Linde Forklift Manual Here is our extensive Linde forklift manual library (PDF formats) that includes the forklift repair and parts documentation and service instructions that you need for your warehouse or forklift-supported operation. These complete Linde forklift manuals contain information you need for your Linde equipment, as provided by the manufacturer of the forklift truck. Linde Forklift Models in our service manual collection: All of the PDF manuals below are available in our Linde manual collection.

1. Linde Service Manuals

. LINDE LIFT TRUCK CORP. A MEMBER OF THE LINDE GROUP IC Sit-Down Rider Trucks SAFETY TIPS and a guide to the Information Plates, Operation and Warning Decals found on your truck 161970 February 2003. NOTE: The descriptions and specifications included in this manual were in effect at the time of printing.

Linde Lift Truck Corporation reserves the right to make improvements and changes in specifications or design without notice and without incurring obligation. Please check with your authorized Linde dealer for information on possible updates or revisions. Operator training and/or maintenance instructions for your truck should you need them. Parts and Service See your Linde dealer for genuine Linde parts (the only factory-authorized replacements), factory-trained service personnel and manuals for your equipment. General Safety Rules Safety signs and messages are placed in this manual and on the truck to provide instructions and identify specific areas where potential hazards exist and special precautions should be taken. Don’t mix drugs or alcohol with your job. The truck is designed for safety.

Unauthorized additions or modifications without Linde’s approval are prohibited. Do not remove or alter nameplates. If you have any questions or concerns about lift truck safety, talk to your supervisor.

If an accident should occur, report it immediately. Checklist for IC Sit-down Trucks OPERATOR’S DAILY CHECKLIST At the beginning of each shift, inspect your truck by using the Linde Operator’s Daily Checklist. Check for damage and maintenance problems. Have repairs made before you operate the truck. SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS Do not make repairs yourself. Lift truck mechanics are trained professionals.

They know how to make repairs. Periodic maintenance is vital to safe operation of the truck. Adhere to a strict inspection, lubrication, and maintenance schedule. Allow only authorized personnel to work on the truck. SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS PEDESTRIANS Watch out for pedestrians. Always yield the right-of-way to pedestrians. Do not drive the truck up to anyone standing in front of a rack or other fixed object.

Do not pass another truck traveling in the same direction at an intersection, blind spot or other dangerous location. SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS Do not engage in stunt driving or horseplay. Use lights in dark and dim areas.

Always ensure that there are no pedestrians in the trucks rear swing area before turning. Watch for pedestrians beside the truck.

SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS OPERATING POSITION Face the truck when mounting and dismounting. Maintain a three-point contact, one foot and two hands with the truck when mounting or dismounting. Never exit a moving truck. Never jump on or off the truck. Operate the truck only when you are in the normal operating position.

SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS DANGER Never allow anyone to walk under raised forks. Wear your seat belt at all times when operating the truck. SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS Do not place yourself between the mast and the body of the truck.

Do not use the upright as a ladder. Do not transport personnel at any time.

Do not lift personnel using the forks of the truck, or with a work platform. SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS TRAVEL The truck is designed for operation on smooth, and dry surfaces such as warehouse and factory floors, loading docks or paved surfaces.

Under all travel conditions, operate the truck at a speed that will permit it to be brought to a stop in a safe manner. Do not travel at excessive speeds. SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS Watch for slack chain condition. Slack chains mean rail or carriage hang-up.

Raise the forks before you move. Do not attemp to repair yourself, always get a trained mechanic. INCLINES, RAMPS, DOCKS, ELEVATORS If you must travel on an incline, do so with caution. SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS Keep the counterweight upgrade when traveling up or down an incline with an empty truck To avoid hazards associated with a dock, you should personally check that the trailer brakes have been applied, wheel chocks are in place, and that any trailer-to-dock locking systems are being utilized. SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS DANGER Never turn on an incline or ramp either loaded or unloaded.

Linde Service Manuals

Travel straight up or straight down. Be especially cautious when driving the truck on ramps or bridge plates. Be sure to maintain a safe distance from each edge. SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS TIP-OVER Lateral tip over can occur with a combination of speed and sharpness of turn. This condition of instability is even more likely with an unloaded truck.

With the load raised, lateral tipover can occur while turning and/or braking when traveling in reverse or accelerating and turning while traveling forward. SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS DANGER If your truck starts to tip over DO NOT JUMP! Make sure your seat belt is securely fastened, stay in the seat, grip the wheel, lean away from impact and brace your feet. WARNING READ OPERATOR’S MANUAL. SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS Confirm the engine type before filling the tank with the recommended fuel. Lift Trucks should be refueled only at designated safe locations. Safe outdoor locations are preferable to those indoors.

Never fill the tank near open flame or when the engine is running. SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS Only Trained, authorized personnel should fill or exchange LP-Gas tanks. Protective clothing such as a face shield, long sleeves and gauntlet gloves should be worn. Do not refuel or store LP-Gas powered life trucks near underground entrances, elevator shafts, or other places where LP-Gas could collect in a pocket and cause potential danger for an explosion. SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS Serious accidents can occur if LP-Gas tanks are not properly handled. To reduce the risk of damage to tanks, use extreme care when transporting them. Do not leave the engine running where there is poor ventilation.

The engine exhaust gas contains carbon monoxide. SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS It is extremely dangerous if you or any tool touches or gets caught in the fan or fan belt when the fan is rotating. Never touch the fan when it is rotating. Always stop the engine before inspecting rotating parts.

SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS Neutral Control Lever Parking Brake Lower forks fully to the floor and tilt forward From Reverse Direction From Forward Direction Parking (3 Position) Directional Control Brake Lever (Option) Key to OFF position (Place in Neutral Position as shown) PARKING. BATTERY CAPACITY TYPE LIFT TRUCK CORP.

A MEMBER OF THE LINDE GROUP AS SHIPPED THIS TRUCK MEETS THE APPLICABLE REQUIREMENTS OF ASME B56.1 1. Model designation of the truck 2.

Truck serial number 3. Truck sales order number - the sales and serial numbers are assigned to each specific truck and should be used when requesting any information on the truck. LIFT TRUCK CORP. TIRES TILT A MEMBER OF THE LINDE GROUP 1. Attachment (Sideshifter, Clamp, etc.) - if an attachment is installed on the truck at the time of purchase, it will be indicated in this block.

Truck serial number 3. SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS OPERATOR WARNING AND SAFETY DECALS (continued) Operator Warnings Decal Read and understand the following before operating the truck. SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS OPERATOR WARNING AND SAFETY DECALS (continued) Trained Operator Warning Decal This decal reinforces the requirement that only trained and authorized personnel are to operate the truck. Hood Latch Warning Decal This decal reinforces that the Operator should verify that the Hood Latch is securely fastened before operating the truck. SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS OPERATOR WARNING AND SAFETY DECALS (continued) “Don’t Walk Under or Stand On Forks” Warning Decal This decal is located on both sides of the Mast Uprights and warns both the Operator and any pedestrians not to stand on or walk under a raised load at any time. SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS OPERATOR WARNING AND SAFETY DECALS (continued) Brake Warning Decal This decal reinforces that the Operator should engage the Parking Brake lever whenever necessary, as it is not automatically applied. Personnel Warning Decal This decal reinforces that the Operator should never use the Forks to lift personnel for any reason.

SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS OPERATOR WARNING AND SAFETY DECALS (continued) Seat Belt / Tip-Over Warning Decal This decal reinforces that the Operator should read the Operator’s Manual and engage the Seat Belt before operating the truck. It also instructs the Operator on what to do in the event of a tip- over of the truck. SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS NOTES. SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS SAFETY TIPS NOTES. LINDE LIFT TRUCK CORP. A MEMBER OF THE LINDE GROUP ©2002 Linde Lift Truck Corporation 2450 West 5 North Street Summerville, S.C.

29484 PHONE (843) 875-8000 FAX (843) 875-8329. Operating Instructions Linde Fork Lift Truck H 50 - 02 / H 60 - 02 / H 70 - 02 H 80 - 02 / H 80/900 - 02 With Diesel Engine 353 804 3001 GB 0702. Werk II, Aschaffenburg-Nilkheim portant countries. Linde industrial trucks enjoy a worldwide reputation - thanks to their high quality in engin- eering, performance and serv- ice. Werk I, Aschaffenburg Werk III, Kahl am Main Linde Heavy Truck Division Ltd., Merthyr Tydfil. Please contact your authorised Linde dealer for this persons, in particular by the operators and service personnel.

The user, and not the manufacturer Linde, is liable for any Only qualified persons authorised by Linde are allowed to hazards arising from unauthorised applications. 1 Operating instructions For repairs use only genuine Linde spare parts to ensure that 1 Manufacturer’s declaration of conformity your truck will retain its original technical standard. (manufacturer declares that the industrial truck conforms. 353 804 3001.0702. Type plates Description Manufacturer’s plate Manufacturer CE symbol (The symbol certifies that the EC directives for machines and all applicable guidelines are fulfilled.) Serial number / year built Weight of empty truck Battery voltage Rated capacity Type Lift mast number (stamped) 10 Chassis number (stamped on side) 11 Working hydraulics pump plate 12 Power steering pump plate. Fork lift truck models H 50 / H 60 / H 70 / H 80 / H 80/900 with Diesel engine Description Innovative technology, easy and ergonomic operation, energy-efficient, environment- and maintenance-friendly, solid manufacture and because almost all spares are of our own manufacture they are readily available!

The success of a company with about 9600 employees in eight manufacturing sites. Table of contents Description Page Page Page Description Starting the engine.24 Operating the horn.34.2 Cold start.25 Check fuses, renew if required. 35 Authorised applications.2 Stopping the engine.25 Before lifting a load. 353 804 3001.0702. Table of contents Description Page Page Page Inspection and maintenance as required Add engine oil.61 3000-hour inspection and maintenance.48.74 Check the hydraulic oil level.61 Cleaning the lift truck.48 Renew the hydraulic oil.

74 Check the coolant concentration. Technical data Description Fork Lift Trucks Data Sheet for Material Handling Equipment VDI 2198 Notes: Designation VDI 2198 to VDI 2198 June 1999 Manufacturer (see page 1) 1) Additional lifting mast heights; see table. Model designation H 50 D H 60 D H 70 D H 80 D H 80 D/900.

Technical data Description Lifting capacity diagrams: Load capacities apply for SE tyres. Mast and lifting height H 50, H 60 (in mm) Lifting height 3550 4150 4550 5250 6050 Mast retracted (with 150 mm free lift for standard) 2730 3030 3230 3580 3980. Technical data Description Noise emission levels Frequency characteristic for human body vibrations (preliminary values as only a Determined in a test cycle in accordance with EN 12053 from draft standard is available) the weighted values in the operating modes DRIVING, LIFT- ING, IDLING.

Overhead tilt cylinders are fitted for sensitive tilting and for Electrical system Hydraulic system mast stabilisation. The LTS (Linde Torsion Support), also functioning as overhead guard, ensures high strength against The electrical system is supplied by a three-phase current The drive system consists of one variable-displacement pump torsion, i.e. General view of truck Description Steering wheel Tilt cylinder Driver’s seat Cabin. Counterweight Bonnet Steering axle Electrical system cover Foot steps Left drive axle hub differential Fork carriage Lift cylinder Forks Fork quick-releases Lift chain Lifting mast Control console d353-02/34. Option.

Controls and indicators Description Toggle switches for supplementary functions. Parking brake lever Steering wheel/hydrostatic power steering Horn button Ignition switch and key switch Toggle switches for supplementary functions. Composite instrument Air outlet. Control lever for supplementary hydraulics (attachments). Label for supplementary hydraulics. Notice label Load capacity diagram Load capacity plate (attachment).

353 804 3001.0702. Composite instrument Description The composite instrument contains the following control and indicator elements: Indicator element Function Possible fault(s) 1 Hour meter 2 Hour meter on indicator light Hour meter (1). The row of figures (13) Indicates lift truck service hours.

The NOTE shows the full service hours, the last display serves as reference for. Safety rules Beginning operation The responsible persons, particularly the truck operator and Important safety information Handling fuels and lubricants servicing personnel, must be instructed in the safety guide- The precautions WARNING, CAUTION, ATTENTION and Always handle fuels and lubricants as required and lines for the normal and proper use of industrial trucks NOTE in this manual are provided to indicate special dangers as specified by the manufacturer. Safety rules Beginning operation Particle filter system inspection (option) Services prior to first operation Accident prevention check The responsible authorities require that particle filter systems Check the engine oil level The accident prevention rules in some countries require that must be serviced every six months by an expert. Record the the fork lift truck must be checked at least once a year for Check the header tank coolant level inspection results in a “Diesel engine emission inspection. Daily checks and servicing before operation Beginning operation Opening the bonnet Closing the bonnet Check the fuel level Lift the lever (9) and tilt the backrest (4) forward. Close the bonnet.

The fuel level warning light (1) at the instrument panel goes on when 8.0 litres of fuel remain in the tank. Daily checks and servicing before operation Beginning operation Refuelling Check the engine oil level Check the header tank coolant level CAUTION ATTENTION ATTENTION Stop the engine before refuelling. No smoking or Follow the rules for handling fuel, lubricants and Follow the rules for handling fuel, lubricants and naked flames when refuelling. Daily checks and servicing before operation Beginning operation Check the tyre inflation pressure Inflate the tyres according to the informations on the front ATTENTION label (1) and rear label.

A low tyre inflation pressure reduces the service life of the tyres and the stability of the truck. Drive axle - single tyre H 50 300-15/22 PR. Daily checks and servicing before operation Beginning operation Applying the seat belt DANGER CAUTION Pull out the knob on the adjusting handwheel (10) and turn The seat belt must always be applied during The webbing should not be twisted, stuck or the handwheel to set the cushioning to the weight of the the operation of the truck! The seat belt is only knotted. Starting the engine Beginning operation Starting the engine NOTE Hold the ignition key in position I until the yellow preheat- ATTENTION. If at all possible, avoid frequent engine starts and short ing indicator light (9) is extinguished, and then turn the key Observe the exhaust nozzle for about 5 s after duty cycles so that the engine can reach its operating further to position II.

Cold start, Stopping the engine Beginning operation Cold start Stopping the engine NOTE NOTE Malfunctions during operation Starting at temperatures below 0 °C should be performed Do not stop the engine at full throttle. With the accelerator pedal fully depressed in order to ATTENTION obtain the extra amount of fuel required for starting. Driving Operation CAUTION Start the engine.

Reversing the direction of travel Do not drive on slopes with gradients over Release the actuated accelerator pedal. The hydrostatic 15%, due to the specified minimum brake appli- Elevate the forks slightly and tilt the mast back. Drive will act as service brake. Single-pedal model Operation Starting the engine NOTE Hold the ignition key in position I until the yellow preheat- ATTENTION. If at all possible, avoid frequent engine starts and short ing indicator light (9) extinguishes, then turn the ignition Observe the exhaust nozzle for about 5 s after duty cycles so that the engine can reach its operating key to position II.

Single-pedal model Operation Cold start Stopping the engine Malfunctions during operation NOTE NOTE ATTENTION Starting at temperatures below 0 °C should be performed Do not stop the engine at full throttle. If one of the following indicator lamps illumi- with the accelerator pedal fully depressed in order to nates during operation, shut off the engine Release the accelerator pedal (4).

Single-pedal model Operation Driving Reversing CAUTION NOTE Pull back the direction control lever (2). Do not drive on slopes with gradients over When the particle filter.

warning light (5) is illuminated 15% due to the specified minimum brake appli- Depress the accelerator pedal (3) gently. Steering, brakes Operation Steering Service brake Parking brake Due to the hydrostatic power steering, very little effort is Allow the accelerator pedals to return to the neutral The multiple disc brakes are used as parking brake. Required to turn the steering wheel. This is especially useful position. Central-lever control of lifting device and attachments Operation ATTENTION Lifting the fork carriage Operating the sideshift Use the lifting device and attachments only for Push the control lever (1) to the right. To move the sideshift to the left, push the control lever (2) authorised applications. Single-lever control of lifting device and attachments Operation Lowering the fork carriage ATTENTION NOTE Use the lifting device and attachments only for For each attachment affix a load capacity plate on the Push the control lever (1) forward.

Authorised applications. The operator must be engine cover and a symbol label depicting the attach- instructed in the handling of the lifting device and attach- ment behind the appropriate control lever.

Turn the front working light on or off with toggle switch (3). Connections beyond this anticipated range are only per- mitted after contacting Linde.

Only qualified skilled per- Intermittent switch for rear and top wind- sons who observe the applicable rules and use appropri. Heater, horn Operation Controls Operating the horn The fan switch (1) turns on the fan and permits air flow NOTE The horn serves as a warning signal at blind corners and When lever (3) is pushed to the right and lever (2) to the regulation in three stages. 4 Seat heater. (9F14).20 A cover (3) of the bottom step. 5 Horn (4F15). 10 A ATTENTION 6 One pedal operation. (9F16).5 A Remove the four screws (4).

Use only original Linde fuses. Remove the cover (3). Option d353-02 /36. Before lifting a load Operation Before lifting a load, check the capacity diagram (1) on the Example bonnet. Load centre distance.1000 mm 1 Maximum allowed load in kg WARNING Height of lift.5650 mm 2 Height of lift in mm If attachments are fitted, check the capacity plate (2) for that equipment.

Loading Operation Adjusting the fork spread Loading CAUTION Raise the fork quick-releases (1). NOTE Do not stand under an elevated load. Drive the Stow loads so that they do not project over the truck load fork lift truck only with the load lowered and the Move the forks further apart or closer together depending area and can not slide, tip over or fall off. Transporting a load, depositing a load Operation Transporting a load Depositing a load Before leaving the lift truck unattended NOTE Carefully approach the area receiving the load. Deposit the load and lower the fork carriage. When sending goods by freight, the consignor must load and fasten, if necessary, the transported goods safely.

Transport, hoisting the truck Operation Transport with lorry or low-bed semi-trailer CAUTION ATTENTION Lower the mast. Only use a hoisting gear and loading crane with After inserting the slings into the crane hook, the Operate the parking brake. Sufficient capacity. Safety lock (4) must close. Hoisting the truck, wheel change Operation Hoisting the truck with lifting eyes Wheel change ATTENTION CAUTION CAUTION The safety lock (5) must close after attaching the Only use a hoisting gear and loading crane with Only use a jack of sufficient lifting capacity. The chains into the crane hook (4).

Mast removal, trailer coupling Operation Mast removal Securing the moveable overhead guard Trailer coupling ATTENTION ATTENTION NOTE Attach the lifting sling on the outer upright of the When removing the mast, the moveable over- The trailer coupling should be used only to tow light mast at the left and right tilt cylinder pivot (1). Towing instructions Operation Towing Releasing the disc brake After towing Should it become necessary to tow the truck, then it is Open bonnet, remove floor plate. Chock the wheels at the lowest wheels. Possible Unscrew the cap nut (4) left of the pedal box and remove Loosen the locknut (8). Emergency exit for trucks with rear windscreen Maintenance Emergency exit for trucks with rear wind- screen NOTE If the truck is fitted with a front and rear windscreen, it may not be possible to dismount at the side if the truck breaks down in a narrow aisle.

Taking the truck out of operation Maintenance If the truck is taken out of operation for over 2 months, it must Putting the truck back into operation General information be parked in a well ventilated, frost-free, clean and dry room Your truck will remain operational only if the maintenance and Thoroughly clean the truck. Maintenance Servicing the mast and the front part of the Standard mast Maintenance after the first 50 service hours truck FUNCTION NOTE When the inner mast is lifted, the fork carriage is raised at a A description of the services can also be found in the WARNING ratio of 2:1. Inspection and maintenance schedule Maintenance Services Before initial After the first Daily checks As required (The description can be found by using the index.) operation 50 service hours Refer to page 19 for servicing.Refer to page 45 for servicing.Check the engine oil level. Inspection and maintenance schedule Maintenance Every 500 Every 1000 Every 2000 Every 3000 Services hours hours hours hours (The description can be found by using the index.) Clean and lubricate the steer axle.

Grease the mast pivots, tilt cylinder and overhead guard pivots.Check the engine mounting, moveable overhead guard, steer axle and drive axle hub differentials for tightness. Inspection and maintenance as required Maintenance Cleaning the lift truck Cleaning and spraying the mast chain When cleaning with compressed air, remove sticking dirt with NOTE NOTE a cold cleaner. The necessity of cleaning depends on the use of the The mast chain must be cleaned if the dust on the chain Clean the oil filler openings, surrounding areas and grease truck.

Inspection and maintenance as required Maintenance Cleaning the air filter Cleaning with compressed air NOTE ATTENTION NOTE Mark every servicing on the filter element. Cleaning the air filter element is necessary only when the Do not clean the filter casing with compressed air filter restriction indicator in the composite instrument air, wipe it with a clean damp cloth. Inspection and maintenance as required Maintenance Emptying the dust bowl in the air filter cover Replacing the safety element Clean the pre-filter NOTE Changing the safety element (3) is required: NOTE The dust bowl should never be more than half filled with The dust bowl (3) should never be more than half full (2) After cleaning the main element (1) five times.

Inspection and maintenance as required Maintenance NOTE Regenerate the particle filter For safety reasons, do not conduct the exhaust gases into an The regeneration procedure runs automatically, i.e. Pre- exhaust facility. WARNING heating about 60 seconds, combustion about 10 minutes ATTENTION Do not refuel during filter regeneration. Inspection and maintenance as required Maintenance Lubricate the steer axle, mast and tilt cylin- Check wheel fastener for tightness Check the tyres for damage and foreign der bearings objects ATTENTION Check the wheel fastener at least every 100 If used in clean and dry areas, truck servicing every 500 Secure the truck against rolling (apply the parking brake).

Inspection and maintenance as required Maintenance Clean the radiator and engine oil, hydraulic oil and fuel cooler, check for leaks NOTE Clean with compressed air Renew porous hoses and tighten hose clamps, if neces- The cooling system may only be cleaned with the engine sary. Inspection and maintenance as required Maintenance Drain the water separator in the fuel system ATTENTION Follow the rules for handling fuel, lubricants and coolant. NOTE The water separator is mounted on the right side of the truck, under the cover above the second step. Remove the four screws (1) and remove the cover (2). Inspection and maintenance as required Maintenance Check seat belt for condition and operation NOTE NOTE CAUTION For safety reasons the condition and operation of the When opening the bonnet, watch out for a possibly To prevent back injury, the weight setting should retention system should be inspected regularly (month- installed rear windscreen.

500-hour inspection and maintenance Maintenance Clean and lubricate the steer axle Grease the mast pivots Grease the tilt cylinder and overhead guard pivots Clean the steer axle with water or a cold cleaner. NOTE Fully lower the mast. NOTE NOTE For lubrication use a specified lubricating grease. 500-hour inspection and maintenance Maintenance Check the engine mounting, movable over- Check the forks and fork quick-releases Check the mast, lift chains and stops for head guard, steer axle and drive axle hub condition, operation and security Inspect the forks for visible distortion, wear and damage. Differentials for tightness Clean the mast channels and chains. Check the fastening and pre-tension of the bonnet lock Tighten the locknut (1) firmly. And grease lock.

Lubricate with chain spray Lubricate the channel surfaces and chain with Linde chain spray. NOTE Trucks in service in the food industry must be lubricated with a thin oil approved for the food industry instead of chain spray. 500-hour inspection and maintenance Maintenance Check the engine cooling system for leaks Check and oil the pedals, accelerator and engine control linkage Open the bonnet.

Remove the cover in the counterweight. ATTENTION Check the coolant header tank (1) and radiator (2) for Check all engine coolant hoses, water pump, header tank The following work must be carried out by qual- and radiator for leaks. 500-hour inspection and maintenance Maintenance Renew the engine oil Renew the engine oil filter (at least every 12 months) Drain the engine oil CAUTION Engine oil may be hot. Danger of scalding! ATTENTION Remove the oil drain plug (2) from below. Follow the safety rules for handling fuel, lubri- Follow the rules for handling fuel, lubricants and cants and fuel.

500-hour inspection and maintenance Maintenance Add engine oil Check the hydraulic oil level NOTE Remove the filler cap (1). ATTENTION The four markings on the oil dipstick are for different Follow the rules for handling fuel, lubricants and mast heights. Fill new engine oil through the filler opening. 500-hour inspection and maintenance Maintenance Check the coolant concentration Check the particle filter system Mixing ratio for lower temperatures: The cooling system must be filled with a mixture of water and Check the electric contacts for tightness, corrosion and antifreeze throughout the year in order to prevent scaling and damage. 500-hour inspection and maintenance Maintenance Drain the water separator in the fuel system Check and tension V-belt drives Tighten V-belt drives ATTENTION ATTENTION If V-belt tension is insufficient: Follow the rules for handling fuel, lubricants and A broken and loose V-belt reduces cooling. Slacken bolt (2) at the alternator. 500-hour inspection and maintenance Maintenance Renew the drive axle hub differential oil and Clean the radiator, hydraulic oil and fuel cooler clean the magnetic plug NOTE ATTENTION NOTE Clean the cooling system only with the engine stopped Do not point the water jet directly at sensitive The oil in the drive axle hub differential must only be and cool.

500-hour inspection and maintenance Maintenance Check the condition and security of electric Check the condition, electrolyte level and cables, connectors and cable connections specific gravity of the battery Remove the cover, located on the left side of the truck ATTENTION Unscrew the caps and check the electrolyte level. 1000-hour inspection and maintenance Maintenance Renew the hydraulic pressure, suction and breather filters Renew the pressure filter Renew the suction filter ATTENTION Remove the fastening nuts (3) on the filter cover (1). Insert a screwdriver through the opening (9) in the filter element and turn it anti-clockwise. 1000-hour inspection and maintenance Maintenance Renew the breather filter Renew the fuel filter canister Check the engine mounting for condition and tightness Pull the breather filter (1) with oil dipstick out of the filler ATTENTION neck. Follow the rules for handling fuel, lubricants and Move the engine mounting to the left and right with a coolant.

1000-hour inspection and maintenance Maintenance Renew and tension the V-belt drive Remove the bolts (1) on the impeller shaft (2) and remove Install the new V-belts (6). The shaft with the fan. Turn the adjusting bolt (4) clockwise until the correct belt Loosen bolt (3). 1000-hour inspection and maintenance Maintenance Check the exhaust system for leaks and Check the hydraulic system, hydraulic tightness pumps, valves and lines for leaks Inspect the air intake and exhaust pipes for leaks. If leaks Examine all connections between the hydraulic oil tank, Remove the cover (1) in the counterweight.

1000-hour inspection and maintenance Maintenance Renew the air filter element, check the va- Check the parking brake cuum switch Drive the lift truck with a maximum load on a 15% slope. (every one year or after cleaning 5 times) Depress the brake pedal (2).

1000-hour inspection and maintenance Maintenance Check the drive axle hub differential oil level Check the particle filter system and for leaks Check that the filter mounting is secure. Park the truck so that the middle points between wheel Examine the exhaust parts for leaks. Bolts (2 and 3) form vertical and horizontal lines. 2000-hour inspection and maintenance Maintenance Check the particle filter system Check valve tip clearances Examine the glow plug helix for strong distortion and Check and adjust the valve tip clearances only when the carbonisation.

Engine is cool. The adjustment must be left to an workshop with the necessary Please contact your authorised distributor for the servicing.

2000-hour inspection and maintenance Maintenance Renew the safety element If the air filter element is damaged. Open the bonnet. Remove the dust bowl. Remove the air filter cover. Remove air filter element (1). Unscrew the hexagonal nut (2) and pull out the safety The safety element (3) is must be renewed: element (3).

3000-hour inspection and maintenance Maintenance Renew the hydraulic oil Drain the hydraulic oil Allow the oil to drain completely. Fill hydraulic oil at the filler opening.

NOTE Clean the area around the oil drain thoroughly. Fully screw in the breather filter with the oil dipstick and The fork carriage must be lowered completely. 3000-hour inspection and maintenance Maintenance Drive axle hub differential: Renew oil and clean the magnetic plug Drive the truck until the drive axle hub differential is at Clean the areas surrounding the level/filler plug (1), filler Check the axle hub differential oil level after approx. 5 operating temperature. 3000-hour inspection and maintenance Maintenance Renew the coolant In all seasons the cooling system must be filled with a mixture Dispose the coolant as required by local laws and regula- of water and unphosphated glycol-based antifreeze with an tions.

Anticorrosion additive to provide protection against calcium Refit the hose and tighten with the clamp. 600 Nm Tilt cylinder pivots/steer axle Grease As required Mast pivots/overhead guard Grease As required Lift chains, mast channels Linde chain spray As required V-belt tension With belt tension gauge: New V-belt After 20 - 30 minutes ±50 Till next inspection. Fuel and oil recommendations Engine oils Oil viscosity API classification CD, CE or CF-4, Since the viscosity of lubricants varies with temperature, the NOTE CCMC classification D4 or D5. Ambient temperature at the site determines the viscosity class Oil additives of any kind may not be added to any of the (SAE class) of the engine oil (see diagram). Do not mix bio-oils with mineral oils. Other fluids from other manufactures cannot Linde chain spray (see Parts Catalogue for order number).

NOTE In case of doubt we recommend that you contact your authorised distributor. Recommendations of representatives of the oil industry should also be checked with your authorised distributor.

Troubleshooting guide (Diesel engine) Malfunction Possible Cause Remedy See Page Engine will not start Fuel tank empty. Fill the tank. Faulty glow plugs. Replace the glow plugs.

Fuel supply not in order. Disconnect injection line at nozzles, start engine, and check if fuel is being delivered. Troubleshooting guide (Diesel engine) Malfunction Possible Cause Remedy See Page Excessive black, Air filter dirty. Clean or replace the air filter element. 49, 70 white exhaust smoke Fuel filter dirty. Renew the fuel filter cartridge.

Maximum RPM out of adjustment. These faults should always be checked and remedied by Faulty injection nozzles. Troubleshooting guide (Diesel engine) Malfunction Possible Cause Remedy See Page Fuel consumption too high Air filter dirty. Clean or renew the filter canister. 49,70 Idle or maximum RPM too high. These faults should always be checked and remedied by Faulty injection nozzles.

Troubleshooting guide (hydraulic system) Malfunction Possible Cause Remedy See Page Abnormal noise Suction filter blocked. Renew filter. Suction hoses leaking. Eliminate leaks in piping.

61, 69, 79 Check oil level and replenish oil, if necessary. Hydraulic pump or motor damage; seals defective, Have hydraulic unit inspected by an authorised distributor. Electric circuit diagram Preheat/starter switch Preheating time controller Wire code colours Engine temperature switch Fuse, MTA 80 A Hydraulic oil temperature switch blue Engine oil pressure switch Fuse (terminal 30, S1) 10 A brown Fuse, preheating time controller supply, shutoff mag- Suction filter vacuum switch yellow net 10 A. Electric circuit diagram. 353 804 3001.0702. Electric circuit diagram (Options) Dip beam, right, 45 W 5S11 Light switch Wire code colours Dip beam, left, 45 W 5S12 Flasher switch blue Side marker light, front right, 4 W 5S13 Direction indicator switch brown Side marker light, front left, 4 W Switch, windscreen wiper front yellow Side marker light, rear light, left, 10 W. Electric circuit diagram (Options).

Electric circuit diagram (Options). Start inhibit relay All cables without information = 0.75 mm Fan 1, 60 W Fan 2, 60 W Metering pump 1 Soot particulate filter with Linde Control Metering pump 2 To starting relay ISO interface Glow plug 1, 24 W. Particle filter wiring diagram. Hydraulic circuit diagram Working hydraulics Engine Travel control unit consisting of: Control valve block assembly consisting of: 3/2-way valve - signal for engine speed Way valve (supplementary hydraulics) Engine speed control cylinder Pressure regulating valve Way valve (supplementary hydraulics) Pressure-relief valve 11 bar Way valve (tilting) Restrictor Variable-displacement hydraulic pump. Hydraulic circuit diagram. Index Page Page Page Accident Prevention Check.19 Check the engine cooling system for leaks.

59 Daily checks and servicing before operation.20 Add engine oil.61 Daily checks. 19 Check the engine mounting for condition and tightness. 67 Adjust the lift chains. Index Page Page Page Gear oil.79 Loading.37 Parking brake.30 General information.44 Particle filter system inspection (option).19 Loading.37 General view of truck.14 Lowering the fork carriage.31 Particle filter wiring diagram. Index Page Page Safety rules. 18 Troubleshooting guide (hydraulic system).83 Turning on the dome light.33 Securing the mast against tilting back.45 Turning on the front working lights.33 Securing the moveable overhead guard.41 Securing the raised standard mast.