Operating instructions Linde fork lift truck Type 322 E15C-E16P-E18P-E18Z With electric motors From serie 9/92 322 804 2501 Eiate- Linde - Your Partner Linde AB une da ante Nn Linde, an enterprise operating worldwide in the investment and service sector, is one of the large industrial enterpris- es in the EC with its three business segments and six divisions. The Linde Material Handling division is a leading manufac- turer of industrial trucks and hydraulics. It includes eight manufacturing plants in the Federal Republic of Germany, France and Great Britain, as wellas subsidiaries and bran- ches in all economically im- portant countries. Linde industrial trucks enjoy a worldwide reputation - thanks to their high quality in engin- eering, performance and serv- ice Were Kar an nto Heavy Trt Dvn Ll, MeyYour Linde lift trucks coffer the best in economy, safety and driving convenience. ‘Therefore itis mainly in the hands of the operator to preserve the qualities of the trucks for a long and profitaole service life and to make full use of their benefits on the job, This manual tells you all you need to know abaut starting, running, servicing and maintaining your Linde lift truck. For some attachments, the propiietary operating instructions supplied with ther are applicable Follow ell hints for operating the lift truck and carry out the ‘maintenance and care prescribed in the inspecion and main. tenance schedule regularly, on time and with the specified lubricants, ‘The terms “front”, wear’, "eft" and “right, refer ‘0 the position in which the item concerned is instafed 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. |n particular, we refer to the VDMA booklet “Rules for the ‘Normal and Proper Use of Industral Trucks" to the accident prevention rules of your employer's liability insu’ance and the ‘special measures for driving on public roads. ‘The rules for use o! industrial rusks must be followed under all circumstances ty the responsible persons, especially by the operating and service personnel The user, and not Linde, is responsible for any danger arising from applications not authorized by the manufacturer. Ifyou desireto use the truck for applications not mentioned in the manual and convert or supplement it for this purpose, please first eontact your authorized Linde dealer No changes, especially conversions or modifications, may be made on your fork truck without the prior permission of the manufacturer Only qualified persons authorized by Linde are allowed to sevice the trucks. Tokeep your warranty valid, keep a record of al the mainte: 2 Technical note ‘Those operating instructions or excerpts thereot may only be copied, translated or transmitted to thicd parties after prior writen approval by the manufacturer. Linde pursues a policy of continuous progress in the design land construction of its products. AS a result, the ilustrations ‘and technical details re‘erring to design, fittings and engineer. ing of lit tucks are sutject to change i progress warrants i Therefore, the manufacturer will not accept any claims based Con the specifications, ilistrations and descriptions contained \n this oferating manual, Please submit all enguties concerning your fork truck and all ‘orders for spare parts 10 your authorized distributor, making sure to state your correct shipping adress. For repairs, use only genuine Linde spare parts to ensure that ‘your Linde fork truck wil maintain its ariginal technical stand- ard, When ordering spare parts, itis important also to give the {following information: Lift truck modal: _ Manufacturer's serial naJYeer built: Handing-over date: ‘Also specify the manuiacturer’s number of the mast when ‘ordering parts. Mast no, Mast fing height: mm When taking over the fork lift truck, transfer the data from the ‘assembly type plates into this operatng manual. Truck takeover the factory in order to make sure that it will be in salistactory Condition and fully equipped as ordered when delivered to the customer. Authorized distributors are under obligation to re inspect the iruck before delivery and to hand it over in good order. In order to avoid ater complaints and inconvenience to customers, you are recuested to ascertain that the lrusk Is in satisfactory condition and fully equippedat thetime of daivery ‘and to acknowledge orderly handing/aking over of the truck. In the manufacturer's certificate of conformity, ‘The following technica’ manuals are supplied with each fork truck: 1 Operating manual 1 EC certiticate of conformity (The manufacturer certifies that the industrial truck con- forms to EC guidelines for machines) 1. Rules for the normal and proper use of industiial trucks (vDMA) We wish you satisfactory operation, Linde AG Linde Material Handling Division AschatfenburgTYPE PLATES 1 Mast number (stamped) 2.Pump for working hydraulics (stamped) 3 Pump for steering hydraulics 4 Drive motor, left-hand 5 Wheel drive, left-hand 6 Drive motor, right-hand 7 Wheel drive, right-hand 8 Vehicle identification plate ® Serial number (stamped) 10 Control valve numberFORK LIFT TRUCK TYPE 322,E15C-E16P-E18P-E18Z Most advanced technolagy, energy seving, environment-consciaus and minimal maintenance, simple and ergonomic operation, solid manufacture and for availability of your lift truck neerly all parts of our own manufacture! ‘The success of a company with 8600 employees in seven plants. and operating features are according to is in ergonomics. Each operating ment is designed with regard to positioning and opet tion for the driver's convenience to guarantee effortless and therefore safe operation. Of course, this includes the effortless hydrostatic steer- ing with non-tetuin lock, the service-proved double- pedal travel control system and just one main control lever for all mast functions.TABLE OF CONTENTS Description Type plates. Technical date Technical description General view of truck Controls and instruments. . Instruments... Before operation Safety rules : Important safety information ‘Aacident. prevention check. Punning-in instructions... : Checks prior 1o initial operation... Dally cheeks Daly checks snd mainienence prior © option Tightening the wheel nuts. Ghecking the tyre inflation pressure ‘Checking the hydraulic oil level. Ghecking the gear oll level atthe wheel dive Ghecking the battery charge. Charging the battery... Connecting the battery to an external charger. Battery: Checking condition, electroiyte level and specific gravity, Battery change, removal with a hoist Positioning the seat... Adjusting the steering column. Operation Driving ‘Travel in the forward direction ‘Travel in the revetse direction Changing the direction of travel. Single-pedal operation (optional). Twin-pedal operation (optional) Steering, brakes... : Operation of mast and attachments, - Single-lever operation of mast and isk” (optional). . Horn, fuses. . Before loading. .. : Adjusting the fork spread... Loading .. Transporting the load. Unloading Before leaving the lift truck. Tow coupling. Locations for jack when hanging wheels Lift mast removal... Towing instructions. . Hoisting the truck. Maintenance General information. Mast versions Work on the mast and front part of the truck. Page ‘Securing the mast against tilting backward. . Ea Securing the raised standard mast. 3 ‘Securing the raised cuplex mast. 32 Securing the raised triplex mast. 32 Inspection and maintenance after 50 hours of operation. 32 Inspection and maintenance schedule. ........ = 38 Maintenance as required. 3a Clean the fit truck. : 3a Clean and spray the mast chain. 38 Check the whee! mounting. 35 250-hour inspection and maintenance... Electrical system: Check cables and cable ‘connections for condition and tightness...... 36 Lubricate lifting mast and tilt cylinder pivots... 36 Clean and lubricate the steering axle.......... 37. Wheel drives: Check the oil level... 37 Wheel drives: Check for oil leaks ov Sideshift: Grease guide rod. . 38. Working and steering hydraulics: Check the oi level teees 38 Clean the fan tor drive motors. - 38 Motors: Clean travel drive (LH and RH), working hydraulics, power steering and electronic control... . 39 Clean and lubricate the steer wheel axle and E 18 Z. 39TABLE OF CONTENTS Page 500-hour inspection and maintenance. Check the contactors, replace contacts if 39 required . 39 Check the carbon brushes of electric motors (renew if necessary). : 40 Check the braking system. 40 Check the brake linings. 40 Working and steering hydraulics: Check pumps, valves and lines for Ie a Check the mounting of the counterweight, elec- ‘ric motors, chassis, over steering or steer wheel axle... a Chock the forks and fork stops. .. a Lift mast and mast chain: mounting... a2 Check the mast chain length, adjust if required ‘and spray with chain spray. - Check the pre-tension of double hoses tachments are fitted... 42 Check and ol! the foot pedal and travel contro! linkage pivots... .. 43 Inspect and oll additional pivots and joints. 43 1500-hour inspection and maintenance... 43 Working and steering hydraulics: Renew the breather filter 43 ‘Working and steering fydraulloe: Renew the hydraulic oil...... Renew the suction filter... ‘Wheel drives: Renew the oil Inspection and maintenance specifications. Recommended oils and lubricants......... ‘Troubleshaoting guide (hydraulic system). Wiring diagram (standard). Wiring diagram (optional equipmen').. Hydrate seutdlagram for working and steering system Index .TECHNICAL DATA DESCRIPTION || =| eta 23] Qe oa taeTECHNICAL DESCRIPTION ‘The 322 series electric fork trucks have a load capacity of 1.5 tonnes with the E 15 C, of 1.6 tonnes with the E16 P and 1.8 tonnes with the E 18 P and E 19 Z. ‘The welded and robust chassis, the driver's workplace with functional design and the electronic control as stan- dard equipment make this truck @ valuable tool. The truck Is distinguished for its compact design and small tuming radius. The E 16 P and E 18 P models are provid- ed with an articulated steering axle so that they are par- ticularly suitable for service on uneven surfsces. ‘The E 15C and E 18 Z models are equipped with a steer ‘wheel axle. They ate idieal for service in halls and in nar- row places. Tho fork truck has an electric travel drive, a hydraulic pump forthe steering and a working hydraulics pump for the mast with lift and tilt cylinders. The SCR lift control for energy-saving operation of the working hydraulics is, standard equipment. Drive The truck Is driven by two 4-KW/ electric motors. These motors drive the left-hand or right-hand traction wheel via the wheel drive for each wh ‘The required energy is supplied by the battery installed In the machine. Stepless forward or reverse travel is provided by the travel control and travel pedals. Steering ‘The models E 16 P and E 18 P are steered manually with the steering wheel of the hydrostatic steering, which operates the steering cylinder of the steering axle. ‘The models E 15 Cand 18 Z are steered menually with the steering whee! of the power steering via a double- acting piston that turns a pinion via a rack. in this way, a steering lock of 90 degrees is achieved. Hydraulic system The hydraulic system comprises an electric motor with the hydraulic pump for the steering system, an electric motor with the hydraulic pump for the working hydraulics, and a hydraulic oil tank with breather filter, dipstick and suction filter. Operation The travel drive motors are controlled by means of separate travel pedals for foward and reverse travel. In- finite control is posible in both directions and from a truck standstill up to maximum speed. Both hands are therefore always free for steering and control of the work- ing operations. The result is fast reversing and energy- saving stacking. Only one control lever is provided for the control of lift, lower and tilt operations (central con- trol lever). Additional control levers are fitted for adal- tional attachments. DESCRIPTION Brakes In addition to countercurrent braking, the fork truck can be braked mechanically through two shoe brakes applied with the STOP pedal. Handbrake (parking brake) The manual parking brake acts on the shoe brakes fied at both drive motors through a cable. When the parking brake is applied, the electric power Is reduced by means of an electric switch,GENERAL VIEW OF TRUCK DESCRIPTION 1 Overhead guard 2 Steering whee! 3 Mast (Tiplex) 4 Mast chain 5 Lift eylinder 8 Fork stop 7 Fork carriage 8 Left-hand wheel drive 9 Forks 10 Right-hand whee! drive 41 Tit eylinder 12 Steering axle 18 Battery compartment +4 Counterweight 15 Battery plug 16 Cover (electrical system) 17 Battery cover 18 Operator's seatCONTROLS AND INSTRUMENTS DESCRIPTION 1 Parking brake 2 Funetion indicator ‘3 Hour meter 4 Carbon brush warning light § Hom button 6 Battery discharge indicator 7 Switch key in switch lock 8 Steering wheel (hydrostatic steering) ‘9 Symbol sticker for pedal operation 410 Load capacity diagram 11 Control lever tor additional hydraulics (attechments*) 42 Control lever for working hydraulics 13 Notice plate 14 Symbol sticker for working hydraulics attachment 15 Load capacity plate (attachments)* 16 Travel pedal for forward travel 117 Brake pedal 18 Travel pedal for reverse travel 49 Clamping lever for steering column adjustment * OptionalINSTRUMENTS Hour meter ‘The hour meter indicates the operating time of the truck in hours. It operates only when the switch is turned on. ‘The hour meter serves as proof of the operating time of the truck and as an aid in scheduling lubrication and periodic maintenance. The function indicator (2) shows. {that the hour meter is in operation. ‘The left-hand figures (1) display the full hours of opera- tion, the right-hand figure (3) indicates tenths of an hour. NOTE ‘When replacing a defective hour meter, the number of ef- fective service hours has to be noted. Affix this informa tion near the new hour meter on durable tape. Battery discharge indicator (with cut-off) With the battery plugged in, ® indicates the charging state ofthe battery. When the switch is turned on, it euts off the working ydraulle system when the battery Is 80 % discharged. Battery voltage is in order ifthe upper, green diode (1) lights up. If the yellow diode (2) in the middle lights up, the battery ‘charge is only 50 % and the battery must be recharged. I the lower, red diode (3) lights up, the battery discharge Is about 80 % anda recharging of the battery is absolut ly necessary. ‘The working hydraulics will only operate for another 3 minutes. NOTE The red diode will start flashing three minutes after lighting up and the power for the working hydraulics will be cut-off. ‘The remaining battery charge will allow limited steering and driving. DESCRIPTION NOTE on battery renewal Allow 8 to 10 minutes to elapse between disconnecting ‘the discharged battery and connecting the fully charged battery. Otherwise, the battery discharge indicator will display an incorrect value and cut off the working hydraulic system again. Functional indicator — Insert the battery lug. — Sit down on the drver's seat (seat switch). — Switch on. ‘The indicator (1) displays that the truck is ready for operation. Carbon brush warning light NOTE ‘The carbon brush waming light (2) illuminates if one of the motor brushes Is worn approx. 60 %. A descriotion of how to check and replace the brushes ‘can found in the index.SAFETY RULES ‘The responsible persons, particularly the truck operators ‘and servicing personnel, must be instructed in the safety ‘guidelines for the normal and proper use of supplied in- ‘dustrial trucks with these operating instructions. Please observe the guidelines and safety rulestherein for: — the operation of industrial trucks, — toadwaysand work areas, — the operator (rights, duties and rules of behaviour), — further applications, — various types of drives, — servicing (maintenance and inspection), — the annual accident prevention check. ‘The operator (owner) or responsible person must ensure that the above guidelines and safety rules are observed, When familiarizing a trained operator with the truck following VBG 12 b, acquaint him with the = special features of the lit truck (double-pedal control, main control lever) — optional attachment — special operating characteristics Practice travel, control and steering operations until they are completely mastered. Only then startto train stacking. ‘The stability of the truck is assured if employed properly, ‘Should the truck tip over during an unauthorized or ap- plication due to improper operation, follow the instruc- tions depicted below. Important safety information ‘The words WARNING, CAUTION, ATTENTION and NOTE are used inthis manual t point out perticular hazards and for information requiring special labeling: WARNING Indicates that, if not heeded, death andior sub- stantial damage to the product can occur. CAUTION Indicates that, ifnot heeded, severe personalin- jury and/or substantial damage to the product ‘can occur. ATTENTION Indicates that,if not heeded, damage tothe pro- duct or Its destruction can occur. NOTE ‘means that technical connections are drawn attention to which may not even be cbvious to skilled personnel, A WARNING @|a| ® Don’t jumpt_ontight Bracefeet__| Lean away Hold 2 BEFORE OPERATIONSAFETY RULES Accident prevention check The accident prevention rules prescribe that the fork lit truck must be checked at least once a year for proper working condition by trained personnel. Please contact your authorized LINDE deaier in this regard. Funning-in instructions ‘The lift truck can be operated at full speed directly. Avoid sustained high loads on the working hydraulic system and the travel drive in the first 50 hours of operation Retighten whee! nuts daily prior to starting operation un- til they are seated firmly, .. until no further tightening is possible, ‘The wheel nuts should be tightened crosswise to a tor- que of 210 Nm (21 kpm) at the front, and 195 Nm (19.5 kpm) at the rear. NOTE ‘Observe the tightening instructions on the tag attached to the steering column. Tighten wheel nuts of wheel-mounting — prior to starting operation of the truck — then every 10 hrs until wheel nuts are tightened — after that every 100 hrs (For torque see operating manual) BEFORE OPERATION Checks prior to ini = Yee inflation — Tightness of wheel mounting = Oil level of wheel drive — Oil level of hydraulic system — Battery connections and electrolyte level — Function of braking system — Function of steering system — Funetion of horn | operation” Daily checks* — Tyre pressure — Oil level in hydraulic system = Battery charge = Operation of brake system * NOTE ‘A description of the services can be located in the Index. 2BEFORE OPERATION Dally checks and maintenance prior to operation Tightening the wheel nuts — Checkthe tightness of all wheel nuts. — Tighten nuts crosswise to a torque of: front wheels 210m rear wheels 495m Checking the tyre inflation pressure — Checktha tyre pressures. — required, inflate tyres according to the information on label (1). Drive axle Steering axle 18x7-8 (16 PR) 16x6-8 (10 PR) 10bar ‘Bbar 1“ Checking the hydraulic oil level NOTE Check the level of the hydraulic oll only with the mast lowered. — Remove the retaining bolts of floor plate (1). Raise the floor plate toward the front end. Disconneet the cable connector (2)atthe travel switch. Removetthe floor plate. Pull outbreather filter (3) with oil dipstick. — Wipe the oil dipstick with a clean cloth. — Fully reinsert breather filter (3) with dipstick and pull it out again. — The oll level should be between the marks on the dipstick (4). — Itneeded, top up the hydraulic oll to upper mark. jevel at the wheel @ Checking the gear drive — Check the oll level in each wheel drive by removing the breather fiter with olldipstick (1). — The oil evel should be between the marks. If topping-up Is required, fll g ‘oll to upper mark (2).Daily checks and maintenance prior to operation Checking the battery charge — Insert battery plug (1). — Check the battery charge at discharge indicator (2). CAUTION For the safe operation and maintenance of the batteries, comply with the following in- structions. The electrolyte in the batteries is a sulphuric acid and water solution, which Is poisonous and caustic. There- fore, wear protective clothing and protective glasses when working around the batteries. Gases are released re being charged. Do not expose the bat- , a6 an explosion could result. Rooms in which batteries are charged or stored must be ventilated accordingly. Charging the battery NOTE Check that the specific gravity of th least 1.14, lectrolyte is at ‘Always charge and service the battery according to the ‘manufacturer's instructions. If you are not in possession of these instructions, please contact your service dealer. ‘Also comply with the operating instructions for the op- tional battery cherger. If a battery charger is already available, follow the instructions thereto. CAUTION Do not place any metal parts on the battery — you risk a short! Connecting the battery to an external charger = Lower the forks = Dieconnect the battery plug at the truck. = uniateh (2) the battery cover (1) and open. = insert the charger plug into the battery socket. = Switch on the oattery charger. ‘Always recharge batteries without delay. Never leave bat- teriesin a discharged state. This also applies to partially discharged batteries. BEFORE OPERATION Battery: Check condition, electrolyte level and specific gravity — Check the battery for casing cracks, lifted plates and. electrolyte leakage. — Unscrew the caps and check the electrolyte level. On batteries with check tubes, the fluid should be at the bottom of the tubes. On batteries without tubes, the fluid should be 10 - 15 mm above the plates. —If the electrolyte level is low, top up with distilled ‘water only. — Remove corrosion on battery poles and coat with non- acidic grease. — Retighten pole clamps firmly. Check the electrolyte using a hydrometer. The specitic gravity of the electrolyte should be between 4.24 and 1.28. NOTE Discharges which are 20% below the rated capacity are deep discharges. Deep discharges shorten the service life of the battery.BEFORE OPERATION Battery changing When changing the battery, at least 8 - 10 minutes must elapse between disconnecting and connecting the bat- teries. Otherwise the battery cischatge indicator will display a false reading and shut off the working hydraulle system, CAUTION ‘The replacement battery must correspond to the standard battery both in size and weight. ‘Deviations in weight must be compensated by additional weights. ‘The battery must be secured agairst sliding. Please consult your authorized dealer. Removal with a hoist Use a hoist and a hoisting gear with a sufficient load capacity (see Technical Data for battery weight). — Completely lower the forks. — Unlock and raise the battery cover. — Pull out the battery plug. — Position the hoist on the right-hand side in the cut-out of the overhead guard. — Attach the hoisting gear to the bettery. — Lift the battery out ofthe compartment. (Pay attention to the overhead guard!) Positioning the seat — Press lever (1) to the left. — Slide seat in guide rails forward or backward usti the best position in regard to steering wheel, drive and brake pedals and control levers has been reached. — Re-engage the lever {1). — Adjust the backrest by turning knob (2). Adjusting the steering calumn — Loosen clamping lever (1) and move the steering wheel to the most convenient operating position. — Retighten the clamping lever (2).TRAVEL Driving caution Travel on long slopes over 15 9 is not allowed as.a ule dueto the preseribed minimum brake applications and truck stabilty characteristics. Before driving on bigger slopes, you should consult your dealer. The climbing a ‘ven in the data sheet were derived from the {ractive force of the truck and they apply only for the crossing of obstacles and for short cit- ferences in evel. NOTE ‘Always adjust your driving to suit the conditions of the roadway (rough surfaces, etc.), especially hazardous ‘work areas and the load. CAUTION The power steering pump motor is turned on when the seat switch is actuated. iis idle speed is 1200 rpm. When the steering is operated, the pump motor spe eased to 2300 ‘pm. ‘When the hydraulic oil temperature is low, the steering pump motor operates at maximum ‘speed until the oll has reached operating temperature. Travel in the forward direction — Insert the battery plug into the truck socket. — The battery discharge indicator (4) will light up. = Sit down on the driver's seat. (Only this will actuate the seat switch beneath the driver's seat.) NoTE All control levers must be in the neutral position. — Insert key (5) into the clockwise. — The function indicator (3) meter (2) will operate. — Raise the forks slightly and tilt the mast back. — Release the parking brake (1). — Depress the right travel pedal smoothly (6). Pushing down on the pedal will Increase truck speed. itch lock and turn the key ht up and the hour ‘Travel in the reverse direction — Depress the left-hand travel pedal (7). The position of the travel pedal determines the reversing speed of the truck. OPERATION Changing the direction of travel — Release the depressed pedal. — Push down on the travel pedal for the opposite direc- tion of travel. The truck will be braked to a standstill electrically and then accelerated in the selected direction. the truck during travel. — The travel pedals can be shifted directly from forward travel into reverse travel. NOTE Pushing down fast on the travel pedal does not change the rate of acceleration as maximum acceleration is controlled automatically. Please ask for a demonstration of counter-current brak- ing when accepting the truck at delivery.SINGLE-PEDAL OPERATION (OPTIONAL) Driving CAUTION Travel on long slopes over 15 % Is not allowed as a rule due to the prescribed minimum brake applications and truck stability characteristics. Before driving on bigger slopes, you should consult your dealer. The climbing ability rates given in the data sheet were derived from the tractive force of the truck and they apply only for the crossing of obstacles and fer short dit. ferences in level. NoTE Always adjust your driving to suit the conditions of the roadway (rough surfaces, etc, especially hazardous work areas and the load. 8 CAUTION The power steering pump motor is tumed on when the seat switch is actuated. Its idle speed Is 1200 rpm. When the steering is operated, the pump motor speed is increased 10 2900 rpm, When the hydraulic oll temperature is low, the steering pump motor operates at maximum. speed until the oll has reached operating temperature. — Insert the battery plug on the machine, — The battery charge indicator will light. — Sit down on the driver's seat. (This alone will operate the seal switch under the operator's seat.) NOTE Directional control lever (2) must be in the neutral position. OPERATION — Insert switch key (3) into the switch lock and turn clockwise to the stop. — The function indicator illuminates and the hour meter Is In operation. — Raise the forks slightly and tilt the mast back by ‘operating the control lever. — Release parking brake (1). Travel in the forward direction — Push directional control lever (2) forward. — Depress travel pedal (4) smoothly. The speed of the truck depends on how far the accelerator is pushed down. NOTE Depressing the travel pedal quickly does not increase the rate of acceleration, since maximum acceleration is con- ‘tolled automatically. Travel in the reverse direction = Shift directional control lever (2) back. — Depress travel pedal (4). The truck reverses at a speed depending on how far the accelerator is. pushed down.SINGLE-PEDAL OPERATION (OPTIONAL) Changing the direction of travel — Release travel pedal (4). = Shift directional control lever (2) to reverse direction of travel. — Depressing travel pedal (4) will accelerate the truck in the new direction. The directional control lever can be shifted directly from forward to reverse travel. The truck will be braked to a standstill electrically without releasing the travel pedal and accelerated in the desired direction. NOTE ‘Ask for a demonstration of counter-current braking when accepting the truck on delivery. Braking Depressing STOP pedal (5) actuates the mechanical brakes. The truck can be braked electrically using counter- current braking by reversing the direction of travel. The ‘manual parking brake is used to prevent truck roll. OPEARTION »TWIN-PEDAL OPERATION (OPTIONAL) Driving CAUTION Travel on long slopes over 15 % is not allowed as a rule due to the prescribed minimum brake ‘applications and truck stability characteristics. Before diving on bigger slopes, you should consult your dealer. The climbing ability rates given in the data sheet were derived from the tractive force of the truck and they apply only for the crossing of obstacles and for short dit- ferences in level. NoTE Always adjust your driving to suit the conditions of the roadway (rough surfaces, etc), especially hazardous ‘work areas and the load. ATTENTION ‘The power steering pump motor is switched on by the set switch. Its speed is 1200 ‘pm. When ‘the steering Is operated, the electric motor runs at 2300 rpm. At a low hydraulic oil temperature the steering pump motor runs at maximum speed until the olf has reached the operating temperature. 20 Travel in the forward direction — Insert the battery plug into the truck socket. — The batlery discharge indicator (4) will light up. — Sit down on the driver's seat. (Only this will actuate the seat switch beneath the driver's seat.) NoTE All control levers must be in the neutral position. — Insert key (5) Into the switch lock and turn the key clockwise. — The function indicator (3) will light up and the hour meter (2) will operate. — Raise the forks slightly and tilt the mast back. — Release the parking brake (1). — Depress the left travel pedal smoothly (6). Pushing down on the pedal will increase truck speed. OPERATION Travel in the reverse direction — Depress the right travel pedal (7). The position of the travel pedel determines the reversing speed of the truck.TWIN-PEDAL OPERATION (OPTIONAL) Changing the direction of travel — Release the depressed pedal. = Push down on the travel pedal for the opposite direc tion of travel. The truck will be Ibraked to a standstill electrically and then accelerated in the selected direction. — The travel pedals can be shifted directly trom forward travel into reverse travel. NOTE Pushing down on the travel pedal does not change the rate of acceleration as maximum acceleration is control- led automatically. Please ask for a demonstration of reverse travel braking when accepting the truck at delivery. Braking When driving, press the STOP pedal (1) for mechanical braking. Counter-current braking is possible by reversing the direction of travel. The parking brake is used to prevent ‘ruck roll, OPERATION 2STEERING, BRAKES Steering Due to the hydrostatic steering, the effort required for fuming the steering wheel ts minimal. This feature Is ‘specially advantageous when working in narrow aisles. Turning radius: E 16 P, E 18 P ECE 18Z 1810 mm Service brake — Release travel pedals (1) and (3). — Depress brake pedal (2). Depressing the brake pedal operates the shoe brakes at both drive motors mechanically, When the brake pedal is operated, the maximum current of the truck is reduced. Counter-current braking — Release the depressed travel pedal and push down on the pedal for travel in the opposite direction until the truck has been stopped electrically. OPERATION Manually-operated parking brake Use the mechanical, manually-operated parking brake to park the fork truck. Both shoe brakes at the drive motors. are applied by means of a cable. NoTE When the parking brakeis applied, the starting current fe reduced via an electric ewitch To engage the parking brake: — Pull parking brake lever (2} back firmly. To release the parking brake: — Press release button 1) on the brake lever and push the lever forward.OPERATION OF MAST AND ATTACHMENTS ‘CAUTION Use the lifting device and attachments only for wuthorized applications. The operator must be Instructed in the handling of the lifting device and attachments. Always shift the control lever smoothly and slowly. ‘The travel of the control lever determines the lifting or lowering and tilting speed. ‘The control lever retums to its init cally when released. NOTE Observe the operating symbols with direction arrows. position automati- Tilt mast forward = Push control lever (1) forward. Tilt mast backward — Pull control lever (1) backward. Lift fork carriage — Push control lever (1) to the right. Lower fork carriage — Push control lever (1) to the left. Operating the attachments Additional equipment can be installed as optional equip- ‘ment (e.g. sideshitt, 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 onto the ‘scuttle and a symbol sticker behind the respective con- trol lever. OPERATION Operating the sideshift — Push contro! lever (2) forward (fork carriage moves to the left). — Pull control lever (2) backward (fork carriage moves to the right). Operating the clamp — Push control lever (2) forward (clamp opens). = Pull control lever (3) backward (clamp closes). cauTION Attachments not supplied with the truck m: only be employed if your authorized dealer ascertains that a safe operation is assured in respect to load capacity and stability. eT es 23SINGLE-LEVER OPERATION OF MAST AND ATTACHMENTS (OPTIONAL) CAUTION 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 shift the control levers smoothly and slowly. ‘The travel of the control levers determines the lifting or lowering and tilting speed. ‘The control levers return to thelr initial position automatically when released. NoTE Observe 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. 24 Tilting the mast forward — Push the control lever (2) forwarc. Tilting the mast back — Pull the contro lever (2) back. Operating the attachments ‘Auxiliary equipment can be installed as optional equip- ‘ment (e.g. sideshift, clamp, etc.). Observe the working pressure and operating instructions of the at- tachments. One or two additional control levers are fit- ted for their operation. NOTE For each attachment affix a load capacity plate and a ‘symbol sticker onto the scuttle and a symbol sticker behind the respective control lever. OPERATION Operating the sideshift — Push control lever (3) forward (fork carriage moves to the left). — Pull control lever (3) back (fork carriage moves to the right). Operating the clamp — Push control lever (4) forward (clamp opens). — Pull control lever (4) back (clamp closes). When other attachments are used affix appropriate sym- bol sticker. ‘CAUTION Attachments not supplied with the truck may only be employed if your authorized desler ascertains that a safe operation is assured in respect to load capacity and stabifty. rar iesHORN, WINDSCREEN WIPER, LIGHTING, FUSES Operating the horn Tne horn serves eg. as a warning signal at and intersections. lind spots — Pressing the horn button 1) on the console will sound. the horn. ‘Switching on the windscreen wiper” — Pressing toggle switch (2) will operate the windscreen wiper. Operating the direction indicators* — Moving the direction indicator switch (3) left or right will operate the left or right dinection indicators and the direction indicator lamps (6) will light. Switching on the hazard flasher unit" = Pressing toggle switch (4) will switch on the hazard flasher unit. * Option Turning on the low beam headlight* — Pressing toggle switch (5) will turn on the low beam headlight and the license plate light. Switching on the working light* ‘The light is ewitched on and off by the toggle switch on the working light. the toggle switch (7) Is loclated on the instrument panel. OPERATION Fuses NOTE ‘The electrical system and fuses are located in the ‘counterweight under the cover, — Screw out the cover screws and remove the cover. 1-2 ym headlight’ 24 V 2x5A 3-4 Side marker light” 24 V 2x5A 5 Light switch/windscreen wiper" 24V_ 15. 6 Hazard flasherwindscreen wiper 24.15 A 7-10 Working light" 48 V 6x5A Free Converter 4aV ‘action motors. 355 A Pump motor for working hydraulics 250 A Key switch BA ‘Faction, fan, steering 5A Lifting, indicator lamp ay Horn 5A 20 Steering 2x208 Battery discharge indicator BABEFORE LOADING Check the load capacity diagram (1) prior to loading. It attachments are fitted, refer to the respective load capacity diagram (2). ‘The weights given in the load capacity diagram are only applicable to compact and homogeneous loads. Never exceed the load capacity of the lift truck. Overloading will impair truck stability and the strength of forks and mast. ‘The maximum load capacity is governed by the height of lift and the load centre distance. NoTE — Before transporting off-centre or swinging 'oads, and — before transporting loads with the mast tilted forward or the load not near the ground, — loads with a great load centre distance, or — before operating attachments, check the load limits and contact your authorized dealer. 26 Example: Model E 16 P Load centre distance: 700 mm Height of lit: 5750 mm — Follow the verti I line for a load centre distance of 700 mm to the point where it intersects the line for a lift height of 5750 mm. of intersection to the left to read the maximum load capacity. — In this case the maximum load is 1050 kg. Proceed in the same manner for other heights and load centre distences. The values in the diagram apply to cer tred and evenly distributed loads. 600 700 OPERATION 4 Maximum load capacity in kg 2 Height of tft 4950 mm 3750 mm 8550 mm 3 Mast type 4 Fork lift truck model 8 Distance of load centre of gravity from fork-face in mm. 4950 mm S750 mm 16550 mm 8C0_900 1000mm (pRz222485-160/16LOADING, TRANSPORTING THE LOAD Adjusting the fork spread — Pull up on the fork release lever. — Position the forks to correspond to the width of the load, Slide the forks right or left. Take care that both forks are ecuidistant from the truck centre, — Allow the fork release lever to seat in anotch. NOTE The load centre of gravity should be in the centre between the forks. Loading — Approach the load carefully and as accurately as possible. — Sel the mast te the vertical position. = Elevate or lower the forks to the proper height. = Carefully move the truck forward under the centre of the load until the load contacts the forkcface, if possi- ble. Do not touch adjacent loads. — Raise the fork carriage untl the load rests freely on the forks. — Back away from the stockpile until the load is clear. = Tilt the mast back and lower the load, it necessary CAUTION Do not allow anyone to stand or pass under the elevated load. While travelling, theload should ‘be as low as possible and the mast should be tilted back. OPERATION NoTE Pick up the load in such a way that it does not project beyond the truck load limit and that it cam neither fall over or off. — Do not transport an off-centre load (e. g. ita sideshitt is fitted). — Transport the load near the ground. — When travelling on a gradient, always drive the truck with the forks facing uphill, when it is loaded. Never drive or turn across the slope. — Hyoudo not have a clear view of your path, work with a guide. = If your load obstructs forwand vision, you must travel with the load trailing, except In the case of climbing ‘a gradient. arUNLOADING Unloading — Carefully drive the truck up to the rack or other storage means. — Elevate the fork carriage to the proper height. — Set the mast to the vertical position, — Drive carefully into the rack. — Lower the load slowiy until the forks are free. — Reverse the truck. WARNING lever park and leave the lift truck with the load elevated, Before leaving the lift truck — Deposit the load or lower the fork carriage. — Slightly tilt the mast forward. The forks must touch the ground. — Engage parking brake (1). — Remove switch key (2). 28 OPERATIONTOW COUPLING, WHEEL CHANGE Tow coupling NoTE Only use the hitch for towing light trailers in the plent area (Bo not exces the rated tractive force given in the Data Sheet.) = Turn tow pin (1) back and pull up. — Insert the tow bar eye into the coupling. — Press downon the tow pin against the pressure of the ‘spring, turn 90° and allow to engage In the retaining device. Locations for jack when changing wheels cauTiON ‘Only use a jack with the sufficient lifting capacity of 3600 kg minimum. — Locate the jack at the front only at the chassis (1) behind the wing. — Locate the jack at the corners of the chassis (2). ‘CAUTION The truck may only be raised at these locations on the left and righthand side. OPERATION Lift mast removal ATTENTION ‘Attach the hoisting gear to the outer ends of the upper ctoss member (1). This work must only be ed personnel of your 2sTOWING THE TRUCK, HOISTING Towing instructions Ht, n exceptional cases, the lift ruck needs to be towed, ‘ow bar oF rope can be attached to the tow pin in the counterweight. A rope ean also be attached at the bot- tom of the mast, CAUTION The truck can only be braked mechanically with the brake pedal or the manual parking brake. Towing procedure NOTE ‘The power steering is inoperative when the battery plug is pulled out. — Pull out the battery plug. — Lower the load, but only so far that the forks will not contact the ground when towing. — Remove the load. — Attach the tow bar to the tow pin or a rope at the bot- tom of the mast. — One driver must steer the truck being towed or operate the brake. ‘Tow the fork truck and do not exceed the maximum operating speed of the truck. Hoisting the truck ‘CAUTION Only use a lifting sling and hoist with a suffi- ient load capacity. For the truck weight see the manufacturer's plate. To holst with a crane, attach the lifting slings at the points provided. — Hook the lifting sling (2) (2000 kg carrying capacity minimum) to the tow pin. — Lock the tow pin. — Attach the lifting sling (3) (2000 kg carrying capacity minimum) to the crass member on the outer upright of the mast. — Hook the ends into the crane hook (1). OPERATION CAUTION Lock the safety clip (4) after suspending the lings in the crane hook. When the truck is being hoisted, the cables ‘must not rub against the sides of the overhead ‘guard or any attachments fitted.MAINTENANCE General information Your truck will remain operational only if the main- tenance and checks are regularly carried out according {0 the information and details given in the operating in- structions. The maintenance may only be performed by qualified authorized personnel. ‘This work ean be carried out by your authorized dealer under a service contract. Ityou wish to do the work yourself, we recommend the first 3 customer service checks be carried out by your dealer's mechanic in the presence of the responsible mechanic In your workshop, so that your staff can receive appropriate instruction. For all Inspections and servicing the truck must be placed on a level surface and secured against rolling. Remove the key and pull out the battery plug. When working on t elevated, secure thi ruck with the forks or attachments against accidental lowering. For work on the front end of the truck, secure the mast against tilting. Perform a funetional check and trial run after every in- spection and servicing. NOTE When operating the truck under extreme conditions (.e. extreme heat or cold, intensive dust concentration, etc.) the intervals given in the maintenance schedule should be reduced accordingly. Clean the surroundings of the respective part before lubrication, filter renewal or repairs in the hydraulic system. Use only clean containers when replenishing lubricants. Follow the safety and disposal instructions of the manu- facturer when handling lubricants and cleaners. MAST VERSIONS Work on the mast and on the front part of the truck ATTENTION Before attempting to carry out repairs or ad- justments on the raised fork carriage, ensure that the following safety procedures are car- ried out. Securing against tilting back ‘To prevent the lifting mast from tilting back accidentally, insert a hardwood block of dimensions 120 x 120 x 800 mam (1). Standard mast FUNCTION When the inner mast is lifted, the chain idler wh also moved upward, thereby raising the fork carriage at a 2:1 ratio, Securing the raised standard mast ATTENTION Use a sultable chain for the particular lifting mast. Take the maximum height of lift into con- ‘sideration. — Raise the mast. — Fasten the chain eround the cross member of the ‘outer upright (1) and the cross member of the inner mast Q). — Lower the inner mast until itis held by the chain. 3MAST VERSIONS Duplex mast ‘The advantage of this version is that the special free lift helght can be used evan In spaces with a low ceiling (cellars, wagons, ships). FUNCTION ‘The fork carriage is raised to tho special free lift height by the centre cylinder via the chain guide roll ‘Then the inner mast is lifted by both exterior cylinders and takes the fork carriage with it. ‘The centre cylinderis fitted to the extendable inner mast. Securing the raised duplex mast ATTENTION Use a suitable chain for the particular lifting mast, Take the maximum height of lit into con- ‘sideration. — 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. — Lower the fork carriage completely. Triplex mast FUNCTION ‘The fork carriage is raised to the special free lift height by the centre cylinder via the chain guide roller, ‘Then both exterior cylinders raise the intermediate mast. Due to the chain guide roller, the inner mast is reised at twice the speed. ‘The centre cylinder is fitted to the extendable inner mast. Securing the raised triplex mast ATTENTION Use a suitable chain for the particular lifting mast. ke the maximum lift height into con- ideration. — Raise the mast. — Fasten the chain around the cross member of the ‘outer mast (1) and the intermediate mast (2). 32 MAINTENANCE — Lower the mast until it is held by the chain. — Fully lower the fork carriage. Inspection and maintenance after the initial 50 hours of operation NoTE ‘A description of the services can be located in the index. — Check the braking system = Tighten the wheel mounting — Check the tyre pressures. — Inspect the tyres for damage and foreign bodies — Whee! drives: Renew the cll — Wheel drives: Check the oil level and oil tightness — Working and steering hydraulic Renew the suction filter and check the oll level — Working and steering hydraulic Check the oil tightness of the pumps, valves and lines — Check the level of battery electrolyte — Check the mounting of the steering axle, olectric motors, wheel drives, counterweight and overhead ‘guard — Lubricate the mast pivots and tilt — Mast and mast chain: Check the condition and mounting, lubricate with chain spray — Electrical system: Check wires, cables and battery ‘connections for condition and tightness — Check carbon brush connections for tightness: — Check the pre-tension of the double hoses. linder pivotsINSPECTION AND MAINTENANCE SCHEDULE MAINTENANCE Every tom As required 250 hours Every 3000 hours Giean and spray the mast chain. Check the wheel mounting (every 100 hours minimum). Check the tyres for damage and foreign objects... Renew the carbon brushes. : Electrical system: Check cables and connections for condition and tightness... . : Lubricate lift mast and tit eyinder pNOts ---. sees eeesveeeese Motors: Clean travel arive RH and LH), working hysaules, power steering and transistor contro! Wheel drives: Check the oil level Wheel drives: Check for oll leaks. . Sideshift: Grease the guide rods Working and steering hydraulics: Check the ol! level. Clean the fan for drive motors Clean and lubricate the steering axle (E 16 P, £18 F). Clean the steer wheel axle (E 15 0, E 18 P) Check the contactors, replace contacts if required Check carbon brushes of electric motors, renew if necessary... Check the braking system Check the brake linings ...... Working and steering hydrates: Check pumps, vales and pipes for leaks Check the mounting of counterweight, electric motors, chassis, wheel drives, overhead guard and steer wheel axle Mast and mast chain: Check condition and mounting Check the mast chain length, adjust and lubricate with chain spray, Check the pretension of double hoses Check the forks and fork stops Check and lubricate the foot pedal and control linkage pivots Check and lubricate other bearings and joints ......... Working and steering hydraulics: Renew the breather filter... . Working hydraulic and power steering systoms: Renew the hydrauic oll Renew the suction filter ........- Wheel drives: Renew the gear oi eeccccee of requiredMAINTENANCE AS REQUIRED Clean the lift truck NOTE The necessity of cleaning depends on the operation of the truck. When working with highly aggressive media like salt water, fertilizers, chemicals, cement, etc., a thorough cleaning will be necessary upon completion of ‘work. Disconnect the battery plug. Hot steam or intensive degreasing solutions should be used with utmost care! The grease in sealed-forlife bearings will dissolve and run out. Since regreasing Is not possible, this would When washing with a cleaning device, do not directly expose the electrical sysiem, electric ‘motors and insulating material to the jet (cover t). Dry the truck after cleaning. Should moisture have penetrated the motors, operate the truck in order to prevent damage by corro- sion (drying by means of truck's heat), or dry the motors by warming and blowing them out. When cleaning with compressed sir, first re- move sticking dirt with a cold cleaner. NOTE ‘The lubrication must be more frequent if cleaning is in- tensive. In particular, clean the oil fill openings and their surroundings and the grease lubrication nipples prior to lubrication. Clean and spray the mast chain NOTE ‘The mast chain must be cleaned if the dust on the chain prevents penetration of the lubricant. — Place a dish under the mast. — Clean the chain using paraffin derivatives such as washing petrol (observe manufacturer's notes on safety). — When using a steam jet, clean without additives. — After cleaning, blow dry the chain at once to remove any water in the chain links and on the surface. During this procedure the chain should be moved several time: 34 MAINTENANCE — Spray LINDE chain spray on the chain, while moving it. CAUTION Lifting chains are safety components. The use of cold cleaners, chemical clezning agents and caustic or acidic and chlorinated flulds can be rect cause of damage to the clINSPECTION AND MAINTENANCE Check the wheel mounting Check the wheels for damage and for (At least every 100 hours) foreign objects = Check all whee! nuts for the proper torque: — Raise the truck so that the wheels are clear of the front 210 Nm, rear 195 Nm. ‘ground. — Block up the squared timber on each side. — Check that the wheels rotate freely and remove any- thing which hinders their movement. — Replace worn out or damaged wheels. MAINTENANCE Renew the carbon brushes ‘The carbon brushes must be renewed when the warning light (1) illuminates. Replace carbon brushes only as a s (Refer to page 40 for instructions.) 35250-HOUR INSPECTION AND MAINTENANCE Electrical system: Check cables and cable connections for condition and tightness Nore Apply the parking brake and disconnect the battery plug before performing any maintenance work. — Electric motor terminals: Check the connectors for tightness and oxidation residues. — Check the battery cable for tight connection. — Inspect the wiring for chafe marks and tight con- nections. NoTE ‘Oxidized terminals and brittle cables will leac ta voltage drops and therefore to malfunctions. — Remove oxidation residues and renew brittle cables. Lubricate lift mast and tilt cylinder pivots NOTE Use a multipurpose grease. — Fully lower the mast — Grease the lubrication nipples (1) of the tit cylinder at the mast and chassis. — Lubricate with a grease gun until fresh grease ‘emerges from pivots, MAINTENANCE — Raise the mast until grease bubrication nipple (2) is accessible, — Secure the mast against accidental lowering with a chain, — Lubricate the mast pivot grease nipple (2) at the frame on both sides.250-HOUR INSPECTION AND MAINTENANCE Motors: Clean travel drive (RH and LH), working hydraulics, power steering and transistor control — Raise the mast and secure. = Disconnect the battery plug. = Loosen the floor plate and lift up. — Clean the electric motors for travel drive, working hydraulics and power steering with compressed — Remove the cover for the electrical system. = Clean the electronic control using compressed air. NOTE Protect the electrical system, the transistor contro! and connections against moisture. Care should be taken not to let water penetrate the elec- tric motor. Should moisture have penetiated never- theless, the litt truck must either be operated (drying with own heat) or the motor must be dried by warming up, blowing out, etc., in order to avoid damage through corrosion. Wheel drives: Check the oil level — Fully lower the mast. — Unscrew oll dipstick (1) with vent fiter at the left and right whee! drives. — Wipe the oll dipstick with a cb n cloth. — Screw in the oil dipstick fully and remove again. — The gear oll level should be between the marks on the dipstick. — If needed, add gear oll up to the upper mark. Max. capacity each side approx. 1.2 L MAINTENANCE Wheel drives: Check for oil leaks — Raise the mast and secure against accidental lower- ing. — Check the left and right wheel drive for oil leaks at the oll dipstick, at the emergence of the drive shaft and at the mounting of the motor.250-HOUR INSPECTION AND MAINTENANCE Sideshift*: Grease the guide rod — Move the sideshift to the left and right and clean. — Lunbricate left and right grease nipples (arrowed) with lithium base grease until grease emerges at the sides. NOTE The guide rod must also be greased after each truck cleaning. Working and steering hydraulics: Check the oil level NOTE Check the oil level only with the mast lowered. — Unbolt floor plate (1) and swing to the rear, — Unplug connector (2) and remove floor plate. — Pull out breather filter (3) with oll dipstick. — Wipe the oil dipstick with a clean cloth. — Fully reinsert the breather filter with dipstick and pull out again. — The oil level should be between the marks. — Add hydraulic olf up to the top mark (4), if needed. MAINTENANCE Clean the fan for drive motors CAUTION ‘The fan moter runs when the traction motors are warm even when the truck is switched off. — Pull out the battery plug. — Unbolt the floor plate (1) and raise rearward. — Disconnect the connector (2) of the cable from the travel control ewiteh, Remove the floor plate. Dismantie the fan. — Clean screen, fan motor and air baffle with compress- d — Remount the fan. — Refit the floor plate with the connector, reconnect the ‘cable and tighten the floor plate. CAUTION ‘The brakes are operative only when the floor Plate Is bolted.250-HOUR INSPECTION AND MAINTENANCE ‘Clean and lubricate the steering axle (E16 P, E 18 P) — Thoroughly clean the steering axle with water or cold cleaner. NOTE Use a lithium-based grease. — Remove cover (1). — Grease t! base grease. jston rod of steering cylinder with lithium — Lubricate the track joints, steering knuckle and steer- ing cylinder bearings with lithium-based grease at the lubrication nipples (see arrows). — Grease witha grease gun until new grease er the bearings. at Clean and lubricate the steer wheel axle E15C,E 182 = Clean the steer wheel axle thoroughly with water or a cold cleaner. 500-HOUR INSPECTION AND MAINTENANCE Check the contactors, replace contacts if required — Check the contactor contacts for pitting, replace if re- quired, Please consult your authorized dealer.500-HOUR INSPECTION AND MAINTENANCE Check carbon brushes of electric motors (renew if necessary) — Raise the mast and secure. — Disconnect the battery plug. — Remove the floor plate. — Flemove the covers from drive motors (3), motor for ‘working hydraulics (1) and motor for power steering @). — Remove the tension trom the carbon brush springs. — Hlomove the carbon brushes from their guides. — Check brush length and replace if too short. — Pretension the brushes and check their connections for tightness. NOTE Replace the brushes only as a kit. Drive motor Pump motor Power steering motor new 32 mm, min, 15 mm new 32 mm, min. 15 mm ‘pew 22 mm, min. 12 mm 40 Check the braking system ‘The proper operation of the parking brake (1) and the STOP pedal (2) must always be reliable. If defects due to mechanical wear should become evident (e.g. worn brake linings or scored brake discs), please contact your authorized distributor. ATTENTION Do not operate your fork truck if the brakes are defective. MAINTENANCE Check the brake linings ATTENTION Raise the mast and secure against accidental lowering. — Pull out the battery plug. = The minimum brake lining thickness is 2 mm. — Inspect the surface of the brake linings and the brake dises. ATTENTION ‘Should defects or wear in the braking system become evident, please contact your author- Ized distributor.500-HOUR INSPECTION AND MAINTENANCE Working and steering hydraulics: Check the mounting of the Check pumps, valves and pipes for leaks counterweight, electric motors, chassis, — Remove the floor plate, overhead guard and steer wheel axle — Check the mounting elements of motor drive units, support of steering and working hydraulics motors, counterweight, chassis, wheel drives, overhead guard and steer wheel axle for tightness and wear. = Check the pumps for working hydraulics and power steering, valves and pipes for leaks. — Replace porous hoses. — Examine the pipes for chafe marks, replace if re _— Tighten loose nuts and bolts. quired — Renew damaged parts. — Touch up the paint, if required. MAINTENANCE Check the forks and fork stops — Examine the forks for visible deformations and damages. — Check the bolts of the fork stops (2) and fork releases. (1) for proper seating and for damage. — Renew defective parts.500-HOUR INSPECTION AND MAINTENANCE Lift mast and mast chair Check condition and mounting — Clean the mast channels and chain thoroughly. — Examine the chain for condition and wear, pat in the area of the guide rollers. larly — Check the mounting of the chain at the chain anchor. — Renew damaged chains. — Inspect the mast, channel surfaces and rollers for condition and proper mounting. — Check bearing support retaining bolts for tight seat. Check the mast chain length, adjust if required NoTE The mast chain will stretch after some time of operation, and must therefore be adjusted. — Lower the mast completely. — Loosen locknut (1). — Adjust the chain by turning adjusting nut (2) of the chain anchor. The lower guide roller of the fork car- riage must not protrude more than 25 mm from the inner mast channel. Lubricate with chain spray — Lubricate chann spray. nore ‘Trucks in service in the food industry must be lubricated with a dry lubricant instead of chain spray. ain roller and chain with chain MAINTENANCE Check the pre-tension of double hoses it attachments are fitted — The pre-tension of the dou! mm per metre (referred to in — Adjust the pre-tension to the specification by moving the hoses in the clamps, 42500-HOUR INSPECTION AND MAINTENANCE ‘Check and oil the foot pedal and travel control linkage pivots ATTENTION The adjustment of travel control switch (i) must only be performed by trained personnel! Please contact your authorized distributor. = Unbott the floor plate and raise forward. = Unplug connector and litt out the floor plate. = Check pin and joint retainers fortfirm seat. — Lightly oil lever pivots and clevises as required. ~ Inspect the function of leg spring (2) and spiral ‘spring ()- Inspect and oil additional pivots and joints Inspect and oil the pivots and joints of: — Seat guide — Battery cover latch — Windscreen washer* — Cab door hinges and locks* * Optional 1500-HOUR INSPECTION AND MAINTENANCE Working and steering hydraulics: Renew the breather filter = Unbolt the floor plate and raise forward. — Unplug connector (1) and lift out the floor plate. — Pull breather filter (2) out of the filler neck. — Pull dipstick (3) out of the breather filter and install a new fier. NoTE In dusty environments the filter may need more frequent renewal.3000-HOUR INSPECTION AND MAINTENANCE Working and steering hydraulics: Renew the hydraulic oil NOTE ‘The hydraulic ol can only be siphoned off witha suitable aid (hand pump). — Fill hydraulic oll at the fill opening. — Check the hydreulic oil level with the oil dipstick and refill to the top mark on the dipstick Capacity: 14 Lts. Renew the suction filter — Unbolt and lift the floor plate. — Unplug the connecter of the cable from the travel con- trol switch, — Remove the floor plate. — Loosen clamp (2), pull up suction filter cover (1) and remove to one si — Pull out suction filter (3) slowly to allow the oll to flow back into the reservoir. — Carefully insert a new suction filter into the housing. — Clean the filter cover seal, coat with oll and re-install. — Secure the fitter cover with the clamp. — Check the oil tightness of the filter in a trial run. — Check the olf level with dipstick (4), add hydraulic oi as required. — Refit the floor plate and connector. MAINTENANCE Wheel drives: Renew the oil — Raise the mast and block against accidental lowering. Place a drain pan underneath the wheel drive. = Remove drain plug (2) and allow the oll ta drain com- pletely. = Install the drain plug. Screw out oil dipstick (1) with breather filter. Refill gear oil at the dipstick opening. NOTE To avoid air inclusions, fill with oil a litle at a time. — Check the oll level with the dipstick and add oil to the upper mark on the dipstick. Capacity per drive: approx. 12 Lts.INSPECTION AND MAINTENANCE SPECIFICATIONS MAINTENANCE ftom Assembly Material/ Capacity! Lubricant Adjustment value 1 Wheel drive Gear oil Per drive 1.2 Lts. 2 Hydraulic system Hydraulic oll 13s. 3 Hydraulic system Filter element Mesh = 25 um ‘4 Tyres Air Front 10 bar, rear 8 bar 5 Wheels Drive wheel Torque to 210 Nm Rear wheel Torque to 195 Nm ‘ Electrical system: Drive motor Fuses 355 A Hydraulic pump motor Fuses 250 A Power steering motor Fuses 2x 208 Control current Fuses 2x 15A 3x 5A 1 Electric motors: Drive motor Carbon brushes New 32 mm — min. 15mm Hydraulic pump motor Carbon brushes New 32 mm — min. 15 mm Power steering motor Carbon brushes . New 22 mm — min. 12mm 8 Battery Distilled water AAs required 9 Mast tilt cylinder bearing As required 0 Sideshitt, steering axle As required 1 Mast channels and chain guides ‘Chain spray [As required RECOMMENDED OILS AND LUBRICANTS Hydraulic oil Hydraulic oil recommendation for light duty at low am- Gear oil 180 VG 68 H-Lor H-LP ace, to DIN 51524 (factory filling) Recommendation for normal duty: Hydraulic oil H-L or H-LP ISO VG 68 average oil temperature 60 - 80 °C Hydraulic oil recommendation for heavy duty: Hydraulic oll H-L or H4LP ISO VG 100 for heavy and multi-shift operation, operation in warm climate zones or at high ambient temperatures, average oll temperature over 80 °C bient temperatures: Hydraulic oll HL or H-LP ISO VG 46 for light and normal duty in cold climate zones, average oll temperature below 60 °C NoTE ‘The foregoing recommendations are only approximate values. In case of doubt, we recommend contacting your authorized dealer Recommendations of representatives of the oll industry should also be checked with your authorized distributor. Use only oil of classification API GL5 SAE 80 (ace. to DIN 51812). Multi-purpose grease Penetration grade 2 acc. to ASTM 265-295 1/10 mm. Lithium-based grease ‘hee 10 DIN 51625-KPF2K-30 Chain Spray LINDE chain sprayTROUBLESHOOTING GUIDE (HYDRAULIC SYSTEM) Trouble Possible Cause Remedy See Page Abnormal noise | Suction filter dity. Giean or replace filter. 4 Suction hoses leak, oll foams. Tighten hose connections. “1 heck oil level, top up if necessary. 38 Hydraulic pump or motor failure, seals detective, | Have hydraulic unit inspected by di causing air intake. it of wrong viscosity, Change oil, a4 tow of level in tank. top up oil 44 No or too low | Pump suction defective, noises. Change oil filer, add oll. 38 ressure ineystem Pump failure, pressure valves do not close, Have repaired by dealer's mechanic. valve seat damage. Pipeline broken or leaky. Replace line or tighten connection a Oil of low viscosity, causing high leakage Change oil 44 losses. Oil pressure Causes 28 under abnormal noise. See under abnormal noise, fluctuates Lift and tit eylincers hove tight spots. Have sleeves replaced by ¢ workshop. Mast does not extend completely or retracts ‘dd oi 28 slighty after being extended. Hydraulic ol! | Pump failure, valves leaky. Have repaired by a workshop. temperature foo nigh Oit level too low or oll cooler defective. Check oil level; if necessary, top up oll. 3 Fallure of the | Battery discharge at 60%. Charge or change the battery. 8 working hydraulic een Feplace the fu 2s Truck does not | Battery is discharged Check the battery, charge or substitute. 15,16 start Loose electrical connections. Tighten battery terminals, coat with non-acidic grease. 6 Check electric motor cable connections. 36 a7WIRING DIAGRAM Leger 1a a3 1M 2a 3at ‘Traction pulse Time relay Accelerator Liting pulse Steering pulse Carbon brush monitor (Accelerator) Current actual value transmitter Temperature switch 80 °C, closing (in 1M2) ‘Temperature switch 80 °C, closing (in 1M) ‘Temperature switeh 160 °C, opening (in 1M2) ‘Temperature switch 160 °C, opening (in M1) Speed transmitter for lft pulse Horn Carbon brushes (4), right traetion motor Carbon brushes (4), right traetion motor Carbon brushes (4), left traction motor Carbon brushes (4), left traction moto: Carban brushes (4), puma motor Carban brushes (4), pumo motor Carban brushes (4), power steering motor Carban brushes (4), power steering motor ‘Suppressor capacitor Traction fuse 355 A Control tuse 15 & ‘Traction/tan/steering fuse 5 & Lifting fuse 250 A Lifting fuse 5A Steering fuse 20 A Steering fuse 20 A Horn fuse 5 A Fuse 15 A Battery Warning famp Carbon brush warning light Reverse directional contactor, right Forward directional contactor, right Reverse directional contactor, left Forward directional contactor, left Right drive motor Left drive motor Pump motor Steering motor Fan motor 6Pt 6P2 aR s1 181 184 185 1812 1813 1850 281 282 283, 284 381 4si 1e4 1v6 151 352 Hour meter Battery discharge indicator Resistor SA for speed limiter* Key switch Curve switch, right Curve switch, loft Handbrake switch Braking current switch Travel switch Single-pedal directional switch"/SRTN Seat switch Lift switen Tilt switeh ‘Switch for attachment 1" ‘Switch for attachment 2* Steering pressure switch Horn button Traction transistors ‘Traction freewheel diode Armature diode (1M) ‘Armature diode (1M2) Lift transistors Lift freewheel diode Steering transistor Steering freewheal diode Battery plug ‘Traction pulse te ‘Traction pulse ter ‘Traction pulse terminal ‘Traction pulse terminal Lift pulse terminal Lift pulse terminal Lift pulse terminal ‘Traction pulse terminal ‘Traction pulse terminal 15-way connector ‘Seway connector ‘eway connector ‘G-way connector ‘-way connector 4-way connector ‘G-way connector 2eway connector ‘25-way connector 4 1x50 xt ‘Seway connector 2-way connector 25-way connector 2X2 G-way connector 2X3. S-way connector 3X1 25-way connector 5X2 2-way connector 6X1 3-way connector &X5__3-way connector €X6 S-way connector &X7 3-way connector &X1_S-way connector 1211 Quench capacitor 4212 Quench capacitor 1221 Quench capacitor 1222 Quench capacitor S21 Circuitry 1 Double pedal Single pedal Colour code bl blue br brown ge yellow gn greent gr grey t red sw black ws white * OptionLIGHTING WIRING DIAGRAM* 1 Working tamp 5X1 9.way connector vin 5X2 _ Edge connector Revolving light 5X3. Edge connector ML Lighting 5X4 Flat plug St Kay awitoh 5X14. 3-way connector (brake U1 Voltage converter 48/36/24 V 8.3 A 9FIS Fuse, front wiper U2 Converter 48:96/24 V 8.3 A 9F16 Fuse, rear wiper No converter in 24 V truck Sa ‘9M Front wiper motor XS Battery 9M2_ Rear wiper motor 5E2 Left low beam 50 W 5E3 Right low beam 50 W 9X1 S-way connector ‘5E4 Front left parking light 4 W 9x2 3-way connector SES Front right parking light 4 W ‘SEG Rear left side marker light 10 W 5E7 Rear right side marker light 10 W Colour code ‘SEB License plate light 5 W blue 5E21 Working lamp No, 1...7 21 W BL blue 5F5 Low beam fuse (5 A) ge yellow 5F6 Low beam fuse (5:A) gn green SF7 Side marker light fuse (5 A) gr grey 5F8 Sido marker light fuse (5 A) red 5F9 Light switch fuse (15 A) sw black SF10 Hazard flasher fuse (15 A) ws white SFI! Working lamp fuse (5 A) SH8 Front left flasher 21 W SH9_ Rear left flasher 21 W SH10 Front right flasher 21 W SH Rear right flesher 21 W SHI2 Flasher indicator light 1.2 W SH4 Revolving light 45 W SHI8. Lighting indicator light 1.2 W ‘SHI9. Hazard flasher indicator light 1.2 W 5H20 Left stop light 21 W 5H21 Right stop light 21 W SKI Flasher unit, 5S11_ Light switch 8812 Hazard flasher switch 5813. Flasher switch 8S14_ Stop light switch * Option 50WIRING DIAGRAM (OPTIONAL EQUIPMENT)HYDRAULIC CIRCUIT DIAGRAM FOR WORKING AND STEERING SYSTEM A Worl 1g hydraulic system 1 Hydraulic ofl reservoir 2° Breather fiter 3 Electrie motors 4 Hydraulic pump (11 cm*/rev) 5 Suction filter (25 um) 6 — Contre! valve (2, 3 or 4-way, depending on model) 7 Relief valve 8 Check valves 9 Tilteylinder 10 Sideshitt 41 Lowering brake valve 124 Lift oylinder, standard mast Type 160 122 Lift cylinder, duplex mast Type 161 42-4 Lift eylinder, triplex mast Type 162 B Steering hydraulic system 13 Hydraulic pump (4.1 cm/rev) +4 Electric motors 15 Power.assisted steering Adjustment pressure 80+ Sbar Shock valve 150 + 20 bar 16 Steering cylinder 47 Steering cylinder for steer axle 18 Steering cylinder tor steer wheel axle 52INDEX Page ‘Accident prevention check..... 13 Battery discharge indicator " Batlery, charging, 15 Battery, cheeking the charg 6 Battery, cheeking condition, electro level” and specific gravity, . 6 Batlery, changing... --. : 16 Battery, connecting to an external sharger 5 Before leaving the truck. . 28 Before loading.......... 23 Before operation. ....-. 2 Brake linings, checking. . 39 Braking system, checking, 39 Breather filter, renewing. 43 Carbon brushes of electric motors, check, renew if necessary. 40 Checks prior to initial operation... 2... 2 Cleaning the truck... : 34 Contactors, checking, replacing contacts. 39 Controls and indicators. : 10 Daily checks. 13 Daily checks ‘and maintenance pr prior to operation 4 Direction of travel, changing. 7 Driving......+++2 7 Electrical system, checking cabies for condition ‘and tightness... . see 86 54 Page F Fan for drive motors, cleaning. 38 Fore and lork stops, checking. at Fork spread, ca 1 25 General information. a General view of truck. 9 Gear oll level, checking at wheel drive. 4 Hoisting the truck. ... 30 Horn...-.--eeeces 25 Hour meter. bitterest eters 1 Hydraulic circuit diagram, working and steering system . seeeeeeees 52 Hydraulic oli level, checking. .-....- 4 Hydraulic oil, changing. . 4 Inspect and oil additional pivots and joints. 43 Inspection and maintenance after the initial 50 hours of operation : 32 Inspection and maintenance as required. 34 Inspection and maintenance, 250-hour. . 36 Inspection and maintenance, 500-hour. . 39 Inspection and maintenance, 1500-hour. 44 Inspection and maintenance, 3000-hour. 44 Inspection and maintenance schedule. 33 Instruments... . L Lift truck, cleaning. Lift mast and mast chain, Shocking ¢ condition ‘and mounting...... Lift mast pivots, lubricating. Loading .... Locations for jack when changing wheels. Maintenance specifications. ... Malfunctions, causes, remedy (hydraulic sytem) Mast chain, adjust and spray. . Mest chain, cleaning and spraying Mast removal. Mast versions. . Motors: cleaning travel drives, working hydraulics, power steering and electronic control... . see Mounting of counterweight, electric motors, chasse fitinge, whee crves, overhead guard and steering axle — checking. O il and lubricant recommendations. Operation of mast and attachments. P Pedal and linkage of travel control, checking. .. Pivots and joints, inspecting and oiling. Prestenalon of double hoses, checking (fate ‘tachments are fitted). R Running-in instructions, Page 45 23 43 2 aINDEX Page Safety information. . 2 Safety rules....... 12 Seat, positioning bees 4 Sideshift, greasing guide rod. 38 Single-pedal operation (optional). 18 Steering 22 Steering axle, cleaning and iubricating 37 Steering column, adjusting. . 16 Steer wheel axle E 18 © and E 18 Z, cleaning ‘and lubricating peseeeeerss 39 Suction filter, renewing. 44 Table of contents... : Technical data...... Technical description... Tilt eylinder pivots, lub cating. ‘Tow coupling, Towing instructions. Transporting the load. Travel In the forward direction... TTavel in the reverse direction. ‘TFoubleshooting guide (hydraulics) ‘win-pedal operation (optional) ‘wpe plates. : ‘yre inflation pressure, checking. U Unloading W. Wheel drives, checking the oil level Wheel drives, checking for oll leaks. Wheel drives, renewing the oll... . Whee! mounting, checking. 28 Wheel nuts, tightening... Wheels, checking for damag objects... Wiring diagrams... Work on the mast and the front part of the truck Working and steering hydraulics: changing the breather filter. Working and steering hydraulics: checking the oil. level. Working and steering hydraulis valves and lines for leaks. : Working and steering hycrautis: Fenewing the hydraulic oll. : ! checking the Page 4 48 31 43 38 aLINDE AG erssgrunpe Flurforderzeuge und Hydrautik a Mates ‘ete 602) sa ‘te 0.60 2) Sos 79 oon a 09 322 804 2501.1192