d3343301

Operating Instructions
Linde Fork Lift Truck
E 10 - 03
With Electric Motor

334 804 3301 GB

0903
Linde - Your Partner Linde AG Linde Material Handling Division

Linde, an enterprise operating

worldwide in the investment
and service sector, is one of the
large industrial enterprises in
the EC with its three business
segments and six divisions.

Fenwick-Linde, Châtellerault The Linde Material Handling

division is a leading manufac-
turer of industrial trucks and
hydraulics. It includes eight
manufacturing plants in the
Federal Republic of Germany,
France and Great Britain, as
well as subsidiaries and bran-
ches in all economically im-
Werk II, Aschaffenburg-Nilkheim Lansing Linde Ltd., Basingstoke
portant countries.

Linde industrial trucks enjoy a

worldwide reputation - thanks to
their high quality in engineering,
performance and service.

Werk I, Aschaffenburg Werk III, Kahl am Main Linde Heavy Truck Division Ltd., Merthyr Tydfil

Your Linde lift truck
offers the best in economy, safety and driving convenience.
Therefore it is mainly in the hands of the operator to preserve
the qualities of the truck for a long and profitable service life
and to make full use of their benefits on the job.
These operating instructions tell you all you need to know
about starting, operation, running and servicing the truck.
For maintenance and repair work not described in these
operating instructions special technical skill and knowledge,
measuring equipment and special workshop tools are often
required. Please contact your authorised Linde dealer for this
service.
Only qualified persons (experts) authorised by Linde are
allowed to service the trucks.
For some attachments, the proprietary operating instructions
supplied with them are applicable.
Follow all tips 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 spec-
ified lubricants.
To keep your warranty valid, all maintenance services must
be performed by qualified persons authorised by Linde.
The terms “front”, “rear”, “left” and “right” refer to the position
in which the item concerned is installed in the truck in relation
to the forward travel direction.
2
Foreword
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 VDMA booklet “Rules for the
Normal and Proper Use of Industrial Trucks”, to the accident
prevention rules of your employer’s liability insurance and
the special measures for driving on public roads.
The rules for use of industrial trucks must be followed under
all circumstances by the responsible persons, especially by
the operating and service personnel.
The user, and not Linde, is responsible for any danger arising
from applications not authorised by the manufacturer.
If you desire to use the truck for applications not mentioned
in the manual and convert or supplement it for this purpose,
please first contact your authorised Linde dealer.
No changes, especially conversions or modifications, may
be made on your fork truck without the prior permission of the
manufacturer.
334 804 3301.0903

Technical note
These operating instructions or excerpts thereof may only be
copied, translated or transmitted to third parties after prior
written approval by the manufacturer.
Linde pursues a policy of continuous progress in the design
and construction of its products. As a result, the illustrations
and technical details referring to design, fittings and engi-
neering of lift trucks are subject to change if progress warrants
it.
Therefore, the manufacturer will not accept any claims based
on the specifications, illustrations and descriptions contained
in this operating manual.
Please submit all enquiries concerning your fork truck and all
orders for spare parts to your authorised distributor, making
sure to state your correct shipping address.
For repairs, use only genuine Linde spare parts to ensure that
your Linde fork truck will maintain its original technical stand-
334 804 3301.0903
ard.
When ordering spare parts, it is important also to give the
following information:
Lift truck model: __________________________________
Manufacturer’s serial no./Year built: __________________
Handing-over date: _______________________________
Also specify the manufacturer’s number of the mast when
ordering parts.
Mast no.: ________________________________________
Mast lifting height: ____________________________ mm
When taking over the fork lift truck, transfer the data from the
assembly type plates into this operating manual.
Foreword
Truck takeover
Every fork truck undergoes careful inspection before leaving
the factory in order to make sure that it will be in satisfactory
condition and fully equipped as ordered when delivered to
the customer. Authorised distributors are under obligation to
reinspect the truck before delivery and to hand it over in good
order. In order to avoid later complaints and inconvenience
to customers, you are requested to ascertain that the truck is
in satisfactory condition and fully equipped at the time of
delivery and to acknowledge orderly handing/taking over of
the truck in the manufacturer’s certificate of conformity.
The following technical manuals are supplied with each fork
truck:
1 Operating manual
1 EC declaration 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 industrial trucks
(VDMA)
Wishing you satisfactory operation and much success,
Your
Linde AG
Linde Material Handling Division
Aschaffenburg
3
334 804 3301.0903
4
 Type plates Description
1 Manufacturer’s plate
2 Manufacturer 1 2
3 CE symbol
(The CE symbol certifies that the EC directives for ma-
chines and all applicable guidelines have been ful-
filled.) 10
4 Serial number / year built 3
5 Weight of unloaded truck
6 Battery voltage 9 4
7 Minimum weight of battery
8 Maximum weight of battery 5
9 Rated capacity
10 Type
11 Mast number (stamped)
12 Drive motor 8 7 6
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13 Reduction gearbox

12 11

e3343300
13

5
Electric lift truck model E 10-03 Description
The latest technology,
simple and ergonomic operation,
energy saving, environmentally-conscious and minimal
maintenance, simple and ergonomic operation,
solid manufacture and for availability of your lift truck
nearly all parts are of our own manufacture!
The success of a company
with about 9600 employees in eight manufacturing sites.

334 804 3301.0903

Driver’s position and operating features are designed using
the latest research in ergonomics. The ergonomic layout of all
operating controls ensures optimum comfort and safe oper-
ation. d3343301
Of course, this also includes the on-demand, easy hydrostatic
steering. The ergonomically styled steering wheel is operat-
ed with the right hand. The left hand operates the multifunc-
tion control for driving, load lifting, load lowering, fork carriage
tilting and sideshift operating.

6
 Table of contents
Seite
Foreword ......................................................................... 2
Approved applications ........................................................ 2
Technical note ..................................................................... 3
Truck takeover ..................................................................... 3
Description ..................................................................... 5
Type plates .......................................................................... 5
Technical data ................................................................... 10
Technical description ........................................................ 12
Drive ............................................................................... 12
Gearbox ......................................................................... 12
Steering .......................................................................... 12
Hydraulic system ........................................................... 12
Mast versions ................................................................. 12
Operation ....................................................................... 12
Brakes ............................................................................ 12
Parking brake ................................................................. 12
334 804 3301.0903
Electrical system ............................................................ 12
General view ..................................................................... 13
Controls and indicators ..................................................... 15
Instruments ........................................................................ 16
Hour meter and battery discharge indicator ................. 16
Battery discharge indicator ............................................ 16
Hour meter ..................................................................... 16
Steer wheel position indicator ...................................... 16
Beginning operation ................................................ 17
Safety rules ........................................................................ 17
Safety information ............................................................. 17
Handling fluids and lubricants .......................................... 17
Accident prevention check ................................................ 18
Operation of industrial trucks in the plant area ................ 18
Running-in instructions ..................................................... 18
Services prior to first operation ......................................... 18
Daily checks ...................................................................... 18
Daily checks and services before operation .................... 19
Check the battery state of charge ..................................... 19
Charging the battery ......................................................... 19
Seite
Connecting the battery to a suitable external charger .... 20
Connecting the battery to a built-in charger ..................... 20
Check the condition, electrolyte level and
specific gravity of the battery ......................................... 21
Changing the battery ........................................................ 21
Check the hydraulic oil level ............................................ 22
Adjust the driver’s platform ............................................... 23
Check the protective pane ................................................ 23
Check the brake fluid level ............................................... 24
Operation ...................................................................... 25
Driving ............................................................................... 25
Driving forward .............................................................. 25
Reversing ....................................................................... 25
Changing the direction of travel .................................... 25
Steering system ................................................................. 26
Steering .......................................................................... 26
Braking system .................................................................. 26
Service brake, reverse current brake ............................ 26
Foot brake ...................................................................... 26
Electric motor brake (LBC) operation ........................... 26
Parking brake ................................................................. 26
Operating the lifting device and attachments .................. 27
Lifting the fork carriage .................................................. 27
Lowering the fork carriage ............................................ 27
Operating attachments .................................................. 27
Tilting the fork carriage forward .................................... 27
Tilting the fork carriage backward ................................. 27
Operating the sideshift .................................................. 27
Operating the horn ............................................................ 28
Electrical system cover ..................................................... 28
Removing, installing the rear cover .............................. 28
Fuses ................................................................................. 29
Check, replace fuses ..................................................... 29
Before picking up a load ................................................... 30
Adjusting the fork spread .................................................. 31
Picking up a load .............................................................. 31
Transporting a load ........................................................... 32
Depositing a load .............................................................. 32
Description
Seite
Parking the truck ............................................................... 32
Transport ........................................................................... 33
Transport with lorry or low-bed semi-trailer .................. 33
Hoisting the truck .............................................................. 33
Hoisting the truck with a crane ...................................... 33
Wheel change ................................................................... 34
Jack locations for wheel change ...................................... 34
Changing the rear wheel ............................................... 34
Changing the front wheels ............................................ 34
Mast removal ..................................................................... 34
Towing instructions ........................................................... 35
Towing ............................................................................ 35
Towing procedure .......................................................... 35
Releasing the pressure of the parking brake .................. 35
After towing ........................................................................ 35
Resetting the brakes ......................................................... 35
Maintenance ............................................................... 37
Taking the truck out of operation ...................................... 37
Measures before taking truck out of operation ................ 37
Recommissioning after taking out of operation ............... 37
General information .......................................................... 37
Mast versions .................................................................... 38
Servicing the mast and the front part of the truck ............ 38
Securing the mast against tilting back ............................. 38
Simplex mast ..................................................................... 38
Securing the raised simplex mast .................................... 38
Duplex mast ...................................................................... 38
Securing the raised duplex mast ...................................... 39
Triplex mast ....................................................................... 39
Securing the triplex mast .................................................. 39
Services after the first 50 service hours ........................... 39
Inspection and maintenance schedule ............................ 40
7
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8
 Table of contents
Seite
Inspection and maintenance as required ...... 42
Clean the truck .................................................................. 42
Clean and spray the lift chains ......................................... 42
Check the wheel nuts for tightness .................................. 42
Check the wheels for damage and foreign objects ......... 42
500-hour inspection and maintenance ........... 43
Check the braking system ................................................ 43
Check and oil the brake pedal linkage ............................ 43
Check the forks and fork quick-releases .......................... 43
Check the mounting, condition and operation
of the mast, lift chains and stops ................................... 44
Adjust the lift chains,
lubricate the chains with chain spray ............................ 44
Lubricate the tilt cylinder pivots at the fork carriage ........ 45
Check and oil other pivots and joints ............................... 45
Lubricate the driver's platform mounting,
334 804 3301.0903
brake cylinder ................................................................ 45
Clean and grease the sideshift, check the mountings .... 45
Clean the electrical system and electric motors .............. 46
Check, renew traction and pump motor brushes ............. 46
Lubricate the drive unit turntable ...................................... 47
Check the gearbox oil level .............................................. 47
Check the electric cables, connectors
and connections for condition and security .................. 47
Check the mounting of the electric motors,
chassis, drive unit, mast, overhead guard
and steering system for security ................................... 48
Check the tension of double hoses if attachments
are fitted ......................................................................... 48
Check the top sideshift sliders for wear and play ............ 48
1000-hour inspection and maintenance ........ 50
Renew the hydraulic oil filter ............................................ 49
Check, clean or renew, the breather filter cartridge ........ 49
Description
Seite
1500-hour inspection and maintenance ........ 50
Check the load wheel brake linings ................................. 50
Change the gearbox oil .................................................... 50
Check, adjust steering chain tension ............................... 51
Lubricate the steering chain
and chain tensioning roller ............................................ 51
Check the bottom sideshift sliders for wear,
and sideshift for play, and adjust, if necessary ............ 51
3000-hour inspection and maintenance ........ 52
Change the hydraulic oil ................................................... 52
Change the brake fluid ..................................................... 52
Inspection and maintenance data .................................... 53
Fuel and oil recommendations ......................................... 54
Hydraulic oil ................................................................... 54
Bio hydraulic oil ............................................................. 54
Gear oil .......................................................................... 54
Grease ............................................................................ 54
Battery grease ................................................................ 54
Chain spray .................................................................... 54
Brake fluid ...................................................................... 54
Troubleshooting guide ...................................................... 55
Electric circuit diagram ...................................................... 56
Working and steering hydraulics diagram ....................... 58
Index .................................................................................. 60
9
Technical data Description
Linde Forklift Trucks EFG
Data Sheet for Material Handling Equipment VDI 2198
September 2002
1.1 Manufacturer (see page 1)
Designation VDI 3586

Linde Linde
to VDI 3586

Linde
Note:
1.2 Model designation E 10 Simplex E 10 Duplex E 10 Triplex
Characteristics

1.3 Power unit: battery, diesel, petrol, LP gas, mains power Battery Battery Battery 1) Data for container version
1.4 Operation: manual, pedestrian, stand-on, seated, order picker Stand-on Stand-on Stand-on
1.5 Load capacity Q [t] 1,0 1,0 1,0
2) Fork tilt is optional
1.6 Load centre c [mm] 600 600 600
1.8 Axle centre to fork face x [mm] 138-196 3) 138-196 3) 138-196 3)
1.9 Wheelbase y [mm] 966 966 966 3) Data for optional side shift (with/without tilt)
Wheels and Tyres Weight

2.1 Service weight [kg] 1595-1588 1) 1698-1685 1) 1822-1804 1)

2.2 Axle load with load, front/rear [kg] 2487-2480 1) / 493 2583-2570 1) / 500 2706-2688 1) / 501
2.3 Axle load without load, front/rear [kg] 723-716 1) / 1257 819-806 1) / 1264 942-924 1) / 1265
3.1 Tyres: solid rubber, contoured solid (superelastic) polyurethane Polyurethane Polyurethane Polyurethane
3.2 Tyre size, front 250 x 80 250 x 80 250 x 80
3.3 Tyre size, rear 254 x 100 254 x 100 254 x 100
3.5 Wheels, number front/rear (x = driven) 2/1x 2/1x 2/1x
3.6 Track width, front b10 [mm] 770 770 770
3.7 Track width, rear b11 [mm] - - -
4.1 Mast/fork carriage tilt, forward/backward degrees 1,4/4 2) 1,4/4 2) 1,4/4 1)
4.2 Height of mast, lowered h1 [mm] 2123-2003 1) 2178-2058 1) 2230-2110 1)
4.3 Free lift h2 [mm 1580-1460 1) 1633-1513 1) 1685-1565 1)

334 804 3301.0903

4.4 Lift h3 [mm 1600-1480 1) 3520-3280 1) 5253-4893 1)
4.5 Height of mast, extended h4 [mm] 2143-2023 1) 4063-3823 1) 5796-5436 1)
4.7 Height of overhead guard (cabin) h6 [mm] 2120-2000 1) 2120-2000 1) 2120-2000 1)
4.8 Height of seat/stand-on platform h7 [mm] 95/195 95/195 95/195
4.19 Overall length l1 [mm] 2402-2460 3) 2402-2460 3) 2402-2460 3)
Dimensions

4.20 Length to fork face l2 [mm] 1252-1310 3) 1252-1310 3) 1252-1310 3)

4.21 Overall width b1/b2 [mm] 850 850 850
4.22 Fork dimensions s/e/l [mm] 40/80/1150 40/80/1150 40/80/1150
4.23 Fork carriage to DIN 15173, class/form A, B 2/A 2/A 2/A
4.24 Width of fork carriage b3 [mm] 820 612 612
4.25 Overall fork width b5 [mm] 540-525 2) -584 3) 540-525 2) -584 3) 540-525 2) -584 3)
4.31 Ground clearance, mast m1 [mm] 63 48 48
4.32 Ground clearance, centre of wheel base m2 [mm] 56 56 56
4.33 Aisle width with pallets 1000x1200 across forks Ast3 [mm] 2600-2653 3) 2600-2653 3) 2600-2653 3)
4.34 Aisle width with pallets 800x1200 along forks Ast3 [mm] 2711-2767 3) 2711-2767 3) 2711-2767 3)
4.35 Turning radius Wa [mm] 1114 1114 1114
5.1 Travel speed, with/without load km/h 8,0/9,0 8,0/9,0 8,0/9,0
Performance

5.2 Lifting speed, with/without load m/s 0,17/0,27 0,16/0,26 0,16/0,25

5.3 Lowering speed, with/without load m/s 0,3 0,3 0,3
5.8 Maximum climbing ability with/without load % 8/15 8/15 8/15
5.9 Acceleration time with/without load (first 10 m) s - - -
5.10 Service brake Hydr./mech. Hydr./mech. Hydr./mech.
6.1 Drive motor power kW 3,0 3,0 3,0
6.2 Lift motor power kW 2,2 2,2 2,2
Drive

6.3 Battery according to IEC DIN 43535-B DIN 43535-B DIN 43535-B
6.4 Battery voltage/ rated capacity K2 V/Ah 24/375-435 24/375-435 24/375-435
6.5 Battery weight kg 385 385 385
8.1 Type of drive control digital with micro processor digital with micro processor digital with micro processor
Others

8.2 Working pressure for attachments bar - - -

8.3 Oil quantity for attachments l/min - - -
8.4 Mean noise level at driver's ear dB (A) <70 <70 <70

10
 Technical data Description

Lifting capacity diagram:

Type: E 10 Standard Type: E 10 Container
334 804 3301.0903

Mast unit Standard

Building height and lift Lift Lift height Height, Free lift Height Tilt
(in mm) mast lowered mast raised (1)
h3 h3 + s h1 h2 h4 V/R

Standard lift mast 1600 1640 2123 1580 2143 1.4/4

Duplex lift mast 3520 3560 2178 1633 4063 1.4/4

Triplex lift mast 5253 5293 2230 1685 5796 1.4/4

Mast unit Container

Building height and lift Lift Lift height Height, Free lift Height Tilt
(in mm) mast lowered mast raised (1)
h3 h3 + s h1 h2 h4 V/R

Standard lift mast 1480 1520 2003 1460 2023 1.4/4

Duplex lift mast 3280 3320 2058 1513 3823 1.4/4

Triplex lift mast 4893 4933 2110 1565 5436 1.4/4

(1) With optional tilting fork carriage unit.

11
Technical description
The 334 series of electric trucks is designed for handling and
stacking loads up to 1 metric tonne with a 600 mm load
distance. The truck is ideal for various applications such as
loading lorries, as well as for bloom and slab yards and light-
and medium-duty racking applications.
The E 10-03 is available in two versions; as a standard
version or as a lower version for containers.
The driver is protected by the solid truck chassis and a rugged
overhead guard.
The mast and overhead guard are welded to the chassis into
one supporting assembly.
The shape of the truck is conical and round toward the traction
end. This makes the truck very manoeuvrable while protect-
ing the load.
The truck can be turned very tightly. On account of its manoeu-
vrability and narrow aisle width it is also suited for confined
work areas.
Steering
The E 10 - 03 features on-demand hydrostatic steering. The
kickback free, sensitive and nearly playless steering of the
truck is by hand with the small steering wheel. The steering
movement is transferred to the turntable of the drive unit via
a chain.
LED’s in the steer wheel position indicator* show the position
of the traction wheel.
Hydraulic system
The hydraulic system is a compact unit consisting of an
electric motor and hydraulic pump for steering, and for the
lifting and tilt cylinders* on the mast, a hydraulic oil reservoir
and a suction filter.
Mast versions
Description
Brakes
In addition to the LBC (Linde Brake Control) (turn the rotary
switch of the control to neutral), the truck can also be braked
with two drum brakes fitted on the load wheels and by the
reverse current brake. The brake is operated mechanically/
hydraulically with the brake pedal via a linkage and brake
cylinder.
Parking brake
The two drum brakes on the load wheels are also used as
parking brake.
When the truck is started, the parking brake is first released
hydraulically. When the driver steps off the platform, the
mechanical parking brake is applied automatically.
Electrical system
The electrical system is mounted well-protected in the coun-

334 804 3301.0903

The truck is equipped with an electric traction drive and a
hydraulic pump motor for the steering and working hydrau-
lics.
Drive
The truck is driven by an electric traction motor acting on the
traction wheel through a reduction gearbox.
The required energy is supplied by a large-capacity 24 V
battery installed in the machine.
Stepless forward and reverse travel is achieved via the
multifunction control and Linde Digital Control (LDC).
Directional contactors, i.e. mechanical wear parts, are no
longer necessary.
When starting, a higher traction current is provided for 2
seconds to give a more powerful starting performance.
Gearbox
The gearbox as a compact unit connects the electric traction
motor, traction wheel and turntable.
This complete assembly is mounted well-protected in the
counterweight.
The E 10 - 03 is equipped with simplex, duplex or triplex
version free-view masts featuring full free lift. The outer terweight. A 24 V battery installed in the chassis supplies the
necessary energy.
upright is firmly connected to the frame and overhead protec-
tion. The battery can be changed with a low-level order picker
which lifts the battery out of the truck from the side.
Operation
The operator stands diagonally to the direction of travel. This
stance allows equal vision to the front and rear without having
to turn the body.
The driver’s platform can be adjusted hydraulically to the size
of the driver.
The multifunction control is manipulated with the left hand for
stepless forward and reverse travel from starting to top speed.
The right hand is always free for steering. This design allows
fast reversing and effortless stacking.
The work movements lifting, lowering, tilting* and sideshift*
operation are also controlled with the left hand with the
multifunction control.
If sideshift* and fork tilting* options are available, they can be
selectively controlled on the multifunction control by operat-
ing an auxiliary selection toggle switch.

* Option

12
 General view Description
1 Rear cover

2 Electrical system
15
3 Access cover for front traction motor brushes (accessible
from driver's platform) 14
4 Traction motor

5 Turntable
13 16
6 Traction wheel

7 Chassis 17
8 Driver’s platform

9 Brake pedal 1
334 804 3301.0903

10 Load wheel

11 Forks 2
12 Fork carriage

13 Protective pane 12
3
14 Mast
4
15 Overhead guard 11
16 Load capacity plate 5
17 Notice label with operating instructions for multifunction
control
e3343302
6
10 9 8 7

13
334 804 3301.0903
14
 Controls and indicators Description
1 Composite instrument:
Battery discharge indicator / hour meter

2 Steering wheel

3 Horn button 1 2 3
4 Battery cover

5 Switch key in key switch 14

6 Fuses
13
7 Connector for diagnostic unit

8 Tray 4
9 Driver’s platform 12
334 804 3301.0903

10 Multifunction control

11 Attachment selection toggle switch*

5
12 Brake pedal

13 Emergency stop button 6

14 Steer wheel position indicator*

e3343303

11 10 9 8

* Option

15
Instruments
Hour meter and battery discharge indicator
The battery discharge indicator (1) and hour meter (9) are
combined in a single housing (composite instrument).
Battery discharge indicator
- When the battery is connected, the emergency switch
pulled up and the key switch is turned on, a LED lights up
in section (1) to show the state of charge.
- The green diode (5) illuminates when the battery is fully
charged.
- As the battery discharges, the green and yellow diodes in
section (4) illuminate successively (from right to left and
only one diode at a time).
- When the red diode (3) flashes, the battery is discharged
approximately 70 %.
- When the red diodes (2) and (3) flash alternately, the
battery discharge has reached 80%. A safety relay is
activated which cuts out the control current for the hydrau-
lic lift function. The battery must be charged or changed
immediately.
2 3 4 5
e334-02/04
16
NOTE
The cutout point can be adjusted for special applications.
Please contact your authorised dealer.
Hour meter
The hour meter (9) indicates the elapsed service hours of the
truck. It operates only when the key switch is turned on, the
emergency stop button is pulled up and the driver’s platform
is operated. Symbol (8) flashes to show that it is on.
The hour meter indicates the operating time of the truck and
aids in scheduling inspections and periodic maintenance.
The LCD hour meter (9) displays the service hours (7) and
tenths of an hour (6) as soon as the battery is connected and
the emergency stop button is pulled up.
7 6 e334-02/03
Description
NOTE
When the battery plug is disconnected, the number of
elapsed service hours are stored in memory. When re-
placing a defective hour meter, the number of expired
service hours has to be noted. Affix this information near
the new hour meter on durable tape.
Steer wheel position indicator*
When travel is enabled, the traction wheel orientation is
indicated by illuminated diodes (10) in the steer wheel posi-
tion indicator.
The illumination of two adjacent diodes shows the position of
the traction wheel between them.
334 804 3301.0903
* Option
 Safety rules
The persons responsible, particularly the truck operators and
servicing personnel, must be instructed in the guidelines for
the normal and proper use of industrial trucks and supplied
with these operating instructions.
The employer must ensure that the driver has understood all
of the safety information.
Please observe the guidelines and safety rules for:
- information related to the operation of counterbalance
trucks,
- rules for roadways and work areas,
- rights, duties and rules of behaviour for the driver,
- applications in special areas,
- information on driving and braking,
- information on maintenance and repairs,
- the routine checks, accident prevention check,
- disposal of greases, oils and batteries,
- residual risks.
The operator (employer) or responsible person must ensure
334 804 3301.0903
that the above guidelines and safety rules are observed.
When familiarising a trained operator with the truck, acquaint
him with the
- special features of the counterbalance truck (multifunc-
tion control)
- optional attachments
- special operating characteristics and particulars of the
work area
and practice travel, control and steering operations until they
are completely mastered.
Only then start to train shelf-stacking.
ATTENTION
The driver must be retrained or reinstructed if the
traction and brake parameters of the LDC control
are modified afterwards.
In case of tip-over
Follow these Stay
WARNING instructions buckled up
The stability of the truck in the work area is ensured if
employed properly. Should the truck tip over during an
unauthorised application due to improper operation, follow
the depicted instructions under all circumstances.
Safety information
The words WARNING, CAUTION, ATTENTION and NOTE
are used in this handbook to point out particular hazards or
for information requiring special labelling:
WARNING
Indicates that, if not heeded, danger to life and/or
substantial damage to the product can occur.
CAUTION
Indicates that, if not heeded, severe personal
injury and/or substantial damage to the product
can occur.
ATTENTION
Indicates that, if not heeded, damage to the prod-
uct or its destruction can occur.
This label is mounted on the truck in locations
where your special attention is required. Read
the appropriate section of these operating in-
structions.
Other warning symbols are also used for your safety. Please
observe the various symbols.
NOTE
indicates technical information requiring special attention
because the connection may not even be obvious to skilled
personnel.
x3512438
Don't jump Hold on tight Brace feet Lean away
Beginning operation
Handling fluids and lubricants
Always handle fluids and lubricants as required and
as specified by the manufacturer.
Only store fluids and lubricants in approved containers at
specified storage places. As they could be inflammable, do
not contact them with hot objects or a naked flame.
Only use clean containers when replenishing fluids and
lubricants.
Follow the manufacturer’s safety and disposal instructions
when using fluids and lubricants and cleaning compounds.
Avoid spilling fluids and lubricants. Remove any spillage
immediately with a suitable binding agent and dispose of as
specified.
Also dispose of used or contaminated fluids and lubricants as
specified.
Observe laws and regulations.
Clean the area surrounding the part in question before
lubrication, filter renewal or repairs in the hydraulic system.
Discard replaced parts in a way friendly to the environment.
CAUTION
Do not allow hydraulic oil under pressure, at a
leak for example, to penetrate the skin. Medical
aid is required if such an injury occurs.
CAUTION
Improper handling of brake fluid puts your health
and the environment at risk.
17
Safety rules
Accident prevention check
The accident prevention rules in some countries require that
the fork lift truck must be checked at least once a year for
proper working condition by trained personnel. Please con-
tact your authorised dealer for this inspection.
Operation of industrial trucks in the plant
area
ATTENTION
Many plant areas are so-called limited public
traffic areas.
We advise you to check if your company liability insurance
covers any damages occurring with your truck against
third parties on "limited" public traffic areas.
18
Beginning operation
Running-in instructions Services prior to first operation*
The counterbalance truck can be operated at full speed - Tighten the wheel nuts
directly. However, avoid sustained high loads on the working - Check electric cables, connectors and connections for
hydraulic system and the travel drive in the first 50 hours of condition and security
operation. - Check the condition, electrolyte level and specific gravity
During initial operation and after each wheel change, tighten of the battery
wheel nuts daily prior to starting operation until they are - Check the hydraulic oil level
seated firmly, i.e. until no further tightening is possible. - Check the brake fluid level
- Check the braking system
Opposite wheel nuts should be tightened to a torque of:
Front and rear ........................................................... 140 Nm - Check the steering system
- Check the lifting device and attachments
NOTE
Observe the tightening instructions on the tag attached to Daily checks*
the steering column.
- Check the hydraulic oil level
- Check the battery state of charge
- Check the brake fluid level
334 804 3301.0903
* A description of the service can also be located in the
index.
 Daily checks and services before operation
Check the battery state of charge
- Connect the battery plug (1).
- Close the battery cover (2).
- Turn the key (3) in the key switch clockwise to full lock.
- Pull up the emergency stop button (4).
- Check the battery state of charge on the discharge indi-
cator (5).
Charging the battery
CAUTION
The following instructions must be followed for
safe operation and servicing of the battery.
334 804 3301.0903
ATTENTION
Batteries contain dissolved sulphuric acid which
is poisonous and caustic. When working with
battery electrolyte always wear personal protective cloth-
ing (protective apron and protective gloves) and protec-
tive goggles.
If clothing, skin or eyes have come into contact with
battery acid, immediately flush the affected parts with
water. If the eyes are affected, seek medical aid at once!
Neutralise spilled battery acid at once.
Gases are released during battery charging. Keep sparks
and naked flames away, for they can cause an explosion.
Enclosed spaces in which batteries are charged or stored
must be ventilated accordingly.
5
2
3 e3343304
Beginning operation
NOTE
The electrolyte specific gravity should never be allowed to
drop below 1.14.
Always charge and service the battery according to the
instructions of the battery manufacturer. If you are not in
possession of these instructions, please contact your
dealer.
Also follow the instructions in the manual provided with the
optional battery charger. If a battery charger is available,
the instructions of this charger alone apply.
CAUTION
Do not place any metal parts on the battery. Risk
of short circuit! Top up distilled water after the
charging procedure only.
e334-02/05
19
Daily checks and services before operation
Connecting the battery to a suitable exter-
nal charger
- Drive to the charging bay.
- Lower the fork carriage.
- Tilt the fork carriage* slightly forward until the forks contact
the ground.
- Depress the emergency stop button.
- Turn off the key switch with the key (8).
- Open the battery cover (1) upwards and allow it to engage
in the latch (2).
- Disconnect the battery connector (3) from the plug (4).
- Insert the charger plug into the battery connector (3).
- Switch on the battery charger.
ATTENTION
Charge a battery immediately, never leave a
battery in a discharged state. This also applies for
partially discharged batteries. The charging time for a
battery 80% discharged is approx. 8 hours.
1 2
4 3
d3343306
20
Beginning operation
Connecting the battery to a built-in charger*
ATTENTION - Connect the mains plug (5) to the mains socket (230V).
The built-in charger is set for standard batteries - Turn the key in the key switch anti-clockwise to full lock (7).
filled with liquid electrolyte. If gel batteries are
used, the device must be adjusted. Please contact your - The charger turns on automatically.
authorised dealer.
ATTENTION
- Lower the fork carriage. Charge a battery immediately, never leave it in a
discharged state. This also applies for partially
- Tilt the fork carriage* slightly forward until the forks contact discharged batteries.
the ground.
- Pull up the emergency stop button. - Refit the battery cell caps after charging.
(Applies only for battery cells without automatic refilling.)
- Turn off the key switch with the key (8).
- Open the battery cover (1) upwards and allow to engage
in the latch (2).
- Disconnect mains plug (5) from the charger socket.
- Open the battery cell caps.
334 804 3301.0903
(Applies only for battery cells without automatic refilling.)
* Option
7 8
e3343305 d3343307
 Daily checks and services before operation
Check the condition, electrolyte level and
specific gravity of the battery
- Check the battery for cracks in the casing, lifted plates and
leaking electrolyte.
- Unscrew the caps and check the electrolyte level.
- In batteries with level marks, the liquid should reach the
marks.
In batteries without marks, the liquid should be 10 to 15
mm above the plates.
- If the electrolyte level is low, top up with distilled water only
(after charging).
- Remove any corrosion on the battery poles and grease
them with Vaseline.
- Tighten the terminal clamps.
- Check the electrolyte specific gravity with a hydrometer.
The specific gravity after charging should be between
1.24 and 1.28.
NOTE
334 804 3301.0903
Battery discharges under 20% of the rated capacity are
considered deep discharges. They shorten the service life
of the battery.
e3343341
Changing the battery
ATTENTION
The battery must correspond in size (width ”x” =
628 mm or ”y” = 655 mm) and weight to the
standard battery. Any deviations in weight must be com-
pensated with ballast weights. The battery must be se-
cured against sliding.
Please consult your authorised dealer.
- Fully lower the fork carriage.
- Tilt the fork carriage* slightly forward until the forks contact
the ground.
- Depress the emergency stop button.
- Turn off the key switch with the key.
- Open the battery cover (1) upwards and allow it to engage
in the latch.
- Disconnect the battery female connector (5) from the male
connector (4).
NOTE
The battery can easily be changed with a pallet truck.
* Option
1 Y
3 e3343344
Beginning operation
- Release the locking pin (2) and completely open the side
door (3).
- Fully lower the pallet truck and drive it into the centre
section as far as necessary under the battery.
- Elevate the pallet truck until the battery is supported by the
forks.
- Slowly reverse the pallet truck with the battery out of the
truck.
- Take the battery to the charging station.
- Install a new or charged battery in the reverse order of
removal.
- Close the side door.
- Pull out the locking pin (2), hold it in place and close the
side door tightly.
- Release the locking pin
- Put the truck into operation.
NOTE
The truck will not operate unless the locking pin is correct-
ly engaged and the microswitch (6) is operated.
2 3
5 4 e334-03/16
21
Daily checks and services before operation
Check the hydraulic oil level
ATTENTION
Follow the precautions for handling fluids and lu-
bricants.
ATTENTION
Check the hydraulic oil level only with the truck
level and the forks fully lowered.
Beginning operation
- If needed, replenish the hydraulic oil after opening the
battery cover. (Battery cover locks in the open position.)
- Remove the hydraulic oil reservoir cap (3) and replenish
the hydraulic oil to the max. mark.
- Refit the hydraulic oil reservoir cap.

- Fully lower the forks. - Pull back the latch pin (2) and close the battery cover.

- Depress the emergency stop button.

NOTE
The hydraulic oil level indicator is located between the mast
uprights seen from the front.

- Check that the oil level is between the min. and max. marks

334 804 3301.0903

in the level indicator field (1).

max.

1 3
min.

334/24 e334-03/02

22
 Daily checks and services before operation
Adjust the driver’s platform
NOTE
The driver’s platform (2) can be adjusted hydraulically to
the size of the driver, but only when no other function has
been preselected.
- Step on the driver’s platform (2).
- Depress the emergency stop button (5).
Beginning operation
Check the protective pane
- Adjust the platform (2) for a comfortable driver position in WARNING
relation to the steering wheel and control and for unre- The protective pane protects the driver and pre-
stricted visibility of the forks and load. vents him from reaching between the mast with
the hands.
NOTE
Standing for long periods puts a strain on the spine. - Check the security and condition of the pane, renew if
Prevent strain with regular, easy exercising. damaged.

- Turn the switch key (4) in the key switch clockwise to the
stop.
- Depress and hold the push-button (3) on the control.
- Turn the steering wheel (1) clockwise to raise the driver’s
platform. Maximum 4 turns for complete elevation.
- Turn the steering wheel (1) anti-clockwise to lower the
driver’s platform. Maximum 4 turns for complete lowering.
334 804 3301.0903

1
5

2 e3343310 2 334/18 e3343309

23
Daily checks and services before operation Beginning operation
Check the brake fluid level
ATTENTION - Replenish the brake fluid in the reservoir (7).
Follow the precautions for handling fluids and - Remove the screws (3) on the cover (4).
lubricants.
- Remove screws (5) and take out the cover to the side.
NOTE - Open the brake fluid reservoir cap (6) and replenish the
The brake fluid indicator is located in the driver's platform brake fluid.
on the right-hand side.
- Refit and tighten the cap and install the cover.
- Lower the fork carriage.
ATTENTION
- Tilt the fork carriage* slightly forward until the forks contact
If the brake fluid loss is high, contact your author-
the ground.
ised dealer.
- Depress the emergency stop button (2).
- The brake fluid level should be between the min. and max.
marking in the level indicator field (1).

WARNING
The brake fluid level must not drop below the min.

334 804 3301.0903

marking, otherwise faulty braking can result.

* Option

6 7

2
1 max.
min.
1
5

e3343311 4 e3343310 e3343313

24
 Driving
Driving
CAUTION
Operation of the truck on gradients over 15% is
generally not allowed due to the specified number
of minimum brake applications and the truck stability
values. Contact your authorised dealer before driving on
steep slopes. The climbing ability values given in the data
sheet are derived from the tractive force and only apply for
crossing obstacles and for low differences in the floor
level.
NOTE
Always adapt your driving style to the roadway (uneven
surfaces, etc.), to particularly hazardous work areas and
to the truck load.
Driving forward
- Gently turn the control (1) in direction (B). The speed of the
truck depends on how far the control is turned.
NOTE
Turning the control quickly will not increase acceleration
as the maximum acceleration is controlled automatically.
Reversing
- Gently turn the control (1) in direction (A). The speed of the
truck depends on how far the control is turned.
The truck will reverse at a speed depending on how far the
control is turned.
Operation
Changing the direction of travel
- Turn the control (1) back to the neutral position.
- Turn control (1) in the opposite direction; the truck will be
braked electrically to a full stop and then accelerated in
the selected direction.
- The control (1) can be turned directly to the opposite
direction of travel.
NOTE
Turning the control quickly will not increase acceleration
as the maximum acceleration is controlled automatically.

ATTENTION
The electric hydraulic pump motor is switched on
334 804 3301.0903

when the steering or the working hydraulics is

turned on.

NOTE
The multifunction control (1) must be in the neutral posi-
tion.
5
- Step on the driver’s platform (7) (only this will operate the
switch under the platform). 4 C
- Pull out the emergency stop button (4).
3 6 2
- Insert the switch key (3) into the key switch and turn 1
clockwise to the stop.
- The battery discharge indicator (6) and hour meter are in
operation.
2 A
- Hold the control (1) with the left hand and the steering
wheel (5) with the right hand.
- Set the driver’s platform (7) to standing height.
- Turn the top part (2) of the control (1) with the thumb in
direction (C) to raise the forks slightly.

NOTE
Travel speed is reduced to 2.5 km/h when the fork carriage
is lifted between 500 and 1000 mm.
B
1 7 e3343314 334/12

25
Steering system, braking system Operation
Steering Service brake, reverse current brake Electric motor brake (LBC) operation
Due to the hydrostatic steering system, the effort required for - Turn the control (1) back to the neutral position and then - Release the multifunction control (1) while driving. The
turning the steering wheel is minimal. This is especially useful turn it to the opposite direction of travel until the truck is control returns to the neutral position automatically and
when stacking in narrow aisles. braked electrically. the truck is braked to a standstill.

- Take the truck into operation, drive and turn the steering - Release the control (1) when the truck has come to a stop. NOTE
wheel left and right to full lock. This function can be switched off with the diagnostic unit.
NOTE
WARNING When taking over the truck ensure that you receive in- Parking brake
If the steering is hard or there is too much play in struction on the operation of the reverse current brake.
the steering, contact your authorised dealer. Do NOTE
not drive your truck with a faulty steering system. Foot brake When the driver steps off the platform, the mechanical
parking brake is applied automatically and the traction
Turning radius: - Depress the brake pedal (2). The two drum brakes on the current is cut out.
- E 10 - 03 .......................................................... 1114 mm load wheels will be applied.
WARNING
ATTENTION If faults or signs of wear should become evident
For emergency braking depress the emergency in the braking system, contact your authorised
stop button (3). dealer.

334 804 3301.0903

Do not drive the truck with a faulty braking system.

e3343316 e3343315

26
 Operating the lifting device and attachments
ATTENTION
Only use the lifting device and attachment for
approved applications. The driver must be in-
structed in handling the lifting device and attachment.
Always operate the top (3) of the control gently, not abruptly.
Using the thumb, turn the top (3) of the multifunction control
(1) in direction C for lifting and in direction D for lowering.
The lifting and lowering speed are determined by how far the
top (3) of the multifunction control is turned.
When released, the top (3) of the multifunction control will
return automatically to the neutral position.
NOTE
Note the symbols with the directional arrows on the over-
head guard (6).
334 804 3301.0903
B A
6 For each attachment, affix a label indicating the capacity
A 1
B 1 2 3
A mines that they do not reduce the safe operation of the
5 D
B
4 e334-03/03
Operation
Lifting the fork carriage Operating attachments*
- Turn the top (3) of the multifunction control (1) in direction C. Available options are, for example, a tiltable fork carriage or
a sideshift. Observe the working pressure for the attachment
Lowering the fork carriage and follow the operating instructions.
- Turn the top (3) of the multifunction control (1) in direction D. NOTE
The truck models fitted with tilting fork carriage* and
sideshift* attachments have a toggle switch (5) mounted
under the multifunction control for selection of the attach-
ment to be operated. Models with only one attachment do
not have this toggle switch.
Tilting the fork carriage forward*
- Switch toggle switch** (5) to position A.
- Depress push-button (4).
Tilting the fork carriage backward*
- Switch toggle switch** (5) to position A.
- Depress push-button (2).
Operating the sideshift*
- Switch toggle switch** (5) to position B.
2 - Depress push-button (2) (Sideshift moves left)
B A C
A - Depress push-button (4) (Sideshift moves right)
3 NOTE
of the truck with the attachment and a symbol label for the
attachment in question near the control.
CAUTION
Attachments not delivered with the truck may
only be used if your authorised dealer deter-
truck in respect to capacity and stability.
A
4
B
* Option
e334-03/04 ** Models with two attachments
27
Horn, electrical system cover Operation
Operating the horn Removing, installing the rear cover
The horn serves as a warning signal at blind corners and NOTE
junctions. The electrical system with the main circuit fuse and the
drive unit are located in the counterweight behind the
- Push the horn button (1) to sound the horn. cover.

- Fully lower the forks.

- Tilt the fork carriage* slightly forward until the forks contact
the ground.

- Depress the emergency stop button (1).

- Remove six screws (2) and take off the cover (3).

- Install the rear cover after the inspections and servicing.

334 804 3301.0903

* Option

1 1

3
e3343317 e3343318

28
 Fuses Operation
Check, replace fuses
NOTE NOTE
The main circuit fuse is easily accessible after removal of Further electrical system fuses are located under the
the counterweight cover. battery cover and they protect the following circuits:

1 Main circuit fuse (F1) ............................................. 300 A - Swing the battery cover upwards and allow to engage in
the latch.
- Remove the fuse box cover.

1 Key switch (F2) .......................................................... 2 A

2 Composite instrument, brake, steering,
steer wheel position indicator*, battery covering
plate, platform, negative circuit (F3) ......................... 2 A
3 Platform, composite instrument, steer wheel
position indicator*, positive circuit (F4) .................... 2 A
4 Solenoids, pulse control (F5) .................................... 4 A
5 Horn (F6) ................................................................. 7.5 A
6 Free (F7)
334 804 3301.0903

* Option

1
2
3
4
5
6

e3343337 e334-03/05

29
Before picking up a load
Before picking up a load, observe the load capacity plate (1).
Similarly, observe the load capacity plate for each attachment
fitted.
WARNING
Values given in the load capacity diagram or plate
are applicable for compact and uniform loads and
they must not be exceeded otherwise the stability and the
strength of the forks and mast will no longer be guaran-
teed.
The maximum load is determined by the lift height and the
load centre distance.
Operation
Example for triplex mast
NOTE 1 Maximum allowed load in kg
With a load centre distance of 600 mm the maximum load
of 1000 kg can be lifted to a height of 4000 mm. 2 Height of lift in mm
For larger load centre distances proceed as follows: 3 Distance of load centre from fork-face in mm
Load centre distance ............................................. 650 mm
Lifting height ......................................................... 4000 mm
- Follow the vertical line for a load centre distance of 650
mm to the point where it intersects the line for a lifting
height of 4000 mm.

NOTE
Observe the load restriction and consult your authorised
dealer
- before transporting off-centre or swinging loads,
- before transporting loads with the mast tilted forward
- Read the maximum load at the left of the point of intersec-
tion of the horizontal line.
- Maximum weight here ........................................ 925 kg

334 804 3301.0903

or the load not near the ground, Proceed accordingly for other lifting heights and load centre
- loads with a larger load centre distance, distances. The determined values apply to loads distributed
- before using attachments and auxiliary equipment. evenly on both forks.

1
1

1000 kg
950 kg
900 kg
850 kg 4000 mm
B A 800 kg
750 kg 4935 mm
700 kg
A 400 500 600 700 mm

B kg mm
BR334/1,0t

3 2
e334-03/14 e3343338

30
 Picking up a load
Adjusting the fork spread
- Lift the fork quick-releases (1).
- Move the forks (2) further apart or closer together as
required by the size of the load. Make sure that the forks
are equally distant from the truck centre.
- Allow the fork quick-releases to engage in a notch.
NOTE
The load centre of gravity should be in the centre between
the forks.
Operation
Picking up a load
- Approach the load and align the forks as carefully and WARNING
accurately as possible. Do not stand under an elevated load. Drive the
counterbalance truck only with the load lowered
- Put the fork carriage to the vertical position.* and the fork carriage* tilted back.
- Lift or lower the fork carriage to the required height.
- Carefully drive the truck forward in the middle section of
the load until the fork-face contacts the load, taking care
not to touch adjacent loads.
- Lift the fork carriage until the load is clear of the stack.

- Reverse the truck until the load is clear.

- Tilt the fork carriage back.*

334 804 3301.0903

* Option

;;;;
2 334/46

;;;; e3343319 e3362301

31
Transporting a load, depositing a load Operation
NOTE Depositing a load Parking the truck
Stow loads so that they do not project over the truck load
area and can not slide, tip or fall. - Carefully drive the truck to the load receiving area. - Deposit the load and lower the fork carriage.

- Do not drive with the load shifted to the side (if a sideshift - Lift the fork carriage to the required height. - Slightly tilt the fork carriage* forward until the forks touch
is fitted, for example). the ground.
- Set the fork carriage to the vertical position (load horizon-
- Transport the load near the ground. tal).* - Depress the emergency stop button (2).

- Always travel with the load facing uphill on gradients and
do not drive across or make U-turns on a slope.
- If visibility is reduced, work with a guide.
- Drive the counterbalance truck in reverse if the load being
transported is stacked so high as to obstruct vision in the
forward direction of travel.
- Carefully position the load over the load receiving area. - Turn off the key switch and remove the key (1).
- Slowly lower the load until the forks are free of the load.
- Reverse the truck.
WARNING
Do not park or leave the truck unattended with the
load lifted.

334 804 3301.0903

* Option

2
1

;;;;
;;;;
32
e3343320 e3343321
 Transport, hoisting the truck
Transport with lorry or low-bed semi-trailer
- Lower the mast.
- Operate the parking brake.
- Chock the truck.
- Lash the truck down.
Hoisting the truck with a crane
WARNING
When hoisting the truck, be sure that
no persons are within the working range of
the crane.
Do not step under a lifted load!
334 804 3301.0903
e3343340
Operation
ATTENTION ATTENTION
Only use a lifting gear and crane of suitable The safety lock (3) must close after the slings are
capacity. inserted into the crane hook.
See the manufacturer’s plate for the weight of the truck
and battery.
To lift the truck, attach the lifting slings at the attachment points
provided (symbol label).
- Put two lifting slings (2) (each minimum capacity
1000 kg) around the overhead guard.
- Use edge protectors on the cross members to protect the
lifting slings against sharp edges.
- Hook the ends into the crane hook (1).
1 3 2
1
2 2
e3343322
33
Wheel change, mast removal
Jack locations for wheel change
Changing the rear wheel
ATTENTION
Only use a jack of sufficient lifting capacity. Lift-
ing capacity should be at least 2000 kg.
- Place the jack only at the locations (1) on the left and right
hand side under the counterweight and lift the truck.
- Secure the truck with suitable squared timbers.
ATTENTION
The truck may only be raised at these locations
at the rear left and right hand side.
1 1
334/23
34
Operation
Changing the front wheels Mast removal
ATTENTION ATTENTION
Only use a jack of sufficient lifting capacity. The Attach the lifting sling to the top cross member of
lifting capacity should be at least 2000 kg. the centre mast (1) and inner mast (2).
This procedure may only be performed by the staff of your
- Place the jack under the chassis (2) and lift the truck. authorised dealer.
- Secure the raised truck with a suitable squared timber.
ATTENTION
The truck may only be raised at these locations
at the front left and right hand side.
334 804 3301.0903
1 2
2 334/29 e3343339
 Towing instructions Operation
Towing Towing procedure
If the truck has to be towed, release the automatic parking - Lower the load until the forks do not contact the ground WARNING
brake at both drum brakes mechanically. during towing. The truck must be towed with utmost caution and
- Remove the load. at a speed not exceeding 3 - 5 km/h.
WARNING - Attach the towing vehicle (with sufficient tractive and The steering is without power assistance and hard to
braking force) with a towing rope to the mast of the truck. operate.
The truck can not be braked now. - Chock the truck.
When towing the truck, use a towing vehicle After towing
with sufficient tractive and braking force for Releasing the pressure of the parking brake
- Chock the wheels.
the unbraked towed load. - To release the parking brake, turn in the screw (2) on the
left and right hand side as far as the stop (3). Resetting the brakes
Torque ................................................................... 10 Nm
- Turn back screw (2) on the left and right side as far as the
WARNING self-locking nut (1).
The braking function of the truck is inoperative The parking brake is operational again.
now.
Check the brake for proper operation after
334 804 3301.0903

completion of repair.

1 2 3 e334-02/11

35
334 804 3301.0903
36
 Taking the truck out of operation, general information
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 performed.
Measures before taking truck out of opera-
tion
- Thoroughly clean the truck.
- Fully elevate the fork carriage several times, tilt the fork
carriage forward and back several times and operate the
attachment, if fitted, several times.
- Lower the fork carriage onto support blocks to take the
load off the chains.
- Check the hydraulic oil level, add oil if needed.
- Cover all unpainted mechanical parts with a thin film of oil
or grease.
- Lubricate the truck.
334 804 3301.0903
- Check the condition and electrolyte of the battery, coat the
battery terminals with non-acidic grease.
(Follow manufacturer’s instructions.)
- Spray all exposed electric contacts with a suitable contact
spray.
ATTENTION
Jack up and secure the truck so that all wheels
are off the ground. This will prevent a permanent
distortion of the tyres.
NOTE
Do not cover the truck with a polythene sheet as this will
cause the formation and collection of condensate water.
NOTE
If the truck is to be taken out of operation for over 6 months,
contact your authorised dealer for further measures.
Maintenance
Recommissioning after taking out of opera- General information
tion Your truck will remain operational only if the maintenance
- Thoroughly clean the truck. and inspections specified in the operating instructions are
- Lubricate the truck. carried out at the correct intervals and according to the
- Clean the battery and coat the battery terminals with non- information and details given. The maintenance may only be
acidic grease. performed by qualified personnel authorised by Linde. This
- Check the condition and electrolyte level of the battery, work can be carried out by your authorised dealer under a
service contract.
charging it if required.
- Check the hydraulic oil for condensate water, change the If you wish to service the truck yourself, we recommend the
oil if necessary. first three customer service checks be carried out in the
- Perform the servicing as for before initial operation. presence of your mechanic by authorised staff, to ensure that
- Take the truck into operation. they receive appropriate maintenance instruction.
- Change the brake fluid. For all services the truck must be parked on firm level ground
and the wheels chocked securely.
Lower the fork carriage and tilt it slightly forward. The forks
must contact the ground. Depress the emergency stop button
and remove the switch key.
When working on the truck with the fork carriage and mast
elevated, secure these components against inadvertent low-
ering.
When servicing the front part of the truck, secure the fork
carriage against tilting back.
No changes, particularly no attachments or retrofits, may be
made on your truck without the prior permission of the man-
ufacturer.
ATTENTION
Missing or damaged plates and/or adhesives
must be replaced. For location and order no. refer
to Parts catalogue.
Perform a functional check or a trial run of the equipment after
any maintenance procedure.
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 as needed.
ATTENTION
Follow the precautions for handling fluids and
lubricants.
37
Mast versions
Servicing the mast and the front part of the
truck
WARNING
Before attempting to carry out repairs or adjust-
ments on the raised mast and fork carriage, be
sure that the following safety procedures are carried out.
These safety precautions suffice only for the general
servicing of your truck (inspections and lubrication). When
carrying out repairs (e.g. chain renewal, lift cylinder re-
moval), further safety measures must be taken. Please
contact your authorised dealer.
Securing the mast against tilting back
- Lower the mast completely.
- Tilt the fork carriage* forward until the forks touch the
ground.
- Depress the emergency stop button (1) and remove the
Simplex mast
METHOD OF OPERATION
When the lift cylinders are extended, the chain pulleys are
raised along with the chains so that the fork carriage is lifted
at a ratio of 2:1.
Securing the raised simplex mast
WARNING
Use a squared timber of suitable size for the
particular lift mast. Do not exceed the maximum
height of lift.
- Raise the mast.
- Place a squared timber (1) of about 80 x 80 x 1700 mm
diagonally between the left and right outer upright. To
prevent the timber from moving, insert it in the outer
upright channels at the top and bottom.
Maintenance
Duplex mast
NOTE
The advantage of this version is that the supplementary
free lift can also be used in spaces with low ceilings
(cellars, railway cars, ships, etc.).
METHOD OF OPERATION
The fork carriage is raised to the supplementary free lift height
by the centre cylinder via the chain guide roller. It moves twice
as fast as the centre cylinder is extended.
Then the inner mast is lifted by the two external cylinders,
taking the fork carriage with it.
The centre cylinder is mounted on the extendable inner mast.

334 804 3301.0903

switch key (2).

- Lower the fork carriage until it is held by the squared

timber.
* Option

1
2

e3343323 334/70

38
 Mast versions Maintenance
Securing the raised duplex mast Triplex mast Services after the first 50 service hours
WARNING METHOD OF OPERATION NOTE
Use a squared timber of a suitable size for the The fork carriage is moved via the chain pulley on the centre A description of the service can also be located in the
particular lift mast. Do not exceed the maximum lift cylinder until the supplementary free lift height is reached. index.
height of lift. Then the inner mast is lifted by the two outer lift cylinders. Due
to the chain pulleys, the inner mast is lifted twice as fast. The - Check the braking system
- Raise the mast. centre cylinder is mounted on the extendable inner mast. - Tighten the wheel nuts
- Place a squared timber (1) of about 80 x 80 x 1700 mm - Check the wheels for damage and foreign objects
Securing the triplex mast
diagonally between the left and right outer upright. To - Change the filter and check oil level of the working and
prevent the timber from moving, insert it in the outer upright WARNING steering hydraulics
channels at the top and bottom. Use a squared timber with a suitable size for the
particular lift mast. Do not exceed the maximum - Change the gearbox oil
- Lower the fork carriage until it is held by the squared height of lift. - Check the gearbox for leaks
timber. - Check pump, valves and hydraulic lines for leaks
- Raise the mast.
- Place a squared timber (1) of about 80 x 80 x 1700 mm - Check electric motors, gearbox, counterweight and over-
diagonally between the left and right outer upright. To head guard for security
prevent the timber from moving, insert it in the outer
334 804 3301.0903

- Lubricate the tilt cylinder pivots

upright channels at the top and bottom.
- Lower the fork carriage until it is held by the squared
timber.
- Check the mounting, condition and operation of the mast,
lift chains and stops
- Clean the lift chains, adjust and lubricate with chain spray
- Check the electric cables, connectors and connections for
condition and security
- Check the motor brush leads for security
- Check the tension of double hoses if attachments are
fitted
- Check the brake fluid level

1 1

334/67 334/30

39
Inspection and maintenance schedule Maintenance
Services Before initial After first Dailly checks As required
(A description of the service can also be located in the index) operation 50 hours

See page 18 for services ..............................................................................................................................................

See page 39 for services ...............................................................................................................................................................................

Check the hydraulic oil level ............................................................................................................................................................................................................

Check the battery state of charge .....................................................................................................................................................................................................

Check the brake fluid level ...............................................................................................................................................................................................................

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

334 804 3301.0903

Clean and spray the lift chains ...........................................................................................................................................................................................................................................

Check the wheel nuts for tightness (at least every 100 hours) .........................................................................................................................................................................................

Check the wheels for damage and foreign objects ...........................................................................................................................................................................................................

40
 Inspection and maintenance schedule Maintenance
Services Every 500 hours Every 1000 hours Every 1500 hours Every 3000 hours
(A description of the service can also be located in the index)

Check the braking system ...........................................................................................................................................

Check and oil the brake pedal linkage .......................................................................................................................

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

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

Clean the lift chains, adjust and lubricate with chain spray .......................................................................................

Lubricate the tilt cylinder pivots at the fork carriage ...................................................................................................

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

Lubricate the driver's platform mounting .....................................................................................................................

Clean and grease the sideshift, check the mountings ...............................................................................................

Clean the electrical system and electric motors .........................................................................................................

334 804 3301.0903

Check, renew traction and pump motor brushes ........................................................................................................

Lubricate the drive unit turntable .................................................................................................................................

Check the gearbox oil level .........................................................................................................................................

Check the electric cables, connectors and connections for condition and security .................................................

Check the mounting of the electric motors, chassis, drive unit, mast, overhead guard and
steering system for security .........................................................................................................................................

Check the tension of double hoses if attachments are fitted .....................................................................................

Check the top sideshift sliders for play .......................................................................................................................

Renew the hydraulic oil filter .......................................................................................................................................................................

Check, clean or renew, the breather filter cartridge ...................................................................................................................................

Check the load wheel brake linings ..............................................................................................................................................................................................

Change the gearbox oil .................................................................................................................................................................................................................

Check, adjust steering chain tension ............................................................................................................................................................................................

Lubricate the steering chain and chain tensioning roller .............................................................................................................................................................

Check the bottom sideshift sliders for wear, and sideshift for play, and renew, if necessary .....................................................................................................

Change the hydraulic oil ..................................................................................................................................................................................................................................................

Change the brake fluid ....................................................................................................................................................................................................................................................

41
Inspection and maintenance as required
Clean the truck
NOTE
The frequency of cleaning depends on the use of the truck.
When working with aggressive media like salt water, fer-
tilizers, chemicals, cement, etc., a thorough cleaning will
be necessary upon completion of work.
Steam cleaners and degreasers should only be used with
utmost caution! The grease in sealed-for-life bearings may
dissolve and run out. Since regreasing is not possible, this will
result in damage to the bearings.
Clean and spray the lift chains
NOTE
The lift chains must be cleaned if the dust on the chains
prevents penetration of the lubricant.
- Place a tray under the mast.
- Clean the chain using paraffin derivatives such as wash-
ing petrol (observe the manufacturer’s notes on safety).
- When employing a steam cleaning machine, do not use
additives.
- After cleaning, dry the chains at once with an air jet to
Maintenance
Check the wheel nuts for tightness
ATTENTION
At least every 100 hours.
- Check the nuts (3) at the left and right load wheel (4).
- Tighten opposite nuts to 140 Nm.
- Turn the traction wheel (1) at the rear until the wheel nuts
(2) are accessible.
- Tighten opposite nuts to 140 Nm.

- Depress the emergency stop button.
ATTENTION
When cleaning with a cleaning machine, do not
expose the electrical system and insulating ma-
terial to the direct jet. Cover them before cleaning.
When cleaning with compressed air, first remove any
tenacious dirt with a cold cleaner.
remove any water in the chain links and on the surface.
During this procedure the chain should be flexed several
times.
- Spray the chain with Linde chain spray immediately,
flexing it during spraying.
ATTENTION
Lift chains are safety components. The use of
cold cleaners, chemical cleaning agents and
Check the wheels for damage and foreign
objects
- Jack up the truck until the wheels are clear of the ground.
- Support the truck with squared timbers.
- Check the wheels for free rotation and remove anything
restricting their movement.

334 804 3301.0903

Clean especially the oil filler openings and the surrounding - Renew worn or damaged wheels.
area as well as lubrication points before servicing. caustic or acidic and chlorinated fluids can be a direct
cause of damage to the chain.

1
e3343324 334/34 e3343325 4 3 2
42
 500-hour inspection and maintenance
Check the braking system
WARNING
The proper operation of the brake pedal (2) must
always be ensured. If signs of mechanical wear
become evident, e.g. worn brake linings, have the braking
system checked by your authorised dealer.
Contact your authorised dealer for the adjustment of the
brake linings at the load wheels.
Maintenance
Check and oil the brake pedal linkage Check the forks and fork quick-releases
- Check the brake pedal pivots, pin and joint retainers for - Inspect the forks for visible bends, wear and damage.
security.
- Check the fork stop bolts (2) and the fork quick-releases (1)
- Lightly oil the pivots and clevises of the braking device on for security and damage.
the load wheels.
- Replace damaged parts.

- Remove the cover (1).

- Clean the master brake cylinder, brake calliper and brake

pipes with compressed air and check for leaks.

- If necessary, tighten any loose pipe connections.

334 804 3301.0903

2 1 e3343326 334/37 2 334/54

43
500-hour inspection and maintenance Maintenance
Check the mounting, condition and opera- Adjust the lift chains Lubricate the chains with chain spray
tion of the mast, lift chains and stops NOTE - Spray mast channels and chains with Linde chain
- Clean the mast channels and the lift chains. The lift chains stretch with use so that they must be spray.
- Inspect the lift chains for wear, particularly in the pulley adjusted.
area. NOTE
- Check the attachment of the chains at the chain anchors. - Completely lower the fork carriage. Counterbalance trucks used in the food industry should
- Replace damaged chains. be lubricated with a thin oil approved for the food industry
- Inspect the mast, mast channels and rollers for condition - Adjust the chain by turning the self-locking nuts instead of Linde chain spray.
and mounting. (4, 5, 6) at the chain anchor. The forks must not be over
- Elevate the mast* slightly and check the end stop (2) for 10 mm above the ground.
condition and porper operation.
- Lower the mast as far as possible and check the operation NOTE
of the stop. (Mechanical stop before hydraulic stop.) (4 and 6) for simplex masts.
- If necessary, adjust or renew the end stop (2). (4, 5, 6) for duplex and triplex masts.
- To do this, loosen the locknut (1) and screw out the stop.
- Firmly tighten the locknut (1). ATTENTION
- Check the stop screws** (3) for correct seating and dam- A circlip (7) must be fitted on the thread end of
age, renew if necessary. each chain anchor. Renew missing or damaged

334 804 3301.0903

circlips.
* Applies for duplex and triplex masts.
** Applies for simplex masts.

1 4 5 6

7 7 7

2 e334-02/24 e3343327 e3343328

44
 500-hour inspection and maintenance Maintenance
Lubricate the tilt cylinder pivots* at the fork Check and oil other pivots and joints Clean and grease the sideshift*, check the
carriage - Check and oil the fork quick-releases. mountings
NOTE - Clean the sideshift with a steam cleaner.
Use a lubricating grease.
Lubricate the driver's platform mounting, - Inspect the hydraulic lines for chafing and renew them, if
- Raise the mast until the fork carriage is above the over- brake cylinder necessary.
head guard.
NOTE - Check all hydraulic connections and fastening elements
- Secure the mast against inadvertent lowering. Use a lubricating grease. for security and wear, tightening and renewing them if
necessary.
- Lubricate the tilt cylinder pivots at grease nipple (1) with - Lubricate the driver's platform mounting, brake cylinder
grease. with lubricating grease at grease nipple (1). - Grease the sideshift guides after each truck cleaning.

- Lubricate with a grease gun until some fresh grease - Lubricate with a grease gun until some fresh grease
emerges at the pivots. emerges.

- Remove the safety block and lower the fork carriage.

334 804 3301.0903

* Option

e334-02/12
1
e3343329 e334-03/07

45
500-hour inspection and maintenance
Clean the electrical system and electric
motors
- Fully lower the fork carriage.
- Park the truck and depress the emergency stop button.
- Remove the rear cover (1).
- Remove panel (4).
- Clean the traction motor (3), steering and working hydrau-
lics motors (5) and the electrical system (2) with com-
pressed air.
NOTE
Protect the electrical system and motor terminals against
moisture. Take care not to let any water get into the electric
motors. If moisture has penetrated the motors neverthe-
less, dry them by operating the truck (drying with the
truck’s heat) or by heating, blowing with compressed air,
etc. to prevent damage by corrosion.
Check, renew traction and pump motor
brushes
ATTENTION
To ensure a long service life of the motor, it is
important to renew the carbon brushes promptly.
NOTE
Only renew motor brushes as a kit.
- Loosen the retaining straps (6), swing the motor (5) to the
side and remove the brush covers (7).
- Lift up the springs (8) at the brushes (9).
- Pull the brushes (9) out of the guide.
- Renew brushes with a length of under 15 mm.
- Tension the carbon brushes and check the connection of
the brush leads for security.
- Mount the brush covers (7).
- Swing the motor (5) back into place and tighten the
retaining straps (6).
Maintenance
NOTE
The traction motor brushes can only be checked and
renewed from two sides.
- Lift up the brush springs (11).
- Pull the brushes (12) out of the guides.
- Renew brushes with a length of under 15 mm.
- Tension the carbon brushes and check the connection of
the brush leads for security.
- Turn the screw (16) with an Allen wrench counter-clock-
wise until the access cover (13) is released.
- Remove the access cover (13).
The brushes (15) can only be accessed through the
service opening.
- Lift up the springs (14) at the brushes (15).
- Pull the brushes (15) out of the guides.
- Renew brushes with a length of under 15 mm.
- Tension the carbon brushes and check the connection of
the brush leads for security.

334 804 3301.0903

- Remove the brush cover (10) on the traction motor (3). - Refit the brush cover (10).
- Install the access cover (13) and tighten with the screw (16).

10
8 3
1 14
2
7
9
6 3 15

5 11

13 10
16
12
4 e334-02/29 e334-02/14 e334-03/15

46
 500-hour inspection and maintenance
Lubricate the drive unit turntable
NOTE
Grease the turntable at two lubrication points.
- Operate the steering and turn the drive unit until the
grease nipples (1) are accessible.
- Grease the nipples successively with grease.
- Lubricate with a grease gun until some fresh grease
emerges at the pivots.
334 804 3301.0903
1
334/36
Check the gearbox oil level
ATTENTION
Follow the precautions for handling fluids and
lubricants.
- Turn the steering until the plug on the drive unit is acces-
sible.
- Clean the area surrounding the level plug (1).
- Remove the level (1) plug at the reduction gearbox.
- The oil must reach the base of the level plug hole.
- If necessary, fill gear oil up to the base of the level plug
hole.
- Install and tighten the level plug (1).
1
334/41
Maintenance
Check the electric cables, connectors and
connections for condition and security
- Electric motor cable connections:
- Check the cable quick-disconnects for secure attachment
and corrosion.
- Examine the electric cables for chafing and for secure
attachment.
- Open the battery cover (1).
- Check the battery leads for secure attachment.
NOTE
Corroded connections and cracked cables lead to drops
in voltage and thus to faults in the electrical system.
- Remove any corrosion and replace cracked cables.
- Refit the battery cover.
e3343330
47
500-hour inspection and maintenance
Check the mounting of the electric motors,
chassis, drive unit, mast, overhead guard
and steering system for security
- Check the mounting elements of the electric motors,
chassis, drive unit, mast, overhead guard and steering
system for security and wear.
- Tighten any loose nuts and bolts.
Check the tension of double hoses if attach-
ments* are fitted
- The tension of the double hoses should be 5 - 10 mm per
meter referred to the initial length.
- Adjust the tension of the hoses by sliding them in the
clamps to the specified dimension.
Maintenance
Check the top sideshift* sliders for wear and
play
NOTE
The wear on the top sideshift sliders is determined by
measuring the gap X on the lower side.
min. gap ................................................................... 1.5 mm
max gap ................................................................... 3.0 mm

- Replace any damaged parts. NOTE

If the max. gap is exceeded the top sideshift sliders must
- Touch up the paint, if necessary. be replaced. Contact your distributor.

- Install the both covers.

334 804 3301.0903

* Option * Option

e3343331 e3343332 e334-03/12

48
 1000-hour inspection and maintenance Maintenance
Renew the hydraulic oil filter Check, clean or renew, the breather filter
ATTENTION - Fill the filter with oil and coat the seal with oil. cartridge
Follow the precautions for handling fluids and - Swing the battery cover up to the lock-in position.
lubricants. - Screw in the filter and when the seal contacts the filter
casing tighten approximately another 3/4 turn. - Release the locking pin and open the side door.
- Lower the mast completely. - Screw the breather filter (1) counter-clockwise out of the
- Use a strap-type filter wrench for tightening. hydraulic oil reservoir.
- Depress the emergency stop button.
- Loosen the cap (2) from the base (4) by pushing the
- Turn the shutoff cock (3) for the hydraulic oil reservoir (2)
locking knobs (3) together and remove the cap.
- Remove the cover (1). anti-clockwise 90° to open the line.
- Clean or replace the filter cartridge (5).
- Turn the shutoff cock (3) for the hydraulic oil reservoir (2) ATTENTION - Place the cartridge in the cap and push the cap onto the
clockwise 90° to close the line. Do not operate the hydraulic system with the base until the cap snaps into place.
shutoff cock (3) closed.
- Loosen the hydraulic oil filter (4) anti-clockwise with a filter - Mount the breather filter (1), close the side door and
wrench. - In a trial run check the filter sealing faces for leaks. engage the locking pin.
- Disengage the locking pin on the battery cover and close
- Remove the filter by hand. - Install the cover (1). it.
334 804 3301.0903

NOTE
Hydraulic oil will run out. Place a cloth underneath and
discard it as required by local regulations.

2 3

4
1

4 5
1 e3343333 3 2 334/59 e334-03/09

49
1500-hour inspection and maintenance Maintenance
Check the load wheel brake linings Change the gearbox oil
WARNING ATTENTION
To check, adjust or renew the brake linings con- Follow the precautions for handling fluids and
tact your authorised dealer. lubricants.

- Remove the rear cover.

- Turn the drive unit with the steering until the level and
drain plugs are accessible.
- Clean the area surrounding the level and drain plugs.
- Remove the level plug (1).
- Place a catch tray under the drain plug (2).
- Remove the drain plug (2) and allow the oil to drain
completely.
- Clean the drain plug and screw it in tightly.
- Fill gear oil to the base of the level plug hole.

334 804 3301.0903

Capacity .......................................................... approx. 1.3 L
- Clean the level plug (1) and screw it in tightly.
- Install the rear cover.

e3343334 334/60

50
 1500-hour inspection and maintenance Maintenance
Check, adjust steering chain tension Lubricate the steering chain and chain ten- Check the bottom sideshift sliders for wear,
- Park the truck, lower the fork carriage and depress the sioning roller and sideshift* for play, and adjust, if neces-
emergency stop button. - Check the condition of the steering chain (2) and pinion. sary
- Remove the battery. - The bottom sliders must be replaced if the min. measure-
- Lubricate the steering chain with Linde chain spray. ment X is less than 5 mm.
- Check the tension of the steering chain (2) with thumb - The sideshift play should be approx. 1.5 mm.
- Lubricate the tensioning roller nipple (5) with grease. - To adjust the sideshift Y play, loosen the security screws
pressure.
Deflection .......................................... approx. 5 - 10 mm (1).
- Lubricate with a grease gun until some fresh grease - Turn the screws (2) clockwise until the sideshift play is
emerges at the bearings. 1.5 mm, check with a feeler gauge.
If chain tension is insufficient:
- Loosen the fastening nut (4) at the chain tensioning roller - Install and connect the battery. NOTE
(3). When tightening the screws, observe the order and torque
on the adhesive on the sideshift.
- Turn the hexagonal nut (1) on the eccentric pin with a
- Torque, screws (2) ................................................ 30 Nm
spanner until the correct tension is obtained.
- Torque, security screws (1) phase 1, .................. 90 Nm;
phase 2, ................. 140 Nm
- Torque the fastening nut (4) to 90 Nm.
NOTE
334 804 3301.0903

Contact your distributor to renew the sideshift sliders.

* Option

1 5
1
5
2
2
3 Y

4
4 3 334/62 334/61 1 2 1 2 1 e334-03/11
51
3000-hour inspection and maintenance Maintenance
Change the hydraulic oil Change the brake fluid
ATTENTION ATTENTION
Follow the instructions for handling oils and lubri- Follow the instructions for handling oils and lubri-
cants. cants.

NOTE ATTENTION
The hydraulic oil can only be sucked out with the appropri- The brake fluid must be changed at least every
ate aid (hand pump). two years. Changing the brake fluid and bleeding
Please contact your authorised dealer. the braking system may only be carried out by your
authorised dealer.
Capacity .......................................................... approx. 8.0 L
Capacity ..................................................................... 270 cc

334 804 3301.0903

d3343335 e3343336

52
 Inspection and maintenance data Maintenance
No. Aids/ Filling Capacity/
Oils and Lubricants Rated Values

1 Hydraulic system Hydraulic oil approx. 8.0 L

2 Gearbox Gear oil approx. 1.3 L

3 Wheels Traction wheel and load wheels Torque 140 Nm

4 Electrical system:
Main circuit Fuse 300 A
Horn Fuse 7.5 A
Solenoids, pulse control Fuse 4A
Platform, composite instrument,
steer wheel position indicator,
positive circuit Fuse 2A
Composite instrument, brake,
steer wheel position indicator,
battery cover plate, platform,
334 804 3301.0903

negative circuit Fuse 2A

Key switch Fuse 2A

5 Electric motors:
Traction motor Carbon brushes min. 15 mm
Pump motor Carbon brushes min. 15 mm

6 Battery Distilled water as required

Non-acidic grease as required

7 Mast tilt cylinder pivots Lubricating grease as required

8 Steering system Lubricating grease as required

9 Mast and chain guides Linde chain spray as required

10 Braking system Brake fluid approx. 270 cc

53
Fuel and oil recommendations
Hydraulic oil
Hydraulic oil recommendation for normal duty:
Hydraulic oil ISO-L-HM 46 acc. to ISO 6743-4 or HLP ISO VG
46 acc. to DIN 51524, part 2 (factory filling), average contin-
uous oil temperature 40 °C – 60 °C.
Hydraulic oil recommendation for heavy duty:
Hydraulic oil ISO-L-HM 68 acc. to ISO 6743-4 or HLP ISO VG
68 acc. to DIN 51524, part 2, average continuous oil temper-
ature over 60 °C.
Hydraulic oil recommendation for light duty and low ambient
temperatures:
Hydraulic oil ISO-L-HM 32 acc. to ISO 6743-4 or HLP ISO VG
32 acc. to DIN 51524, part 2, average continuous oil temper-
ature under 40 °C.
Hydraulic oil recommendation for strongly varying operat-
ing conditions:
Gear oil
Use oil of classification SAE 80 W - 90 API GL5 by choice, also
suitable is SAE 85 W - 90 API GL4 (acc. to DIN 51512).
Grease
Linde heavy duty grease, lithium base, with EP and MOS2
additives.
Designation acc. to DIN 51825-KPF 2N-20 (see the Parts
Catalogue for the order number).
Do not mix with grease types other than lithium-base greases.
Battery grease
Non-acidic grease (terminal grease)
Chain spray

334 804 3301.0903

All of the above applications can be covered with a hydraulic Linde chain spray (see the Parts Catalogue for order number).
oil conforming to ISO-L-HV 46 acc. to ISO 6743-4 or HVLP ISO
VG 46 acc. to DIN 51524, part 3. Brake fluid
Such hydraulic oils have a high viscosity index (multigrade Brake fluid DOT 3 to SAE J 1703
oils). (e.g. Ate type S) or DOT 4 to SAE J 1704 or FMVSS 116 (e.g.
Ate type SL).
Bio hydraulic oil
Biologically fast-degradable pressure fluid
Aral Forbex SE 46

ATTENTION
Do not mix bio-oils with mineral oils. Other fluids
from other manufactures cannot be recommended.

NOTE
The above-mentioned recommendations are only ap-
proximate values.
In case of doubt we recommend that you contact your
authorised dealer.
Recommendations of representatives of the oil industry
should also be checked with your authorised dealer.
Only the above-mentioned oils are approved by the man-
ufacturer. If other hydraulic oils are used or mixed, costly
damage can result.

54
 Troubleshooting guide
Malfunction
Abnormal noise
No or low pressure in system
334 804 3301.0903
Oil pressure fluctuates
Working hydraulics not
operating
Truck not driving
Truck moves only slowly
Possible Cause Remedy See Page
Suction filter blocked. Clean or renew filter. 49
Piping is leaking. Oil foaming. Eliminate leaks in piping. 22, 52
Check oil level and replenish oil, if necessary.
Hydraulic pump or motor damage; Have hydraulic unit inspected by an authorised dealer.
seals defective, causing air intake.
Incorrect oil viscosity, Change the oil, using specified viscosity. Replenish oil. 22, 52, 54
low oil level in reservoir.
Suction faulty, noises. Change oil, add oil. 22, 52, 54
Pump faulty, leakage loss, Have repaired by an authorised workshop.
pressure valves not closing, valve seat damaged.
Pipeline broken or leaking. Replace line or eliminate leaks.
Oil of low viscosity, causing high leakage losses. Change the oil, use specified viscosity. 52, 54
Same cause as under abnormal noise. See under abnormal noise.
Lift and tilt cylinders have tight spots. Have linings replaced by a workshop.
Mast does not extend completely or Replenish oil. 22
retracts slightly after being raised.
Battery 80 % discharged. Check, charge or change battery. 12, 21
Fuse blown. Renew fuse. 29
Battery discharged. Check, charge or change battery. 19, 21
Tighten terminal clamps, coat with non-acidic grease. 21
Check electric motor connections. 47
Fuses faulty. Renew the fuses. 29
Side door locking pin not correctly engaged. Engage the locking pin correctly. 21
Low hydraulic oil level. Top up hydraulic oil. 22, 52, 54
Forks lifted between 500 and 1000 mm. Lower the forks to less than 500 mm. 25
55
Electric circuit diagram
A1 Connector 55 pins, controller S1 Key switch X17 Connector 2 pins, solenoid valve 2Y6
A2 Joystick (multifunction control lever) S2 Emergency isolator button X18 Connector 2 pins, solenoid valve 2Y7
A3 Fuse holder S6 Brake circuit pressure switch X19 Connector 2 pins, solenoid valve 2Y8
A5 Mains plug, battery charger* S9 Switch, side door for battery change X20 Connector 2 pins, solenoid valve 2Y1
A6 Socket, battery charger* S10 Toggle switch, side shift / tilting X21 Terminal, controller
2S3 MFL pushbutton, tilting forward X22 Terminal, controller
1B1 Actual current value sender, traction motor 2S4 MFL pushbutton, tilting back X22 Terminal, controller
2B1 Actual current value sender, pump motor 3S1 Sensor, steer control valve X23 Terminal, controller
4B1 Horn 3S5 MFL pushbutton, platform lift X24 Terminal, controller
4S1 Horn button X25 Terminal, controller
C1-8 Intermediate circuit capacitors 7S1 Platform sensor X26 Terminal, controller
7S2 Oil level switch X27 Terminal, controller
E4 Protective circuitry, horn X28 Connector 2 pins, battery charger*
1V1-13 MOSFET, traction motor X29 Battery plug
F1 Main current fuse, controller 300A 1V2-13 MOSFET, traction motor X33 MFL calibration switch
F2 Fuse, key switch 2A 1V14 Freewheel diode, controller X34 Connector, oil level switch
F3 Fuse, negative lead 2A 1V15 Freewheel diode, controller X35 Connector, steer control valve sensor
F4 Fuse, instrument sensors 2A 2V1-13 MOSFET, pump motor
F5 Fuse, solenoid valves 4A 2V14 Freewheel diode, controller 2Y1 Proportional valve, lifting

334 804 3301.0903

F6 Fuse, horn 7.5A 2Y2 Solenoid valve, lowering
X1 Connector for controller, 55 pins 2Y3 Solenoid valve, brake release
G1 Battery X2 Connector for controller, 16 pins MFL 2Y4 Solenoid valve, brake released
G2 Battery charger* X3 Connector 6P1 2Y5 Solenoid valve, tilting forward
X4 Socket for diagnostic unit 2Y6 Solenoid valve, tilting back
K1 Main contactor X5 Connector 4 pins, battery charger* 2Y7 Solenoid valve, platform lift
X6 Connector, platform sensor 2Y8 Proportional valve, lowering
1M1 Traction motor X7 Connector, steer wheel position indicator potenti- 2Y9 Solenoid valve
2M1 Pump motor ometer
9M1 Pump motor fan X8 Connector, horn button
X9 Connector 2 pins
6P1 Composite instrument: hour meter / battery X12 Connector 3 pins, switch for battery side door
discharge indicator X13 Connector 2 pins, solenoid valve 2Y2
6P2 Steer wheel position indicator* X14 Connector 2 pins, solenoid valve 2Y3
X15 Connector 2 pins, solenoid valve 2Y4
6R1 Steer wheel position indicator potentiometer* X16 Connector 2 pins, solenoid valve 2Y5

* Option

56
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Electric circuit diagram

57
Working and steering hydraulics diagram
1 Side lift cylinders
2 Pipe safety valve
3 Central lift cylinder
4 Pipe safety valve
5 Bypass valve
6 Tilt cylinder*
7 Side shift cylinder*
8 Platform lift cylinder
9 Steering servomotor
10 Steering column sensor
11 Breather filter
12 Hydraulic oil tank
13 Suction filter
14 Motor/pump unit

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15 Brake circuit pressure switch
16 Brake cylinder

2Y1 Proportional valve, lifting

2Y2 Solenoid valve, lifting / lowering
2Y3 Solenoid valve, brake release
2Y4 Solenoid valve, brake released
2Y5 Solenoid valve, tilting forward*
2Y6 Solenoid valve, tilting back*
2Y7 Solenoid valve, platform lift
2Y8 Proportional valve, lowering
2Y9 Solenoid valve, shifting to side shifter*

A Steer control valve

B Valve block

* Option

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Working and steering hydraulics diagram

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Index
Page
A
Accident prevention check ................................................ 18
Adjust the driver’s platform ............................................... 23
Adjust the lift chains,
lubricate the chains with chain spray ............................ 44
Adjusting the fork spread .................................................. 31
After towing ........................................................................ 35
Approved applications ........................................................ 2
B Check the mounting of the electric motors,
Battery discharge indicator ............................................... 16
Battery grease ................................................................... 54
Before picking up a load ................................................... 30
Beginning operation ......................................................... 17
Bio hydraulic oil ................................................................ 54
Brake fluid ......................................................................... 54
Brakes ................................................................................ 12
Braking system .................................................................. 26
C Check, replace fuses ........................................................ 29
Chain spray ....................................................................... 54
Change the brake fluid ..................................................... 52
Change the gearbox oil .................................................... 50
Change the hydraulic oil ................................................... 52
Changing the battery ........................................................ 21
Changing the direction of travel ....................................... 25
Changing the front wheels ................................................ 34
Changing the rear wheel .................................................. 34
Charging the battery ......................................................... 19
Check and oil other pivots and joints ............................... 45
Check and oil the brake pedal linkage ............................ 43
Check the mounting, condition and operation
of the mast, lift chains and stops ................................... 44
Check the battery state of charge ..................................... 19
Check the bottom sideshift sliders for wear,
and sideshift for play, and adjust, if necessary ............ 51
Check the brake fluid level ............................................... 24
Check the braking system ................................................ 43
60
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Check the condition, electrolyte level and
E
Electric circuit diagram ...................................................... 56
specific gravity of the battery ......................................... 21 Electric motor brake (LBC) operation ............................... 26
Check the electric cables, connectors Electrical system cover ..................................................... 28
and connections for condition and security .................. 47 Electrical system ............................................................... 12
Check the forks and fork quick-releases .......................... 43
F
Check the gearbox oil level .............................................. 47
Check the hydraulic oil level ............................................ 22
Check the load wheel brake linings ................................. 50
Foot brake ......................................................................... 26
chassis, drive unit, mast, overhead guard Foreword ............................................................................. 2
and steering system for security ................................... 48 Fuel and oil recommendations ......................................... 54
Check the protective pane ................................................ 23 Fuses ................................................................................. 29
Check the tension of double hoses if attachments
G
are fitted ......................................................................... 48
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Check the top sideshift sliders for wear and play ............ 48
Check the wheel nuts for tightness .................................. 42
Check the wheels for damage and foreign objects ......... 42 Gear oil .............................................................................. 54
Check, adjust steering chain tension ............................... 51 Gearbox ............................................................................. 12
Check, clean or renew, the breather filter cartridge ........ 49 General information .......................................................... 37
Check, renew traction and pump motor brushes ............. 46 General view ..................................................................... 13
Grease ............................................................................... 54
Clean and grease the sideshift, check the mountings .... 45
Clean and spray the lift chains ......................................... 42
Clean the electrical system and electric motors .............. 46
Clean the truck .................................................................. 42
Connecting the battery to a built-in charger ..................... 20
H
Handling fluids and lubricants .......................................... 17
Connecting the battery to a suitable external charger .... 20 Hoisting the truck with a crane ......................................... 33
Controls and indicators ..................................................... 15 Hoisting the truck .............................................................. 33
Hour meter and battery discharge indicator .................... 16
D
Hour meter ........................................................................ 16
Hydraulic oil ...................................................................... 54
Hydraulic system ............................................................... 12
Daily checks and services before operation .................... 19
Daily checks ...................................................................... 18
Depositing a load .............................................................. 32
Description .......................................................................... 5
Drive .................................................................................. 12
Driving forward .................................................................. 25
Driving ............................................................................... 25
Duplex mast ...................................................................... 38
 Index
Page
I
Inspection and maintenance as required ........................ 42
1000-hour inspection and maintenance .......................... 50
1500-hour inspection and maintenance .......................... 50
3000-hour inspection and maintenance .......................... 52
500-hour inspection and maintenance ............................ 43
Inspection and maintenance data .................................... 53
Inspection and maintenance schedule ............................ 40
Instruments ........................................................................ 16
J Picking up a load .............................................................. 31
Jack locations for wheel change ...................................... 34
L
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Lifting the fork carriage ..................................................... 27
Lowering the fork carriage ................................................ 27
Lubricate the drive unit turntable ...................................... 47
Lubricate the driver’s platform mounting,
brake cylinder ................................................................ 45
Lubricate the steering chain
and chain tensioning roller ............................................ 51
Lubricate the tilt cylinder pivots at the fork carriage ........ 45
M
Maintenance ..................................................................... 37
Mast removal ..................................................................... 34
Mast versions .............................................................. 12, 38
Measures before taking truck out of operation ................ 37
O
Operating attachments ...................................................... 27
Operating the horn ............................................................ 28
Operating the lifting device and attachments .................. 27
Page Page
Operating the sideshift ...................................................... 27
T
Table of contents ................................................................. 7
Operation ..................................................................... 12, 25 Taking the truck out of operation ...................................... 37
Operation of industrial trucks in the plant area ................ 18 Technical data ................................................................... 10
Technical description ........................................................ 12
P
Technical note ..................................................................... 3
Tilting the fork carriage backward .................................... 27
Tilting the fork carriage forward ........................................ 27
Parking brake .............................................................. 12, 26 Towing instructions ........................................................... 35
Parking the truck ............................................................... 32 Towing procedure ............................................................. 35
Towing ............................................................................... 35
Transport with lorry or low-bed semi-trailer ..................... 33
R
Transport ........................................................................... 33
Transporting a load ........................................................... 32
Triplex mast ....................................................................... 39
Recommissioning after taking out of operation ............... 37 Troubleshooting guide ...................................................... 55
Releasing the pressure of the parking brake .................. 35 Truck takeover ..................................................................... 3
Removing, installing the rear cover ................................. 28 Type plates .......................................................................... 5
Renew the hydraulic oil filter ............................................ 49
W
Resetting the brakes ......................................................... 35
Reversing .......................................................................... 25
Running-in instructions ..................................................... 18
Wheel change ................................................................... 34
S
Working and steering hydraulics diagram ....................... 58
Safety information ............................................................. 17
Safety rules ........................................................................ 17
Securing the mast against tilting back ............................. 38
Securing the raised duplex mast ...................................... 39
Securing the raised simplex mast .................................... 38
Securing the triplex mast .................................................. 39
Service brake, reverse current brake ............................... 26
Services after the first 50 service hours ........................... 39
Services prior to first operation ......................................... 18
Servicing the mast and the front part of the truck ............ 38
Simplex mast ..................................................................... 38
Steer wheel position indicator .......................................... 16
Steering system ................................................................. 26
Steering ....................................................................... 12, 26
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