
nections for condition and tightness ....................... 49 and tightness .............................................................. 58
Drain the fuel system water preseparator .................. 49 Check the air intake and exhaust pipes for leaks ...... 59 Inspection and maintenance data ................................ 66
Sideshift: clean and grease, check the mounting ..... 50 Check the hydraulic system, compact axle,
Battery: Check condition, electrolyte level ................ 50 pumps, valves and lines for leaks ........................... 59 Fuel and recommendations .......................................... 67
and specific gravity ....................................................... 50 Hydraulic system: Renew the pressure, Engine oils .................................................................. 67
suction and breather filters ...................................... 60 Oil grades .................................................................... 67
500-hour inspection and maintenance . 51 Renew the pressure filter .......................................... 60 Oil viscosity ................................................................ 67
Check the mast and mast chains for condition Renew the suction filter ............................................ 60 Diesel fuel ................................................................... 68
and security ................................................................ 51 Renew the breather filter ........................................... 61 Hydraulic oil ................................................................ 69
Adjust the mast chain length and lubricate Check the wheel drive oil level .................................... 61 Lubricating grease ..................................................... 69
with chain spray ......................................................... 51 Check the particle filter system ................................... 62 Coolant ........................................................................ 69
Change the engine oil (every 12 months minimum) . 52 Check the parking brake ............................................... 62 Battery grease ............................................................ 69
Drain the engine oil ....................................................... 52 Chain spray ................................................................. 69
Renew the engine oil filter ............................................ 52 2000-hour inspection and maintenance 63
Top up engine oil ........................................................... 53 Renew the alternator and fan V-belt ............................ 63 Engine Troubleshooting guide (diesel engine) .......... 70
Check coolant strength ................................................. 53 Tighten the V-belt .......................................................... 63 Troubleshooting guide (hydraulic system) ................ 73
Check the mounting of the compact axle Check the injection nozzles ......................................... 63 Wiring diagram .............................................................. 74
at the engine ............................................................... 54 Check, adjust valve clearance ..................................... 64 Hydraulic circuit schematic ......................................... 76
Check the engine mounting, counterweight, Check the particle filter system ................................... 64 Index ................................................................................ 78
overhead guard, steering axle and wheel
drives for tightness .................................................... 54
Check and oil the pedals, travel control and
engine control linkages ............................................. 54
Check the tension and condition of the
alternator and fan V-belt ............................................ 55
Tighten the alternator and fan V-belt .......................... 55
Renew the fuel filter (every 12 months minimum) .... 56
Clean the radiator and hydraulic oil cooler ................ 56
Checking the particle filter system ............................. 56
Check and oil other pivots and joints ......................... 57
Check the fork stops and fork quick-releases ........... 57
Check the pre-tension of double hoses if
attachments are fitted ................................................ 57

6
TECHNICAL DATA DESCRIPTION

7
TECHNICAL DESCRIPTION
The 351 series fork lift truck is designed for loading and
depositing loads weighing up to 2 tonnes with the H 20-
02, 2.5 tonnes with the H 25-02 and 3 tonnes with the H 30-
02. Its compact design and small turning radius make the
truck especially suited for small gates and narrow wor-
king areas.
Engine
The truck is equipped with a 3-cylinder four-stroke diesel
engine. It drives the hydraulic pumps at load-dependent
speed. The engine is cooled by a closed-loop coolant
circuit with coolant reservoir.
Hydraulic system
The hydraulic system consists of a variable-displace-
ment pump and two fixed-displacement motors installed
as a unit in the compact axle, and a tandem pump (fixed
displacement) for 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.
8
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 ef-
ficient 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 con-
trol levers are installed.
DESCRIPTION
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.
GENERAL VIEW DESCRIPTION

1 Counterweight
5 6 7 8 9
2 Engine cover

3 Battery compartment
4 10
4 Rear silencer

5 Overhead guard 3
6 Driver’s seat
2
7 Instrument panel
1 11
8 Lift cylinder

9 Mast

10 Lift chain

11 Fork quick-releases

12 Fork carriage

13 Forks
12
14 Wheel drive

15 Chassis

16 Steering axle

351-02/03
16 15 14 13

9
CONTROLS AND INDICATORS DESCRIPTION
1 Parking brake lever 1 2 3 4 5 6
2 Ignition switch with switch key

3 Steering wheel/power steering

4 Horn button

5 Composite instrument (covered)

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 diagram

11 Load capacity plate (attachment)*

12 Symbol label for working hydraulics

13 Control lever for working hydraulics

14 Forward accelerator pedal

15 Brake pedal

16 Reverse accelerator pedal

351-02/04
17 Fuses (covered)

* Option 17 16 15 14 13 12 11 10 9 8 7
10
COMPOSITE INSTRUMENT DESCRIPTION
The composite instrument contains the following control
and indicator elements: Indicator element Function Possible fault(s)
Hour meter (1). The left digits (13) indicates lift truck service
1 Hour meter indicate full service hours, the hours. The meter indicates the NOTE
right digit (12) 1/10th of an hour. elapsed service hours of the Record elapsed service hours
2 Hour meter on light
truck and the required when replacing a defective hour
3 Coolant temperature warning light inspection and maintenance meter. Record data on durable
4 Particle filter warning light* services. tape and affix next to the hour
meter.
5 Oil temperature warning light for hydraulic system "ON" light for hour meter (2) indicates operation of meter
6 Engine oil pressure warning light
7 Preheat indicator light* Coolant temperature warning light (3) indicates coolant temperature is - fan V-belt slack
too high - radiator dirty
8 Flasher warning light* - leak in cooling circuit
9 Discharge indicator light - low coolant level
10 Fuel level warning light
Particle filter warning light* (4) indicates that the particle filter - regenerate the particle filter
11 Air filter warning light must be regenerated

Oil temperature warning light monitors the oil temperature of - oil level in hydraulic system is
(5) for hydraulic system the hydraulic system too low
* Option - oil not as specified
- oil filter clogged
- dirt on oil cooler
6 7 8 9 Engine oil pressure warning indicates low oil pressure of - low oil level in crankcase
light (6) engine lubrication - engine is overheated
5 10 - oil not as specified
-internal leakage in lubricating
system

Preheat indicator light* (7) indicates cold start* function

4 3
Flasher warning light* (8) indicates function of flasher
3 (optional) unit when flasher is turned on

Discharge indicator light (9) indicates malfunctions in the - V-belt broken or slipping
electrical system - cables faulty
2 - alternator faulty
- regulator or charger switch faulty

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

approx. 5.5 litres.

1 Air filter warning light (11) indicates restriced air filter element - air filter element restricted
13 12 351-02/05

11
SAFETY RULES
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 under-
stood 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)
- optional attachments
- special operating characteristics,
by training and practicing driving, shifting and steering
operations until they are completely mastered.
Only then start to practice shelf-stacking.
Important safety information
The precautions WARNING, CAUTION, ATTENTION and
NOTE in this manual are provided to indicate special
dangers or unusual information requiring special identi-
fication:
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 pro-
duct.
ATTENTION
indicates hazards that may result in damage
to or destruction of the product.
NOTE
identifies technical information requiring special atten-
tion because the connection may not even be obvious to
skilled personnel.
BEGINNING OPERATION
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 inflamma-
ble, do not contact them with hot objects or a naked
flame.
Follow the manufacturer’s safety and disposal instruc-
tions 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 lubri-
cants as specified.
Follow laws and regulations.
Clean the area surrounding the part in question before
lubrication, filter renewal or repairs in the hydraulic
system.
Only use clean containers when replenishing fuels and
lubricants.
Discard parts in a way friendly to the environment.
ATTENTION
Do not allow hydraulic oil under pressure, for
example at a leak, to penetrate the skin. Medi-
cal aid is required if such an injury occurs.
ATTENTION
Improper handling of coolants and coolant
additives puts your health and the environ-
ment at risk.

The stability of the truck in the work area is ensured if

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

IN CASE
OF TIP-OVER

Follow these Hold

WARNING instructions: Don't jump! on tight Brace feet Lean away

12
SAFETY RULES BEGINNING OPERATION
Accident prevention check Checks and services before initial
The accident prevention rules in some countries prescri- operation*
be that the fork lift truck must be checked at least once a
year for proper working condition by trained personnel. - Coolant level in the reservoir
Please contact your authorized distributor in this regard. - Engine oil level
- Fill fuel
- Electrical system: Check wiring, connectors and ter-
Particle filter inspection minals for condition and tightness
(option) - Battery: check condition, electolyte level and specific
gravity
The responsible authorities specify that particle filters - Tyre pressure
must be inspected and serviced every six months by an - Tighten wheel nuts
expert. The results of the inspection must be recorded in - Hydraulic oil level
a “Diesel Engine Emissions Inspection Certificate” and - Oil level of wheel drive reduction gearboxes
attached to the log book (e.g. the truck Accident Preven- - Function of braking system
tion Inspection booklet) - Function of steering system
Tighten wheel nuts of - Lifting device and attachments
wheel-mounting - Regenerate the particle filter (Option)
Running-in instructions
- prior to starting operation
The lift truck can be operated at full speed directly. Avoid
sustained high loads on the working hydraulic system
of the truck
and the travel drive in the first 50 hours of operation. - then every 10 hrs until Daily checks*
wheel nuts are tightened - Coolant level in the reservoir
Tighten wheel nuts daily before each shift until they are
seated firmly, i.e. until no further tightening is possible.
- after that every 100 hrs - Engine oil level
(For torque see operating manual) - Fuel level
- Hydraulic oil level
Tighten opposite wheel nuts to a torque of 400 Nm
- Tyre pressure
(40 kpm).

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

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

13
BEGINNING OPERATION
Daily pre-operational checks and services
Opening the engine cover
- Lift and tilt back the backrest (3).
- Pull the lever (2) and slide the seat fully forward.
- Open the engine cover (1) by tilting it back.
NOTE
The engine cover is held in place by a gas-filled strut.
1 2
3
351-02/06
14
Checking the engine oil level Checking the fuel level
- Pull out the oil dipstick (5) at the engine on the left side. A warning light in the instrument panel lights to indicate
a fuel level of 5.5 litres.
- Clean the dipstick with a clean cloth.
Fill fuel when the light comes on.
- 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 (4).
Difference between max. and min. markings .......... 1.5 L
- Refit and tighten the filler cap.
4 5
351-02/07 351-02/08
 BEGINNING OPERATION
Daily pre-operational checks and services
Filling fuel Hydraulic system: Checking the oil level
CAUTION ATTENTION - Wipe the oil dipstick with a clean cloth.
Stop the engine before filling fuel. No smo- Follow the precautions for handling fuels and
king or naked light when filling fuel. Avoid lubricants. - Screw in the breather filter with oil dipstick fully and
spilling fuel and do not allow fuel to contact screw out again.
hot components. Follow the precautions for
handling diesel fuel. NOTE - Oil level should be between both markings on the
For the oil level check, the fork carriage of the mast must dipstick.
be lowered completely.
- Open the filler cap (1) on fuel tank and fill clean diesel - If necessary, add hydraulic oil up to the upper mark.
fuel. - Open the engine cover.
Capacity between max. and min. marks ... approx. 2.0 L
max. capacity ............................................................ 41.0 L - Screw out the breather filter (1) with oil dipstick on the
right side of the truck. - Close the engine cover.
ATTENTION
Never drive fuel tank empty in order to pre- NOTE
vent malfunction by air in the fuel injection The tank is slightly pressurized. Some air will escape.
system.

1 1 1

351-02/09 351-02/10 351-01/11

15
BEGINNING OPERATION
Daily pre-operational checks and services
Checking the fluid level in coolant reservoir CAUTION
Do not open the reservoir cap (2) when the
ATTENTION tank is hot. Risk of scalding!
Follow the precautions for handling fuels and
lubricants.
- Add coolant as required, after opening the reservoir
cap (2).
- Pull back the battery compartment cover (1) and lift up
and remove.
NOTE
- Coolant must be visible between the max. and min. The reservoir is slightly pressurized.
marks (3) on the reservoir.
- Engage the battery compartment cover at the top and
push down at the bottom.

1
2

max.

min.

351-02/12
3 351-02/13

16
 BEGINNING OPERATION
Daily pre-operational checks and services
Adjusting the driver’s seat
- To adjust the seat horizontally, pull lever (2) out to the - Raise the backrest (1) to tilt it. - On models with an adjustable backrest, lift lever (5).
side.
- Move the backrest forward or back until the seating
- Slide the driver’s seat forward or back until the best position is comfortable.
position for operating the steering wheel, pedals and
control levers is obtained. - Re-engage lever (5).

- Re-engage lever (2). - When leaving the lift truck, always tilt the backrest (1)
forward to keep the seat clean.
- Set the cushioning with the hand wheel (4) acc. to the
driver’s weight. - To adjust the cushioning* (7) of the backrest (1), turn
The adjustment range of 50 kg to 130 kg in steps of 10 the hand wheel (6) clockwise or anti-clockwise until a
kg is displayed on the range indicator (3). comfortable seating position is obtained.

* Option

1 1

4 3 2 351-02/14 351-02/15 5 351-02/16

17
BEGINNING OPERATION
Daily pre-operational checks and services
Checking the typre pressure
ATTENTION Inflate or deflate the tyres to the pressure specified on the Example:
Low inflation pressure reduces tyre service sticker on the inside of the overhead guard.
life and truck stability. Tyre pressure sticker
H 20-02 H 25-02 H 30-02
Drive axle Drive axle
- Check the tyres for specified pressure. - Single tyre ............................................................ 10 bar
- Single tyre
- Twin tyre ................................................................. 7 bar
7,00-12/16PR 10 bar 10 bar -
- If necessary, inflate or deflate at the filler valves.
27x10-12/14PR 7 bar 7 bar 7 bar
Steering axle
28x9-15/14PR - - 8.5 bar
- Single tyre .............................................................. 8 bar
- Twin tyre
7,00-12/16PR - - 7 bar

Steering axle
- Single tyre
6,50-10/10PR 8 bar 8 bar -
23x9-10/14PR 7 bar 7 bar 7 bar

351-02/17 351-02/18

18
STARTING THE ENGINE
Starting the engine
NOTE
All control levers must be in neutral.
- Sit down on the driver’s seat.
- Place both feet on the accelerator pedals (3) without
depressing them (brake pedal (4) locked; engine will
start only with brake pedal locked).
- Insert the key (1) into the preheat/start switch and turn
from the zero position to position (I).
The electrical system is turned on.
- The engine oil pressure warning light (7), discharge
indicator light* (9) and the particle filter* LED* (2) are
illuminated red. The coolant temperature warning
light (5) is illuminated dark red, the preheat indicator*
(8) and particle filter warning light* (6) are illuminated
yellow.
- Turn the ignition key to position (II). Release the key
when the engine has started.
If the engine does not start, cease the starting proce-
dure and repeat it after waiting for at least 1 minute.
* Option
2 7
1
3 4 3 351-02/20
BEGINNING OPERATION
Wait at least 1 minute between starting attempts to spare Cold start*
the battery. If the engine does not start after the third
attempt, refer to: Engine Troubleshooting Guide. - Keep the key in position (I) until the yellow preheat
- The discharge indicator, engine oil pressure and coo- indicator (8) extinguishes. Then turn the key further to
lant temperature and particle filter* warning lights position (II). Release the key when the engine is run-
must extinguish when the engine is running. ning.
Engine speed is governed automatically, depending on
the load. - For further procedures refer to: Starting the engine.
NOTE
When warning light (6) is illuminated or the particle filter*
LED* (2) is flashing, refer to: Regenerating the particle
filter.
WARNING
Do not let the engine run in unventilated enclo-
sed spaces. Risk of carbon monoxide poison-
ing!
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.
* Option
8 9 2
6
5 5
351-02/21 351-02/22
19
BEGINNING OPERATION, STOPPING THE ENGINE, MALFUNCTIONS
Stopping the engine Malfunctions during operation
NOTE NOTE CAUTION
Do not stop the engine with a full load. The brake engages when the engine is stopped. If one of the following indicator lamps illumi-
nates during operation, the engine must be
- Release the accelerator pedals (3). - Push up parking brake lever (1). stopped immediately and the malfunction eli-
minated.
- Turn switch key (2) to the zero position. - Push down stop pedal (4). The stop pedal engages in (see: Diesel Engine Troubleshooting Guide)
this position.

- Remove the switch key when leaving the truck unat- - Coolant temperature warning light (1)
tended. - 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.
When the particle filter warning light* (4) is illuminated,
the particle filter must be regenerated.

* Option

1 2 3 4 5

1 1

3 4 3 351-02/23 351-02/30

20
TRAVEL
CAUTION
Travel on long slopes over 15 % is not allowed
as a rule due to the prescribed minimum brake
applications and truck stability characteri-
stics. 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 obsta-
cles and for short differences in level.
Always accommodate your driving style to suit the con-
ditions of the roadway (rough surfaces, etc.), especially
hazardous work areas and the load.
NOTE
When the warning light* (6) is illuminated or the particle
filter* LED* (2) is flashing, refer to: Regenerating the
particle filter.
* Option
- 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 (3) smoothly. Truck
speed will increase with the pedal stroke.
NOTE
Quick flooring of the accelerator pedal is not recommen-
ded as the maximum acceleration rate is regulated auto-
matically.
Reverse travel
- Depress the left accelerator pedal (4). The truck will
reverse at a speed depending on the position of the
accelerator pedal.
OPERATION
Changing the travel direction
- Release the actuated accelerator pedal. The hydro-
static drive will act as service brake.
- Depress the accelerator pedal for the opposite direc-
tion 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.

1 2

4 5 3 351-02/25
4 3 351-02/26 351-02/28

21
SINGLE-PEDAL MODEL
Starting the engine
- Sit down on the driver’s seat.
- Stop pedal (4) is locked (engine will start only with stop
pedal locked).
- The travel direction control lever (2) and the control
lever must be in the neutral position.
- 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.
- The engine oil pressure warning light (7), discharge
indicator light* (9) and the particle filter* LED* (3) are
illuminated red. The coolant temperature warning light
(5) is illuminated dark red, the preheat indicator* (8)
and particle filter warning light* (6) are illuminated
yellow.
- Turn the switch key to position (II). Release the key
when the engine has started.
- If the engine does not start, cease the starting pro-
cedure and repeat it after waiting for at least 1 minute.
* Option
2 7
3
1
4 351-02/27
22
OPERATION
Cold start*
Wait at least 1 minute between starting attempts to spare
- Keep switch key in position (I) until the yellow preheat
the battery. If the engine does not start after the third
indicator (8) is extinguished. Then turn further to
attempt, refer to: Engine Troubleshooting Guide.
position (II). Release the key when the engine is run-
- The discharge indicator, engine oil pressure and coo- ning.
lant temperature and particle filter* warning lights
must extinguish when the engine is running. - For further procedures refer to: Starting the engine.
Engine speed is governed automatically, depending on
the load.
NOTE
When warning light (6) is illuminated or the particle filter*
LED* (3) is flashing, refer to: Regenerating the particle
filter.
WARNING
Do not let the engine run in unventilated enclo-
sed spaces. Risk of carbon monoxide poison-
ing!
NOTE
Do not warm up the engine in idle.
The engine will attain its running temperature after run-
ning briefly with a moderate load and at various speeds. * Option
8 9 3
5 5
351-02/21 351-02/132
SINGLE-PEDAL MODEL
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.
OPERATION
Malfunctions during operation
ATTENTION
If one of the following indicator lamps illumi-
nates during operation, the engine must be
stopped immediately and the malfunction eli-
minated.
(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.
When the particle filter warning light* (4) is illuminated,
the particle filter must be regenerated.

- Remove the switch key when leaving the truck unat-

tended. * Option

1 2 3 3 4 5

1 1

5 4 351-02/29 351-02/30

23
SINGLE-PEDAL MODEL
Travel
CAUTION
Travel on long slopes over 15 % is not allowed
as a rule due to the prescribed minimum brake
applications and truck stability characteri-
stics. 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 con-
ditions of the roadway (rough surfaces, etc.), especially
hazardous work areas and the load.
NOTE
When warning light* (6) is illuminated or the particle filter*
LED* (3) is flashing, refer to: Regenerating the particle
filter.
* Option
1 2
5 4 351-02/31
24
- Start the engine.
- Slightly raise the forks and tilt the mast backward.
- Push the parking brake lever (1) forward to release the
stop pedal (5).
Forward travel
- Shift the travel direction lever (2) forward.
- Depress the accelerator pedal (4) gently. Truck speed
depends on how for the pedal is depressed.
NOTE
Quick flooring of the accelerator pedal is not recom-
mended as the maximum acceleration rate is regulated
automatically.
5 4
351-02/32
OPERATION
Reverse travel
- Pull back the travel direction control lever (2).
- Depress the accelerator pedal (4) gently. Truck speed
depends on how far the pedal is pushed.
Changing the travel direction
- Release the depressed accelerator pedal (4). The hy-
drostatic drive will act as service brake.
- Shift the travel direction control lever (2) to the oppo-
site travel direction.
- Depress the accelerator pedal (4). 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.
351-02/28
STEERING SYSTEM, BRAKING SYSTEM OPERATION
Steering Service brake Parking brake
Due to the hydrostatic power steering, very little effort is - Allow the accelerator pedals to return to the neutral The multiple disc brakes are used as a parking brake.
required to turn the steering wheel. This is especially position. The hydrostatic drive will act as a service
advantageous when stacking in narrow aisles. brake. Applying the parking brake:
- Start the engine and drive the truck. - Set the parking brake lever (2) to the vertical position.
- Turn the steering wheel from left to right full lock and ATTENTION - Depress the stop pedal (1). The stop pedal will lock in
vice versa. For emergency braking depress the STOP this position.
pedal located between the accelerator pe-
dals. Releasing the parking brake:
WARNING It is recommended that the operator acquaint NOTE
Contact your distributor if steering becomes himself with the function and effect of this
hard or if there is excessive play in the steer- The multiple disc brakes will only be released when the
emergency brake without a load being on the
ing wheel. engine is running.
truck. Drive on a roadway without traffic at a
Do not drive the lift truck with a faulty steering slow speed. - Push the parking brake lever (2) forward to disengage
system. the stop pedal.
WARNING
Turning radius Contact your authorized distributor if faults or
- H 20 - 02 / H 25 - 02 ........................................ 2270 mm signs of wear become evident in the braking
- H 30 - 02 ........................................................... 2315 mm system.
Do not drive the truck with a faulty braking
system.

1 2

351-02/33 351-02/34 351-02/35

25
LIFTING DEVICE AND ATTACHMENTS
ATTENTION
Use the lifting device and attachments only for
authorized applications. The operator must be
instructed in the handling of the lifting device
and attachments.
Always operate the control levers smoothly, not jerkily.
The lifting, lowering and tilting speed is determined by
how far the control levers are moved.
The control levers return to their neutral position auto-
matically 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.
351-02/36
26
Lifting the fork carriage
- Push the control lever (1) to the right.
Lowering the fork carriage
- Push the control lever (1) to the left.
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 engine cover and a symbol label
behind the appropriate control lever.
OPERATION
Operating the sideshift
- To move the fork carriage to the left, push the control
lever (2) forward.
- To move the fork carriage 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 authorized distribu-
tor ascertains that they will not reduce the
load capacity and stability of the truck.
SINGLE-LEVER OPERATION OF LIFTING DEVICE AND ATTACHMENTS
ATTENTION
Use the lifting device and attachments only for
authorized applications. The operator must be
instructed in the handling of the lifting device
and attachments.
Always operate the control levers smoothly, not jerkily.
The lifting, lowering and tilting speed is determined by
how far the control levers are moved.
The control lever returns to its initial position automati-
cally when released.
NOTE
Note the operating symbols with direction arrows.
Lifting the fork carriage
- Pull the control lever (1) back.
Lowering the fork carriage
- Push the control lever (1) forward.
1 2 3 4
351-02/39
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 attach-
ment behind the appropriate control lever.
OPERATION
Operating the sideshift
- To move fork carriage to the left, the push the control
lever (3) forward.
- To move fork carriage 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.
If other attachments are fitted, affix appropriate symbol
labels for the equipment.
CAUTION
Attachments not supplied with the truck may
only be employed if your authorized distribu-
tor ascertains that a safe operation is assured
in respect to load capacity and stability.
27
WINDSCREEN WIPER*, LIGHTING*, VENTILATION*, WORKING LIGHTS*
NOTE
The switches can be arranged in a different order, depen-
ding on the model.
Turning on the windscreen wipers
- To actuate the front windscreen wiper, press the
windscreen wiper switch (1) to intermediate position.
- To also operate the rear windscreen wiper, depress
windscreen wiper switch fully.
Switching on the hazard warning light
- Depress the hazard warning light switch (3).
Turning on the ventilation
- Depress the ventilation switch (6) to operate the
ventilator.
OPERATION
Front working lights
The working lights are turned on and off with toggle
switch (4) on the instrument panel.
Rear working lights
The working lights are turned on and off with toggle
switch (5) on the instrument panel.

Switching on the lights

- Depress the light switch (2) to the intermediate posi-
tion to switch on the side marker lights and license
plate lights.
- Depress the light switch to switch on low beam.
- Move the directional indicator switch on the steering
column forward or back to operate the directional
indicators on the left or right.

* Option

1 2 3 4 5 6

351-02/42

28
HEATER (OPTIONAL) OPERATION
Heater controls Fan motor fuse
The air flow can be regulated in two stages with the fan NOTE - Screw the fuse holder (9) out of the casing and remove
switch (1). When lever (3) is pushed up and lever (4) down, fresh air with the 8 ampere fuse (8).
from outside the cabin flows through the air vents and
Temperature control lever (3): the air outlet. To prevent contaminated outside air from
- Push up for less heat. being drawn in, push lever (4) up.
- Push down for more heat.
All heater controls (except the fan switch) are infinitely
variable.
Air flow control lever (4):
- Push up for more air intake through the opening (10)
in the cabin.
- Push down for air intake from outside the cabin.

The swivelling air vents (5, 6 and 7) and the air outlet (2)
can be opened singly. Depending on the position of lever
(3), either warm or unwarmed fresh air flows through the
air vents and the air outlet.

1 2

7
5
4 3
6

9 8

10 351-02/45

29
HORN, FUSES OPERATION
Operating the horn Fuses
The horn serves as warning signal when operating at The fuses in the fuse box mounted on the left side 11 Left side lights, front and rear, taillight*
blind corners and junctions. underneath the instrument panel protect the electrical 12 Right side lights, front and rear, taillight*
system. For access to fuses, lower the bottom part of the
instrument console after first removing the 4 screws. 13 Flasher*
- Pressing the horn button on the steering wheel sounds
The fuses (8 A) protect the following circuits: 14 Hazard warning light*
the horn.
1 Composite instrument
The particle filter* fuse (30 A) is located in the control
2 Horn box.
3 Single-pedal model* 15 Particle filter system*
4 Wiper motor*
Another fuse in the engine compartment protects the
5 Front working light* following circuit:
6 Front working light*
7 Front working light* 16 Preheating relay*
8 Rear working light*
9 Low beam, front left*
10 Low beam, front right*
* Option
* Option

16

15

351-02/46 351-02/48

30
BEFORE LIFTING A LOAD OPERATION
Before lifting a load, check the capacity diagram (1) on the Example
engine cover.
Load centre distance ............................................. 650 mm 1 Max. liftable load in kg
When attachments are fitted, check the capacity plate (2) Height of lift .......................................................... 5500 mm
for that equipment. 2 Height of lift in mm
- Follow the vertical line for a load distance of 650 mm
Figures stated in the capacity diagram or plate apply to 3 Mast type
to where it intersects the line for a height of lift of 5500
compact and regular loads and must not be exceeded, as
mm.
this will reduce the stability of the fork truck and the 4 Fork truck type with rated capacity
- Read to the left of the point of intersection of the
strength of the forks and mast.
horizontal line for max. permitted load.
5 Distance of load centre from fork-face in mm
- Max. weight here is ......................................... 1500 kg.
The maximum capacity is determined by the height of lift
and the load centre distance.
Proceed accordingly for other lift heights and load centre
distances. Values ascertained apply to even distribution
NOTE
of the load on the forks.
Check the load capacity limits and contact your author-
ized 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.

1 2

27x10-12 SE
5
1 351-02 (2t) + 183 S/T,ß=6˚

2
351-02/49 4 3 351-02/50

31
LOADING
Adjusting the fork spread
- Raise the fork quick-release levers (1).
- Move the forks further apart or closer together depen-
ding 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.
NOTE
The load centre should be in the centre between the forks.
351-02/51
32
OPERATION
Loading
- Approach the load to be lifted carefully and as accu- WARNING
rately as possible. Do not stand under an elevated load. Drive the
fork lift truck only with the load lowered and
- Put the mast to the vertical position. the mast tilted back.
- 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 poss-
ible, while taking care not to dislodge adjacent loads.
- Lift the fork carriage until the load rests on the forks.
- Reverse the lift truck until the load is clear.
- Tilt the mast back.
351-02/52
TRAVEL WITH A LOAD, UNLOADING
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.
Travel with a load
- 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.
Unloading
- Carefully approach the stack or the device receiving
the load.
- Lift fork carriage to required height.
- Put mast into vertical position.
- Carefully drive into the stack.
- Carefully lower the load until the forks are free.
- Reverse the lift truck
WARNING
Never park the truck and leave it unattended
with the load raised.
OPERATION
Before leaving the lift truck unattended
- 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).

1 2

351-02/54 351-02/55 3 351-02/24

33
HOISTING THE TRUCK, WHEEL CHANGE
Hoisting the truck with a crane
CAUTION
Only use a lifting sling and crane with a
sufficient capacity.
See the manufacturer’s plate for the truck weight.
To hoist with a crane, attach the lifting slings at the points
provided.
- 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.
- 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 attach-
ments fitted.
1 3 4 1
3 3
1
2 linde-zubehör: wagenheb.eps
351-02/57
34
OPERATION
Hoisting the truck with a crane using the Jack locations when changing wheels
lifting eyes* CAUTION
CAUTION Only use a jack with a sufficient lifting capa-
Only use a lifting sling and crane with a city. The minimum capacity should be 3600
sufficient capacity. kg.
See the manufacturer’s plate for the truck weight.
- Locate the jack only at the counterweight (1) and at the
To hoist with a crane, attach the lifting slings at the
frame (2) behind the wheel box.
points provided.
- Attach the lifting sling (2) (3000 kg carrying capacity
minimum) to the lifting eyes (5) on the counterweight. CAUTION
- Attach the lifting sling (3) (3000 kg carrying capacity The truck may only be raised at these loca-
minimum) to the lifting eyes (6) on the frame. tions on the left and right side.
- 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 attach-
ments fitted.
* Option
3 4
1
6 2
2
1
5 351-02/58 351-02/59
351-02T/59.eps aus stamm/19mitte
TRAILER COUPLING, MAST REMOVAL OPERATION
Trailer coupling Mast removal
NOTE ATTENTION
The trailer coupling should be used only to tow light Attach the lifting sling to the top cross mem-
trailers inside the plant (see technical data for tractive ber (1) of the outer upright of the mast.
force rating).
The mast may only be dismantled by your distributor’s
skilled staff.
- Turn the lever 90° 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.

351-02/60 351-02/61

351-02T/61.eps aus stamm/19mitte,eps

35
TOWING INSTRUCTIONS OPERATION
Towing After towing
Should it become necessary to tow the truck, then it is - Secure the tractor (observe sufficient tractive and - Chock the wheels on the slope side.
possible braking power) with tow bar to towing pin of lift truck. - Loosen locknut (7).
- to by-pass the hydraulic oil circuit at the variable- - Place chocks (wedges) behind the wheels on the slope
- Screw in setscrew (8) (on size 6 socket head screw)
displacement pump (9), side.
and torque to 54 Nm.
- to release the multiple disc brakes in the wheel drives Releasing the wheel drive brake pressure - Lock set screw by tightening the locknut (7) to 40 Nm.
(1). - Unscrew the cap nut (2) and remove seal ring (4).
CAUTION - Loosen the nut (3). Re-establishing braking power
- Screw in the threaded pin (6) to stop and tighten to 10
The truck cannot be braked now. Nm. - Loosen locknut (3).
- Lock the threaded pin with nut (3). Tighten the nut to 25 - Loosen threaded pin (6) two turns.
Nm. - Lock threaded pin with nut (3), torque to 25 Nm.
The tractor used to tow the fork truck must - Apply about 4 shots of grease with a grease gun - Fit the sealing ring (4).
have sufficient tractive and braking power through the lubricating nipple (5) until the brake is
- Screw on cap nut (2) and tighten to 30 Nm.
clear.
for the unbraked towed load. - Install the floor plate and close the engine cover.
Towing the truck is only allowed with a rigid connection Opening the hydraulic by-pass valve
(tow bar). - Open the engine cover and remove the floor plate.
- Loosen the locknut (7) size 19 or 18 on the housing in Check brake function after completing re-
front of the servo unit cover. pairs.
Towing procedure - Loosen the setscrew (8) (on the size 6 socket head
- Lower the load so far that the forks do not scrape on the screw) by 2 turns.
ground during towing. - Lock the setscrew with the locknut (7). Torque the nut
- Deposit the load. to 40 Nm.

1
351-02/62 9 8 7 351-02/64

351-02/62.eps + 1t0238lupe.eps
36
TAKING THE TRUCK OUT OF OPERATION
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 batte-
ry. 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 deforma-
tion.
- Cover the truck with a cotton sheet to protect it against
dust.
NOTE
Do not use plastic foil as this enhances the formation and
collection of condensation water.
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 batte-
ry.
- 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.
If the vehicle is to be taken out of operation for over 6
months, contact your authorized dealer for further mea-
sures.
MAINTENANCE
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 autho-
rized 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 respo-
nsible 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.
Perform a functional check and trial run after every
servicing.
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.
37
MAINTENANCE
Work on the mast and on the front part of
the truck
WARNING
Before attempting to carry out repairs or ad-
justments on the raised mast and fork car-
riage, ensure that the following safety pro-
cedures are carried out!
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).
351-02/65
38
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.
2 351-02/66
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.

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 up-
right (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.
1 1
2 351-02/67
Triplex mast
FUNCTION
The fork carriage is raised to the special free lift height by
the centre cylinder via the chain guide roller. Both exte-
rior cylinders then raise the inner mast. Due to the chain
guide roller, the inner mast is raised twice as fast. The
centre cylinder is mounted within the extendible inner
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.
2 351-02/68
MAINTENANCE
Checks and services after the first 50 ser-
vice hours
NOTE
A description of the services can be located in the index.
- Change the engine oil
- Replace the engine oil filter
- Check the tension and condition of alternator and fan
V-belt
- Check valve clearance
- Check the air intake and exhaust pipes for leaks
- Check parking brake
- Check tyre inflation pressure
- Tighten wheel nuts
- Check tyres for damage and foreign objects
- Wheel drives: Check oil level and for leaks
- Check hydraulic system, compact axle, pumps, val-
ves, 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 and mast chains for condition and
security
- 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 connec-
tions for condition and tightness
- Check the mounting of the steering cylinder and king
pin at the steering axle
- Drain the fuel system water preseparator
39
INSPECTION AND MAINTENANCE CHART MAINTENANCE
Services Before initial After the first
Daily checks As required
(Description of the services can be located in the index) operation 50 hours

For services see page 13 ....................................................................................................................................... ●

For services see page 39 ......................................................................................................................................................................... ●

Check the coolant level in the reservoir .................................................................................................................................................................................. ●

Check the engine oil level ......................................................................................................................................................................................................... ●
Check the fuel level .................................................................................................................................................................................................................... ●
Check the hydraulic oil level ..................................................................................................................................................................................................... ●
Check the tyre pressure ............................................................................................................................................................................................................. ●

Clean the truck .............................................................................................................................................................................................................................................................. ●

Clean and spray the mast chain ................................................................................................................................................................................................................................. ●
Clean the air filter ......................................................................................................................................................................................................................................................... ●
Replace the safety element ......................................................................................................................................................................................................................................... ●
Check the dust discharge valve .................................................................................................................................................................................................................................. ●
Clean the prefilter ......................................................................................................................................................................................................................................................... ●
Check the mounting of the steering cylinder and king pin at the steering axle ................................................................................................................................................... ●
Regenerate the particle filter ....................................................................................................................................................................................................................................... ●
Clean and check the radiator and hydraulic oil cooler for leaks ............................................................................................................................................................................ ●
Drain the fuel system water preseparator ................................................................................................................................................................................................................. ●
Tighten wheel nuts (at least every 100 hours) .......................................................................................................................................................................................................... ●
Check the tyres for damage and foreign objects ..................................................................................................................................................................................................... ●

40
INSPECTION AND MAINTENANCE CHART MAINTENANCE
Services Every 250 Every 500 Every 1000 Every 2000 Every 3000
(Description of services can be located in the index) hours hours hours hours hours

Clean and grease the steering axle .................................................................................... ●

Grease the mast and tilt cylinder pivots ............................................................................ ●
Check electric cables, cable connectors and connections for condition
and tightness ..................................................................................................................... ●
Drain the fuel system water preseparator ......................................................................... ●
Sideshift: Clean and grease, check the mounting ............................................................ ●
Battery: Check condition, electrolyte level and specific gravity .................................... ●

Check the mast and mast chains for condition and security ............................................................................ ●
Adjust the mast chain length, lubricate with chain spray ................................................................................. ●
Change the engine oil and renew the engine oil filter
(every 12 months minimum) .............................................................................................................................. ●
Check coolant strength .......................................................................................................................................... ●
Check the mounting of the compact axle at the engine .................................................................................... ●
Check the engine mounting, counterweight, overhead guard, steering axle
and wheel drives for tightness .......................................................................................................................... ●
Check and oil the pedals, travel control and engine control linkages ............................................................. ●
Check the tension and condition of the alternator and fan V-belt .................................................................... ●
Renew the fuel filter (every 12 months minimum) ............................................................................................. ●
Clean the radiator and hydraulic oil cooler ......................................................................................................... ●
Check the particle filter system ............................................................................................................................ ●
Check and oil other pivots and joints .................................................................................................................. ●
Check the fork stops and fork quick-releases .................................................................................................... ●
Check the pre-tension of double hoses if attachments are fitted .................................................................... ●

Renew the air filter element, check the vacuum switch

(every 12 months minimum or after 5 cleanings) ............................................................................................................................. ●
Check the engine mounting for condition and tightness .................................................................................................................... ●
Check the air intake and exhaust pipes for leaks ................................................................................................................................. ●
Check the hydraulic system, compact axle, pumps, valves and lines for leaks .................................................................................. ●
Hydraulic system: Renew the pressure, suction and breather filters ................................................................................................ ●
Check the wheel drive oil level ............................................................................................................................................................... ●
Check the particle filter system .............................................................................................................................................................. ●
Check the parking brake .......................................................................................................................................................................... ●
Renew the alternator and fan V-belt ....................................................................................................................................................... ●

Check the injection nozzles ........................................................................................................................................................................................................ ●

Check, adjust valve clearance .................................................................................................................................................................................................... ●
Check the particle filter system .................................................................................................................................................................................................. ●

Renew the hydraulic oil ............................................................................................................................................................................................................................................... ●

Check the mounting of the compact axle on the engine ........................................................................................................................................................................................ ●

41
INSPECTION AND MAINTENANCE AS REQUIRED
Cleaning the lift truck
NOTE
The necessity of cleaning depends on the use of the truck.
If used with aggressive media such as salt water, fertili-
zer, 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-for-life bearings will dissolve and leak out. As
regreasing is not possible, damage to the bearings will
result.
ATTENTION
Do not aim the jet directly on the electrical
system and the insulating material, cover them
first.
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 safe-
ty).
- 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.
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).

351-02/69 351-02/70 2 1 351-02/71

42
INSPECTION AND MAINTENANCE AS REQUIRED
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.
Wet cleaning
NOTE
We recommend first cleaning the filter element with
compressed air.
- Clean the filter element by moving it back and forth in
lukewarm water containing a regular fine detergent.
- Rinse the filter element well in clear water, shake out
the water and let dry.
4 351-02/72
MAINTENANCE
Replacing the safety element*
ATTENTION Note
Never clean the filter with a steam-jet cleaner, The safety element* is only installed if a prefilter* is fitted
bleaching, solution, petrol or similar means. to the air filter.
Changing the safety element (5) is required:
After cleaning the main element (4) five times.
- Before installing the cleaned air filter element, exam-
The number of services (renewal or cleaning) must be
ine it for damage with an inspection lamp.
recorded on the appropriate marks of the safety element.
After 2 years of operation maximum.
- Examine the seal for cracks and damage.
If, after servicing the main element, the maintenance
indicator responds again.
NOTE When the main element is damaged:
Mark every servicing on the filter element. - Remove the main element.
Discard the filter element if it has been cleaned 5 times, - Unscrew the hexagon nut (6) and pull out the safety
if damaged, after 1000 service hours, or at least every 12 element (5).
months. - Install the new safety element (4) and fasten with the
- Re-install the filter element into the filter casing. Make hexagonal nut (6).
- Install the main element.
sure that the filter element is not damaged and that the
seal on the filter casing fits properly. ATTENTION
Safety elements may neither be cleaned nor
- Note the arrow symbol on the dust bowl indicating the re-used.
top.
* Option
351-02/73 6 5 351-02/131
43
INSPECTION AND MAINTENANCE AS REQUIRED
Checking the dust discharge valve
NOTE
The dust discharge valve (7) is largely maintenance-free.
- If required, squeeze the valve and remove the remai-
ning 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 exces-
sive dust conditions.
- Loosen clips (1) and remove dust bowl (3). Clean the
dust bowl.
- Refit the dust bowl and secure with the clips.
MAINTENANCE
Checking the mounting of the steering cy-
linder and king pin at the steering axle
NOTE
This service is required only once after the first 50 service
hours.
- Tighten the nuts (1) of the king pin at the steering axle.
Torque ..................................................................... 250 mm
- Tighten the steering cylinder mounting bolts (2).

Torque ..................................................................... 210 mm

* Option

7 351-02/74 3 351-02/75 2 351-02/76

44
INSPECTION AND MAINTENANCE AS REQUIRED
Regenerating the particle filter*
WARNING
Do not fuel the truck during filter regeneration.
NOTE
The particle filter must be regenerated at least every 8
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. Then the acoustic
signal will sound. Now the truck must be shut down at
once and the filter regenerated.
ATTENTION
During a power failure (e.g. battery discon-
nected), the service hours stored in the con-
trol unit will be lost.
Regenerate the particle filter at once for safety reasons so
as not to exceed the filter capacity (filter malfunction!).
The system wil report back with a soot warning (yellow
lamp (1) in the composite instrument).
1 If a fault occurs during regeneration, the soot
4 3 2 351-02/77
NOTE
A regeneration can also be started before the maximum
exhaustion time is reached.
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.
ATTENTION
The filter can be regenerated only when the
engine is stationary.
- Press lockable switch (4) for approx. 6 seconds, until
the built-in yellow switch light (ON indicator) illumina-
tes. The lamp will stay on until the end of the regene-
ration cycle, which lasts approx. 20 minutes.
* Option
351-02/78
MAINTENANCE
NOTE
Regeneration proceeds automatically, i. e. preheating
approx. 60 seconds, burning approx. 15 minutes and
after-ventilation approx. 5 minutes. After a successful
regeneration, the switch lamp (ON indicator) will extin-
guish and the truck can be operated again.
ATTENTION
The engine cannot be started during regenera-
tion. If the truck must be removed from a
security area, or the regeneration must be
stopped for safety reasons,
- Unlock and operate EMERGENCY switch (2).
The regeneration procedure will be stopped
immediately and the truck can be started.
ATTENTION
The particel filter is not regenerated if the
regeneration procedure is interrupted!
The soot warning lamp (yellow) will light! Perform a full
filter regeneration immediately.
ATTENTION
warning (yellow lamp) will light again after the
end of the regeneration procedure and the
LED (3) indicates a fault by means of various
flashing codes. Start regeneration again. If a
fault occurs again, shut down the truck an
contact your authorized distributor.
NOTE
When driving, an intermediate cleaning of the regenera-
tion system glow plug takes place every two hours. As a
result, the yellow ON indicator in the switch (4) is illumi-
nated for approx. one minute.
If the engine is stopped during the intermediate cleaning
phase, the engine starter will be disabled briefly for the
remaining heating period. In all other cases, only the red
LED (3) is illuminated when driving.
45
INSPECTION AND MAINTENANCE AS REQUIRED
Cleaning and checking radiator and hy-
draulic oil cooler for leaks
NOTE
Only clean the radiator and hydraulic oil cooler when the
engine is stopped and cool.
- Open the engine cover (1).
- Remove the radiator cover (2).
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 connectors, coolant hoses and pipes at the
radiator and hydraulic oil cooler for leaks.
MAINTENANCE
Drain the fuel system water preseparator
ATTENTION
Follow the precautions for handling fuels and
lubricants.
- Remove the floor plate.
- Make a visual inspection for any water in the presepa-
rator and drain it, if necessary.
- Loosen the drain plug (1) and drain approx. 100 cc in
a container until clean fuel flows out.
- Retighten the drain plug.
- Install the floor plate and close the engine cover.

- Renew porous hoses, retighten loose clamps, if ne-

cessary.

- Refit the cover.

1 2

351-02/79 351-02/80 351-02/81

46
INSPECTION AND MAINTENANCE AS REQUIRED MAINTENANCE
Tightening the wheel nuts Check the tyres for damage and foreign
CAUTION objects
At least every 100 hours. - Raise the truck with a jack until the wheels are clear of
the ground.

- Torque all wheel mounting nuts to 400 Nm (40 kpm). - 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.

351-02/82 351-02/133

47
250-HOUR INSPECTION AND MAINTENANCE MAINTENANCE
Clean and grease the steering axle Grease the mast and tilt cylinder pivots
- Thoroughly clean the steering axle with water or cold - Lubricate the tilt cylinder nipples on the mast through - Lubricate the mast pivot at the frame with grease.
cleaner. the hole in the boot with grease.
- Lubricate with a grease gun until new grease emerges
NOTE - Open the engine cover and remove the floor plate. at the pivots.
Lubricate with grease.
- Lubricate the nipples of the tilt cylinder pivot at the
- Lubricate the piston rod of steering cylinder with grame with grease.
lubricating grease.

- Lubricate the track joints and stub axles with lubrica-

ting grease at the grease nipples (see arrows).

- Grease with a grease gun unti fresh grease is visible at

the bearings.

351-02/84 351-02/85 351-02/86

48
250-HOUR INSPECTION AND MAINTENANCE MAINTENANCE
Check electric cables, cable connectors Drain the fuel system water preseparator
and connections for condition and tight-
ATTENTION
ness Follow the precautions for handling fuels and
- Check cable connections for tightness and oxidation. lubricants.

- Check earth lead for tightness.

- Make a visual inspection for any water in the presepa-
- Check electric wiring for chafe marks and tightness. rator and drain it, if necessary.

- Loosen the drain plug (1) and drain approx. 100 cc in

NOTE a container until clean fuel flows out.
Oxidized terminals and cracked cables result in loss of
voltage, thus leading to starting difficulties. - Retighten the drain plug.

- Remove oxidation remains and replace cracked ca- - Install the floor plate and close the engine cover.
bles.

351-02/79 351-02/81

49
250-HOUR INSPECTION AND MAINTENANCE
Sideshift*:
Clean and grease, check the mounting
- Clean the sideshift with a steam jet cleaner.
- Inspect the hydraulic lines for chafing, renew if neces-
sary.
- Check the hydraulic unions and mounting elements
for tightness and wear, tighten or renew if necessary.
- Lubricate the roller nipples (1) on the truck and nipples
(2) on the fork carriage with lubricating grease until
fresh grease emerges at the side.
- Lubricate the left and right piston rods (3) with lubri-
cating grease.
NOTE
The piston rods must also be greased each time the truck
is cleaned.
* Option
2 351-02/90
50
Battery: Check 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.
351-02/88
MAINTENANCE
- 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.
351-02/89
500-HOUR INSPECTION AND MAINTENANCE
Check the mast and mast chains for condi-
tion and security
- Thoroughly 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.
Adjust the mast chain length*
NOTE
As mast 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.
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.
MAINTENANCE
Adjust the mast chain length*
NOTE
As mast 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.
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 and triplex mast only * Duplex and triplex mast only

1 2

351-02/92 351-02/93 1 351-02/94

51
500-HOUR INSPECTION AND MAINTENANCE MAINTENANCE
Change the engine oil (every 12 months minimum) Renew the engine oil filter
Drain the engine oil - Loosen the engine oil filter (1) using a filter spanner
ATTENTION - Push up the rubber mat over the opening in the frame and remove by hand.
Follow the precautions for handling fuels and from below.
lubricants. - Catch any oil flowing out and dispose of in an environ-
- Remove the engine oil drain plug (2) on the engine ment-friendly way.
sump from below.
NOTE - Lightly coat the seal of the new filter with engine oil.
Change oil only when the engine is at operating tem- - Allow the oil to drain completely into the container.
perature. - Screw in the oil filter by hand until the seal is seated,
- Refit the drain plug with a new sealing ring. then tighten an additional one-half turn.

- Drive truck over a repair pit.

Torque to ................................................................... 30 Nm
- Place a suitable container under the frame.
- Lower the rubber mat back in place.
- Open the engine cover.

- Remove the cap (1) from the filler opening.

1 1

351-02/95 351-02/96 351-02/97

52
500-HOUR INSPECTION AND MAINTENANCE MAINTENANCE
Top up engine oil Check coolant strength
- Remove the cap (1) on the filler opening. - Remove the battery compartment cover. Mixing ratio for lower temperatures:
Temperature Antifreeze Water
- Fill new engine oil through the filler opening. The cooling system must be filled in all seasons with a -30 °C 45 % 55 %
mixture of water and an unphosphated glycol-based -35 °C 50 % 50 %
Filling capacity antifreeze/anticorrosion additive in order to provide pro-
tection against calcium deposits, frost and corrosion - If there is too little antifreeze:
- with filter renewal ......................................... max. 6.5 L damages, and to raise the boiling temperature.
- Remove the drain plug (2) at the cylinder block and
CAUTION
- After refilling, check the engine oil level with the partially drain the coolant.
Do not open the reservoir cap (1) when the
dipstick (3) and add oil to the maximum mark, if engine is hot.
necessary. - Re-install and tighten the drain plug.

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.
ATTENTION - Add antifreeze into the coolant reservoir until the
Follow the precautions for handling fuels and correct mixing ratio is obtained.
lubricants.
Cooling system capacity ........................................... 9.5 L
- Check the strength of the coolant in the reservoir.
- The antifreeze should be sufficient for temperatures - Refit the battery compartment cover.
down to -25 °C. The mixing ratio for this is 40 %
antifreeze and 60 % water.

1 3
1

max.

min.

351-02/98 351-02/102 351-02/101

53
500-HOUR INSPECTION AND MAINTENANCE
Check the mounting of the compact axle at
the engine
- Remove the floor plate.
- Tighten any loose bolts to a torque of 64 Nm.
NOTE
The compact axle is attached to the intermediate housing
by means of eight M10 bolts.
The intermediate housing is mounted on the engine with
nine M10 bolts.
Check the engine mounting, counterweight,
overhead guard, steering axle and wheel
drives for tightness
- Check the engine mounting, 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.
MAINTENANCE
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
authorized dealer.
- Check pedals for ease of operation.
- Check the pin and pivot circlips for tight seating.
- If necessary, slightly oil lever pivots and clevises.

- Install the floor plate.

351T-02/RENAULT-stapler.eps

351-02/99 351-02/100 351-02/103

351-02T/351-02/100.eps aus stamm/stapler.eps
54
500-HOUR INSPECTION AND MAINTENANCE MAINTENANCE
Check the tension and condition of the Tighten the alternator and fan V-belt
alternator and fan V-belt
- Loosen the hexagonal nut (1) and fastening bolt (2) at
the adjusting bracket.
ATTENTION Checking with thumb pressure:
A broken or slack V-belt reduces cooling. - Push the alternator down until the specified tension is
- Check V-belt tension using thumb pressure. obtained.
V-belt deflection should be approx. 10 mm midway
- Check the V-belt for excessive wear, worn flanks, between the pulleys. - Tighten the hexagonal nut (1) and fastening bolt (2).
cracks and traces of oil.
- If the tension is insufficient, tighten the V-belt.
- Renew a damaged V-belt.

Checking with a gauge:

- Mount the gauge (1) on the V-belt (2) and perform the
measurement.

Specified tension .................................................... 355 N

1 2

351-02/134 2 351-02/128

55
500-HOUR INSPECTION AND MAINTENANCE
Renew the fuel filter (every 12 months minimum)
ATTENTION
Follow the precautions for handling fuels and
lubricants.
- Place a suitable container beneath the fuel filter.
- Clean the exterior of the filter.
- Unscrew bolt (1) and remove filter (2) with bowl (3).
- Clean the sealing surface of the filter head and bowl.
- Coat the rubber gasket of a new filter with fuel.
- Place new fuel filter on bowl and tighten filter head (4)
with bolt (1).
Clean the radiator and hydraulic oil cooler
NOTE
Only clean the radiator and hydraulic oil cooler when the
engine is stopped and cool.
- Open engine cover (1) and remove the radiator cover (2).
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.
- Close the engine cover.
MAINTENANCE
Checking the particle 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.
Please contact your authorized distributor for the ser-
vicing.
* Option

1 1 2

3 351-02/104 351-02/91 351-02/78

56
500-HOUR INSPECTION AND MAINTENANCE
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
* Option
351-02/105
Check the fork stops and fork quick-re-
leases
- Inspect the forks for visible deformation, wear and
damage.
- Check the bolts and roll pins of fork stops and fork
quick-releases for correct seating and damage.
- Replace any damaged parts.
351-02/106
MAINTENANCE
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.
351-02/107
57
1000-HOUR INSPECTION AND MAINTENANCE
Renew the air filter element, check the va-
cuum 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).
MAINTENANCE
Check the engine mounting for condition
and tightness
- Unscrew nut (3) and remove air filter element (4).
The flexible engine mountings are subject to great stres-
- Thoroughly clean the inside of the air filter housing. ses.
Depending on the operating conditions, their service life
Do not blow out with compressed air.
is limited.
- Take care not to damage the element during installa-
tion, and be sure that the correct end is in. - Check the rubber elements for cracks and replace, if
necessary.
- Fasten element with nut and mount the filter cover.
NOTE
Please contact your authorized distributor.
- Remove the hose (5) from the air inlet.

- With the engine running, place hand over nozzle of air

cleaner. The warning light in the composite instru-
ment must light up.

- Refit the hose.

* Option

3 4

2 1 351-02/108 351-02/109 351/02-113

58
1000-HOUR INSPECTION AND 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.
351-02/111
- Remove the cover (2) 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.
351-02/112
MAINTENANCE
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 repla-
ce, if necessary.
351-02/121
59
1000-HOUR INSPECTION AND MAINTENANCE
Hydraulic system: Renew the pressure, suction, and breather filters
Renew the pressure filter
- 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.
MAINTENANCE
Renew the suction filter
- Remove the front cover.
- Draw out the filter element (4) slowly so that the oil can
flow back into the tank.
- Loosen and remove the fastening screw (1).
- Then draw out the filter completely.
- Remove the filter cover (2) along with the fastening
screw. - Carefully insert a new filter element into the filter bowl.
- Clean the seal (3) on the filter cover (5) and coat it with
oil.
- Refit the filter cover (5).
- 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.

1 3 4

351-02/114 2 351-02/115 5 351-02/116

60
1000-HOUR INSPECTION AND MAINTENANCE MAINTENANCE
Renew the breather filter Check the wheel drive oil level
- Screw the hydraulic oil tank breather filter from the - Park the fork lift truck and lower forks completely. CAUTION
filler neck. If the forks or mast are raised for filling or
- Remove the front cover plate. draining oil, the mast must be secured against
- Unscrew the dipstick (2) from the breather filter (1) and accidental lowering.
mount onto the new filter. - Check the oil level of both wheel drives.

NOTE - The oil must be visible at the sight glass (1).

In a dusty atmosphere it may become necessary to renew
the filter earlier.
- Install the floor plate and close the engine cover.
- If necessary, fill gear oil as far as the upper edge of the
sight glass (1).
- For filling, screw out the filler plug (2).

Capacity per drive ........................................ approx. 2.0 L

- Refit cover plate.

1 351-02/118

351-01/117 2 1 1 2 351-02/68

61
1000-HOUR INSPECTION AND MAINTENANCE MAINTENANCE
Check the particle filter system* Check the parking brake
- Inspect the filter mounts for security. Drive the lift truck with the maximum load onto a 15 %
slope.
- Check the parts conducting exhaust gases for leaks.
- Depress the brake pedal (1).
- Clean the air intake tube at the burner (for this loosen
the olive fitting and remove any soot with a round wire
- Place the parking brake lever (2) in the up position. The
brush).
brake pedal will lock. The truck must not move.
- Check the screws on the filter casing and parts con-
- Release the parking brake lever (2). The brake pedal
ducting exhaust gases for tightness.
will return to its initial position.
Please contact your authorized distributor for these ser-
- Stop the engine.
vices.
The lift truck must not move.

NOTE
If the parking brake is not operating correctly, contact
your authorized distributor.

* Option

1 2

351-02/78 351-02/110

62
 2000-HOUR INSPECTION AND MAINTENANCE
Renew the alternator and fan V-belt
- Open the engine cover (1).
- Remove the air filter (2).
- Loosen the hexagonal nut (3) on the adjusting bracket.
- Loosen the fastening screws (4).
- Press the alternator (5) fully against the engine.
MAINTENANCE
Tighten the V-belt Check the injection nozzles
- Pivot the alternator (5) until the correct belt tension is
obtained. The check and adjustment of the injection nozzles should
- Retighten the fastening screws (4) and hexagonal nuts be performed by your authorized distributor as special
(3). skills and special tools are required for this service.
- Check the belt tension and retighten, if necessary.
Nozzle injection pressure: ..................................... 300 bar
Checking with a gauge:
- Mount the gauge (7) on the V-belt (6) and perform the
measurement.
Specified tension ....................................................... 355 N

- In this position the V-belt can be removed over the fan.
- Pass a new V-belt over the fan and install in place.
Checking with thumb pressure:
- Check belt tension using thumb pressure.
Belt deflection should be approx. 10 mm midway
between the pulleys.
- If the tension is insufficient, tighten the V-belt.
- Install the air filter.

NOTE
Retighten the V-belt after running the engine for approx.
15 to 20 minutes.

1 3 4

4
6
2 351-02/122 351-02/135

63
2000-HOUR INSPECTION AND MAINTENANCE
Check, adjust valve clearance
Valve clearance can be checked with the engine warm or
cool.
NOTE
Valve clearance is the necessary air gap (A) between the
rocker arms (B) and valves (C). Smooth engine running
and full power indicate correct adjustment.
The adjustment of the valve clearance requires special
tools and skills. Please contact your authorized dealer.
NOTE
Cylinder 1 is at the water pump end.
- Open the engine cover.
- Remove the valve cover.
MAITNENANCE
Step I Check the particle filter system*
- Set the valves at cylinder 1 to position X with one valve
just opening and the other just closing. - Check the glow filament of the heater plug for strong
- Check the intake valve clearance (6) at cylinder 2 and deformation, carbon deposits.
exhaust valve clearance (9) at cylinder 3. Adjust the
valve clearance, if necessary.
Please contact your authorized distributor for these ser-
Step II
vices.
- Rotate the flywheel until the valves of cylinder 2 are in
position X with one valve just opening and the other
just closing.
- Check the exhaust valve clearance (5) at cylinder 1 and
exhaust valve clearance (8) at cylinder 3. Adjust the
valve clearance, if necessary.
Step III
- Rotate the flywheel until the valves of cylinder 3 are in
position X with one valve just opening and the other
just closing.
- Check the exhaust valve clearance (4) at cylinder 1 and
exhaust valve clearance (7) at cylinder 2. Adjust the
valve clearance, if necessary.
Valve clearance:
Intake valve ........................................................... 0.20 mm
Exhaust valve ........................................................ 0.45 mm
- Install the valve cover with a new gasket.
* Option
- Close the engine cover.

A B C 1 2 3

I
4 5 6 7 8 9
1 2 3

II
4 5 6 7 8 9
1 2 3

III
4 5 6 7 8 9

351-02/123 351-02/130 351-02/78

64
3000-HOUR INSPECTION AND MAINTENANCE MAINTENANCE
Renew the hydraulic oil Check the mounting of the compact axle on
Draining the hydraulic oil Filling/adding hydraulic oil engine
- Remove the floor plate.
NOTE Capacity
The fork carriage must be lowered completely. without draining the hydraulic unit .......... approx. 20.0 L - Tighten all bolts to the specified torque of 64 Nm.
ATTENTION NOTE
Total capacity:
Follow the precautions for handling fuels and incl. filling of hydraulic unit ...................... approx. 39.0 L The compact axle is mounted to the intermediate casing
lubricants. by means of eight M10 bolts.
- Fill hydraulic oil at the filler opening.
- Check the oil level with the dipstick (2) and fill oil until
The intermediate casing in mounted on the engine with
- Drive the truck over a repair pit. the upper mark on the dipstick is reached.
nine M10 bolts.
- Put a container under the lift truck at the right side. - Run the engine briefly and repeat the check.
- Remove the floor plate. - Close the engine cover.
- Install the floor plate and close the engine cover.
- Remove the breather filter with the oil dipstick (2).
- Remove the hydraulic oil drain plug (1) at the hydraulic NOTE
oil tank. The hydraulic system is bled automatically when the
- Allow the oil to drain completely. engine is running.
- Clean the area around the oil drain thoroughly.
- Re-install the drain plug.
Torque ........................................................................ 25 Nm

351-02/125 351-01/126 351-02/99

65
INSPECTION AND MAINTENANCE DATA MAINTENANCE

No. Assembly Aids/Oils and lubricants Filling capacity/Settings

1 Engine Engine oil 6.5 L

2 Air filter Industrial detergent

3 Valve clearance Intake valve 0.20 mm

(with engine warm or cold) Exhaust valve 0.45 mm

4 Fuel tank Diesel fuel 41.0 L

5 Cooling system Antifreeze / water approx. 9.5 L

6 Hydraulic system Hydraulic oil without filling hydraulic unit approx. 20.0 L
with filling hydraulic unit approx. 39.0 L

7 Wheel drives Gear oil Each wheel drive approx. 2.0 L

8 Battery Distilled water As required

9 Tyres Air See information on label on inside of

overhead guard

10 Wheel mounting nuts - tighten 400 Nm (40 kpm)

11 Mast and tilt cylinder pivots Lubricating grease As required

12 Piston rod of steering cylinder, Lubricating grease As required

steering axle

13 Lift chains, mast channels Linde chain spray As required

14 Fuel injection nozzle Diesel Operating pressure 300 bar

15 V-belt tension
- Fan New V-belt with gauge: 355 Nm
- Alternator Strong thumb pressure Deflection 10 mm

66
FUEL AND OIL RECOMMENDATIONS
Engine oils
API classification: CC (MIL-L-46152) or
CD (MIL-L-2104C)
Oil grades
Use engine oils meeting the API classification CC.
Do not fill engine oils of API classification CD for the initial
50 service hours and for extra light duty applications.
Trucks equipped with a particle filter should only be
operated with ash-free oils. Residues from the combusti-
on 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 (“consumed”). The
products of combustion and the high temperatures com-
bined 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.
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 authorized distributor
renew the engine oil and filter.
Oil viscosity
Since the viscosity of lubricants varies with temperature, Since the temperature ranges of adjacent SAE class-
the ambient temperature at the site determines the vis- ifications overlap, the oil does not need to be changed
cosity class (SAE class) of the engine oil (see diagram). when short-term temperature fluctuations occur.
If the ambient temperature occasionally falls below the
temperature limit (e.g. using SAE 15 W/40 at -15°C/5°F), NOTE
the cold start capability of the engine can be reduced, but For problem-free cold starts it is important to select the
no damage to the engine will result. viscosity of the engine oil (SAE grade) on the basis of the
ambient temperature when starting the engine.
If the viscosity of the oil is too high, the engine will
experience starting problems. Therefore the ambient At temperatures below -10 °C, SAE grade 5W / 30 engine
temperature when the engine is started determines the oil is recommended.
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.
0W
5W20 5W30
10W30
15W40
20W50
20
30

351-02/136
40

-30 -20 -10 0 10 20 30 40 50 ˚C

67
FUEL AND OIL RECOMMENDATIONS
Diesel fuel
Use only Diesel fuel to DIN 51601 with a cetane number
not lower than 45.
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 -15 °C is
available in the cold season of the year.
If ambient temperatures are even lower, the addition of
regular petrol to the fuel is recommended for satisfactory
operation. The amount of petrol (regular) to be added,
depending on the ambient temperature, is listed in the
table below.
In winter, fill only winter diesel fuel to prevent any clog-
ging caused by paraffin precipitation. At very low tem-
peratures you must reckon with disturbing precipitations
even if winter diesel fuel is used. If only summer diesel
fuel is available or winter diesel fuel must be used at very
low temperatures, we recommend adding regular petrol
with the mixing ratios in the table below. This practice
should only be regarded as a stop-gap measure, and no
more than one tank filling should be used.
ATTENTION
Mix the fuel with petrol only in the tank itself.
First fill the required quantity of petrol, then
add the diesel fuel. The petrol-diesel fuel mix-
ture is as inflammable as the petrol.

Ambient Summer Petroleum or Winter diesel Petroleum or

temperature diesel fuel % regular petrol % *) fuel % regular petrol % *)
down to
-10 °C (+ 14 °F) 90 10 100 -
-14 °C (+ 7 °F) 70 30**) 100 -
-20 °C (- 4 °F) 50 50**) 80 20
-30 °C (- 22 °F) - - 50 50**)

*) Never premium petrol

**) Regular petrol mixture maximum 20 %. Use only petroleum for mixtures with over 20 % additive.

68
FUEL AND OIL RECOMMENDATIONS
Hydraulic oil
Recommendation for normal duty:
Hydraulic oil HLP ISO VG 68 to DIN 51524, T.2 (factory
filling), average continuous oil temperature 60 °C - 80 °C.
Hydraulic oil recommendation for heavy duty:
Hydraulic oil HLP ISO VG 100 to DIN 51524 T.2 for heavy
duty and multi-shift operation, operation in extreme cli-
mate zones or high ambient temperatures, average con-
tinuous oil temperature over 80 °C.
For normal and heavy duty:
Hydraulic oil HLP ISO VG 68 to DIN 51524 T.3 (multigrade
oil).
If it is difficult to obtain hydraulic oils that must be
imported, a SAE 20W/20 engine oil can be used instead of
hydraulic oil HLP 68, and a SAE 30 engine oil can be used
instead of HLP 100.
NOTE
The choice of the correct oil is determined by the oil
temperature in the hydrostatic transmission.
Lubricating grease
Linde heavy duty grease with additives EP and MOS2.
Designation acc. to DIN 51825-KPF 2K-20 (see the Parts
Catalogue for the order number); a greater temperature
range than K-20 is allowed, e.g. N-30.
Any mixing with grease types other than lithium-based
greases is not allowed.
Coolant
Only use coolants with a monoethylene glycol base and
containing a rust inhibitor.
Do not mix with antifreeze containing ethanolamine.
Battery grease
Non-acidic grease (pole grease)
Chain spray
Linde chain spray (see the Parts Catalogue for the order
number).

The above-mentioned recommendations are only approx-

imate values.

If in doubt, contact your authorized distributor.

Recommendations of representatives of the oil industry

should also be checked with your authorized distributor.

Only the above-mentioned mineral oils are approved by

the manufacturer. If other hydraulic oils are used or
mixed, costly damage can result.

Gear oil
Preferably SAE 80 W - 90 API GL5, also suitable is SAE 85
W 90 - GL4 (to DIN 51512).

69
ENGINE TROUBLESHOOTING GUIDE (DIESEL ENGINE)
Trouble Possible Cause Correction See Page
Engine will not start Fuel tank empty. Refill the tank. 16
Fuel filter clogged, in winter by paraffin deposit. Renew the filter, use winter fuel. 56, 68
Water in fuel system water preseparator. Drain the water preseparator. 46
Fuel solenoid fails to open. Check for electric current with test lamp. If there is no
current, check fuse (1) and switch.

Fuel line leaking. Check all pipe connections for leaks and tighten fittings.

Charging indicator light not illuminated Tighten connecting clamps at battery, check cable connec- 49, 50
although lamp is okay. tions.

Preheating system defective. Check the power supply. Check the cables and connections
at the preheat/starting switch. If the fault can not be reme-
died, contact your authorized distributor.

Fuel pump defective. These faults should always be checked and corrected by
Injection nozzles defective. skilled staff.
Injection pump defective. Please contact your authorized distributor.
Engine idling speed incorrect.

Engine starting performance Battery power is too low. Battery terminal Check battery, clean battery terminals, tighten clamps and 50
is poor loose or oxidized, causing the starter to turn cover with non-acidic grease.
only slowly.

Fuel supply insufficient. Renew the fuel filter. Check the fuel line connections for 56
Restriction or air in fuel system due to paraffin leaks and tighten fittings.
deposits in winter. Use winter fuel in the cold season. 68

Particularly in winter:
Engine oil viscosity too high. Use engine oil appropriate for the ambient temperature. 67

70
ENGINE TROUBLESHOOTING GUIDE (DIESEL ENGINE)
Trouble
Engine running unevenly
with poor performance
Exhaust smokes excessively
Idle running trouble
Engine overheating, red
warning light in composite
instrument illuminated.
Stop the engine immediately.
Engine oil pressure too low.
Stop the engine immediately.
Charging indicator light illu-
minated during operation
Possible Cause Correction See Page
Fuel supply insufficient. Renew the fuel filter. Check the fuel line connections for 56
Restriction or air in fuel system due to paraffin leaks and tighten fittings. 68
deposits in winter. Use winter fuel in the cold season.
Injection pump overflow valve not functioning Contact your authorized distributor.
correctly.
Valve clearance not as specified. Adjust valve clearance. 64
Injection nozzles defextive. Contact your authorized distributor.
Engine oil level too high. Drain oil to the top mark on the dipstick. 52
Poor compression due to burned-in or broken Adjust valve clearance. 64
piston rings or incorrect valve clearance. Contact your authorized distributor.
Fuel system not in order. Replace fuel filter. 46, 56
Repair or replace leaky, fouled or bent fuel return lines and
injection lines.
Speed setting incorrect. Should only be adjusted by skilled staff. Contact your
authorized distributor.
Coolant level low. Check cooling system for leaks, seal if necessary. 16, 46
Add coolant.
Fan V-belt either slack or broken. Tighten or renew the V-belt. 55, 63
Radiator fins restricted due to dirt or foreign Clean the radiator. 46
objects.
Injection system setting incorrect. Contact your authorized distributor.
Leaks in the lubricating system. Contact your authorized distributor.
Oil level too low. Add lubricating oil. 14
Alternator RPM too low. Check V-belt tension. 55
Alternator not charging the battery because
alternator or relay defective.
Contact your authorized distributor.
71
TROUBLESHOOTING GUIDE (HYDRAULIC SYSTEM)
Trouble
Abnormal noise
No or too low pressure in
system
Oil pressure fluctuates
No oil flow or low oil flow
Hydraulic oil temperature too
high
Possible Cause Correction See Page
Suction filter restricted. Renew the filter. 60
Suction hoses leaking, oil foaming. Tighten lines. Check oil level, top up if necessary. 15, 59
Hydraulic pump or motor failure, seals defective, Have hydraulic unit inspected by your authorized
causing air intake. distributor. -
Incorrect oil viscosity, low oil level in tank or in Change oil, be sure to use the correct viscosity, top
hydraulic pump. up oil. 65 ,69
Pump suction defective, noise. Change oil, top up oil. 15, 65, 69
Pump failure, leakages, pressure valves do not Contact your authorized distributor.
close, valve seat damage.
Pipe broken or leaky. Replace or tighten line, 59
Oil of low viscosity, causing high leakage losses. Change oil, be sure to use oil of correct viscosity. 65, 69
Oil temperature warning lamp illuminated. Check oil level, clean oil cooler. 15, 46
Cause as under abnormal noise. See abnormal noise.
Pressure limiting valves or boost pressure valves Contact your authorized distributor.
sticking.
Lift and tilt cylinders have tight spots. Contact your authorized distributor.
Mast does not extend completely or retracts slightly Top up hydraulic oil. 15
after being extended.
Filter restricted (if accompanied by noise). Clean or replace filter. 60
Pump failure, leakages, pressure limiting valves Contact your authorized distributor.
do not close, valve seat damaged.
Pipe broken or leaky. Replace or tighten line. 59
Valves restricted. Contact your authorized dealer.
Hydraulic system overheating. Check oil level, use specified oil, clean oil cooler, if needed. 15, 46, 69
Pump failure, valves leaky. Contact your authorized distributor. -
Oil level too low or oil cooler defective. Check oil level, if necessary top up oil. Clean cooler and 15, 46
check for leaks. If defective, contact your authorized distri-
butor.
73
WIRING DIAGRAM
A1 Ignition control relay P1 Hour meter 1 Lighting*
2 Flasher and hazard warning flasher unit*
E2 Low beam, left, 55 W* 6P3 Composite instrument 3 Soot filter connection*
E3 Low beam, right, 55 W*
E4 Side light, front, left, 5 W* R1 Glow plugs
E5 Side light, front, right 5 W* R2 Waxmotor heater*
E6 Side light, rear, left, 5 W* Colour code
E7 Side light, rear, right, 5 W* S1 Ignition switch
E8 License plate light, 5 W* S2 Engine temperature switch BU blue
E21-24 Working light, 55 W* S3 Oil temperature switch BN brown
S4 Engine oil pressure switch YE yellow
F1-15 Fuses S5 Air filter vacuum switch GN green
S6 Fuel level warning light switch GY grey
G1 Alternator with regulator S7 Travel direction switch* RD red
G2 Battery, 92 Ah (single-pedal model) BK black
S8 Horn button WH white
H1 Battery charging lamp, 1.2 W S9, 9.1 Working light switch* VT violet
H2-3 Engine oil temperature warning lamp, 1.2 W S10 Wiper motor switch* OG orange
H4 Hydraulic oil temperature S11 Headlight switch*
warning lamp, 1.2 W S12 Hazard warning light switch*
H5 Engine oil pressure warning lamp, 1.2 W S13 Flasher switch*
H6 Air filter warning lamp, 1.2 W S14 Starter lock-out
H7 Horn, 42 W S15 Revolving light switch*
H8 Flasher, front left, 21 W* S16 Thermal switch 50°C
H9 Flasher, rear left, 21 W*
H10 Flasher, front right, 21 W* V1-3 De-coupling diode
H11 Flasher, rear right, 21 W* V4 Free wheel diode
H12 Flasher indicator lamp, 1.2 W*
H13 Fuel level warning lamp, 1.2 W
H14 Revolving light, 55 W* Y1 Fuel shutoff solenoid
H15-19, 23 Switch lights, 1.2 W Y2-3 Solenoid valve, single-pedal model*
H24 Cooling fan
H25 Preheating X15 Connector
H26 Soot filter warning lamp*

K1 Flasher relay*
K2 Starter relay

M1 Starter
M2 Wiper motor*
M3 Wiper motor, rear*
M4 Windscreen washer*

* Optional

74
WIRING DIAGRAM

75
HYDRAULIC CIRCUIT SCHEMATIC
A Working hydraulic system C Tandem pump assembly J Combustion engine
1 Control valve block assembly consisting of: consisting of:
n = 800 ... 2250 RPM
2 2/2-way valve (pressure balance) 26 Gear pump
3 Maximum pressure valve 27 Gear pump
3a Restrictor 28 Priority flow regulator K Control cylinder for engine speed
4 Pressure reducing valve 28a 2/2-way valve
4a Restrictor 29 Check valve
5 Check valve (pilot operated) L Shuttle valve
6 Way valve - lifting
7 Way valve - tilting D Change filter
8 Way valve - auxiliary hydraulics M Check valve 1.0 bar
9 Way valve - auxiliary hydraulics
10 Shuttle valve
11 Service cylinder (auxiliary hydraulics) E Suction filter
12 Service cylinder (auxiliary hydraulics) N Oil cooler
13 Tilt cylinder
14-1 Standard lift cylinder
14-2 Duplex lift cylinder G Oil tank including:
O Hydraulic snubber
14-3 Triplex lift cylinder 30 Make-up valve
15 Lowering brake valve 31 Breather filter with suction and pressurizing
valve P Steering control valve assembly
B Compact axle AK 30-01 assembly consisting of:
consisting of:
H Travel control unit consisting of: 39 Steer valve
16 Variable-displacement hydraulic pump 90 cc/rev 40 Max. pressure-relief valve 130 bar
17 Control piston 32 2/2-way valve 12 bar 41 Shock valve 190 + 10 bar
18 Combined boost and pressure relief valve 33 Restrictor 42 Make-up valve
420 bar 34 Pressure-relief valve 11 bar
19 Boost pressure valve 16 bar 35 Pressure-reducing valve
20 Pilot piston 36 4/2-way valve - brakes Q Steering cylinder
21 Servo piston 37 4/3-way valve - direction of travel
22 2/2-way valve (logic lock-out) 23 bar 38 3/2-way valve - signal for speed control
23 3/2-way valve (logic lock-out) 38a Way valve, direction selection (single pedal)
23a By-pass valve 38b 2/2- way valve (towing device)
(towing device)
24 Fixed-displacement hydraulic motor HMF 43 S
25 Disc brake

76
HYDRAULIC CIRCUIT SCHEMATIC

77
INDEX
Page Page Page
A G
Accident prevention check ........................................... 13 Coolant ............................................................................ 69 General information ...................................................... 37
Adjust the mast chain length ....................................... 51 Coolant strength, check ................................................ 53 General View .................................................................. 9
Adjusting the driver’s seat ........................................... 17 Counterweight, check for tightness ............................ 54
Adjusting the fork spread ............................................. 32
After towing .................................................................... 36
D H
Air filter element, renew ............................................... 58 Handling fuels and lubricants ...................................... 12
Air filter, cleaning .......................................................... 42 Daily checks ................................................................... 13 Hazard warning light ..................................................... 28
Air intake and exhaust pipes for leaks, check ........... 59 Daily pre-operational checks and services ................ 14 Heater controls .............................................................. 29
Alternator and fan V-belt, Description ..................................................................... 8 Heater .............................................................................. 29
check the tension and condition ............................. 55 Diesel fuel ....................................................................... 68 Hoisting the truck with a crane .................................... 34
Alternator and fan V-belt, renew .................................. 63 Duplex mast ................................................................... 38 Hoisting the truck with a crane using
Applying the parking brake: ......................................... 25 Dust discharge valve check ......................................... 44 the lifting eyes ............................................................ 34
Approved applications .................................................. 2 Horn ................................................................................. 30
Attachments, operating ................................................ 26
E 250-Hour inspection and maintenance .......................
500-Hour inspection and maintenance .......................
48
51
B Electric cables, cable connectors and
connections for condition and tightness, check .... 49
1000-Hour inspection and maintenance .....................
2000-Hour inspection and maintenance .....................
58
63
Battery grease ................................................................ 69 Electrical system ........................................................... 8 3000-Hour inspection and maintenance ..................... 65
Battery: check condition, electrolyte level Engine ............................................................................. 8 Hydraulic by-pass valve, opening ............................... 36
and specific gravity .................................................... 50 Engine cover, opening .................................................. 14 Hydraulic circuit schematic ......................................... 76
Before leaving the lift truck unattended ..................... 33 Engine mounting for condition Hydraulic oil ................................................................... 69
Before lifting a load ....................................................... 31 and tightness, check .................................................. 58 Hydraulic oil, renew ...................................................... 65
Beginning operation ...................................................... 12 Engine mounting, check for tightness ........................ 54 Hydraulic system ........................................................... 8
Brake function after completing repairs, check. ....... 36 Engine oil drain .............................................................. 52 Hydraulic system, check for leaks .............................. 59
Brakes ............................................................................. 8 Engine oil filter, renew .................................................. 52 Hydraulic system: checking the oil level .................... 15
Braking system .............................................................. 25 Engine oil level check ................................................... 14 Hydraulic system: renew the pressure,
Breather filter, renew .................................................... 61 Engine oil, top up .......................................................... 53 suction, and breather filters ..................................... 60
Engine oils ...................................................................... 67
Engine Troubleshooting Guide (Diesel Engine) ........ 70
C Example .......................................................................... 31 I
Chain spray .................................................................... 69 Important safety information ....................................... 12
Change the engine oil ...................................................
Changing the travel direction .......................................
52
21
F Index ................................................................................
Injection nozzles, check ...............................................
78
63
Checks and services after the first 50 service hours 39 Fan motor fuse ............................................................... 29 Inspection and maintenance as required ................... 42
Checks and services before initial operation ............ 13 Filling fuel ....................................................................... 15 Inspection and maintenance chart .............................. 40
Cleaning the lift truck .................................................... 42 Fluid level in coolant reservoir, check ........................ 16 Inspection and maintenance data ................................ 66
Cleaning the prefilter .................................................... 44 Fork stops and fork quick-releases, check ................ 57
Cleaning with compressed air ..................................... 43 Forward travel ................................................................ 21
Cold start ........................................................................ 19 Front working lights ...................................................... 28 J
Compact axle on engine, check the mounting ........... 65 Fuel and oil recommendations .................................... 67 Jack locations when changing wheels ....................... 34
Compact axle, check for leaks ..................................... 59 Fuel filter, renew ............................................................ 56
Composite instrument .................................................. 11 Fuel level check ............................................................. 14
Controls and indicators ................................................ 10 Fuel system water preseparator drain ................. 46, 49
Fuses ............................................................................... 30

78

Page
L T
Lifting device and attachments ................................... 26
Lifting the fork carriage ................................................ 26
Lighting ........................................................................... 28
Lines, check for leaks ................................................... 59
Loading ...........................................................................
Lowering the fork carriage ...........................................
32
26
Lubricate with chain spray ........................................... 51
Lubricating grease ........................................................ 69
M Rear working lights .......................................................
Maintenance ................................................................... 38
Malfunctions ................................................................... 20
Mast and mast chains for
condition and security, check .................................. 51
Mast and tilt cylinder pivots, grease ........................... 48
Mast chain, cleaning and spraying .............................. 42
Mast removal .................................................................. 35
Mast removal .................................................................. 35
Measures before taking the truck out of operation ...
Mounting of the compact axle at the engine, check .
37
54
O Securing the mast against tilting back ....................... 38
Oil grades ....................................................................... 67
Oil viscosity ................................................................... 67
Operating the attachments ........................................... 26
Operation ................................................................. 8, 13
Overhead guard, check for tightness .......................... 54
P device and attachments ............................................ 27
Parking brake ................................................................. 25
Parking brake check ...................................................... 62
Particle filter inspection ............................................... 13
Particle filter system check ............................. 56, 62, 64
Particle filter, regenerating ........................................... 45
Pedals, travel control
and engine control linkages, check and oil ............ 54
Pivots and joints, check and oil ................................... 57
Pre-tension of double hoses
if attachments are fitted, check ................................ 57
Prefilter, cleaning .......................................................... 44
INDEX
Page Page
Pressure filter, renew .................................................... 60 Table of contents ........................................................... 5
Pumps, check for leaks ................................................ 59 Taking the truck out of operation ................................ 37
Putting the truck back into operation ......................... 37 Technical data ................................................................ 7
Technical description .................................................... 8
R Technical note ................................................................
Tilting mast back ...........................................................
2
27
Radiator and hydraulic oil cooler, clean ..................... 56 Tilting the mast forward ............................................... 26
Radiator and hydraulic oil cooler, cleaning Towing ............................................................................ 36
and checking for leaks .............................................. 46 Towing procedure .......................................................... 36
Re-establishing braking power .................................... 36 Trailer coupling .............................................................. 35
28 Travel .............................................................................. 21
Regenerating the particle filter .................................... 45 Travel with a load .......................................................... 33
Releasing the parking brake: ....................................... 25 Triplex mast ................................................................... 39
Releasing the wheel drive brake pressure ................. 36 Troubleshooting guide (hydraulic system) ................ 73
Renew the air filter element, check the Truck takeover ............................................................... 2
vacuum switch ........................................................... 58 Type plates ..................................................................... 3
Reverse travel ................................................................ 21 Typre pressure check ................................................... 18
Running-in instructions ................................................ 13 Tyres, check for damage and foreign objects ............ 47
S U
Safety element, replacing ............................................. 43 Unloading ....................................................................... 33
Safety rules .................................................................... 13
Securing the raised duplex mast ................................. 39 V
Securing the raised standard mast ............................. 38 V-belt, tighten ................................................................. 63
Securing the raised triplex mast .................................. 39 Vacuum switch, check .................................................. 58
Service brake ................................................................. 25 Valve clearance check, adjust ..................................... 64
Sideshift, operating ....................................................... 26 Valves, check for leaks ................................................. 59
Sideshift: clean and grease, check the mounting ..... 50 Ventilation ...................................................................... 28
Single-lever operation of lifting
Single-pedal model operation ...................................... 22
Standard mast ................................................................ 38
W
Starting the engine ........................................................ 19 Water preseparator, drain the fuel system ............ 46, 49
Steering ...................................................................... 8, 25 Wet cleaning ................................................................... 43
Steering axle, check for tightness ............................... 54 Wheel change ................................................................. 34
Steering axle, clean and grease ................................... 48 Wheel drive oil level, check .......................................... 61
Steering cylinder and king pin at Wheel drives, check for tightness ............................... 54
the steering axle, checking the mounting ............... 44 Wheel nuts, tightening .................................................. 47
Steering system ............................................................. 25 Windscreen wiper .......................................................... 28
Stopping the engine ...................................................... 20 Wiring diagram .............................................................. 74
Suction filter, renew ...................................................... 60 Work on the mast and on the front part of the truck . 38
Working Lights ............................................................... 28
79
LINDE AG
Werksgruppe Flurförderzeuge und Hydraulik
D-63736 Aschaffenburg
Postfach 62
Telefon (0 60 21) 99-0
Telefax (0 60 21) 99-15 70
Telex 4 188 01-0 lg d Printed in Germany 351 804 3001.02.95