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Operating Instructions
Linde Fork Lift Truck H 12 T - 03 / H 16 T - 03 / H 18 T - 03 / H 20 T - 03
With LPG Engine
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.
The Linde Material Handling division is a leading manufacturer 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 branches in all economically important countries.
Linde industrial trucks enjoy a worldwide reputation - thanks to their high quality in engineering, performance and service.
Foreword
Your Linde lift trucks
offer the best in economy, safety and driving convenience. Therefore it is mainly in the hands of the operator to preserve the qualities of the trucks for a long and profitable service life and to make full use of their benefits on the job. These operating instructions tell you all you need to know about starting, operation, running, and servicing the truck. For maintenance and repair work not described in these operating instructions special technical skill and knowledge, measuring equipment and special worshop tools are often required. Please contact your authorised Linde dealer for this service. Only qualified persons authorised by Linde are allowed to service the truck. For some attachments, the proprietary operating instructions supplied with them are applicable. Follow all hints for operating the lift truck and carry out the maintenance and care prescribed in the inspection and maintenance schedule regularly, on time and with the specified lubricants. To keep your warranty valid, keep a record of all maintance services performed. The terms front, rear, left and right refer to the position in which the item concerned is installed in the truck, looking forward in the travel direction.
Approved applications
Linde lift trucks are designed for transporting and lifting the loads stated in the load capacity diagram. In particular, we refer to the "Rules for the Normal and Proper Use of Industrial Trucks" (VDMA) supplied with this manual, to excerpts from the safety regulations for the use of liquefied petrol gas with the safety measures for transistorized ignition systems on pages 111, 112 of this manual, to the accident prevention rules of your employers liability insurance and to the requirements of traffic regulations. The safety rules for the use of industrial trucks must be followed under all circumstances by the responsible persons, especially by the operator and service personnel. The user, and not Linde, is responsible for any danger arising from applications not authorised by the manufacturer. If you desire to use the truck for applications not mentioned in the manual and convert or supplement it for this purpose, please first contact your authorised Linde dealer. No changes, especially conversions or modifications, may be made on your fork truck without the prior permission of the manufacturer.
350 804 3351.0705
Foreword
Technical note
These operating instructions or excerpts thereof may only be copied, translated or transmitted to third parties after prior written approval by the manufacturer. Linde pursues a policy of continuous progress in the design and construction of its products. As a result, the illustrations and technical details referring to design, fittings and engineering of lift trucks are subject to change if progress warrants it. Therefore, the manufacturer will not accept any claims based on the specifications, illustrations and descriptions contained in this operating manual. Please submit all enquiries concerning your fork truck and all orders for spare parts to your authorised dealer, making sure to state your correct shipping address. For repairs, use only genuine Linde spare parts to ensure that your Linde fork truck will maintain its original technical standard. When ordering spare parts, it is important to specify the part numbers and to include the following truck data: Lift truck model: __________________________________ Serial number/Year built: ___________________________ Handing-over date: ________________________________ Additionally specify the production no. of engine, mast, hydraulic pump and drive axle when ordering parts for these assemblies. Engine number: __________________________________ Mast number: ____________________________________ Mast lift height: ________________________________ mm Drive axle number: ________________________________ When taking over the fork lift truck, transfer the data from the assembly type plates into this manual. Wishing you satisfactory operation, Linde AG Linde Material Handling Division Schweinheimerstrae 34 63743 Aschaffenburg Phone +49 (0)6021 99-0 Fax +49 (0)6021 99-1570 3
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 dealers 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 manufacturers certificate of conformity. The following technical manuals are supplied with each fork truck: 1 Operating manual 1 EC certificate of conformity (The manufacturer certifies that the industrial truck conforms to EC directives for machines) 1 Rules for the normal and proper use of industrial trucks (VDMA)
Type plates
1 2 3 Lift truck type plate Manufacturer CE symbol (The symbol certifies that EC directives for machines and all applicable guidelines are fulfilled.) Serial no./year Unladen mass Battery voltage Rated load capacity Type Mast no. (glued) Drive axle type plate Chassis serial number (stamped on side) Engine number type plate
Description
4 5 6 7 8 9 10 11 12
350 804 3351.0705
8 3 7 4 5 6
5
Description
Drivers position and operating features are according to the latest findings of ergonomics. Each control is designed in regard to positioning and operation for the drivers convenience to guarantee effortless and therefore safe operation. Of course, this also includes the easy hydrostatic power steering with a kick-back safety, the service-proved doublepedal travel control system: forward travel with the right foot, reversing with the left, and only one main control lever for all mast functions. 6
Table of contents
Page Page Adjusting the operator seat ............................................... 25 Opening the gas cylinder or gas tank shutoff valve ......... 25
Description
Page Fan motor fuse ............................................................... 39 Turning on the heater (version 2) ..................................... 40 Operating the horn ............................................................ 40 Truck Data Management .................................................. 41 Truck data acquisition ................................................... 41 Condition code .............................................................. 41 Truck data acquisition - default setting (PIN number and condition code) ................................. 42 Truck data acquisition - special setting (PIN number) ................................................................. 43 Fuses ................................................................................. 44 Check fuses, renew if required ..................................... 44 Before lifting a load ........................................................... 45 Adjusting the fork spread .................................................. 46 Loading ............................................................................. 46 Travel with a load .............................................................. 47 Unloading .......................................................................... 47 Parking the truck ............................................................... 47 Transport ........................................................................... 48 Transport with lorry or low-bed semi-trailer .................. 48 Hoisting the truck .............................................................. 48 Hoisting the truck with a crane ...................................... 48 Hoisting the truck with the eyebolts .............................. 48 Wheel change ................................................................... 49 Catalytic converter, unregulated ...................................... 49 Trailer coupling ................................................................. 49 Mast removal ..................................................................... 49 Towing instructions ........................................................... 50 Towing ............................................................................ 50 Towing procedure .......................................................... 50 Release the multiple disc brake ................................... 50 Open hydraulic pump pressure-relief valves ............... 50 After towing .................................................................... 50 Reset brake .................................................................... 50 Emergency exit for trucks with rear windscreen .............. 51 Taking the truck out of operation ...................................... 51 Measures before taking the truck out of operation ....... 51 Putting the truck back into operation ............................. 51 Disposal of old vehicles .................................................... 52
Foreword ......................................................................... 2 Approved applications ......................................................... 2 Technical note ..................................................................... 3 Truck takeover ..................................................................... 3 Description ..................................................................... 5 Type plates .......................................................................... 5 Technical data ................................................................... 10 Noise emission levels ........................................................ 12 Frequency characteristic for human body vibrations ........ 12 Technical description ......................................................... 13 Engine ............................................................................ 13 Hydraulic system ............................................................ 13 Operation ........................................................................ 13 LHC control .................................................................... 13 Brakes ............................................................................ 13 Steering .......................................................................... 13 Electrical system ............................................................ 13 General view of truck ......................................................... 14 Controls and indicators ..................................................... 15 Composite instrument ....................................................... 16 Beginning operation ................................................ 17
Safety rules ........................................................................ 17 Important safety information .............................................. 17 Handling fuels and lubricants ............................................ 17 Accident prevention check ................................................ 18 Operation of industrial trucks in the plant area ................. 18 Running-in instructions ...................................................... 18 Experts ............................................................................... 18 Safety instructions for the LPG system ............................. 18 Checks and services before initial operation .................... 19 Daily checks ....................................................................... 19 Daily pre-operational checks and services ....................... 19 Opening the bonnet ........................................................... 19 Closing the bonnet ............................................................ 19 Check the engine oil level ................................................ 20 Checking the LP gas level ................................................ 20 Check the coolant level in recovery tank ......................... 21 Visual, olfactory inspection of LPG system ...................... 21 Changing the LPG cylinder .............................................. 22 Filling the LPG tank ........................................................... 23 Check the tyre inflation pressure ...................................... 24
Operation ...................................................................... 26 Applying the seat belt ....................................................... 26 Opening the seat belt ........................................................ 26 Starting the engine ............................................................ 27 Stopping the engine ......................................................... 28 Closing the gas cylinder or LPG tank shutoff valve ......... 28 Malfunctions during operation .......................................... 29 Driving ............................................................................... 30 Forward travel ................................................................ 30 Reverse travel ................................................................ 30 Changing the travel direction ........................................ 30 Stopping ......................................................................... 30 Single-pedal model .......................................................... 31 Steering system ................................................................. 35 Steering .......................................................................... 35 Braking system .................................................................. 35 Service brake ................................................................. 35 Stop pedal ...................................................................... 35 Parking brake ................................................................. 35 Applying the parking brake ........................................... 35 Releasing the parking brake ......................................... 35 Central-lever control of lifting device and attachments ... 36 Tilting the mast forward ................................................. 36 Tilting the mast back ...................................................... 36 Lifting the fork carriage .................................................. 36 Lowering the fork carriage ............................................ 36 Operating the attachments ............................................ 36 Operating the sideshift .................................................. 36 Operating the clamp ...................................................... 36 Single-lever control of lifting device and attachments ..... 37 Installation of additional equipment ................................. 38 Switching on the front working lights ................................ 38 Switching on the rear working lights ................................ 38 Switching on the lights ...................................................... 38 Switching on the hazard warning lights ........................... 38 Turning on the front windscreen wiper ............................. 38 Turning on the rear windscreen wiper ............................. 38 Operating the turn indicator lights .................................... 38 Heater ................................................................................ 39 Turning on the heater (version 1) ................................. 39
Table of contents
Page Page Check the LPG system for damage and for leaks with leakage spray ......................................... 68 Change the LPG filter ....................................................... 68 Renew the engine oil ........................................................ 69 Drain the engine oil ....................................................... 69 Renew the engine oil filter ............................................ 69 Top up the engine oil ..................................................... 70 Check and oil other pivots and joints ............................... 70 Check the coolant strength ............................................... 71 Check and oil the pedals, the travel and engine control linkage ................................................... 71 Check the tension and condition of the alternator and coolant pump drivebelt .................................................. 72 Tighten the alternator and coolant pump drivebelt ......... 72 Renew the spark plugs ..................................................... 72 Check the tension and condition of the toothed belt, renew if necessary ........................................................ 73 Check the CO contens in the exhaust gas ....................... 73 Check the mounting of the counterweight, overhead guard, steer axle and drive axle ................... 74 Retighten the mast fastening bolts ................................... 74 Catalytic converter: Check the basic adjustment of the LPG system .......................................................... 74 Check the mast, lift chains, lift cylinders and stops for condition, mounting and operation ............................... 75 Adjust the lift chain length, lubricate with chain spray ..... 75 Clean the radiator and hydraulic oil cooler ..................... 76 Check the forks and fork quick-releases .......................... 76 Check the tension of double hoses when attachments are fitted .................................................... 76
Description
Page
Maintenance ............................................................... 53
General information .......................................................... 53 Work on the mast and on the front part of the truck ......... 53 Securing the mast against tilting back ............................. 53 Lift mast types .................................................................... 54 Standard mast ................................................................... 54 Securing the raised standard mast .................................. 54 Duplex mast ...................................................................... 54 Securing the raised duplex mast ...................................... 54 Triplex mast ....................................................................... 55 Securing the raised triplex mast ....................................... 55 Inspection and maintenance after the first 50 service hours ............................................................ 55 Inspection and maintenance schedule ............................ 56
350 804 3351.0705
Inspection and maintenance data .................................... 85 Fuel and oil recommendations ......................................... 86 Engine oil ....................................................................... 86 Hydraulic oil ................................................................... 87 Lubricating grease ........................................................ 87 Coolant .......................................................................... 87 Battery grease ................................................................ 87 Chain spray .................................................................... 87 Fuel gas ......................................................................... 87 Troubleshooting guide (LPG engine) .............................. 88 Troubleshooting guide (hydraulic system) ...................... 91 Electric circuit diagram (standard equipment) ................. 92 Electric circuit diagram (options) ...................................... 96 Electric circuit diagram (Truck Data Management) ....... 104 Hydraulic schematic ....................................................... 106 Index ................................................................................ 108 Safety rules for LP gas (excerpt) .................................... 111 Safety precautions for transistorised ignition systems .. 112
Technical data
Data Sheet for Material Handling Equipment
Designation VDI 3586
Description
Forklift Trucks
H 12 T LPG H 16 T LPG
to VDI 3586
July 2002
1.1 Manufacturer (see page 1) Model designation
Model types
VDI 2198 V
Registration note
Notes:
All the data refer to trucks with standard equipment and standard mast type 3050. 1) The values refer to standard/duplex/triplex masts with a free lift of 150 mm. 2) Super elastic (SE) tyres optional. 3) The values in brackets apply if SE tyres SE 200/50-10 are fitted. 4) On short slopes, when crossing obstacles (refer to section "Travel").
Characteristics
H 18 T LPG
H 20 T LPG
Power unit: battery, diesel, petrol, LPG, mains power Operation: manu., pedest., stand-on, seated, ord. pic. Load capacity Load centre Axle centre to fork face Wheelbase Service weight Axle load with load, front/rear Axle load without load, front/rear Tyres, front/rear (SE = CS superelastic, L = pneum.) Tyre size, front Tyre size, rear Wheels, number front/rear (x = driven) Track width, front Track width, rear Mast/fork carriage tilt, forward/backward Height of mast, lowered Free lift Lift Height of mast, extended Height of overhead guard (cabin) Height of seat/stand-on platform 1) 1) 1) b10 [mm] b11 [mm] degrees h1 [mm] h2 [mm] h3 [mm] h4 [mm] h6 [mm] h7 [mm] h10 [mm] l1 [mm] l2 [mm] b1/b2 [mm] s/e/l [mm] Q [kg] c [mm] x [mm] y [mm] [kg] [kg] [kg]
seated
1200 500 375 1460 2525 3116/609 1222/1303 L (SE) 18x7-8/16 PR 18x7-8/16 PR 2x/2 910 874 6/10 2095/2070/2070 1) 150 3050/3070/4470 1) 3658/3678/5078 1) 2070 1000 560 3074 2174 1087 40 x 80 x 900 2A b3 [mm] m1 [mm] m2 [mm] Ast [mm] Ast [mm] Wa [mm] b13 [mm] km/h m/s m/s N % s 1040 90 127 3523 3723 1948 590 18/18,5 0,57/0,58 0,58/0,47 14200/9220 42/30 4,5/4,0 hydrostatic VW/ADF kW RPM n/cc l/h 27 2300 4/1800 2,2 hydrostatic/infinitely variable bar l/min dB (A) 175 18 2) 2)
seated
1600 500 375 1460 2660 3693/567 1167/1493 L (SE) 18x7-8/16 PR 18x7-8/16 PR 2x/2 910 874 6/10 2095/2070/2070 1) 150 3050/3070/4470 1) 3658/3678/5078 1) 2070 1000 560 3119 2219 1087 40 x 80 x 900 2A 1040 90 127 3565 3765 1990 590 18/18,5 0,57/0,58 0,58/0,47 14200/9220 34/26 4,8/4,2 hydrostatic VW/ADF 27 2300 4/1800 2,3 hydrostatic/infinitely variable 215 18 2) 2)
seated
1800 500 380 1500 2890 4063/628 1243/1648 L (SE) 18x7-8/16 PR 18x7-8/16 PR 2x/2 910 874 6/10 2095/2070/2070 1) 150 3050/3070/4470 1) 3658/3678/5078 1) 2070 1000 560 3160 2260 1087 (1168) 3) 45 x 100 x 900 2A 1040 90 (98) 3) 127 3606 3806 2026 605 18/18,5 0,57/0,58 0,59/0,47 14200/9220 31/26 4,9/4,4 hydrostatic VW/ADF 27 2300 4/1800 2,3 hydrostatic/infinitely variable 230 18 2) 2)
seated
2000 500 384 1560 3108 4370/738 1274/1834 SE 200/50-10 18x7-8 2x/2 945 874 6/10 3003/2078/2078 1) 150 3050/3070/4470 1) 3658/3678/5078 1) 2070 1000 560 3246 2346 1168 45 x 100 x 900 2A 1040 98 135 3690 3890 2105 630 18/18,5 0,57/0,58 0,59/0,47 14200/9220 31/26 5,0/4,5 hydrostatic VW/ADF 27 2300 4/1800 2,4 hydrostatic/infinitely variable 250 18 -
2.1 2.2 2.3 3.1 3.2 3.3 3.5 3.6 3.7 4.1 4.2 4.3 4.4 4.5 4.7 4.8
Dimensions
4.19 Overall length 4.20 Length to fork face 4.21 Overall width 4.22 Fork dimensions 4.23 Fork carriage to DIN 15173, class/form A, B 4.24 Width of fork carriage 4.31 Ground clearance, mast 4.32 Ground clearance, centre of wheel base 4.33 Aisle width with pallets 1000x1200 across forks 4.34 Aisle width with pallets 800x1200 along forks 4.35 Turning radius 4.36 Min. distance between the centres of rotation 5.1 Travel speed, with/without load Lifting speed, with/without load Lowering speed, with/without load Tractive force, with/without load, 60 minute rating Climb. ability with/without load, 30 minute rating 4) Acceleration time with/without load (first 10 m)
Performance
5.10 Service brake 7.1 Manufacturer of engine/type Engine rated power to ISO 1585 Rated rpm Number of cylinders / cc Fuel consumption to VDI Type of drive control Working pressure for attachments Oil quantity for attachments Mean noise level at driver's ear Towing coupling, design/type DIN, no.
IC engine Others
10
Technical data
Lifting capacity diagrams:
Type: H 12 T Type: H 16 T Type: H 18 T Type: H 20 T
Description
Load capacity diagrams apply for standard and duplex mast with super elastik tires
Standard h3 h1 # h4 2850 2000 3458 3050 2100 3658 3850 2500 4458 4250 2700 4858 4850 3000 5458
Heights, min. lift (with 150 mm free lift for standard) Heights, max. lift
Heights and lift height (mm) Lift height Heights, min. lift Heights, max. lift Special lift height h3 h1 h4 h2
Triplex 3070 3770 4020 2075 2425 1925 3678 4378 4628 1468 1818 1318 4470 5470 2075 2475 5078 6078 1468 1868 5920 2625 6528 2018 6220 2725 6828 2118
11
Technical data
Noise emission levels
Determined in a test cycle in accordance with EN 12053 from the weighted values in the operating modes DRIVING, LIFTING, IDLING. Noise level at drivers station H 12 T - H 20 T Uncertainty Sound level at drivers place While lifting While idling While driving Uncertainty Acoustic power level H 12 T - H 20 T Uncertainty Acoustic power level While lifting While idling While driving Uncertainty Guaranteed acoustic power level Acc. to directive 2000/14/EC
Description
Frequency characteristic for human body vibrations
The values are determined in conformance with EN 13059 on trucks with standard equipment according to the technical data sheet (driving over test course with bumps). Frequency characteristic acc. to EN 12096 Measured frequency characteristic aw.zs = 0.9 m/s Uncertainty K = 0.3 m/s Frequency characteristic given for hand and arm vibrations Frequency characteristic < 2.5 m/s NOTE The frequency characteristic for the human body can not be used to determine the actual frequency load during operation. This load depends on the working conditions (condition of roadway, type of operation, etc) and must therefore be determined at the site, if necessary. The specification of hand and arm vibrations is required by law, even if the values, as in this case, do not indicate any danger.
LPAZ = 76 dB (A) KPA = 4 dB (A) LPa LPb LPc KPA = 79 dB (A) = 61 dB (A) = 81 dB (A) = 4 dB (A)
LWAZ = 94 dB (A) KWA = 2 dB (A) LWa LWb LWc KWA = 93 = 82 = 100 = 2 dB dB dB dB (A) (A) (A) (A)
The directive legally requires this information. This value has been calculated from the acoustic power levels for Lifting and Driving and is only be used as a comparable value for different trucks. For the determination of the real environmental noise stress this value is less appropriate, as it is not representative of normal truck operation, which includes Idling. NOTE Higher or lower noise emissions can exist during operation of the truck, for example due to type of operation, environmental influences and additional noise emission sources.
12
Technical description
The 350 series fork trucks are designed for loading and stacking loads of up to 1.2 t with the H 12 T, 1.6 t with the H 16 T, 1.8 t with the H 18 T and 2.0 t with the H 20 T. They are of compact design and have a small turning radius. The trucks are therefore especially suitable for narrow passages and close working areas.
Description
Operation
The variable-displacement hydraulic pump and engine speed are simultaneously controlled by one pedal each for forward and reverse travel. With the hydrostatic drive, truck speed can be regulated from a standstill up to maximum speed with infinitely variable control in both directions. The double pedal control permits easy as well as safe and quick handling of the lift truck. Both hands are always free for steering and control of the work movements. The result is quick reversing and efficient stacking. Another version allows control of the truck speed with one accelerator pedal (single-pedal control) and the direction of travel with a directional switch. There is only one control lever (main control lever) for controlling the work motions lifting, lowering and tilting. Further control levers are supplied for the operation of additional attachments. The work motions can be controlled with two control levers (single lever version).
Brakes
The hydrostatic transmission is used as service brake. The two multiple disc brakes integrated in the drive axle are utilised as a parking brake. When the engine is stopped, the multiple disc brakes are applied = automatic braking. The brake pedal is also designed as parking brake so that it must be locked mechanically when the truck is shut down.
Engine
The engine fitted is a 4-cylinder, 4-stroke type with overhead camshaft and self-adjusting hydraulic tappets. It provides power to the hydraulic pumps of the lift truck at load-dependent speed. The engine is cooled with a closed-loop cooling system with a recovery tank. The engine speed varies depending on the lift and truck speed. The electronic control keeps it constantly at the maximum limit, independent of the loads experienced. Thus the engine power available always corresponds to the speed set by the position of the accelerator pedal. The engine is fired via the transistorised ignition system, ignition coil, distributor and spark plugs. The fuel used is liquefied gas stored in the gas cylinder or LPG tank. CAUTION Components conducting exhaust gases or outgoing air may become hot depending on conditions and duration of use.
Steering
The steering system consists of a hydrostatic steering, which operates the rear wheels by the steering wheel via the steering cylinder. The steering can also be operated when the engine is stopped, but a greater effort is required to turn the steering wheel.
Electrical system
The electrical system is supplied with 12 VDC by a threephase current alternator. A 12 V battery is installed for starting the engine.
LHC control
LHC = Linde Hydraulic Control The electronic control unit governs the engine speed and the swash plate angle of the hydraulic pump automatically to maintain a preset travel speed (wheel rpm). System faults are detected by the electronic control unit and indicated with a warning light. Depending upon the fault, a travel speed reduction and even shutoff of the engine may occur as a damage prevention measure. Any faults occurring can be determined with the diagnostic unit.
Hydraulic system
The travel drive consists of a variable-displacement pump and two fixed-displacement motors installed as a unit in the drive axle, and a tandem pump (fixed displacement) for the working hydraulics and power steering system. Travel direction and speed are controlled with two accelerator pedals via the variable-displacement pump. The fixed-displacement motors in the drive axle are supplied with oil by the variable-displacement pump, and they each power a drive wheel via a reduction gear.
13
Description
14
Description
Parking brake lever Ignition switch, switch key Steering wheel/hydrostatic power steering Horn button Composite instrument Toggle switch for supplementary function* Auxiliary hydraulics lever (attachments)* Symbol label for auxiliary hydraulics (attachments)* Notice plate Load capacity plate (attachment)* Load capacity diagram Symbol label for working hydraulics Working hydraulics lever Forward accelerator pedal Brake pedal Reverse accelerator pedal Fuses (in bottom of console) Label Guaranteed acoustic power level
14 15 16 17 18
* Option
15
Composite instrument
The composite instrument contains the following control and indicator elements: 1 2 3 4 5 6 7 8 9 10 11 Hour meter Hour meter ON indicator Engine temperature warning light Hydraulic oil temperature warning light Engine oil pressure warning light Directional indicator light* Low gas level warning light Battery charge indicator light Fan warning light LHC warning light for system faults in the electronic control unit Air filter warning light Hydraulic oil temperature warning light (4) Monitors the oil temperature of the hydraulic system. Hour meter ON indicator (2) Engine temperature warning light (3)
Description
Indicator
Hour meter (1). The figure section (13) indicates full hours of operation, the single figure (12) tenths of an hour
Function
Indicates lift truck service hours. The meter indicates the elapsed service hours of the truck and serves to determine inspection and maintenance intervals. Indicates operation of the hour meter. Indicates coolant temperature is too high.
Possible cause(s)
NOTE The elapsed service hours should be recorded when replacing a faulty hour meter. Record the data on durable tape and affix near the hour meter. Fan faulty Fan motor brushes worn Fan motor fuse blown Thermal switch faulty Radiator faulty Cables defective Leak in cooling circuit Dirt on radiator Low hydraulic oil level Oil not as specified Oil filter restricted Dirt on oil cooler Low oil level in crankcase Engine is overheating Oil not as specified Internal leakage in lubricating system
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6 5 4 3
8
Directional indicator light* (6) Indicates the operation of the directional indicator when actuated. Indicates low level in the LP gas tank* Indicates malfunctions in the electrical system.
9 10
V-belt broken or slipping Cables defective Alternator faulty Regulator faulty Fuse defective Fan motor defective Fan motor shorted Fault can be identified with the diagnostic equipment Air filter element restricted
2 1
11
Indicates that voltage is applied to the fan motor. Indicates system faults in the electronic control unit. Indicates excessive accumulation of dirt in the air filter element.
13
16
12
T350-3/032
* Option
Safety rules
The responsible persons, particularly the truck operator and servicing personnel, must be instructed in the safety guidelines for the normal and proper use of industrial trucks included with these operating instructions. The employer must ensure that the operator has understood all safety informations. Please observe the guidelines and safety rules therein for example: - information on the operation of industrial trucks - rules for roadways and work areas - rights, duties and safety rules for the operator - operation in special areas - information related to starting, driving and braking - service and repair information - recurrent inspections, accident prevention check - disposal of greases, oil and batteries - remaining risks.
350 804 3351.0705
Beginning operation
Important safety information
The precautions WARNING, CAUTION, ATTENTION and NOTE in this manual are provided to indicate special dangers or unusual information requiring special identification: WARNING indicates hazards that may result in personal injury or death and/or substantial damage to the product. CAUTION indicates hazards that may result in personal injury and/or substantial damage to the product. ATTENTION indicates hazards that may result in damage to or destruction of the product. This note is found on various positions of the truck where special attention is required. Read the appropriate section of your operating instructions.
The operator (employer) or the responsible person must ensure that all the guidelines and safety rules applicable for your truck are observed. When instructing a trained operator, acquaint him with the - special features of the lift truck (double-pedal control, main control lever, brake pedal) - optional attachments - special operating and working area characteristics, by training and practicing driving, shifting and steering operations until they are completely mastered. Only then start to practice shelf-stacking. The stability of the truck in the work area is ensured if employed properly. Should the truck tip over during an unauthorised application or due to incorrect operation, always follow the instructions depicted below.
Further warning notices are also used for your safety. Please observe the various symbols. NOTE identifies technical information requiring special attention because the connection may not even be obvious to skilled personnel.
In case of tip-over
E335-2/149
WARNING Released LP gas becomes gaseous instantly so that the formation of a hazardous and explosive atmosphere is immediately given.
WARNING
Stay buckled up
Don't jump
Hold on tight
Brace feet
Lean away
17
Safety rules
Accident prevention check
The accident prevention rules in some countries prescribe that the fork lift truck must be checked at least once a year for proper working condition by trained personnel. Please contact your authorised dealer in this regard.
Beginning operation
Running-in instructions
The lift truck can be operated at full speed directly. Avoid sustained high loads on the working hydraulic system and the travel drive in the first 50 hours of operation. Tighten wheel fasteners daily before each shift and after each wheel change until they are seated firmly, i.e. until no further tightening is possible. Tighten opposite wheel fasteners to a torque of 210 Nm. NOTE Observe the tightening instructions on the tag attached to the steering column.
Experts
Experts are specially skilled persons who have thorough knowledge and experience in servicing and testing industrial trucks and being furthermore sufficiently familiar with the national industrial safety and accident prevention regulations and all further general technical rules and guidelines (DIN and ISO standards, technical rules arising from EC directives or EEA agreements), so that they can give a qualified judgement upon the safe operating conditions of the truck.
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Beginning operation
Closing the bonnet
Close the bonnet with the grip (2). Hook the tongue (7) into the bracket (8). Turn the rotary lever (6) clockwise as far as possible. Turn the key (5) clockwise as far as possible and remove it.
Check the engine oil level Check the coolant level in the recovery tank Check battery condition, electrolyte level and specific gravity Tyre inflation pressure Tighten wheel fasteners Check hydraulic oil level Check the LPG-system for damage and leaks using a leakage spray Braking system Steering system Lifting device and attachments
Daily checks*
Engine oil level Check the coolant level in recovery tank Tyre inflation pressure Visual, olfactory inspection of LPG system
5
* A description of the service can also be found in the index.
6 7 2 8
D350-3/004
D350/006
19
Beginning operation
Checking the LP gas level
The truck is provided with a sensor for monitoring the gas level in the LP gas bottle. The gas level is indicated by the fuel meter (2). The gas level indication system is adjusted for full LP gas bottles. It is not suited for measuring different gas levels of partially filled LP gas bottles. Faulty indications can result. Turn on the ignition. The gas level will be indicated after a few seconds. The bottle is full if the dial (4) is positioned on the 1 (3) fully to the right. As the bottle gets empty, the dial moves from the right to the left. When the dial is over the 0 (1) at the left, the LP gas bottle must be changed within the next 5 - 25 minutes, depending on the driving style and ambient temperature.
2
1 2
T350-3/001
T350-3/003
20
Beginning operation
Visual, olfactory inspection of LPG system
WARNING The driver must make a visual and olfactory inspection of the LPG system daily before beginning the shift. If any problems are detected, the truck must not be taken into operation. Report the problems immediately to an expert. A relief valve (1) beneath the overhead guard and beside the LPG filter protects the gas line against overpressure.
CAUTION Do not open the tank cap (2) when the recovery tank is hot. Risk of scalding! NOTE The tank is pressurised.
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*Option
T350/020
T350-3/004
T350-3/030
21
Beginning operation
Screw plastic plug onto connecting fitting. Loosen the two locks on the ratchet (6) and pull the retaining belt (5) out of the ratchet. Immediately fit the valve cover on the empty cylinder. If necessary, carefully clean the mating surface of the sensor (7) with water or a soap solution and a soft cloth. Install a new LP gas bottle.
NOTE Secure the LPG cylinder in the holder so that the shutoff valve connector on the gas cylinder points down. Insert the retaining belt (5) into the ratchet (6) and tension it with the ratchet. Make sure the bottle is placed correctly on the mounting area (pretension about 9 mm).
Replacement LPG cylinders to DIN 4661 (BS 5045/211 B in UK) should be used. Capacity of replacement LPG cylinder ..... 11 kg (12 kg in UK) Reconnect the hose as specified. Check for leaks according to inspection and maintenance instructions using a leakage spray. Attach the gas cylinder cover (1) at the top and push down into the retainer.
350 804 3351.0705
NOTE The union nut has a left-hand thread. Unscrew the union nut fully and remove the hose.
4 3 2
T350-3/035
T350-2/052
22
Beginning operation
ATTENTION The LP-gas tank may only be filled until the metering valve shuts off and not according to the reading on the fuel level gauge (1). Carefully unscrew the pistol from the filler valve (2). Screw the cap onto the filler valve.
Loosen the fastening nut using lever (3) and pivot the gas cylinder and mounting out as far as possible to the rear. Put on protective gloves. Close the shutoff valve (4). Remove the cap from the filler valve (2). Check the thread of the filling pistol for cleanliness. Connect the filling pistol to the filler valve (2) tightly. Open the main shutoff valve of the LPG station and operate the pump motor or filling pistol until the valve installed in the tank stops the filling. Capacity .............................................. approx. 36.0 litres Release the filling pistol control immediately and terminate the filling procedure. Turn off the pump motor and the main shutoff valve at the LPG station.
ATTENTION Notify the responsible persons if problems or irregularities occur during the filling and have them corrected. Perform a leak test as described in the inspection and maintenance procedures. Push in the gas cylinder as far as possible and tighten the fastening nut using lever (3). Attach the gas cylinder cover at the top and push down into the retainer.
WARNING No smoking, no naked lights and open fires are permitted when filling the tank. CAUTION While removing the filling pistol a small quantity of gas streams out. As this can cause frostbite, always put on protective gloves. NOTE We recommend to top up gas before beginning work, as long as the truck is still cold. If temperatures differ much between the supply tank in the open and the tank on the truck it may be possible that the supply pressure of the pump is not sufficient to fill the tank completely. WARNING When LP gas leaks out, there is an immediate danger of explosion resulting in the risk of burns. Stop the truck engine and combustion chamber heater, if fitted, and allow them to cool. Remove the gas cylinder cover by pulling it back and up.
* Option 23
Beginning operation
T350-2/053
T350-2/054
24
Beginning operation
Opening the gas cylinder or gas tank* shutoff valve
WARNING If the truck has been parked in an enclosed space for a long time, ventilate well before switching on the electrical system. Slowly open the shutoff valve (1) of the liquefied gas cylinder or the LPG tank* with caution.
NOTE Long sitting puts excessive strain on the spinal column. Prevent strain with regular, light exercising.
* Option
T350-3/005
25
Operation
Opening the seat belt
Press the red button (5) on the lock (4) to disengage the belt. Return the tongue (2) back to the retractor (3) by hand.
CAUTION The webbing should not be twisted, stuck or knotted. Protect the lock (4) and retractor (3) against foreign particles, damage and dirt. NOTE During operation of the truck (e.g. driving, lifting, etc.) the operator should sit as far back as possible so that the back contacts the backrest. The automatic lock of the retractor allows sufficient freedom of movement on the seat during normal operation of the truck.
NOTE A belt which returns too fast can trigger the automatic lock when the tongue hits the enclosure. The belt can then not be pulled out with the usual force.
2 3
26
T352-3/001
Operation
Sit down on the drivers seat. Apply the seat belt. Place both feet on the accelerator pedals (3 and 5) (brake pedal (4) locked, engine can only be started with brake pedal engaged). Insert the key (2) into the ignition switch and turn from the zero position clockwise to the first switch position. The electrical system is now switched on. The LHC warning light (8) will illuminate. After a few seconds, the gas level of the LP gas bottle can be read on the meter (1). The battery charging indicator light (7) and engine oil pressure warning light (6) will light red. Turn the switch key fully clockwise to the stop. Release the key when the engine starts and is running. If engine does not start after 20 seconds, discontinue the starting procedure and repeat as described. Pause at least one minute between starting attempts to save your battery. It the engine falls to start after three attempts, refer to the troubleshooting guide for the LPG engine. WARNING If malfunctions and starting problems occur on your truck, the LPG system must be checked by an expert with special knowledge of this system. The battery charge indicator, engine oil pressure and the LHC warning lights should go out as soon as the engine is running. The engine rpm is governed by demand automatically. WARNING Do not operate the engine in unventilated spaces. Risk of carbon monoxide poisoning! NOTE Do not warm up the engine in idle. Drive the truck briskly with a load. The engine will quickly reach operating temperature.
T350-3/006
T350-3/007
27
Operation
Closing the gas cylinder or LPG tank* shutoff valve
Close the gas cylinder or LPG tank* shutoff valve (3) tightly immediately after stopping the engine. Remove the key when you leave the truck unattended. When it is freezing park the truck as far as possible in closed rooms, e.g. garages, because liquefied petrol gas evaporates only sufficiently at temperatures over -5 C (propane), respectively +5 C (propane/butane) to start the engine.
NOTE The brake is applied when the engine is stopped. Put the parking brake lever (2) up. Depress the brake pedal (1). The brake pedal will lock in this position.
WARNING Garages, storage areas and service workshops must be well ventilated. Note that LP gases are heavier than air. They collect on the ground, in pits and other low areas and form explosive air-gas mixtures (see local accident prevention regulations).
ATTENTION Do not park the truck in halls or garages in the immediate vicinity of equipment radiating heat or radiators.
350 804 3351.0705
* Option
1 2
d351-02/35
T350-3/008
28
Malfunctions
Malfunctions during operation
ATTENTION If one of the following indicator lamps illuminates during operation, the engine must be stopped immediately and the malfunction eliminated (see Troubleshooting Guide). Engine temperature warning light (1) Hydraulic oil temperature warning light (2) Engine oil pressure warning light (3) Battery charge indicator light (5) Electric fan warning light (7) ATTENTION If warning light (8) of the LHC control is flashing, system faults have occurred in the electronic control unit. Depending upon the fault, the truck can either only be driven at a slow speed or not at all. The fault can be determined with the diagnostic unit. Please contact your authorised dealer.
Operation
NOTE If the air filter restriction indicator (6) lights up during operation, the air filter must be serviced.
350 804 3351.0705
NOTE When the low gas level warning light* (4) in the composite instrument illuminates, replenish immediately the LPG tank*. * Option
4 3 2 1
7 8
T350-3/040
29
Driving
Driving
CAUTION Travel on gradients over 15 % is not allowed, due to the prescribed minimum brake applications and truck stability characteristics. Before driving on steep slopes, you should consult your dealer. The climbing ability rates given in the data sheet were derived from the drawbar pull of the truck and they apply only for crossing obstacles and for low differences in ground level. Always drive consistent with road conditions (uneven surfaces, etc.), especially hazardous work areas, and the load. CAUTION When using rear view mirrors it should be noted that the latter are only provided to monitor the rear traffic area and that reversing is only allowed with a direct view in the reverse direction of travel. Start the engine. Elevate the forks slightly and tilt the mast back. Push the parking brake lever (1) forward to disengage the brake pedal (4).
Operation
Forward travel
Depress the right accelerator pedal (2) gently. The truck will drive at a speed depending on how far the accelerator pedal is depressed.
NOTE Quick flooring of the accelerator pedal is not recommended as the maximum acceleration rate is regulated automatically.
Reverse travel
Depress the left accelerator pedal (3) gently. The truck will reverse at a speed depending on how far the accelerator pedal is depressed. -
Stopping
Slowly release the depressed accelerator pedal. The hydrostatic travel drive will act as service brake. When stopping on gradients during upgrade travel, leave both feet on the pedals and equalise any drive slippage due to technical reasons by depressing the pedal slightly, or depress the brake pedal for a long stop. When dismounting from the truck with the engine running, for example, in order to briefly perform some action in close vicinity to the truck (opening a gate, unhitching a trailer, etc.), the brake pedal must be depressed and locked, open the seat belt. Shut down the engine if making a long stop. When leaving the truck unattended, remove the ignition key.
1
-
4
30
T350/003
T352/003
Single-pedal model
Starting the engine
NOTE If at all possible, avoid frequent engine starts and short duty cycles so that the engine can reach its operating temperature. Frequent cold starts increase engine wear. NOTE In case of low ambient temperatures (below 10 C), let the engine run at least 1-2 minutes between starting and stopping in order to avoid malfunctions in the LPG system. NOTE The directional lever (3) and all other control levers must be in the neutral position. NOTE On certain Linde fork trucks (eg with container overhead guard, swivel seat) the torso clearance is reduced. Therefore only persons with a headroom of 30 mm between the head and overhead guard should operate this truck. Sit down on the drivers seat. Apply the seat belt. Brake pedal (4) locked (engine will start only with brake pedal engaged). Insert the switch key (2) into the ignition switch. Turn the key switch clockwise from the zero position to first position. The electrical system is now switched on. The LHC warning light (8) will illuminate. After a few seconds, the gas level of the LP gas bottle can be read on the meter (1). The battery charge indicator (7) and the engine oil pressure (6) lights will illuminate red. Turn the key switch fully clockwise. As soon as the engine has started, release the switch key. If engine does not start after 20 seconds, discontinue the starting procedure and repeat as described.
Operation
WARNING If malfunctions and starting problems occur on your truck, the LPG system must be checked by an expert with special knowledge of this system. The battery charge indicator, engine oil pressure and the LHC warning lights should go out as soon as the engine is running. The engine rpm is governed by demand automatically. WARNING Do not operate the engine in unventilated enclosures. Danger of poisoning! NOTE Do not warm up the engine in idle. Drive the truck briskly with a load. The engine will quickly reach operating temperature.
Pause at least one minute between starting attempts to save your battery. It the engine fails to start after three attempts, refer to the troubleshooting guide for the LPG engine. * Option
3 6 7
T350-3/010
T350-3/007
31
Single-pedal model
Stopping the engine
Release the accelerator pedal (4). Place the directional lever (3) to the neutral position. Turn the switch key (2) to the zero position. -
Operation
Closing the gas cylinder or LPG tank* shutoff valve
Close the gas cylinder or gas tank* shutoff valve (6) tightly immediately after stopping the engine. Remove the switch key when leaving the truck unattended. When it is freezing park the truck as far as possible in closed rooms, e.g. garages, because liquefied petrol gas evaporates only sufficiently at temperatures over -5 C (propane), respectively +5 C (propane/butane) to start the engine.
NOTE The brake engages when the engine is stopped. Set the parking brake lever (1) vertical. Depress the brake pedal (5). The brake pedal engages in this position.
WARNING Garages, storage areas and service workshops must be well ventilated. Note that LP gases are heavier than air. They collect on the ground, in pits and other low areas and form explosive air-gas mixtures (see local accident prevention regulations).
ATTENTION Do not park the truck in halls or garages in the immediate vicinity of equipment radiating heat or radiators.
* Option
2 3
5
32
351-2/029
T350-3/029
Single-pedal model
Malfunctions during operation
ATTENTION If one of the following indicator lights illuminates during operation, stop the engine immediately and the malfunction eliminated (see the troubleshooting guide). Engine temperature warning light (1) Hydraulic oil temperature warning light (2) Engine oil pressure warning light (3) Battery charging indicator light (5) Electric fan warning light (7) ATTENTION If warning light (8) of the LHC control is flashing, system faults have occurred in the electronic control unit. Depending upon the fault, the truck can either only be driven a slow speed or not at all. The fault can be determined with the diagnostic unit. Please contact your authorised dealer.
Operation
NOTE Service the air filter if the air filter restriction indicator (6) lights during operation. NOTE When the low gas level warning light* (4) in the composite instrument illuminates, replenish immediately the LPG tank*. * Option
4 3 2 1
7 8
T350-3/040
33
Single-pedal model
Driving
CAUTION Travel on gradients over 15 % is not allowed due to the specified minimum brake applications and truck stability characteristics. Consult your dealer before driving on steep slopes. The climbing ability rates given in the data sheet were derived from the drawbar pull of the truck and they apply only for crossing obstacles and for low differences in height. Always drive consistent with road conditions (uneven surfaces, etc.), especially hazardous work areas, and the load. CAUTION When using rear view mirrors it should be noted that the latter are only provided to monitor the rear traffic area and that reversing is only allowed with a direct view in the reverse direction of travel. Start the engine. Elevate the forks slightly and tilt the mast back. Push the parking brake lever (1) forward to disengage the brake pedal (4). -
Operation
Forward travel
Shift the travel direction control lever (2) forward. Depress the accelerator pedal (3) gently. Truck speed depends on how for the pedal is depressed.
NOTE Quick flooring of the accelerator pedal is not recommended as the maximum acceleration rate is regulated automatically.
Reverse travel
Pull back the travel direction control lever (2). Depress the accelerator pedal (3) gently. The truck will reverse at a speed depending on how far the pedal is depressed.
Stopping
Slowly release the depressed accelerator pedal. The hydrostatic travel drive will act as service brake. When stopping on gradients during upgrade travel, leave the foot on the accelerator pedal, set the travel direction control lever (2) to the uphill position and equalise any drive slippage due to technical reasons by depressing the pedal slightly, or depress the brake pedal for a long stop. When dismounting from the truck with the engine running, for example, in order to briefly perform some action in close vicinity to the truck (opening a gate, unhitching a trailer, etc.), the brake pedal must be depressed and locked, open the seat belt. Shut down the engine if making a long stop. When leaving the truck unattended, remove the ignition key.
350 804 3351.0705
2
-
T350/017
T352-3/009
34
Operation
Parking brake
The multiple disc brakes are used as a parking brake.
Stop pedal
ATTENTION The stop pedal (1) does not operate a sensitive service brake but a firmly-acting parking brake. Avoid using it while driving as the traction wheels can block und the load possibly slide off the forks. In unfavourable circumstances the engine may also stall. In this case wait 30 seconds before restarting it until the traction drive pump has returned to neutral. NOTE It is recommended that the operator acquaint himself with the function and effect of this brake without a load on the truck. Drive on a roadway without traffic at a slow speed.
Service brake
350 804 3351.0705
Allow the accelerator pedals to return to the neutral position. The hydrostatic drive will act as a service brake. The braking can be controlled from gentle to abrupt braking by allowing the accelerator pedals to return to the neutral position slowly or quickly.
WARNING Contact your authorised dealer if faults or signs of wear become evident in the braking system. Do not drive the truck with a faulty braking system.
1 2
1
D351-2/033 D350-3/059
d351-02/35
35
Operation
Operating the sideshift
To move the sideshift to the left, push the control lever (2) forward. To move the sideshift to the right, pull the control lever (2) back.
CAUTION Attachments not supplied with the truck may only be employed if your authorised dealer ascertains that they will not reduce the load capacity and stability of the truck.
350 804 3351.0705
351-2/036
36
T350-3/037
Operation
NOTE For each attachment affix a load capacity plate on the engine cover and a symbol label depicting the attachment behind the appropriate control lever.
WARNING Do not step on raised forks. Increased danger of falling and being squeezed. Pull the control lever (1) back.
CAUTION Attachments not supplied with the truck may only be employed if your authorised dealer ascertains that a safe operation is assured in respect to load capacity and stability.
351-2/039
37
T350-3/038
Windscreen wipers*, lighting*, hazard warning lights*, working lights*, turn indicator lights*
Installation of additional equipment
ATTENTION Electrical additional equipment (lights, seat heater etc.) should be connected to the free connectors of the cable loom provided for this purpose. Further connections beyond this anticipated range are only permitted after contacting Linde. Only qualified skilled persons who observe the applicable rules and use appropriate material should carry out these activities. NOTE The switches can be arranged in a different order, depending on the model. Please observe the switch symbols.
Operation
* Option
D350-3/038
D350/032
D350-3/043
38
Heater
Turning on the heater* (version 1)
Heater controls: The fan switch (1) is used to turn on the fan and to regulate the air flow in 3 stages. Temperature control lever (3): Push up for less heat. Push down for more heat. NOTE When lever (3) is pushed up and lever (4) down, fresh air from outside the cabin flows through the air vents and the air outlet. To prevent outside air from being drawn in, push lever (4) up. All heater controls (except the fan switch) are infinitely variable.
Operation
Air flow control lever (4): Push up for more air intake through the opening (10) in the cabin. Push down for air intake from outside the cabin.
The swivelling air vents (5, 6 and 7) and the air outlet (2) can be opened singly. Depending on the position of lever (3), either warm or unwarmed fresh air flows through the air vents and the air outlet.
* Option
2 3
7 4 6 8 9
10
D352-4/018
39
Heater, horn
Turning on the heater* (version 2)
Heater controls: The fan switch (2) is used to turn on the fan and to regulate the air flow in 3 stages. Temperature control knob (1): Anti- clockwise: for less heat. Clockwise: for more heat. NOTE If the knobs (1) and (3) are in the left position, fresh air from outside flows through the outlets. If no air from the outside is to be taken in, turn the air intake knob (3) to the right. All heater controls (except the fan switch) are infinitely variable.
Operation
Operating the horn
The horn serves as warning signal when operating at blind corners and junctions. Pressing the horn button on the steering wheel sounds the horn.
Air intake knob (3) intake (fresh air - circulating air): Anti- clockwise: air intake in to the interior. Clockwise: for air intake from outside the cabin.
If necessary, also check fuse 9F14 in fuse box III. The swivelling air outlets (4) can be opened individually. Depending on the position of the temperature control knob (2), either heated or unheated air flows out.
350 804 3351.0705
* Option
351-2/046
40
Operation
Condition code
NOTE The code indicates the state of the truck. The following code numbers are available: 0 1 2 3 4 5 6 7 8 9 = Truck in working order = Request Service (truck cannot be started) = Request Maintenance (truck can be started) = Driving problem = Lifting problem = Steering problem = Damaged in accident = User-defined** = User-defined** = User-defined** NOTE If you notice one of these conditions (eg driving problem) only after you have first logged in with condition code 0 (truck in working order), you must first log out (turn the rotary knob (2) anticlockwise as far as possible) and log in again with condition code 3 (driving problem).
** The condition codes 7, 8, 9 can be defined by the user as he chooses. Please contact your truck pool manager for the definition of these condition codes.
* Option
41
Operation
NOTE If the green (2) and red (1) LEDs are both illuminated steadily, the data must be read out. Please inform your pool manager at once. Turning the truck off and logging out: - Turn the rotary knob (5) anticlockwise as far as possible to turn off the engine. - After an delay period (factory setting = 10 seconds), the red LED (1) comes on briefly and then the green (2) and red (1) LEDs flash about 3 seconds. During this time the truck can be started any time. The LEDs then go out and the PIN number is no longer stored. NOTE The delay time can be set between 10 seconds and 10 minutes with the FDE configuration software. Please contact your Linde dealer in this regard. NOTE Pressing the key (3) with the #-symbol after the engine is turned off terminates the delay period at once and the PIN number is deleted from memory.
NOTE If the truck does not start properly at the first attempt, the starting procedure can be repeated until the rotary knob (5) is returned to zero and the PIN number is deleted from memory after the expiration of the delay period.
* Option
42
Operation
NOTE If the green (2) and red (1) LEDs are both illuminated steadily, the data must be read out. Please inform your pool manager at once. Turning the truck off and logging out: - Turn the rotary knob (5) anticlockwise as far as possible to turn off the engine. - After an delay period (factory setting = 10 seconds), the red LED (1) comes on briefly and then the green (2) and red (1) LED flash about 3 seconds. During this time the truck can be started any time. The LEDs then go out and the PIN number is no longer stored. NOTE The delay time can be set between 10 seconds and 10 minutes with the FDE configuration software. Please contact your Linde dealer in this regard. NOTE Pressing the key (3) with the #-symbol after the engine is turned off terminates the delay period at once and the PIN number is deleted from memory.
NOTE If the truck does not start properly at the first attempt, the starting procedure can be repeated until the rotary knob (5) is returned to zero and the PIN number is deleted from memory after the expiration of the delay period.
* Option
43
Fuses
Check fuses, renew if required
NOTE For the protection of the electrical system, up to 3 fuse boxes can be installed in the console (arrow), depending on the model. The fuse boxes can be accessed by lowering the cover on the underside of the console after first removing 4 screws. Remove the cover of the appropriate fuse box. Fuse box I 1 2 3 4 5 6 Starter relay (F2) ........................................................ 5 A Composite instrument (F3) ........................................ 5 A Electronic ignition system (F4) ................................ 15 A Horn and auxiliary relay, terminal 15 (F5) .............. 10 A Electronic LHC traction control (1F17) ..................... 1 A Electronic LHC traction control (1F18) ................... 15 A Fuse box III 1 2 3 4 5 6
Operation
Heater (9F14) ........................................................... Working light, revolving light, flashing light (9F13) ................................................. Working light (9F12) ................................................ Working light (9F11) ................................................ Rear window wiper (9F5) ......................................... Windscreen wiper (9F4) ..........................................
10 A 15 15 15 10 10 A A A A A
The fuses protect the following circuits: Observe the numbers or letters on the fuse boxes and in the cover (1 = A left).
Fuse box II 1 2 3 4 5 6 Left dip beam (5F5) ................................................. 10 A Right dip beam (5F6) ............................................... 10 A Left side marker light (5F7) ....................................... 5 A Right side marker light (5F8) ..................................... 5 A Main fuse lighting, terminal 15 (5F9) ....................... 15 A Main fuse lighting, terminal 30 (5F10) ..................... 15 A Another two MTA fuses in the engine compartment protect the following electric circuits: 8 9 Open the bonnet, remove the covers (7) (2 items). Main fuse for complete electrical system except fan (F1) ......................................................... 50 A Fan (9F16) ............................................................... 30 A ATTENTION Only use genuine Linde fuses.
1 2 3 4 5 6 II I 1 2 3 4 5 6 III
7 8 9 1 2 3 4 5 6
T350-3/031
T350-2/031
T350-2/049
44
Operation
Example
Load centre distance ............................................... 600 mm Height of lift ............................................................. 5500 mm Follow the vertical line for a load centre distance of 600 mm to where it intersects the line for a height of 5500 mm. Read to the left of the point of intersection of the horizontal line for the maximum permitted load. Maximum weight here is ....................................... 900 kg 1 2 3 4 Max. permitted load in kg Height of lift in mm Fork truck model with max. load capacity Distance of load centre from fork-face in mm
Proceed accordingly for other lift heights and load centre distances. The weights apply to both forks with the load distributed evenly on the forks.
1 2
T350-3/023
351-2/049
45
Loading
Adjusting the fork spread
Raise the fork quick-release levers (1). Move the forks further apart or closer together depending to the size of the load to be lifted. Make sure that both forks are equally distant from the truck centre. Allow the quick-release levers to engage in a notch. -
Operation
Loading
NOTE The loads must be picked up so that they do not project beyond the loading area of the truck and will not slide, fall over or off. Approach the load to be lifted carefully and as accurately as possible. Put the mast to the vertical position. Lift or lower the fork carriage to the required height. Carefully drive the truck forward under the centre of the load until the load contacts the fork-face, if possible, while taking care not to dislodge adjacent loads. Lift the fork carriage until the load is clear off the ground
350 804 3351.0705
WARNING Do not stand under an elevated load. Drive the fork lift truck only with the load lowered and the mast tilted back.
NOTE The load centre should be in the centre between the forks.
Reverse the lift truck until the load is clear. Tilt the mast back.
D351-2/052
E336-2/081
46
Operation
Unloading
Carefully approach the racking receiving the load. Lift the fork carriage to the required height. Put the mast into vertical position (load horizontal). Carefully drive into the racking. Carefully lower the load until the forks are clear. Reverse the lift truck. WARNING Never park the truck and leave it unattended with the load raised. Depress the stop pedal (3). The stop pedal will lock in this position. Stop the engine. Remove the switch key (2). Close the shutoff valve on the gas cylinder or LPG tank*. Set the parking brake lever (1) to the vertical position.
D350-3/011
T350-2/058
351-02/24
47
Operation
Hoisting the truck with the eyebolts*
CAUTION Only use a slifting sling and acrane with a sufficient capacity. See the manufacturers plae for the truck. ATTENTION The truck may be hoisted with the eyebolts (1) only if the appropriate lifting equipment (3) is used with which the chains (2, 6) lead straight up from the eyebolts (1). Hook the chains (6) (minimum capacity 2000 kg) into the eyebolts (1) on the counterweight. Hook the chains (2) (minimum capacity 2000 kg) into the eyebolts on the mast.
Hoisting the truck with a crane WARNING When hoisting the truck by crane make sure no persons are within the working range of the crane! Do not step under the elevated load!
ATTENTION After inserting the slings into the crane hook, the safety lock (4) must close. When the truck is hoisted, the slings must not rub against the sides of the overhead guard or gas tank* and any attachments fitted. * Option
ATTENTION After attaching the lifting slings to the crane hook (4), the hook safety (5) must close. The lifting gear must not touch the overhead guard and any attachments fitted.
1 2 3
4 3
T350-2/059
48
Mast removal
Operation
ATTENTION Attach the lifting sling to the top cross member (1) of the outer upright of the mast. CAUTION Do not step under the elevated load.
Trailer coupling
NOTE The trailer coupling should be used only to tow light trailers inside the plant. (Observe the applicable accident prevention guidelines and VDI 3973.) Turn the lever 90o degrees to the rear and then raise the tow bolt. Place the towbar in the coupling sleeve. Press down the tow bolt against spring pressure, turn through 90 and let engage.
NOTE Locate the jack only at the counterweight (1) and at the frame (2) behind the wheel box. CAUTION The truck may only be raised at these locations on the left and right side. 350 804 3351.0705
Raise the truck with the jack until the wheels are clear. Secure the truck with wooden blocks under the frame or counterweight. Remove the wheel fasteners and change the wheel. Install the wheel fasteners and tighten them by hand. Lower the truck. Torque the wheel fasteners to 210 Nm.
T350-2/063
D350/026
t350-02/64
49
Towing instructions
Towing
Should it become necessary to tow the truck, then it is possible to by-pass the hydraulic oil circuit, to release the multiple disc brakes in the drive axle. Secure tractor (observe sufficient tractive and braking power) with tow bar to towing pin of lift truck.
Operation
After towing
Place chocks under slope-side of wheels. Loosen the locknut (6). Screw in the 8 mm threaded pin (7) and tighten to 20 +5 Nm. Lock the threaded pin with locknut (6), tighten the nut to 60 Nm. -
CAUTION The truck cannot be braked now. The tractor used to tow the fork truck must thus possess sufficient tractive and braking power for the unbraked towed load.
Towing the truck is only allowed with a rigid connection (tow bar).
Reset brake
Loosen locknut (5). Loosen threaded pin (4) two turns. Lock threaded pin with nut (5), torque to 25 Nm. Fit the sealing ring (3). Screw on cap nut (1) and tighten to 30 Nm. Install the cover at the front of the truck. Close and lock the bonnet.
350 804 3351.0705
Towing procedure
Lower the load so far that forks do not scrape the ground during towing. Deposit load.
4 3 1 2
5 1
6 7
D350-3/012
D350-3/019
50
Operation
Putting the truck back into operation
Coat the battery terminals with non-acidic grease. Check the condition and acid density of the battery. Check the engine oil for condensation water and change the oil, if necessary. Check the hydraulic oil for condensation water and change the oil, if necessary. Perform the same services as for commissioning. Install and connect an LPG cylinder. Take the truck into service.
T350-3/041
51
Disposal
Disposal of old vehicles
The disposal of old vehicles is regulated in directive 2000/53/ EC of the European Parliament and Council. We therefore recommend to entrust this work to a licensed salvage company. If you want to carry out this work yourself, you must first get an approval from the responsible authorities according to articles 9, 10 and 11 of directive 75/442/EEC. The following minimum requirements must also be observed: - The locations for storing old vehicles before their treatment must be suitable areas with an impermeable surface and provided with collecting facilities and separators for leaking fluids and grease grease-cutting cleaning agents. - The locations for the treatment must be suitable areas with an impermeable surface and provided with collecting facilities and separators for leaking fluids and grease grease-cutting cleaning agents. There must be suitable storerooms for removed and partially oily parts and for tyres, including fire protection measures. There must also be suitable storage tanks for fluids such as fuel, engine oil, coolant, hydraulic oil, fluids from air conditioners. - For the disposal of harmful substances from old vehicles the batteries and LPG containers must be removed. The following substances must also be removed, collected and stored separately: fuel, engine oil, coolant, hydraulic oil, fluids from air conditioners. - The following parts can be collected and recycled separately: catalytic converters, metal parts containing copper and aluminium, tyres, big plastic parts (console, fluid reservoirs), glass. NOTE The operator is responsible for compliance with the directive and further national regulations.
Operation
52
General information
General information
Your truck will remain operational only if the maintenance and checks are carried out regularly and according to the information and instructions in the operating manual. The maintenance may only be performed by qualified authorised personnel. This work can be carried out by your authorised dealer under a service contract. If you wish to do the work yourself, we recommend that the first three customer service checks be carried out by your dealers engineer in the presence of the responsible mechanic in your workshop, so that your staff can receive the appropriate instruction. ATTENTION Maintenance, inspections and care of the LPG system may only be carried out by qualified staff with a knowledge of the test specifications and settings for this system as special test equipment and tools are required. Please contact your authorised dealer. ATTENTION The test, inspection and servicing of the LPG system must be recorded in a test report (e.g. ZH 1/57). Only use genuine spare parts for repairs to ensure the safety of the installation. For all servicing, the truck must be placed on a level surface and the wheels secured. Stop the engine and remove the ignition key. When working on the truck with the fork carriage and/or mast elevated, secure them against inadvertent lowering. For work on the front end of the truck, secure the mast against tilting back. ATTENTION Before doing electric welding on the truck, fully disconnect the battery, the cable connectors and plugs. If not, the electronic equipment can be destroyed. No changes, particulary no modifications and additions, may be made to the truck without the approval of the manufacturer. ATTENTION Missing or damaged plates and/or adhesives must be replaced. For location and order no. refer to Parts catalogue. Perform a functional check and trial run after every servicing. NOTE When operating the truck under extreme conditions (i.e. extreme heat or cold, intensive dust concentration, etc.), the intervals given in the maintenance schedule should be reduced accordingly. ATTENTION Follow the precautions for handling fuels and lubricants.
Maintenance
Work on the mast and on the front part of the truck
WARNING Before attempting to carry out repairs or adjustments on the raised mast and fork carriage, ensure that the following safety procedures are carried out! These safety measures are only sufficient for general maintenance on your truck (tests and lubrication). For repairs (e.g. replacement of chains or lift jack), further additional safety measures must be applied. Please contact your authorised dealer.
;; ;;
T350-2/060
53
Maintenance
Duplex mast
NOTE The advantage of this mast version is that the special free lift height can be used even in spaces with a low ceiling (cellars, wagons, ships). METHOD OF OPERATION The fork carriage is raised to the special free lift height by the centre lift cylinder via the chain guide roller. It moves at twice the rate of the centre cylinder. The inner mast and the fork carriage is then raised together by both the secondary exterior lift cylinders. The centre cylinder is mounted within the extendible inner mast. -
2
54
T350-2/061
T350-2/065
Maintenance
Securing the raised triplex mast
WARNING Use a suitable chain for the particular lifting mast. Do not exceed the maximum height of lift. Raise the mast. Fasten the chain around the cross member outer mast (1) and the intermediate mast (2). Lower the mast until it is held by the chain. Fully lower the fork carriage.
T350-2/066
55
Maintenance
Inspection as required
Check the engine oil level ................................................................................................................................................................................................................ Check the tyre inflation pressure ..................................................................................................................................................................................................... Check the coolant level in recovery tank ......................................................................................................................................................................................... Visual, olfactory inspection of LPG system ......................................................................................................................................................................................
350 804 3351.0705
Clean the lift truck ............................................................................................................................................................................................................................................................. Clean and spray the lift chains ......................................................................................................................................................................................................................................... Clean the air filter ............................................................................................................................................................................................................................................................. Check the dust ejection valve .......................................................................................................................................................................................................................................... Check the mounting of the hydraulic oil tank ................................................................................................................................................................................................................... Clean the prefilter ............................................................................................................................................................................................................................................................. Tighten the wheel fasteners (at least every 100 hours) .................................................................................................................................................................................................. Check the tyres for damage and foreign objects ............................................................................................................................................................................................................. Clean the radiator and hydraulic oil cooler, check for leaks ........................................................................................................................................................................................... Lubricate the steer axle, mast and tilt cylinder bearings ................................................................................................................................................................................................. Check and adjust the ignition timing ................................................................................................................................................................................................................................ Check seat belt for condition and proper operation ........................................................................................................................................................................................................
56
Maintenance
every 3000 hours
Grease the mast and tilt cylinder bearings .................................................................................................................... Clean and grease the steer axle .................................................................................................................................... Sideshift: Clean, grease and check the mountings ....................................................................................................... Check the hydraulic system oil level .............................................................................................................................. Check electric cables, cable connectors and connections for condition and tightness .............................................. Battery: Check condition, electrolyte level and specific gravity (even with a maintenance-free battery) ................... Check the LPG system for damage and for leaks with leakage spray ......................................................................... Change the LPG filter ..................................................................................................................................................... Renew the engine oil and engine oil filter (every 12 months minimum) ...................................................................... Check and oil other pivots and joints ............................................................................................................................. Check the coolant strength ............................................................................................................................................. Check and oil the pedals, the travel and engine control linkage .................................................................................. Check the tension and condition of the alternator and coolant pump drivebelt ........................................................... Renew the spark plugs ................................................................................................................................................... Check the tension and condition of the toothed belt, renew if necessary .................................................................... Check the CO contents in the exhaust gas .................................................................................................................... Check the mounting of the counterweight, overhead guard, steer axle and drive axle .............................................. Retighten the mast fastening bolts ................................................................................................................................. Catalytic converter: Check the basic adjustment of the LPG system ............................................................................ Check the mast, lift chains, lift cylinders and stops for condition, mounting and operation ........................................ Adjust the lift chain length and lubricate with chain spray ............................................................................................ Clean the radiator and hydraulic oil cooler ................................................................................................................... Check the forks and fork quick-releases ........................................................................................................................ Check the tension of double hoses when attachments are fitted ................................................................................. Renew the air filter element, check the vacuum switch (every 12 months or after 5 cleanings minimum) ........................................................................................................................................ Check the mounting of the engine and engine support for condition and security ........................................................................................ Check the hydraulic system, drive axle, pumps, valves and lines for leaks .................................................................................................. Check the air intake and exhaust pipes for leaks ........................................................................................................................................... Renew the hydraulic system pressure, suction and breather filters .............................................................................................................. Check the parking brake ................................................................................................................................................................................. Clean the evaporator/pressure regulator (install new repair kit, every 12 months minimum) ....................................................................... Check the LPG mixer adjustment ................................................................................................................................................................... Check the distributor and ignition cables ......................................................................................................................................................................................... Renew Renew Renew Renew Renew the coolant (or every 2 years) ............................................................................................................................................................................................................................... the alternator and coolant pump drivebelts .......................................................................................................................................................................................................... the toothed belt ..................................................................................................................................................................................................................................................... the hydraulic oil (Bio hydraulic oil Aral Forbex SE 46 every 6000 hours) ........................................................................................................................................................... the high-pressure hoses (or every 2 years) ......................................................................................................................................................................................................... 57
Maintenance
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 container under the mast. Clean the chain with paraffin derivatives such as washing petrol (observe manufacturers notes on safety). When using a steam jet, clean without additives. After cleaning, blow dry the chain at once to remove any water in the chain links and on the surface. Move the chain several times during this procedure. Immediately spray Linde chain spray onto the chain while moving it.
ATTENTION Lift chains are safety components. The use of cold cleaners, chemical cleaning agents and caustic or acidic and chlorinated fluids can be a direct cause of damage to the chains.
D350/018
D350-3/041
58
Maintenance
NOTE Mark every servicing on the filter element. Discard the filter element if it has been cleaned 5 times, if damaged, after 1000 service hours, or at least every 12 months. Reinstall the filter element into the filter casing. Make sure that the filter element is not damaged and that the seal on the filter casing fits properly. Note the arrow symbol on the dust bowl indicating the top. Refit the air filter cover.
Screw out the nut (4) and pull out the air filter element (3).
2
T350-3/028
3 4
T350-2/036
59
Maintenance
Clean the prefilter*
NOTE The dust bowl (3) should never be more than half filled (2) with dust. Daily servicing may be necessary under excessive dust conditions. Loosen clips (1) and remove dust bowl (3). Clean the dust bowl. Refit the dust bowl and secure with the clips.
* Option
1 2 1 2 3
5
T350-2/038
T350-2/045
D350/035
60
Maintenance
D350-3/040
D350/014
61
Maintenance
Lubricate the steer axle, mast and tilt cylinder bearings
If used in clean and dry areas, truck servicing every 500 service hours is sufficient as a rule. For mixed use inside and outside, it is recommended that the lubrication interval be halved. In an environment with dust, dirt, water and possibly de-icing salt or chemicals, weekly lubrication will extend the service life of the bearings substantially. NOTE Preferably lubricate the bearings with less grease more often than a lot of grease less frequently.
Cleaning with compressed air Clean the cooling fins of the radiator (1) and the hydraulic oil cooler (2) with compressed air. Flush off any loosened dirt with a water hose.
2
62
T350-2/047
Maintenance
Adjust the ignition timing
NOTE Adjustment conditions are the same as for checking ignition timing. Loosen clamping screws (2) on the ignition distributor (1) until it can just be turned by hand. Point the stroboscope light at the marks (5). Turn the distributor so that the 18 mark (5) on the flywheel is aligned with the pin (4) on the housing. Clockwise rotation advances ignition. Anti-clockwise rotation retards ignition. +50
Jack up the truck so that both drive wheels are free to rotate. Let the engine run warm until the oil temperature is at least 60 C. Stop the engine and switch off the ignition. Connect the stroboscope lamp according to manufacturers instructions. Start the engine. Run the engine at the rated speed of 950 rpm. Direct the stroboscopic light straight down at the ignition timing mark (5) 18 before TDC on the flywheel (3) (vertically from top).
Tighten the clamping screws after the adjustment and recheck the timing. Stop the engine. Disconnect the stroboscopic light. Close the bonnet.
The adjustment is correct when the flywheel mark (5) is aligned with the pin (4) on the housing.
T350-2/011
T350-2/050
63
Maintenance
CAUTION Do not operate the truck with a faulty seat belt. Have a defective seat belt replaced immediately by your authorised dealer.
CAUTION After an accident, the seat belt must be renewed. In the case of seat belts attached to the operator seat, the seat and mounting of the seat must also be inspected by qualified personnel. Nuts and bolts should be checked regularly for tightness. A wobbling of the seat can indicate loose bolts or other faults. If malfunctions in the operation of the seat are detected (e.g. seat cushioning), contact your authorised dealer immediately to eliminate the cause. In case of nonobservance, you put your health in danger and there is a higher risk of accidents.
* Option
30o
2
64
t352-03/03
T352-3/004
Maintenance
Clean and grease the steer axle
Thoroughly clean the steer axle with water or a cold cleaner.
NOTE Only use lubricating grease. Grease the track rods and steering knuckles at the grease nipples (see arrows) with lubricating grease. Lubricate with a grease gun until new grease emerges at the bearings.
D350-3/037
T350-2/071
351-2/084
65
Maintenance
ATTENTION Follow the precautions for handling fuel, lubricants and coolant. Fully screw in the breather filter (1) and oil dipstick and remove it again. The oil level should be between the two marks on the dipstick (2). If necessary, fill hydraulic oil up to the high mark.
NOTE To check the oil level, fully lower the fork carriage of mast. Remove the breather filter (1) with oil dipstick from the oil tank.
Capacity between high and low marks: ................................... approx. 2.5 litres
NOTE The tank is pressurised, some air may escape. Wipe the dipstick with a clean cloth.
NOTE The sideshift must be greased each time the truck is cleaned.
* Option
1
66
D350-3/046
T350-2/072
T350-2/034
Maintenance
NOTE Oxidised terminals and cracked cables result in loss of voltage, thus leading to starting difficulties. Remove oxidation remains and replace any cracked cables.
T350-2/039
67
Maintenance
Change the LPG filter
Close the shutoff valve on the LPG cylinder or gas tank*. Let the engine run until the gas in the system is used up. Unscrew the union nut (2) and remove the filter housing (1). Take out the old filter element. Remove the magnet (lies loosely in the filter housing) and clean it. Clean the housing and re-insert the magnet. Insert the new filter element and install the housing. Check for leaks after changing the filter.
350 804 3351.0705
NOTE The formation of ice and foamy yellowish deposits on the gas unit indicate leaks. * Option
T350/005
T350-3/011
T350-3/012
68
Maintenance
Renew the engine oil filter
ATTENTION Engine oil may be hot. Danger of scalding.
NOTE Change the oil only when engine is at operating temperature. 350 804 3351.0705
Loosen the oil filter (4) in the engine compartment using a filter spanner and remove by hand. Catch the oil running out and discard in a way friendly to the environment. Coat the seal of the new filter lightly with engine oil. Install and handtighten the oil filter, until the seal contacts the mating surface.
Drive the truck over a pit. Place a suitable catch tray under the frame. Open the bonnet. Remove the filler cap (1).
T350-3/013
T350-2/077
T350-3/018
69
Maintenance
Check and oil other pivots and joints
Inspect and oil the pivots and mountings of: Seat guide, bonnet mounting pivot pin
* Option
T350-3/013
T350-2/016
70
Maintenance
Check and oil the pedals, the travel and engine control linkage
ATTENTION The following adjustments must be carried out by qualified service personnel. Please contact your authorised dealer. Remove the floor plate. Check the pedals for ease of movement. Check the pin and pivot retainers for security. If necessary, slightly oil the lever pivots and clevises. Install the floor plate.
The cooling system must be filled in all seasons with a mixture of water and an unphosphated glycol-based antifreeze/anticorrosion additive in order to provide protection against calcium deposits, frost and corrosion, and to raise the boiling temperature. CAUTION The radiator cap (2) should not be opened when the engine is hot. Danger of scalding! ATTENTION Follow the precautions for handling fuel, lubricants and coolant. 350 804 3351.0705
If there is too little coolant additive: Open the bonnet. Remove the drain plug on the cylinder block and allow some coolant to drain. Install and tighten the drain plug. Add coolant additive into the recovery tank until the right mixing ratio is reached.
Cooling system capacity ......................................... 7.0 litres Attach the LPG cylinder cover at the top and press down into the retainer.
Check the strength of the coolant in the recovery tank. The frost protection should be sufficient for temperatures down to -25 C. The mixing ratio for this is 40 % coolant additive and 60 % drinking water.
2
1
D350/051
T350/008
T350-2/041
71
Maintenance
Renew the spark plugs
Thoroughly clean the area surrounding the spark plugs on the cylinder head. Pull off the plug connectors and remove the spark plugs. Check the gap of the new plugs with a feeler gauge and adjust, if necessary.
Check the drivebelt for excessive wear, worn flanks, cracks and traces of oil. Renew a damaged drivebelt. ATTENTION A broken or slack drivebelt reduces cooling.
Electrode gap ................................................... 0.6 - 0.8 mm Use the following spark plugs: BOSCH Champion W8DTC N9BYC4
NOTE Check belt tension with thumb pressure. Retighten new drivebelts after they have run 15 to 20 minutes.
Check the drivebelt tension by depressing it with a thumb. New drivebelt ............................................ approx. 2 mm Run-in drivebelt ........................................ approx. 5 mm Tighten the drivebelt if the tension is insufficient.
Screw in the spark plugs by hand and tighten to a torque of 20 Nm. ATTENTION Do not start the engine without spark plugs. Damage to the ingnition system can result.
350 804 3351.0705
T350-2/079
T350-3/017
72
Maintenance
Check the CO contents in the exhaust gas
NOTE The Trade Association prescribes checking the CO contents in the exhaust gas every 500 service hours, but at least every 6 months (German regulations). Special tools and knowledge are required for this check. Please contact your autorised dealer.
Torque ........................................................................ 45 Nm
T350-3/025
4 3
T350-3/026
73
Maintenance
Catalytic converter* Check the basic adjustment of the LPG system
A condition for the adjustment with the lambda viewer is the correct adjustment of the engine and truck. Throttle valve angle Upper and lower idle speed Ignition timing Pressure-relief valve setting
Technical skill and knowledge are required for this work, please contact your authorised dealer.
350 804 3351.0705
* Option
D350/017
D350-3/039
T350-3/014
74
Maintenance
Adjust the lift chain length**
NOTE The lift chain must be adjusted as it stretches with use. Completely lower the mast and fork carriage. Loosen the locknut (1). Adjust chain length with the adjusting nut (2) on the chain anchor. The lower guide roller of fork carriage may project a maximum of 25 mm from inner mast channel. Tighten the locknut (1) firmly. ATTENTION Extend the mast fully and then check the clearance between the end stops.
NOTE Trucks in service in the food industry must be lubricated with a thin oil approved for the food industry instead of chain spray. * for standard masts only
NOTE Trucks in service in the food industry must be lubricated with a thin oil approved for the food industry instead of chain spray. ** for duplex and triplex masts only
2 1
E336/087
D351-2/094
75
Maintenance
Check the tension of double hoses when attachments are fitted
The tension of the double hoses should be 5 - 10 mm per metre referred to initial length. Adjust the tension to the specified value by shifting the hoses in the clamps.
2
76
T350-2/047
D350-3/049
E336/088
Maintenance
Check the engine and engine support mounting for condition and tightness
Tighten the engine and engine support mounting nuts and bolts on both sides.
Torque (6) Nut M10 (4 items) ................................................. 46 Nm (7) Nut M10 (2 items) ................................................. 46 Nm (8) Bolt M16 (2 items) ............................................... 195 Nm
NOTE If the air filter restriction indicator does not light, contact your authorised dealer. Refit the hose (5).
2
T350-2/044
3 4
6 7 6 8
t350-03/24
D350-3/060
77
Maintenance
T350-2/013
T350-3/015
78
Maintenance
Renew the breather filter
Screw the breather filter (4) with the dipstick (5) out of the hydraulic oil tank. Withdraw the dipstick (5) from the breather filter (4) and mount it on the new filter.
NOTE Place a dish under the filter to collect any hydraulic oil flowing out. Unscrew the housing by hand. Remove and discard the filter element as required by local laws and regulations. Check O-ring on the filter head, renew if required. Insert a new filter element. Refit the filter housing and tighten by hand. Check oil tightness of the filter in a trial run. Refit the cover at the front of the truck.
4 5
D350-3/029
D350-3/034
T350-3/016
79
Maintenance
Check the LPG mixer adjustment
Check the LPG mixer adjustment, correcting it if necessary. CAUTION Special knowledge is required for this service. Please contact your authorised dealer.
NOTE If the parking brake is not operating correctly, contact your authorised dealer.
350 804 3351.0705
1 2
d351-02/110
T350-3/019
80
Maintenance
T350-2/018
81
Maintenance
Cooling system capacity ........................... approx. 7.0 litres The antifreeze should be sufficient for temperatures down to -25 C. The mixing ratio for this is 40 % coolant additive and 60 % drinking water.
Mixing ratio for lower temperatures: Temperature Coolant additive -30 C 45 % -35 C 50 % -
Drinking water 55 % 50 %
Run the engine until all of the air in the cooling system is eliminated. Screw on the coolant reservoir cap (2). Hook in the LPG cylinder cover (1) at the top and push into the retainer at the bottom. Close the bonnet.
2
1
T350-2/051
T350/008
82
Maintenance
Renew the toothed belt
NOTE Special equipment is necessary for renewing the toothed belt. Please contact your authorised dealer.
1 3
T350-3/020
T350-3/027
83
Maintenance
Renew the high-pressure hoses
WARNING The high-pressure hoses of the LPG system must be renewed every 3000 operating hours or every 2 years. Please contact your authorised dealer for this service.
NOTE The hydraulic system bleeds itself while engine is running. Close the bonnet.
Torque ........................................................................ 25 Nm
2 3
1
84
T350-2/083
T350-2/019
Maintenance
approx. 11 kg (12 kg in UK) approx. 36.0 litres approx. 7.0 litres approx. 17.0 litres As required See information on label on the inside of the overhead guard 210 Nm Lubricating grease Linde chain spray As required As required Electrode gap 0.6 - 0.8 mm W8DTC N9BYC4 18 before TDC 950 + 50 rpm 2070 rpm
3 4 5 6
7
350 804 3351.0705
Wheel fasteners - tighten Mast and tilt cylinder bearings Lift chains, mast channels Spark plugs BOSCH CHAMPION
8 9 10
11 12 13 14
Ignition timing Idling speed Rated speed Drivebelt tension - Coolant pump - Alternator
85
A - Multigrade light oils B - Multigrade oils ATTENTION Used oil must be stored safely outside the range of children before being disposed of. Never allow the oil to sicker into the sewer system or the ground. Due to the disposal problem and the required special tools and expertise, have the engine oil and filter changed by your authorised dealer.
86
Lubricating grease
Linde heavy duty grease with a lithium base and EP additives and MOS2. Designation to DIN 51825-KPF 2N-20 (see Parts Catalogue for the Order No. Never mix grease types that are not lithium-based.
Coolant
Only use coolant additive with a monoethenglycol base with corrosion inhibitor. Do not mix with coolant additive containing enthanolamine. Temperature -25 oC -30 oC -35 oC Coolant additive 40 % 45 % 50 % Drinking Water 60 % 55 % 50 %
NOTE The choice of the proper oil depends on the operating temperature of the oil in the hydrostatic drive. The above recommendations can only be guidelines.
Battery grease
Non-acidic gease (terminal grease).
Chain spray
Linde chain spray (see Parts Catalogue for the Order No.).
Fuel gas
Only use LPG cylinders with an LP gas filling acc. to DIN 51622 or liquid gas acc. to EN 589 (car gas) with gas removal in the liquid phase. WARNING Do not use domestic gas bottles!
87
Possible Cause
LPG cylinder or LPG tank shutoff valve closed. LPG cylinder or LPG tank empty. Temperature in LPG tank too low.
Remedy
Open the shutoff valve. Change the LPG cylinder, fill the LPG tank. Preheat the LPG system and piping with hot water. Dont use a naked flame or hot air! Check for current with a test lamp; if no current, check lead and correct the fault or replace the shutoff valve, if necessary. Replace the LPG filter. Clean, replace if necessary. Check the circuit, beginning with the battery. Dry the distributor cap and spray with contact spray, if necessary. Ignition sequence 1-3-4-2. Dry the spark plugs thoroughly. Replace spark plugs and/or have the engine checked by your dealers workshop. Adjust electrode gap or replace plugs. Fault can be localised by means of diagnostic device. Please contact your authorised dealer. Have idle speed adjusted by your authorised dealer with a diagnostic unit for smooth running of engine. Tighten the mounting. Renew the flange seal and check the intake hose for cracks.
See Page
25 22, 23
LPG filter restricted. Mixer, evaporator-pressure regulator restricted. Fault in the ignition circuit. Distributor cap is wet.
68 80 67
350 804 3351.0705
81
Spark plug leads interchanged, loose or wet. Spark plugs are wet (condensation). Plugs are oiled up due to defective piston rings or worn out pistons. Plugs faulty, electrode gap is too wide. System fault in the electronic control.
63 72 72
72
78 78
88
Possible Cause
Ignition cable loose or detached. Faulty ignition cable or connector (electrical leak). Faulty or dirty plugs. Leaky or sticking valve.
Remedy
Check the cable connections and secure, if necessary. Check cable and connector and replace faulty parts, if necessary. Clean plugs, check electrode gap and replace plugs, if necessary. Contact your authorised dealer.
See Page
81 81 72
Check and clean plugs, adjust electrode gap and renew plugs, if necessary. Renew faulty connector, generally recognizable by burn marks. Dry wet cables, renew if faulty. Check the cap for puncture and cracking (burn marks). Dry wet distributor cap carefully. Check the gas system.
72
81 81
Check the cable connections, renew the solenoid shutoff valve, if necessary.
85
Pre-ignition. Engine runs hot. Automatic ignition advance is premature. Deposits in combustion chamber. Heat value of plugs is too low.
Adjust ignition timing. See under engine overheating. Contact your authorised dealer. Contact your authorised dealer. Use specified spark plugs. Pay attention to seal on spark plugs.
63
72, 85
89
Possible cause
Thermal fuse of fan motor blown. Thermal switch defective. Ignition timing set incorrectly. Air-gas mixture is too lean. Automatic ignition advance device not functioning properly. Coolant level too low.
Remedy
Replace the fuse. Replace the thermal switch. Adjust ignition timing as specified. Check the gas system, have it adjusted if necessary. Clean ignition advance device in distributor and overhaul, if necessary. Top up coolant. Examine cooling system for leaks, repair as necessary. Tighten or replace belt.
See page
44
63
21 62 72
350 804 3351.0705
Coolant pump and alternator drivebelt loose or broken. Radiator fins fouled or partly restricted.
Flush the cooling system with water and clean the radiator fins with compressed air, if required. ATTENTION Air pressure must not be too high to avoid damage to the radiator.
76
90
Possible Cause
Suction filter restricted. Inlet hoses leak, oil foams. Hydraulic pump or engine failure, seals defective causing air intake. Oil of wrong viscosity, low oil level in tank or hydraulic pump.
Remedy
Clean or replace the filter. Tighten the pipes and hoses. Check oil level and top up the oil, if necessary. Have hydraulic unit inspected by authorised dealer. Change the oil grade. Top up oil, select the specified viscosity.
See Page
79 66, 85
84, 85 66, 87
Pump inlet defective, noise. Pump failure, leakage loss, pressure relief valves do not close, valve seat damaged. Pipeline broken or leaky. Oil of low viscosity, causing high leakage losses. Oil cooler defective. Oil temperature warning lamp goes on.
Change oil, fill up oil. Contact your authorised dealer. Replace the line or tighten connections. Change the oil grade. Eliminate the leak. Check oil level, clean oil the cooler.
84, 87
78 84 62 62, 66
Cause as under abnormal noise. Pressure relief valves or boost pressure valves sticking. Lift and tilt cylinders have chafe spots. Mast does not extend completely or retracts slightly.
See under abnormal noise. Contact your authorised dealer. Contact your authorised dealer. Add oil. Clean or replace the filter. Contact your authorised dealer. Replace the pipeline or tighten connections. Contact your authorised dealer. Check oil level, use specified oil, clean oil cooler. Have repaired by your authorised dealer. Check oil level, top up oil, if necessary. Clean oil cooler and examine for leaks. If defective, contact your authorised dealer. 62, 66, 87 78 62, 66, 87 66, 87 79
Filter restricted (if accompanied by noise). Pump failure, leakage loss, pressure relief valves do no close, valve seats damaged. Pipeline broken or leaky. Valves blocked. Hydraulic system overheating. Pump failure, valves leaky. Oil level too low or oil cooler defective.
91
(a)
Wire code
BK WH BU OG BN GN VT RD YE GY black white blue orange brown green violet red yellow grey
The number ahead of the cable colour represents the cable gauge. Cables without gauge indication = 0.75 mm
9R1/2/3 Resistor 9R4 Resistor for fan S1 S2 S3 S4 S5 S6 S14 4S8 Ignition/starter switch Engine temperature switch Oil temperature switch Engine oil pressure switch Suction filter vacuum switch Minimum gas reserve switch* Brake pedal switch 2 (start inhibit) Horn button
92
93
Fan control Electro-hydraulic truck control Wiring diagram for options Stop light Increase in RPM, auxiliary hydraulics Reversing flasher signal Permanent reversing signal Engine shutoff
Wire code
BK WH BU OG BN GN VT RD YE GY black white blue orange brown green violet red yellow grey
The number ahead of the cable colour represents the cable gauge. Cables without gauge indication = 0.75 mm
Engine RPM operating magnet (throttle valve) Solenoid valve y forward* Solenoid valve z reverse* Enable valve LP gas shutoff valve
Platzhalter
95
Colour code
BU BN YE GN GY RD BK WH VT OG blue brown yellow green grey red black white violet orange
Working lights Lighting Turn signal and hazard flasher system Wiring diagram for stndard equipment 5X2 not used if lighting is higher Revolving light Wiring diagram for stndard equipment Stop light Wiring diagram for stndard equipment If total load > 170 W: use a 20 A fuse Max. total power: 200 W Load depending on application: eg stop light, reversing light, rotating beacon for reversing Flashing reversing signal Wiring diagram for stndard equipment If total load > 170 W: use a 20 A fuse Max. total power: 200 W Load depending on application: eg stop light, reversing light, rotating beacon for reversing
The number before the cable colour specifies the cable diameter. Cables without specification of diameter = 0.75 mm, broken lines in wiring diagram are also present in basic equipment diagram.
96
97
Colour code
BU BN YE GN GY RD BK WH VT OG blue brown yellow green grey red black white violet orange
The number before the cable colour specifies the cable diameter. Cables without specification of diameter = 0.75 mm, broken lines in wiring diagram are also present in basic equipment diagram.
98
99
Colour code
BU BN YE GN RD BK WH VI blue brown yellow green red black white violet
7S16 Starting switch** 7S17 Emergency off switch** 7V1 X3 X3.1 4X1 6X8 7X2 7X4 7X8 7X9 7X10 7Y1 Free wheel diode** Connector, Connector, Connector, Connector, Connector, Connector, Connector, Connector, Connector, 1 1 2 4 4 2 1 6 6 way** way** way way** way** way** way** way** way**
Cables without specification of diameter = 0.75 mm2 The number before the cable colour corresponds to the cable cross section.
100
101
9K11 Consumer cut-off relay 1N2 6P5 Electronic travel control LHC Fuel gauge
Colour code
BU BN YE GN RD BK WH VI blue brown yellow green red black white violet
9S10 Seat switch 6X7 Connector, 4 way 9X24 Connector, 1 way 9X27 Connector, 3 way 1Y5 Fuel shut-off valve
Cables without specification of diameter = 0.75 mm2 The number before the cable colour corresponds to the cable cross section.
102
103
Colour code
BK WH BU OG BN GN VT RO YE GY black white blue orange brown green violet red yellow gray
F2 Fuse 5 A F3 Fuse 5 A 1F18 Fuse 15 A 9S10 6W1 6X3 6X4 6X5 6X7 6X8 6X9 6X10 9X27 Seat switch Antenna (LFM on-line module) Connector Connector Connector Connector Connector Connector Connector Connector 14 pins (6A3) 10 pins (6A3) 1 pin 4 pins (6B1) 4 pins (6B2) 5 pins (data transfer) 4 pins 3 pins (9S10)
The number before the cable colour corresponds to the cable cross section. Cables without diameter information = 0.75 mm
Particle filter**
350 804 3351.0705
Electric circuit diagram for options For particulate filter warning buzzer 7B1:30 optional equipment wiring diagram**
105
Hydraulic schematic
A
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Working hydraulics
Service cylinder (auxiliary hydraulics) Service cylinder (auxiliary hydraulics) Tilt cylinder Lift cylinder, standard series 180 Pipe safety valve Lift cylinder, duplex series 180 Lift cylinder, triplex series 180 Slow lowering valve Control valve block assy. consisting of: Way valve - auxiliary hydraulics Way valve - auxiliary hydraulics Check valve (pilot-operated) Way valve - tilting Way valve - lifting 2/2 way valve (pressure balance) Maximum pressure valve Standard/ Duplex Triplex H 12 175+5 bar H 16 215+5 bar H 18 230+5 bar H 20 250+5 bar Restrictor Changeover valve Pressure reducing valve 165+5 200+5 210+5 230+5 bar bar bar bar
D
36 37 38 39
O
55 56
E F G H
40 41 42 43 44
Steer cylinder Engine Engine speed control cylinder Variable-displacement pump HPV 55-02 assembly consisting of:
Variable-displacement pump Proportional valve Control magnet Enable valve Control cylinder A = forwards B = reverse Control circuit jets 4/2 Way valve Pilot valve Servo piston Y = forwards Z = reverse Boost pressure valve 17.5 +0.5 bar Combined boost pressure and maximum pressure valve 420 +15 bar
P Q
57
Breather filter with pressurising filter 0.35 0.15 bar Towing device (bypass valve) Engine speed governing when pushing for H 20
Control valve block Restrictor 2/2 Way valve
350 804 3351.0705
S T
58 59 60
17 18 19
45 46 47 48
B C
21 22 23 24 25 26 27 28 29 30 31 32 33 34
49 50
J
51 52 53 54
K L M N
106
Hydraulic schematic
107
Index
Page Page Page
Accident prevention check ................................................ 18 Adjust the ignition timing ................................................... 63 Adjust the lift chain length, lubricate with chain spray ..... 75 Adjusting the fork spread .................................................. 46 Adjusting the operator seat ............................................... 25 Air filter, clean with compressed air ................................. 59 Applying the parking brake ............................................... 35 Applying the seat belt ....................................................... 26 Approved applications ........................................................ 2
A B
Battery grease ................................................................... 87 Battery: Check condition, electrolyte level and specific gravity ........................................................ 67 Before lifting a load ........................................................... 45 Beginning operation ......................................................... 17 Brakes ................................................................................ 13 Braking system .................................................................. 35
Catalytic converter, unregulated ...................................... 49 Catalytic converter: Check the basic adjustment of the LPG system .......................................................... 74 Central-lever control of lifting device and attachments ... 36 Chain spray ....................................................................... 87 Change the LPG filter ....................................................... 68 Changing the LPG cylinder .............................................. 22 Changing the travel direction ........................................... 30 Check and oil other pivots and joints ............................... 70 Check and oil the pedals, the travel and engine control linkage ................................................... 71 Check electric cables, cable connectors and connections for condition and tightness ....................... 67 Check fuses, renew if required ......................................... 44 Check seat belt for condition and proper operation ........ 64 Check the air intake and exhaust pipes for leaks ............ 78
Check the CO contents in the exhaust gas ...................... 73 Check the coolant level in recovery tank ......................... 21 Check the coolant strength ............................................... 71 Check the distributor and ignition cables ........................ 81 Check the dust ejection valve .......................................... 60 Check the engine oil level ................................................ 20 Check the forks and fork quick-releases .......................... 76 Check the hydraulic system oil level ................................ 66 Check the hydraulic system, drive axle, pumps, valves and lines for leaks .............................................. 78 Check the ignition timing .................................................. 63 Check the LPG mixer adjustment ..................................... 80 Check the LPG system for damage and for leaks with leakage spray ......................................... 68 Check the mast, lift chains, lift cylinders and stops for condition, mounting and operation ............................... 75 Check the mounting of the counterweight, overhead guard, steer axle and drive axle ................... 74 Check the mounting of the engine and engine support for condition and security ................................. 77 Check the mounting of the hydraulic oil tank ................... 60 Check the parking brake ................................................... 80 Check the tension and condition of the alternator and coolant pump drivebelt .................................................. 72 Check the tension and condition of the toothed belt, renew if necessary ........................................................ 73 Check the tension of double hoses when attachments are fitted .................................................... 76 Check the tyre inflation pressure ...................................... 24 Check the tyres for damage and foreign objects ............. 61 Checking the LP gas level ................................................ 20 Checks and services before initial operation .................. 19 Clean and grease the steer axle ...................................... 65 Clean and spray the lift chains ......................................... 58 Clean the air filter .............................................................. 59 Clean the evaporator/pressure regulator ........................ 80 Clean the lift truck ............................................................. 58 Clean the prefilter ............................................................. 60 Clean the radiator and hydraulic oil cooler ..................... 76 Clean the radiator and hydraulic oil cooler, check for leaks ............................................................... 62
Closing the bonnet ............................................................ 19 Closing the gas cylinder or gas tank shutoff valve .......... 28 Composite instrument ....................................................... 16 Condition code .................................................................. 41 Controls and indicators ..................................................... 15 Coolant .............................................................................. 87
D E F
Daily checks ....................................................................... 19 Daily pre-operational checks and services ....................... 19 Description .......................................................................... 5 Disposal of old vehicles .................................................... 52 Drain the engine oil .......................................................... 69 Driving ............................................................................... 30 Duplex mast ...................................................................... 54
Electric circuit diagram (options) ...................................... 96 Electric circuit diagram (standard equipment) ................. 92 Electric circuit diagram (Truck Data Management) ....... 104 Electrical system ............................................................... 13 Emergency exit for trucks with rear windscreen .............. 51 Engine ............................................................................... 13 Engine oil, grade and viscosity ........................................ 86 Experts .............................................................................. 18
Fan motor fuse .................................................................. 39 Filling the LPG tank ........................................................... 23 Foreword ............................................................................. 2 Forward travel ................................................................... 30 Frequency characteristic for human body vibrations ...... 12 Fuel and oil recommendations ......................................... 86 Fuel gas ............................................................................. 87 Fuses ................................................................................. 44
108
Index
Page Page Page
G H
350 804 3351.0705
General view of truck ........................................................ 14 Grease the mast and tilt cylinder bearings ...................... 65
Handling fuels and lubricants ............................................ 17 Hazard warning lights ....................................................... 38 Heater ................................................................................ 39 Hoisting the truck .............................................................. 48 Hoisting the truck with a crane ......................................... 48 Hoisting the truck with the eyebolts .................................. 48 Horn ................................................................................... 39 Hydraulic oil ...................................................................... 87 Hydraulic schematic ....................................................... 106 Hydraulic system ............................................................... 13
LHC control ........................................................................ 13 Lift mast types .................................................................... 54 Lifting the fork carriage ..................................................... 36 Lighting .............................................................................. 38 Loading ............................................................................. 46 Lowering the fork carriage ................................................ 36 Lubricate the steer axle, mast and tilt cylinder bearings . 62 Lubricating grease ............................................................ 87
Parking brake .................................................................... 35 Parking the truck ............................................................... 47 Putting the truck back into operation ................................ 51
M N O
Maintenance, general information ................................... 53 Malfunctions during operation .......................................... 29 Mast removal ..................................................................... 49 Measures before taking the truck out of operation .......... 51
Important safety information .............................................. 17 500-hour inspection and maintenance ............................ 65 1000-hour inspection and maintenance .......................... 77 2000-hour inspection and maintenance .......................... 81 3000-hour inspection and maintenance .......................... 82 Inspection and maintenance after the first 50 service hours ............................................................ 55 Inspection and maintenance as required ........................ 58 Inspection and maintenance data .................................... 85 Inspection and maintenance schedule ............................ 56 Installation of additional equipment ................................. 38
Releasing the parking brake ............................................ 35 Renew the air filter element, check the vacuum switch ... 77 Renew the alternator and coolant pump drivebelts ........ 83 Renew the breather filter .................................................. 79 Renew the coolant ............................................................ 82 Renew the engine oil ........................................................ 69 Renew the engine oil filter ................................................ 69 Renew the high-pressure hoses ...................................... 84 Renew the hydraulic oil .................................................... 84 Renew the pressure filter .................................................. 79 Renew the spark plugs ..................................................... 72 Renew the suction filter .................................................... 79 Renew the toothed belt ..................................................... 83 Retighten the mast fastening bolts ................................... 74 Reverse travel ................................................................... 30 Running-in instructions ..................................................... 18
Opening the bonnet ........................................................... 19 Opening the gas cylinder or gas tank shutoff valve ......... 25 Opening the seat belt ........................................................ 26 Operating the attachments ................................................ 36 Operating the clamp ......................................................... 36 Operating the horn ............................................................ 40 Operating the sideshift ...................................................... 36 Operating the turn indicator lights .................................... 38 Operation ..................................................................... 13, 26 Operation of industrial trucks in the plant area ................ 18
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Index
Page Page
Safety instructions for the LPG system ............................. 18 Safety precautions for transistorised ignition systems ...... 112 Safety rules ........................................................................ 17 Safety rules for LP gas (excerpt) .................................... 111 Securing the mast against tilting back ............................. 53 Securing the raised duplex mast ...................................... 54 Securing the raised standard mast .................................. 54 Securing the raised triplex mast ....................................... 56 Service brake .................................................................... 35 Sideshift: Clean, grease and check the mounting ........... 66 Single-lever control of lifting device and attachments ..... 37 Single-pedal model .......................................................... 31 Standard mast ................................................................... 54 Starting the engine ............................................................ 27 Steering system ................................................................. 35 Steering ....................................................................... 13, 35 Stop pedal ......................................................................... 35 Stopping ............................................................................ 30 Stopping the engine ......................................................... 28 Switching on the front working lights ................................ 38 Switching on the hazard warning lights ........................... 38 Switching on the lights ...................................................... 38 Switching on the rear working light .................................. 38
Table of contents ................................................................. 7 Taking the truck out of operation ...................................... 51 Technical data ................................................................... 10 Technical description ........................................................ 13 Technical note ..................................................................... 3 Tighten the alternator and coolant pump drivebelt ......... 72 Tighten the wheel fasteners ............................................. 61 Tilting the mast back ......................................................... 36 Tilting the mast forward ..................................................... 36 Top up the engine oil ........................................................ 70 Towing ............................................................................... 50 Towing instructions ........................................................... 50 Towing procedure ............................................................. 50 Trailer coupling ................................................................. 49 Transport with lorry or low-bed semi-trailer ..................... 48 Travel with a load .............................................................. 47 Triplex mast ....................................................................... 55 Troubleshooting guide (hydraulic system) ...................... 91 Troubleshooting guide (LPG engine) .............................. 88 Truck data acquisition ....................................................... 41 Truck Data Management .................................................. 41 Truck data acquisition - default setting (PIN number and condition code) ................................. 42 Truck data acquisition - special setting (PIN number) ................................................................. 43 Truck takeover ..................................................................... 3 Turn indicator lights .......................................................... 38 Turning on the front windscreen wiper ............................. 38 Turning on the rear windscreen wiper ............................. 38 Turning on the heater (version 1) ..................................... 39 Turning on the heater (version 2) ..................................... 40 Type plates .......................................................................... 5
U V W
Unloading .......................................................................... 47
Wheel change ................................................................... 49 Windscreen wipers ........................................................... 38 Work on the mast and on the front part of the truck ......... 53 Working lights .................................................................... 38
350 804 3351.0705
110
A. During operation
1. Close the cylinder shutoff valve and main shutoff valve before disconnecting the pipe or hose connection. Loosen the union nuts on the cylinders slowly and only slightly at first, otherwise the gas still in the line will spurt out. CAUTION LP gas can cause frostbite on bare skin!
5. The entire LPG system must be monitored continually for safe condition, particularly for leaks. It is forbidden to use the vehicle with the gas system leaking. Use soapy water, a Nekal solution or another foam-forming agent when checking for leaks. Do not inspect the LPG system for leaks with a naked flame. 6. Be sure to adjust the LPG systems so that the exhaust emissions are kept as low as possible. 7. Frozen parts of the LPG system may only be thawed with hot water, hot sandbags or the like. Naked flames, red-hot objects, etc. can cause explosions. 8. The manufacturers installation instructions must be followed when changing single parts of the system. Cylinder valves and main shut off valves must also be closed for the procedure. 9. The condition of the electrical system of industrial trucks powered by LP gas should be monitored continuously. Sparks can cause explosions if there are leaks in the gas system. If a LPG powered industrial truck has not been used for a long time, ventilate the garage thoroughly before starting the vehicle or operating its electrical equipment. 10. Your industrial trade association and the responsible trade supervisory authority should be notified immediately of any explosions involving gas cylinders or LPG systems, even if no injury resulted from the accident. Damaged parts should be kept in safekeeping until the conclusion of the investigation. 11. LPG powered vehicles may only be operated in entirely or partially enclosed spaces if no dangerous concentrations of exhaust components hazardous to health can accumulate in the breathing air.
Do not expose LPG tanks and pipes and hoses and their fittings for gas in the liquefied phase to inadmissible extraneous heat. 2. Removable LPG tanks (LPG cylinders) must be mounted on the truck so that they are in the horizontal position and with the cutout in the collar pointing down. During installation and removal, the gas outlet fitting on the cylinder valve must be sealed with a locknut tightened securely with a special key. Before connecting the gas cylinders, check the connecting fittings for proper condition. After removal, screw the cylinder cap immediately onto the cylinder with the locknut. 3. Open the valves slowly! Do not open or close valves by striking them with tools. Danger of sparks causing an explosion. ATTENTION Only use CO2 powder type fire extinguishers or CO2 gas extinguishers for LP gas fires. 4. Leaking gas cylinders must be taken out of use. They should be emptied immediately in the open air by releasing the gas in accordance with all the relevant safety measures and then tagged as leaking. When returning damaged gas cylinders, notify the distributor or his representative (e.g. service station attendant) immediately of the damage, in writing if possible.
111
Wash the engine only with the ignition turned off. Disconnect the battery completely before carrying out electric welding or spot-welding. Do not connect a capacitor to terminal 1 (-).
Please observe the section "General Requirements for Gas Cylinders" in the Technical Rules for Gas Cylinders (TRG 380 and 404) or your local regulations.
112