You are on page 1of 114

D350-3/016

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

350 804 3351 GB


0705

Linde - Your Partner

Linde AG Linde Material Handling Division

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

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)

350 804 3351.0705

350 804 3351.0705

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

Fork lift truck H 12 / H 16 / H 18 / H 20 with LPG engine


Innovative technology, simple and ergonomic operation, energy saving, environment-friendly and minimal maintenance, solid manufacture and because almost all spares are of our own manufacture they are readily available. The success of a company with about 9600 employees in eight manufacturing sites.

Description

350 804 3351.0705


D350-3/016

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

350 804 3351.0705

350 804 3351.0705

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

2000-hour inspection and maintenance ........ 81


Check the distributor and ignition cables ........................ 81

3000-hour inspection and maintenance ........ 82


Renew Renew Renew Renew Renew the coolant ............................................................ 82 the alternator and coolant pump drivebelts ........ 83 the toothed belt ..................................................... 83 the hydraulic oil .................................................... 84 the high-pressure hoses ...................................... 84

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

Inspection and maintenance as required ...... 58


Clean the lift truck ............................................................. 58 Clean and spray the lift chains ......................................... 58 Clean the air filter .............................................................. 59 Clean with compressed air ............................................ 59 Check the dust ejection valve .......................................... 60 Check the mounting of the hydraulic oil tank ................... 60 Clean the prefilter ............................................................. 60 Tighten the wheel fasteners ............................................. 61 Check the tyres for damage and foreign objects ............. 61 Clean the radiator and hydraulic oil cooler, check for leaks ............................................................... 62 Lubricate the steer axle, mast and tilt cylinder bearings . 62 Check the ignition timing .................................................. 63 Adjust the ignition timing ................................................... 63 Check seat belt for condition and proper operation ........ 64

1000-hour inspection and maintenance ........ 77


Renew the air filter element, check the vacuum switch ... 77 Check the mounting of the engine and engine support for condition and security ................................. 77 Check the hydraulic system, drive axle, pumps, valves and lines for leaks .............................................. 78 Check the air intake and exhaust pipes for leaks ............ 78 Renew the pressure filter .................................................. 79 Renew the suction filter .................................................... 79 Renew the breather filter .................................................. 79 Check the parking brake ................................................... 80 Clean the evaporator/pressure regulator ........................ 80 Check the LPG mixer adjustment ..................................... 80 9

500-hour inspection and maintenance ........... 65


Grease the mast and tilt cylinder bearings ...................... 65 Clean and grease the steer axle ...................................... 65 Sideshift: Clean, grease and check the mounting ........... 66 Check the hydraulic system oil level ................................ 66 Check electric cables, cable connectors and connections for condition and tightness ....................... 67 Battery: Check condition, electrolyte level and specific gravity ....................................................... 67

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

Manufacturer's Data and Design Characteristics

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

1.2 1.3 1.4 1.5 1.6 1.8 1.9

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 -

Wheels and Tyres Weight

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

350 804 3351.0705

4.12 Tow coupling height

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

5.2 5.3 5.5 5.7 5.9

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

7.2 7.3 7.4 7.5 8.1 8.2 8.3 8.4 8.5

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

Figures for triplex masts on request.

Heights and lift height (mm) Lift height


350 804 3351.0705

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

Duplex 2770 1925 3378 1318

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)

350 804 3351.0705

LWA = 101 dB (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.

350 804 3351.0705

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

General view of truck


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Overhead guard Drivers seat LPG cylinder Counterweight Steering axle Engine cover Frame Foot step (for mounting and dismounting) Wheel drive Forks Fork carriage Fork quick-release Lift cylinders Lift chains Mast Instrument panel

Description

350 804 3351.0705

14

Controls and indicators


1 2 3 4 5 6 7 8 9 10 11 12 13
350 804 3351.0705

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
350 804 3351.0705

Engine oil pressure warning light (5)

6 5 4 3

Indicates low oil pressure of engine lubrication.

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

Low gas level warning light* (7)

Battery charge indicator light (8)

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

Fan warning light (9)

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.

LHC warning light (10) Air filter warning light (11)

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.

Handling fuels and lubricants


Always handle fuels and lubricants as required and as specified by the manufacturer. Only store fuels and lubricants in approved containers at specified storage places. As they could be inflammable, do not contact them with hot objects or a naked flame. Only use clean containers when replenishing fuels and lubricants. Follow the manufacturers safety and disposal instructions when using fuels and lubricants and cleaning compounds. Avoid spilling fuels and lubricants. Remove any spillage immediately with a suitable binding agent and dispose of as specified. Also dispose of used or contaminated fuels and lubricants as specified. Follow laws and regulations. Clean the area surrounding the part in question before lubrication, filter renewal or repairs in the hydraulic system. Discard parts in a way friendly to the environment. CAUTION Do not allow hydraulic oil under pressure, for example at a leak, to penetrate the skin. Medical aid is required if such an injury occurs. CAUTION Improper handling of coolants and coolant additives puts your health and the environment at risk. ATTENTION LP gas can cause frostbite on bare skin!

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

Follow these instructions

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.

Safety instructions for the LPG system


Linde wishes you a long use of your LPG truck with maximum safety. WARNING When LP gas leaks out, there is an immediate danger of explosion resulting in the risk of burns. This is particularly the case when: - leaks occur on the LPG system, - the engine does not start or starts poorly. For this reason it is absolutely: - forbidden to manipulate the LPG system in any way if any malfunctions occur, - forbidden to continue to operate the truck if any malfunctions occur.

Operation of industrial trucks in the plant area


ATTENTION Many plant areas are so-called limited public traffic areas. We advise you to check if your company liability insurance covers any damages occurring with your fork truck against third parties on "limited" public traffic areas.

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.

350 804 3351.0705

18

Daily pre-operational checks and services


Checks and services before initial operation*
350 804 3351.0705

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.

Opening the bonnet


Push the lever (9) up and tilt the backrest (1) forward. Pull lever (3) and slide the seat fully forward. Release the bonnet lock (4) by inserting the key (5) and turning it anti-clockwise as far as possible. Lift up the rotary lever (6) and turn anti-clockwise as far as possible. Unhook the tongue (7) from the bracket (8) and lift it. Open the bonnet with the grip (2) to the rear.

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

NOTE The bonnet is held open by a gas-filled strut.

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

Daily pre-operational checks and services


Check the engine oil level
ATTENTION Follow the precautions for handling fuels, coolant and lubricants. Open the bonnet. Difference between max. and min. marks: ..... approx. 1.0 litre Pull out the oil dipstick (1) at the front of the engine. Clean the dipstick with a clean cloth. Reinsert the dipstick completely and pull it out again. The oil level should be between the two marks. Close the bonnet. Refit and tighten the filler cap. If necessary, fill engine oil through the filler neck up to the upper mark. To fill oil, remove the cap (2) on the filler neck.

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.

350 804 3351.0705

2
1 2

T350-3/001

T350-3/003

20

Daily pre-operational checks and services


Check the coolant level in recovery tank
ATTENTION Follow the precautions for handling fuels, coolant and lubricants. Remove the gas cylinder or LPG tank* cover (1) by pulling it back out of the retainer and swinging it up. Coolant must be visible between the max. and min. markings (3) in the recovery tank. Add coolant as required after removing the recovery tank cap (2). After topping up refit tank cap tightly. Attach the gas cylinder or LPG tank* cover (1) at the top and push it down into the retainer.

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.
350 804 3351.0705

*Option

T350/020

T350-3/004

T350-3/030

21

Daily pre-operational checks and services


Changing the LPG cylinder
NOTE The sensor for monitoring the gas level is located under the LP gas bottle and is calibrated for LP gas bottles with a filling weight of 11 kg acc. to DIN 4661 and a gas mixture acc. to DIN 51622. The sensor must be recalibrated if the bottle diameters or gas mixture fillings (with a propane share under 90 %) deviate. Please contact your authorised dealer for this service. If partially filled LP gas bottles are used, the indication of the gas level can be incorrect. WARNING The inspection intervals required by the regulations governing pressurised containers must be observed. The last inspection date marked on the gas cylinder indicates the next date. Gas cylinders with an expired inspection date must not be operated. NOTE Observe the safety precautions for LPG vehicles. Cylinders must be changed only by trained staff. WARNING Do not smoke when changing bottles and extinguish all naked lights and fires. Change LP-gas bottles only in well-ventilated spaces and not in the vicinity of pits. Shut off the engine and heater with combustion chamber, if installed, and allow them to cool down. CAUTION When the LPG hose is disconnected, a small amount of gas leaks out. This gas can cause freezing of the skin,. Always put on protective gloves. Close the LPG cylinder shutoff valve (4) tightly. Remove the gas cylinder cover (1) by pulling it back and up. Hold the fitting at the holding grip (2) and loosen the union nut (3) carefully and only slightly. -

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

Daily pre-operational checks and services


Filling the LPG tank*
WARNING Before connecting the filling pistol, check that the fuel gas tank or the instruments are not defective and that the safety inspection date of the tank has not yet expired. The inspection intervals required by the regulations governing pressurised containers must be observed. The last inspection date marked on the gas cylinder indicates the next date. Gas cylinders with an expired inspection date must not be operated. Do not fill the tank if any defects are found or the safety inspection has expired. NOTE Follow the safety guidelines for LPG vehicles and the safety notices at the filling station. The LPG tank should only be filled by qualified staff.
350 804 3351.0705

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

Daily pre-operational checks and services


Check the tyre inflation pressure
ATTENTION Low inflation pressure reduces tyre service life and truck stability. Check the tyres for specified pressure. If necessary, inflate or deflate at the filler valves. Adjust the tyre inflation according to the information on the label inside the overhead guard. Drive axle H 12 T, H 16 T, H 18 T H 20 T 18 x 7 - 8/16 PR ....... 10 bar 200/50 - 10 SE Example Tyre inflation label

Beginning operation

Drive axle .................................................................... 10 bar Steering axle ................................................................. 8 bar

Steering axle H 12 T, H 16 T, H 18 T H 20 T 18 x 7 - 8/16 PR ......... 8 bar 18 x 7 - 8 SE

350 804 3351.0705

T350-2/053

T350-2/054

24

Daily pre-operational checks and services


Adjusting the operator seat
CAUTION To prevent back injury, the weight setting should be set to the individual weight of the driver. To prevent injuries, do not store any objects in the tilting range of the seat. To prevent accidents, check that all adjustments are properly engaged before operating the truck. Do not operate the seat adjusting devices while operating the truck. For a horizontal adjustment of the seat, pull the adjustment lever (4) out. Slide the seat in the guide rails either forward or back until the optimum position in relation to the steering wheel, accelerator pedals and control levers is obtained. Re-engage the lever. The adjustment of the backrest is by means of the backrest adjuster (1). Push up and hold the backrest adjuster (1). Tilt the backrest forward or back until the position is comfortable for the driver. Release the backrest adjuster (1). Pull out the knob on the adjusting handwheel (6) and turn the handwheel to set the cushioning to the weight of the driver. The adjustment range from 50 kg to 130 kg is visible at the weight range indicator (5). To increase the weight, turn handwheel clockwise. To reduce the weight, turn handwheel anti-clockwise. To adjust the backrest upholstery* (2), move button (3) until a comfortable sitting position is reached. Turning the knob anti-clockwise makes the backrest upholstery arch out. Turning the knob clockwise returns the backrest upholstery to its original position.

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.

350 804 3351.0705

NOTE Long sitting puts excessive strain on the spinal column. Prevent strain with regular, light exercising.

* Option

T350-3/005

25

Applying the seat belt


Applying the seat belt
WARNING The seat belt must always be applied during the operation of the truck! The seat belt is only for securing one person. Drivercabs with closed, solid doors or bar-type doors comply with the safety requirements for driver retaining systems. We recommend the additional use of the seat belt. The seat belt must be used if the truck is operated with the doors open or removed. PVC doors are not considered to be a driver restraint system. NOTE The automatic lock blocks the belt when the truck is tilting heavily. The belt can then not be pulled out of the retractor. To unlock the automatic lock, carefully drive the truck off the side slope. Pull the seat belt (1) out of the retractor with a smooth movement. Place the seat belt over the loin area, not over the belly. Engage the tongue (2) in the lock (4). Check seat belt tension. The belt should be snug on the body.

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.

350 804 3351.0705

2 3
26

T352-3/001

Starting the engine


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 All control levers must be in neutral. 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.
350 804 3351.0705

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

Stopping the engine


Stopping the engine
Remove feet from the accelerator pedals. Turn the switch key to the zero position.

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.

Changing the travel direction


Release the actuated accelerator pedal. The hydrostatic drive will act as service brake. Depress the accelerator pedal for the opposite direction of travel. The truck will now be accelerated in the selected direction. During travel, keep both feet on the accelerator pedals in order to be able to control all movements of the truck easily. The accelerator pedals can be operated from forward to reverse travel directly. The hydrostatic drive will brake the truck to a standstill and then accelerate it in the opposite direction.
350 804 3351.0705

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.

350 804 3351.0705

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.

350 804 3351.0705

* 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

350 804 3351.0705

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.

Changing the travel direction


Release the depressed accelerator pedal (3). The hydrostatic drive will act as service brake. Shift the travel direction control lever (2) to the opposite travel direction. Depress the accelerator pedal (3). The lift truck will be accelerated in the new direction of travel. The travel direction control lever (2) can be shifted from forward travel directly to reverse travel. The hydrostatic drive will brake the lift truck to a standstill and then accelerate the truck in the opposite travel direction.

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

Steering system, braking system


Steering
Due to the hydrostatic power steering, very little effort is required to turn the steering wheel. This is especially advantageous when stacking in narrow aisles. - Start the engine and drive the truck. - Turn the steering wheel as far as possible through the full cycle. WARNING Contact your dealer if steering becomes hard or if excessive play exists. Do not drive the lift truck with a faulty steering. Turning radius - H 12 T ............................................................... 1948 mm - H 16 T ............................................................... 1990 mm - H 18 T ............................................................... 2026 mm - H 20 T ............................................................... 2105 mm ATTENTION For emergency braking depress the STOP pedal located between the accelerator pedals. This will bring the truck to a full stop.

Operation
Parking brake
The multiple disc brakes are used as a parking brake.

Applying the parking brake:


Set the parking brake lever (2) to the vertical position. Depress the stop pedal (1). The stop pedal will lock in this position.

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.

Releasing the parking brake:


NOTE The multiple disc brakes will only be released when the engine is running. Push the parking brake lever (2) forward to disengage the stop pedal.

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

Central-lever control of lifting device and attachments


ATTENTION Use the lifting device and attachments only for authorised applications. The operator must be instructed in the handling of the lifting device and attachments. Observe the maximum height of lift. Do not put your hands into or step into the mast or in the area between the mast and truck. Always operate the control levers smoothly and without jerking. The lifting, lowering and tilting speed is determined by how far the control levers are moved. The control levers return to their neutral position automatically when released. NOTE Note the operating symbols with direction arrows.

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.

Lifting the fork carriage


WARNING Do not step on raised forks. Increased danger of falling and being squeezed. Push the control lever (1) to the right.

Lowering the fork carriage


Push the control lever (1) to the left. CAUTION The mast and fork carriage can be lowered even when the engine is shut off.

Operating the clamp


To open the clamp, push the control lever (3) forward. To close the clamp, pull the control lever (3) back.

Operating the attachments


Attachments can be installed as options (e.g. sideshift, clamp, etc.). Note the working pressure and operating instructions of the attachments. One or two additional control levers are fitted for their operation. NOTE For each attachment, affix a load capacity plate and a symbol label on the bonnet and a symbol label behind the appropriate control lever.

Tilting the mast forward


Push the control lever (1) forward.

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

Tilting the mast back


Pull the control lever (1) back.

351-2/036

36

T350-3/037

Single-lever control of lifting device and attachments


ATTENTION Use the lifting device and attachments only for authorised applications. The operator must be instructed in the handling of the lifting device and attachments. Observe the maximum height of lift. Do not put your hands into or step into the mast or in the area between the mast and truck. Always operate the control levers smoothly and without jerking. The lifting, lowering and tilting speed is determined by how far the control levers are moved. The control lever returns to its initial position automatically when released. NOTE Note the operating symbols with direction arrows.

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.

Lowering the fork carriage


Push the control lever (1) forward. CAUTION The mast and fork carriage can be lowered even when the engine is shut off.

Operating the sideshift


To move the sideshift to the left, push the control lever (3) forward. To move the sideshift to the right, pull control lever (3) back.

Tilting the mast forward


Push the control lever (2) forward.

Tilting mast back


Pull control lever (2) back. -

Operating the clamp


To open the clamp, push the control lever (4) forward. To close the clamp, pull the control lever (4) back.

Lifting the fork carriage


350 804 3351.0705

Operating the attachments


Additional equipment can be installed as option (e.g. sideshift, clamp, etc.). Observe the working pressure and operating instructions of the attachments. One or two additional control levers are fitted for their operation.

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

Switching on the rear working light (8)


The working light is turned on and off with toggle switch (2).

Turning on the rear windscreen wiper


Depress switch (6) to the intermediate position to turn on the front windscreen wiper with intermittent operation. Depress switch (6) fully for continuous wiper operation.

Switching on the lights


Depress the light switch (3) to the intermediate position to switch on the side marker lights and license plate lights. Depress the light switch to switch on low beam.

Operating the turn indicator lights


Move the turn indicator switch (9) on the steering column forward or back to operate the turn indicator lights on the left or right.

Switching on the hazard warning lights


Depress the hazard warning light switch (4).

Turning on the front windscreen wiper


Depress switch (5) to the intermediate position to turn on the front windscreen wiper with intermittent operation. Depress switch (5) fully for continuous wiper operation.
350 804 3351.0705

Switching on the front working lights (7)


The working lights are turned on and off with toggle switch (1).

* 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.

Fan motor fuse


Screw the fuse holder (9) out of the casing and remove with the 8 ampere fuse (8).

If necessary, also check fuse 9F14 in fuse box III.

350 804 3351.0705

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.

Fan motor fuse


Screw the fuse holder (9) out of the casing and remove with the 8 ampere fuse (8).

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

Truck Data Management (LFM)*


Truck data acquisition
The input unit (1) for entering vehicle data is located next to the console. The terminal has a keypad (3) with 12 keys. With the standard setting, a 5-digit PIN number assigned to the operator ensures that only authorised personnel can operate the truck. The truck can only be started after this PIN number and maybe a condition code (depending on the setting) has been entered. NOTE The PIN number can be enlarged from 5 to 8 digits. Before entry of the PIN number, please request your truck pool manager to give you the number of digits of the PIN number and the setting of the truck.

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).

350 804 3351.0705

** 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

Truck Data Management (LFM)*


Truck data acquisition - default setting (PIN number and condition code)
Logging in and starting the truck: - Engage the parking brake. - Press any key to take the terminal into operation. The green LED (2) flashes. - Enter your PIN number and condition code (factory setting = 0 0 0 0 0). On a truck in proper working order as the following PIN No.: 00000 0. NOTE In case the incorrect PIN number was entered, it can be corrected after pressing the key (4) with the asterisk. Confirm the entry by pressing the #-key (3). The green LED (2) is on steadily. NOTE If the red LED (1) comes on, an incorrect PIN number was entered. Press the key (4) with the asterisk and enter the correct number. After more than three incorrect inputs (factory setting), the red LED (1) is on steadily and the green LED (2) flashes. A valid PIN input is disabled for 10 minutes. The disable period can be terminated by entering a special PIN number. Please contact your pool manager. Turn the rotary knob (5) clockwise as far as possible and start the truck.

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.

350 804 3351.0705

* Option

42

Truck Data Management (LFM)*


Truck data acquisition - special setting (PIN number)
Logging in and starting the truck: - Engage the parking brake. - Press any key to take the terminal into operation. The green LED (2) flashes. - Enter your PIN number (factory setting = 0 0 0 0 0). NOTE In case the incorrect PIN number was entered, it can be corrected after pressing the key (4) with the asterisk. Confirm the entry by pressing the #-key (3). The green LED (2) is on steadily. NOTE If the red LED (1) comes on, an incorrect PIN number was entered. Press the key (4) with the asterisk and enter the correct number. After more than three incorrect inputs (factory setting), the red LED (1) and the green LEDs (2) flash. A valid PIN input is disabled for 10 minutes. The disable period can be terminated by entering a special PIN number. Please contact your pool manager. Turn the rotary knob (5) clockwise as far as possible and start the truck.

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.

350 804 3351.0705

* 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.

350 804 3351.0705

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

Before lifting a load


Before lifting a load, check the load capacity diagram (1) on the engine cover. WARNING When attachments are fitted, check the capacity plate (2) for that equipment. Figures stated in the capacity diagram or plate apply to compact and regular loads and must not be exceeded, as this will reduce the stability of the fork truck and the strength of the forks and mast. The maximum capacity is determined by the height of lift and the load centre distance. NOTE Check the load capacity limits and contact your authorised dealer before transporting - off-centre or swinging loads, - loads with the mast tilted forward or the load not near the ground, - loads beyond the centre of gravity, - before operating attachments, - loads at wind force 6 and higher.

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.

350 804 3351.0705

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

Travel with a load, unloading


Travel with a load
NOTE When sending goods by freight, the consignor must load and fasten, if necessary, the transported goods safely. Pay attention to proper stacking and make sure that the packaging, pallets, etc. are not damaged. The freight carrier is responsible for the safe handling. Do not drive with the load shifted to the side (e.g. with sideshift). Transport the load near the ground. Always travel with the load facing uphill on inclines, never travel or turn across the slope. If visibility is reduced, work with a guide. Operate the lift truck only in reverse if the load being transported is stacked so high as to obstruct visibility in the forward direction of travel. * Option

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.

Parking the truck


Deposit the load or lower the fork carriage. Tilt the mast slightly forward so that the forks touch the ground.

350 804 3351.0705

D350-3/011

T350-2/058

351-02/24

47

Transport, hoisting the truck


Transport with lorry or low-bed semi-trailer
Lower the mast. Operate the parking brake. Chock the truck. Lash the truck down. CAUTION Only use a lifting sling and crane with a sufficient capacity. See the manufacturers plate for the truck weight. To hoist with a crane, attach the lifting slings at the points provided. The lifting points on your truck are not labelled extra. Attach the lifting sling (2) (2000 kg carrying capacity minimum) to the tow bolt. Lock the tow bolt. Attach the lifting sling (3) (2000 kg carrying capacity minimum) to the cross member on the outer upright of the mast. Use edge protectors on sharp edges. Attach all the ends to the crane hook (1).

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.

350 804 3351.0705

1 2 3

4 3

T350-2/059

48

Wheel change, catalytic converter, trailer coupling, mast removal


Wheel change
CAUTION Only use a jack with a sufficient lifting capacity. The minimum capacity should be 3600 kg. Loosen the fasteners of the wheel to be changed. Locate the jack.

Catalytic converter, unregulated


NOTE If your truck is equipped with a catalytic converter, no servicing or adjustments are required. Please contact your authorised dealer.

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

The mast may only be dismantled by your dealers skilled staff.

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. -

Releasing the multiple disc brake


Remove the front cover on the truck. Unscrew the cap nut (1) and remove the seal ring (3). Loosen the nut (5). Screw in the threaded pin (4) as far as the stop and tighten to 10 Nm. Lock threaded pin with nut (5). Tighten nut to 25 Nm. Apply about 4 shots of grease with a grease gun through lubricating nipple (2) until the brake is clear.

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

Open hydraulic pump pressure-relief valves


Open the bonnet. Loosen the 18 or 19 mm locknut (6) at the variabledisplacement pump. Using a socket, turn the 8 mm threaded pin (7) out three turns. Lock the threaded pin with locknut (6) and tighten to 60 Nm.

Towing procedure
Lower the load so far that forks do not scrape the ground during towing. Deposit load.

Check the brake for operation after completing repairs.

4 3 1 2

5 1

6 7

D350-3/012

D350-3/019

50

Taking the truck out of operation


Emergency exit for trucks with rear windscreen
NOTE If the truck is fitted with a front and rear windscreen, it may not be possible to dismount at the side if the truck breaks down in a narrow aisle. In case of acute danger, the driver can leave the truck through the rear window. To do so, the driver must pull the rip-cord integrated in the window weather strip to cut it. Pull the red ring (1) at the lower rear window edge and pull out the rip-cord. Remove the rear windscreen. Dismount from the truck carefully through the rear window. If the truck is taken out of operation for over 2 months, it must be parked in a well ventilated, frost-free, clean and dry room and the following measures must be carried out. Thoroughly clean the truck. Lubricate the truck.

Operation
Putting the truck back into operation

Measures before taking the truck out of operation


Thoroughly clean the truck. Fully elevate the fork carriage several times, tilt the mast forward and back and, if fitted, operate the attachment several times. Lower the forks on a support until the chains are slack. Check the hydraulic oil level and add oil, if needed. Close shutoff valve of LPG cylinder or LPG tank firmly. Empty LPG line by starting the engine. Remove the LPG cylinder. Apply a thin film of oil or grease on all unpainted mechanical parts. Lubricate the truck. Check the condition and acid density of the battery. Coat the battery terminals with non-acidic grease. (Follow the instructions of the battery manufacturer.) Spray all open electrical contacts with a suitable contact spray. ATTENTION Block up the truck so that all wheels are clear off the ground. This will prevent tyre deformation. NOTE Do not use plastic foil as this enhances the formation and collection of condensation water. NOTE If the truck is to be taken out of operation for over 6 months, contact your authorised dealer for further measures.

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.

350 804 3351.0705

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

350 804 3351.0705

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.

Securing the mast against tilting back


To prevent the lift mast from tilting back accidentally, insert a 800 mm long 120 x 120 mm hardwood block (1).

350 804 3351.0705

;; ;;
T350-2/060

53

Lift mast types


Standard mast
METHOD OF OPERATION When the inner mast is lifted, the chain pulleys are also moved up so that the fork carriage is raised at a speed ratio of 2:1.

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. -

Securing the raised duplex mast


WARNING Use a suitable chain for the particular lifting mast. Do not exceed the maximum height of lift. Raise the mast. Fasten the chain around the cross member of the outer upright (1) and the cross member of the inner mast (2). Lower the inner mast until it is held by the chain. Fully lower the fork carriage.

Securing the raised standard mast


WARNING Use a suitable chain for the particular lifting mast. Do not exceed the maximum height of lift. Raise the mast. Fasten the chain around the cross member of the outer upright (1) and the cross member of the inner mast (2). Lower the inner mast until it is held by the chain.

350 804 3351.0705

2
54

T350-2/061

T350-2/065

Lift mast types


Triplex mast
METHOD OF OPERATION The fork carriage is raised to the special free lift height by the centre cylinder via the chain guide roller. The two lift cylinders then raise the inner upright. When the inner mast is raised fully, two further lift cylinders raise the outer upright, which is lifted together with the inner upright and fork carriage. The centre cylinder is mounted within the extendible inner mast.

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.

Inspection and maintenance after the first 50 service hours


NOTE A description of the maintenance activities can also be found in the index. Change the engine oil Renew the engine oil filter Check, tighten coolant pump - alternator drivebelt tension and condition Inspect the intake and exhaust pipes for leaks Check the LPG-system for damage and leaks using a leakage spray Check the parking brake Tighten the wheel fasteners Check the tyre inflation Check the tyres for damage and foreign objects Check the hydraulic system, drive axle, hydraulic pumps, valves and lines for leaks Renew the hydraulic system pressure, suction and breather filters Check the battery condition, electrolyte level and specific gravity Check the mounting of the engine and engine support for condition and security Check the mounting of the counterweight, overhead guard, steer axle and drive axle Check the mast, lift chains, lift cylinders and stops for condition, mounting and operation Clean, adjust and spray lift chains with chain spray Clean and grease the steer axle Grease the mast and tilt cylinder bearings Check the electric cables and cable connections for condition and security Check the pre-tension of double hoses if attachments are fitted Check the catalytic converter basic adjustment of the LP gas system Check the LPG mixer adjustment

350 804 3351.0705

T350-2/066

55

Inspection and maintenance schedule


Service (A description of the service can also be located in the index) Prior to first operation After the first 50 service hours Daily checks

Maintenance
Inspection as required

For services see page 19 ...........................................................................................................................................

For services see page 55 ............................................................................................................................................................................

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

Inspection and maintenance schedule


Service (A description of the service can also be located in the index) every 500 hours every 1000 hours every 2000 hours

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

350 804 3351.0705

Inspection and maintenance as required


Clean the lift truck
NOTE The necessity of cleaning depends on the use of the truck. If used with aggressive media such as salt water, fertilizer, chemicals, cement, etc., clean the truck thoroughly after every use. Hot steam or intensive degreasing solution should be used with the utmost care! If not, the grease in the lubricated-for-life bearings will dissolve and leak out. As regreasing is not possible, damage to the bearings will result. Dont wash the truck whilst the engine is running or hot. ATTENTION When cleaning with a water jet (high pressure or steam jet cleaning device, etc.) do not directly expose the electrical or electronic components as well as the connectors to the jet. If this cannot be avoided, cover them first. Regularly remove inflammable debris especially on or in the area of parts with a high temperature (such as exhaust pipes). When cleaning with compressed air, remove sticking dirt with a cold cleaner. Clean the oil filler openings, surrounding areas and grease nipples before lubrication.

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.

350 804 3351.0705

D350/018

D350-3/041

58

Inspection and maintenance as required


Clean the air filter
NOTE Cleaning the air filter element is necessary only when the air filter restriction indicator in the composite instrument illuminates. A restricted air filter results in loss of power and increased engine wear. Careful and regular servicing of the air filter is therefore essential for the engine. Carry out all services on the air intake system with the engine stationary. Do not start the engine when the filter element is removed. Open the bonnet. Screw off the wing nut (2) and remove the air filter cover (1). 350 804 3351.0705

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.

Clean with compressed air


ATTENTION Do not clean the filter casing with compressed air, wipe it with a clean cloth. To clean the filter element (3), blow dry compressed air at max. 5 bar pressure from the inside to the outside until the filter is free of dust. Before installing the cleaned air filter element, examine it for damage eg at paper of filter element, rubber seals, for dents or bulges on the metal frame. Using an inspection lamp, examine the paper part of the filter element for cracks and holes. Renew a damaged filter element.

Screw out the nut (4) and pull out the air filter element (3).

2
T350-3/028

3 4

T350-2/036

59

Inspection and maintenance as required


Check the dust ejection valve
NOTE The dust ejection valve (5) is largely maintenance-free. If required, squeeze the valve and remove the remaining dust. Replace a damaged valve. -

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.

Check the mounting of the hydraulic oil tank


Remove the floor plate. Check the retaining belt (1) on the hydraulic tank (3) and tighten, if necessary, with the ratchet belt (2). Install the floor plate.

350 804 3351.0705

* Option

1 2 1 2 3

5
T350-2/038

T350-2/045

D350/035

60

Inspection and maintenance as required


Tighten the wheel fasteners
ATTENTION Every 100 hours at the latest.

Maintenance

Check the tyres for damage and foreign objects


Secure the truck against rolling (apply parking brake). Chock a wheel that is not to be jacked up. Raise the truck with a jack until the wheels are clear off the ground. Secure the truck with squared timbers. Check the wheels for ease of rotation and remove anything hindering their free movement. Replace worn or damaged tyres.

Tighten all wheel fasteners to a torque of 210 Nm.

350 804 3351.0705

D350-3/040

D350/014

61

Inspection and maintenance as required


Clean the radiator and hydraulic oil cooler, check for leaks
NOTE Clean radiator and hydraulic oil cooler only with engine shut off and cool. Open the bonnet. Cleaning with a cold cleaner Clean the radiator fins with a regular cold cleaner and allow to soak for about 10 minutes. Flush the radiator fins with a strong water jet from the engine side. ATTENTION Cover the alternator before flushing with a water jet. Let the engine run warm to evaporate any residual water and to prevent corrosion. Check connectors, coolant hoses and pipes at the radiator and hydraulic oil cooler for leaks. Renew cracked hoses, retighten loose clamps, if necessary.

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.

350 804 3351.0705

2
62

T350-2/047

Inspection and maintenance as required


Check the ignition timing
NOTE This test and adjustment must be performed by trained skilled personnel! Contact your authorised dealer for this service. Accurate testing and timing of the transistorised ignition is only possible using a stroboscopic timing light. CAUTION Observe the appropriate safety measures when handling transistorised ignitions. 350 804 3351.0705

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

Inspection and maintenance as required


Check seat belt for condition and proper operation
NOTE For safety reasons the condition and operation of the retention system should be inspected regularly (monthly). Under extreme operating conditions this check is required daily before taking the truck into operation. Pull the belt (1) out fully and inspect for fraying. Check the lock (3) for correct operation and the retractor for proper return of the belt. Check covers for damage. Check the automatic lock. - Park the truck on level ground. - Pull out the belt with a jerk. The automatic lock should prevent the belt from unrolling from the retractor (2). - Slide the seat fully forward. NOTE When opening the bonnet, watch out for a possibly installed rear windscreen*. Open the bonnet (4) about 30. The automatic lock should prevent the belt from unrolling from the retractor (2).

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.

350 804 3351.0705

* Option

30o

2
64

t352-03/03

T352-3/004

500-hour inspection and maintenance


Grease the mast and tilt cylinder bearings
NOTE Lubricate with lubricating grease. Lubricate the nipple (1) of tilt cylinder bearing at the mast from the inside with lubricating grease. Lubricate the nipple (2) of the mast pivot at the chassis with lubricating grease. Lubricate with a grease gun until some fresh grease is visible at the bearings. Open the bonnet. Lubricate the nipple of tilt cylinder bearings with lubricating grease through left and right holes in the chassis. Lubricate with a grease gun until some fresh grease is visible at the bearings. -

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.

350 804 3351.0705

D350-3/037

T350-2/071

351-2/084

65

500-hour inspection and maintenance


Sideshift*: Clean, grease and check the mounting
Clean the sideshift with a steam jet. Inspect the hydraulic pipes and hoses for chafe marks, and replace any pipes and hoses, if required. Check the hydraulic fittings and mounting elements for security and wear, and tighten or replace them, if required. Adjust the forks to gain access to the 4 grease nipples (1). Lubricate the roller grease nipples (1) on the fork carriage with lubricating grease until new grease emerges at the side.

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.

Check the hydraulic system oil level

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.

350 804 3351.0705

* Option

1
66

D350-3/046

T350-2/072

T350-2/034

500-hour inspection and maintenance


Check electric cables, cable connectors and connections for condition and tightness
Check cable connections for tightness and oxidation. Check earth lead for tightness. Check electric wiring for chafe marks and tightness.

Maintenance

Battery: Check condition, electrolyte level and specific gravity


ATTENTION Even a so-called maintenance-free battery must be checked for proper condition, electrolyte level and specific gravity. ATTENTION Battery electrolyte is very caustic. Avoid any contact with battery electrolyte. If clothing, skin or eyes nevertheless come in contact with electrolyte, flush the areas respective immediately with water. If electrolyte comes into contact with the eyes, seek medical aid immediately! Neutralise spilled electrolyte at once. Check the battery to see whether tray is cracked, plates are lifted or acid has drained. Unscrew caps and check the electrolyte level. On batteries with check tubes, the liquid should be at the bottom of the tubes. On batteries without tubes, the liquid should be 10 to 15 mm above the plates. If the electrolyte level is low, top up with distilled water only. Remove any oxidation at the battery poles and grease with non-acidic grease. Retighten the pole clamps firmly. Check electrolyte specific gravity with a hydrometer. The specific gravity should be between 1.24 and 1.28. Close the bonnet.

NOTE Oxidised terminals and cracked cables result in loss of voltage, thus leading to starting difficulties. Remove oxidation remains and replace any cracked cables.

350 804 3351.0705

T350-2/039

67

500-hour inspection and maintenance


Check the LPG system for damage and for leaks with leakage spray
NOTE The LPG system should be checked at least once a year for leaks by qualified staff. Open the bonnet. Open the LP gas cylinder. Check the LPG cylinder shutoff valve or gas tank*, hose unions and hoses for leaks and damage. Spray leakage spray on hose and pipe unions, gas filter with shutoff valve, evaporator-pressure regulator, vacuum chamber, shutoff valve and LPG mixer and check for bubbles. With LPG tank* Check the shutoff valve, level gauge, filler valve, and metering valve for leaks. Tighten any loose fittings, renew damaged hoses and recheck for leaks. Leaks on the LPG filter, evaporator-regulator, shutoff valves and LPG mixer may only be sealed by your authorised dealer.

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

Close the bonnet.

T350/005

T350-3/011

T350-3/012

68

500-hour inspection and maintenance


Renew the engine oil (every 12 months minimum) Drain the engine oil
ATTENTION Follow the precautions for handling fuel, lubricants and coolant. ATTENTION Engine oil may be hot. Danger of scalding. Push up the rubber cover (2) over the opening in the frame from below. Screw out the engine oil drain plug (3) at the oil sump. Allow the oil to drain completely into the tray. Refit the drain plug using a new sealing ring. -

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.

Torque ........................................................................ 30 Nm Put the rubber cover back in place.

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

500-hour inspection and maintenance


Top up the engine oil
Remove the cap (1) on the filler opening. Fill new engine oil through the filler opening. Filling capacity - with filter renewal ...................................... max. 5.0 litres Close the bonnet. NOTE During the trial run after the oil change and filter renewal, observe the oil pressure warning light and watch for leakage at the oil drain plug and oil filter. An accurate check of the oil level, particularly after renewing the oil filter, requires stopping the engine again and rechecking the oil level after about one minute. Windscreen wiper pivots* Cab* door hinges and locks Check the engine oil level after filling with the dipstick and add oil, if necessary, up to the maximum mark.

Maintenance
Check and oil other pivots and joints
Inspect and oil the pivots and mountings of: Seat guide, bonnet mounting pivot pin

Check and grease the engine lock mounting and pretension.

350 804 3351.0705

* Option

T350-3/013

T350-2/016

70

500-hour inspection and maintenance


Check the coolant strength
Remove the LPG cylinder cover (1). Mixing ratio for lower temperatures: Temperature -30 C -35 C Coolant additive 45 % 50 % Drinking water 55 % 50 %

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

500-hour inspection and maintenance


Check the tension and condition of the alternator and coolant pump drivebelt
CAUTION Stop the engine and remove the ignition key.

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.

Tighten the alternator and coolant pump drivebelt


Loosen the screw (1). Turn the tensioning screw (2) until the belt tension is reached. Tighten the screw (1).

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

500-hour inspection and maintenance


Check the tension and condition of the toothed belt, renew if necessary
CAUTION Stop the engine and remove the ignition key. Remove the top toothed belt cover (1) at the engine. Check the drivebelt for excessive wear, worn flanks, damaged teeth, cracks and traces of oil. If the toothed belt is damaged, have it renewed by your authorised dealer. Twist the toothed belt (2) with the fingers. Midway between the camshaft and intermediate shaft gear it should be possible to twist the belt (2) just 90 still with the thumb and index finger. In case of insufficient tension, retighten the toothed belt by turning the idler roller (3) clockwise with a spanner (4) until the tension is achieved. Tighten the clamping nut on the tension roller. Rotate the crankshaft twice and recheck the tension of the toothed belt. Repeat the adjustment if necessary. Install the top toothed belt cover (1) at the engine.

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.

350 804 3351.0705

Torque ........................................................................ 45 Nm

T350-3/025

4 3

T350-3/026

73

500-hour inspection and maintenance


Check the mounting of the counterweight, overhead guard, steer axle and drive axle
Check the mounting of the counterweight, overhead guard, steer axle and drive axle for security of the fastening elements and for wear. Tighten any loose nuts and bolts. Renew damaged parts. Touch up the paint coat, if necessary. Close the bonnet.

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

Retighten the mast fastening bolts


Elevate the fork carriage and secure against inadvertent lowering. Check the fastening bolts (1) (2 on each side) of the mast bearing shells for tightness. Torque: ................................................................ 800 Nm

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

500-hour inspection and maintenance


Check the mast, lift chains, lift cylinders and stops for condition, mounting and operation
Clean the mast channels and lift chains. Inspect the chains for condition and wear, especially in the pulley area. Check the security of the chain at the chain anchor. Replace any damaged chains. Check mast, channels and rollers for condition and mounting. Check the condition, mounting and operation of the stops. Check lift cylinder fastening. Check the circlip of the piston rod fastener on the top of the lift mast for security. -

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.

Adjust the lift chain length*


NOTE As lift chains stretch with use, they must be adjusted on the left and right hand side. Completely lower the mast. Loosen the locknut (1). Adjust chain length with the adjusting nut (2) at the chain anchor. The lower guide pulley on the fork carriage can project max. 25 mm from the inner mast channel. Tighten locknut (1) firmly. Adjust the second chain. ATTENTION Extend the mast fully and then check the clearance between the end stops.

Lubricate the lift chain with chain spray


Spray the guiding surfaces and chain with Linde chain spray.

350 804 3351.0705

Lubricate with chain spray


Spray channel surfaces, pulleys and chains with Linde chain spray.

NOTE Trucks in service in the food industry must be lubricated with a 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

500-hour inspection and maintenance


Clean the radiator and hydraulic oil cooler
NOTE Clean radiator and hydraulic oil cooler only with engine shut off and cool. Open the bonnet. 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. Cleaning with a cold cleaner - Clean the radiator fins with a regular cold cleaner and allow to soak for about 10 minutes. - Flush the radiator fins with a strong water jet from the engine side. ATTENTION Cover the alternator before flushing with a water jet. Let the engine run warm to evaporate any residual water and to prevent corrosion. Close the bonnet.

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.

Check the forks and fork quick-releases


Inspect the forks for visible deformation, wear and damage. Check the fork stop bolts and the fork quick-releases for correct seating and damage. Replace any damaged parts.

350 804 3351.0705

2
76

T350-2/047

D350-3/049

E336/088

1000-hour inspection and maintenance


Renew the air filter element, check the vacuum switch
(at least every year or after 5 cleanings) Open the bonnet. Unscrew the fastening nut (2) and remove the air filter cover (1). Unscrew the nut (4) and take out the air filter element (3). ATTENTION Clean the filter casing thoroughly on the inside. Do not clean with compressed air. When installing, take care not to damage the element and make sure it is positioned correctly. Secure the element with the nut and re-install the filter cover. Remove the hose (5) from the air filter inlet. With the engine running, slowly close the air filter intake opening (eg with a cardboard or metal plate) until the air filter restricted warning light in the composite instrument lights up. To prevent damage, do not close the opening further after the warning light illuminates.

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

350 804 3351.0705

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

1000-hour inspection and maintenance


Check the hydraulic system, drive axle, pumps, valves and lines for leaks
Examine all connections between the oil reservoir, drive axle, pumps and control valves for leaks. If necessary, tighten any loose connections. Check the lift, tilt and steering cylinders for leaks. Replace any cracked hoses. Inspect the hydraulic lines for chafe marks and replace any lines, if necessary. -

Maintenance

Check the air intake and exhaust pipes for leaks


Examine the intake and exhaust manifolds at the cylinder heads. If they are loose, tighten fastening screws or replace the gaskets. Check the condition and tightness of the air intake hoses on the air filter, tighten the hose clamps and replace porous hoses, if necessary. Close the bonnet.

350 804 3351.0705

T350-2/013

T350-3/015

78

1000-hour inspection and maintenance


Renew the pressure filter
ATTENTION Follow the precautions for handling fluids and lubricants. Lower the mast. Remove the cover at the front of the truck. Loosen filter housing (1) by hand.

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.

Renew the suction filter


Remove the fastening screws (2) on the suction filter cover (3). Lift the suction filter cover and put it aside. Slowly extract the filter element so that the oil can flow back to the tank. Carefully insert a new element into the bowl. Clean the sealing ring on the filter cover, oil slightly and install it with the fastening screws (2). Check the filter for leaks in a trial run. Check oil level with the dipstick (5), if necessary add hydraulic oil. NOTE In an excessively dusty atmosphere it be necessary to renew the filter earlier. Install the floor plate. Close the bonnet.

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.

350 804 3351.0705

4 5

D350-3/029

D350-3/034

T350-3/016

79

1000-hour inspection and maintenance


Check the parking brake
Drive the lift truck with maximum load on a 15 % slope. Depress the brake pedal (1). Place the parking brake lever (2) in the vertical position. The brake pedal will lock. The truck must not move. Release the parking brake lever (2). The brake pedal will return to its initial position. Stop the engine. The lift truck must not move. -

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.

Clean the evaporator/pressure regulator


(install a new repair kit, every 12 months minimum) Disassemble the evaporator/pressure regulator, clean, inspect and install with a new repair kit. Measure the CO content and check engine performance with the stall speed. 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

2000-hour inspection and maintenance


Check the distributor and ignition cables
Open the bonnet. Remove the distributor cap. Clean the distributor cap and rotor, and check for cracks, damage and oxidation residues. Replace the cap if the distributor contacts are damaged and/or pitted. Check the ignition cable and spark plug connectors for damage and breaks. Replace damaged parts. Close the bonnet.

Maintenance

350 804 3351.0705

T350-2/018

81

3000-hour inspection and maintenance


Renew the coolant
In all seasons the cooling system must be filled with a mixture of water and unphosphated glycol-based antifreeze with an anticorrosion additive to provide protection against calcium deposits, frost and corrosion damage, and to raise the boiling temperature. Pull the LPG cylinder cover (1) out of the retainer at the bottom and remove it upwards. CAUTION Do not open the coolant reservoir cap (2) when the engine is hot. Danger of scalding. ATTENTION Follow the precautions for handling fuels and lubricants. Open the bonnet. Place a dish of sufficient capacity under the drain plug. Drain the coolant, either via the coolant hose or via the flange at the coolant pump. Dispose the coolant as required by local laws and regulations. Connect the coolant hoses or tighten the flange at the coolant pump. Fill new coolant into the coolant reservoir.

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.

350 804 3351.0705

2
1

T350-2/051

T350/008

82

3000-hour inspection and maintenance


Renew the alternator and coolant pump drivebelts
CAUTION Stop the engine and remove the ignition key. NOTE Check belt tension with thumb pressure. Retighten new drivebelts after they have run 15 to 20 minutes. Turn the tensioning screw (2) to pivot the alternator towards the engine. In this position it is possible to remove the drivebelt (3). Install a new drivebelt (3). Turn the tensioning screw (2) until the belt is tensioned. Tighten the locknut (1) firmly. New drivebelt ............................................ approx. 2 mm Tighten the drivebelt if the tension is insufficient. Close the bonnet.

Maintenance
Renew the toothed belt
NOTE Special equipment is necessary for renewing the toothed belt. Please contact your authorised dealer.

Loosen the screw (1).

350 804 3351.0705

1 3

T350-3/020

T350-3/027

83

3000-hour inspection and maintenance


Renew the hydraulic oil
Draining the hydraulic oil NOTE The fork carriage must be lowered completely. ATTENTION Follow the precautions for handling fuels and lubricants. Drive the truck over a repair pit. Put a container underneath the lift truck on the right side. Open the bonnet. Remove the breather filter (2) with the dipstick (3). Remove the hydraulic oil drain plug (1) at the hydraulic oil tank. Allow the oil to drain completely. Clean the area around the oil drain thoroughly. Reinstall the drain plug. Filling/adding hydraulic oil Filling capacity .......................................... approx. 17.0 litres Fill hydraulic oil at the filler opening. Check the oil level with the dipstick (3) and fill oil until the upper mark on the dipstick is reached. Run the engine briefly and repeat the check.

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.

350 804 3351.0705

Torque ........................................................................ 25 Nm

2 3

1
84

T350-2/083

T350-2/019

Inspection and maintenance data


No. 1 2 Assembly Engine LPG cylinder - LPG cylinder - Refillable LPG tank Cooling system Hydraulic system Battery Tyres Coolant additive / water Hydraulic oil Distilled water Air Aids/Fuel and Lubricants Engine oil Capacities/Settings incl. oil filter renewal

Maintenance

approx. 5.0 litres

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

Strong thumb pressure New drivebelt Run-in drivebelt approx. 2 mm approx. 5 mm

85

Fuel and oil recommendations


Engine oil Oil grade and viscosity
CCMC specification: G4/G5 API classification: SF/SG/SH Volkswagen specification: 500 00/501 01 A special high-grade multigrade oil has been filled at the factory that can be used all year round, except in extreme climates. As the trouble-free operation and long service life of the engine depends upon a good engine oil, use only high-grade engine oil when topping up. The specifications given on this page must be stated on the container, either alone or together with other specifications. When adding oil, the oils can also be mixed. Select the viscosity range of the oil according to the table. If the ambient temperature exceeds the specified range only briefly, the oil does not need to be changed. NOTE Single grade oils can usually not be used the year round because of their limited viscosity range. These oils should only be used in extreme climates. Regardless of the oil change intervals, change the engine oil at least once a year. Do not add any additives of any kind to the lubricating oils.

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.

350 804 3351.0705

86

Fuel and oil recommendations


Hydraulic oil
Recommendation for normal duty: Hydraulic oil ISO - L - HM 68 to ISO 6743 - 4 or HLP ISO VG 68 to DIN 51524, T.2 (factory filling), average oil temperature 60 C - 80 C. Hydraulic oil recommendation for heavy duty: Hydraulic oil ISO - L - HM 100 to ISO 6743 - 4 or HLP ISO VG 100 to DIN 51524, T.2 for heavy and multi-shift operation, operation in extreme climate zones or at high ambient temperatures, average continuous oil temperature over 80 C. For normal and heavy duty: Hydraulic oil ISO - L - HV 68 to ISO 6743 - 4 orHVLP ISO VG 68 to DIN 51524, T.3 (multigrade oil).
350 804 3351.0705

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).

Bio hydraulic oil


Biologically fast-degradable pressure fluid Aral Forbex SE 46 ATTENTION Do not mix bio-oils with mineral oils. Other fluids from other manufactures cannot be recommended. NOTE In case of doubt we recommend contacting your authorised dealer. Even recommendations of representatives of the mineral oil industry should be checked with your authorised dealer. The manufacturers approval covers only the oils mentioned above. If other hydraulic oils or a mixture is used, expensive damage can result.

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

Troubleshooting guide (LPG engine)


Trouble
Engine does not fire ATTENTION If the LHC warning lights are flashing, the faults can be determined by your authorised dealer with the diagnostic unit.

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

Solenoid shutoff valve does not open.

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

Engine starts, but runs irregularly in idle or not at all

Idling speed setting incorrect.

Intake manifold connections leaky.

78 78

88

Troubleshooting guide (LPG engine)


Trouble
Engine does not fire on all 4 cylinders

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

Engine runs unevenly or misfires

Plugs are misfiring.

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

Plug connector is faulty. Electrical leaks on ignition cable.


350 804 3351.0705

81 81

Distributor cap has electrical leak (hair-line cracks).

Gas supply inadequate or interrupted.

Engine continues to run when stopped

Solenoid shutoff valve does not close.

Check the cable connections, renew the solenoid shutoff valve, if necessary.

Warm engine runs unevenly; exhaust fumes have carbon

Idling speed setting incorrect.

Adjust the idling speed so that the engine runs smoothly.

85

Engine knocks under load

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

Troubleshooting guide (LPG engine)


Trouble
Engine overheating ATTENTION Shut off engine at once.

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

Troubleshooting guide (hydraulic system)


Trouble
Abnormal noise

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

No or too low pressure in system


350 804 3351.0705

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

Oil pressure fluctuates

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

No oil flow or low oil flow

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.

Hydraulic oil temperature too high

91

Electric circuit diagram (Standard equipment)


1A1 1E40 1E41 F1 F2 F3 F4 F5 G1 G2 H1 H2 H3 H4 H5 H6 H12 H13 H24 H25 H26 4H7 K2 K3 M1 P1 6P3 Ignition control unit Ignition distributor Spark plugs MTA fuse 50 A Fuse 5 A Fuse 5 A Fuse 15 A Fuse 10 A Alternator with regulator 660 W Battery 88 Ah Battery charging indicator light 2 W Fault in electronic control unit 1.2 W Engine temperature warning light 1.2 W Hydraulic oil temperature warning light 1.2 W Oil pressure warning light 1.2 W Air filter restriction warning light 1.2 W Turn indicator light 1.2 W Low fuel level indicator** Fan 1.2 W Preheating** Soot filter warning** Horn 60 W Relay for starter Auxiliary relay terminal 15 Starter 1.7 kW Hour meter Composite instrument 1T1 V1/3 X1 X2 X3 Ignition coil Decoupling diodes Connector, 16 way Connector, 3 way Connector, 1 way

(a)

Wiring diagram for options

Wire code
BK WH BU OG BN GN VT RD YE GY black white blue orange brown green violet red yellow grey

350 804 3351.0705

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

* Option ** Not used if LPG engine is installed

92

Electric circuit diagram (Standard equipment)

350 804 3351.0705

93

Electric circuit diagram (Standard equipment)


9A2 1B1 1B2 1B10 1F17 1F18 9F16 Fan control Actual rpm transmitter Accelerator twin potentiometer Pressure sensor Fuse, LHC control 1 A Fuse, LHC control 15 A MTA fuse, fan 30 A (I) (II) (a) (b) (c) (d) (e) 9M5 1N2 Fan 324 W (f) Electronic travel control LHC (g) 1R1 Resistor 120 Ohm 9R1/2/3 Resistor 9R4 Resistor for fan 1S5 1S25 9S17 Brake pedal switch 1 Directional switch, single pedal model* Thermal switch (85/93 oC) (h) (j) (k) (l) 9V1/2/3 Decoupling diodes (m) 1X10 1X20 1X21 1X23 6X6 9X5 1Y1 1Y2 1Y3 1Y4 1Y5 Connector, Connector, Connector, Connector, Connector, Connector, 3 3 6 6 4 2 way way way way way way (n) Code plug for twin pedal detection Directional switch for single pedal model* Seat switch, make Seat switch, break Speed limiter Speed limiting reference Door switch
350 804 3351.0705

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

9K1/2/3 Relay 9K4 Auxiliary relay

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

* Option ** Not used if LPG engine is installed 94

Electric circuit diagram (Standard equipment)

Platzhalter

350 804 3351.0705

95

Electric circuit diagram (Options)


5E2 5E3 5E4 5E5 5E6 5E7 5E8 9E21-26 5F5 5F6 5F7 5F8 5F9 5F10 9F11 9F12 9F13 4H14 5H8 5H9 5H10 5H11 5H18 5H19 9H16 9H17 5K1 5K10 Dipped headlight, left 55 W Dipped headlight, right 55 W Left side marker light, front 5 W Right side marker light, front 5 W Left side marker light, rear 10 W Right side marker light, rear 10 W Number plate light 5 W Working lights 55 W Fuse 10 A Fuse 10 A Fuse 5 A Fuse 5 A Fuse 15 A Fuse 15 A Fuse 15 A Fuse 15 A Fuse 15 A Revolving light 55 W Turn signal light, front left 21 W Turn signal light, rear left 21 W Turn signal light, front right 21 W Turn signal light, rear right 21 W Switch illumination 1.2 W Switch illumination 1.2 W Switch illumination 1.2 W Switch illumination 1.2 W Flasher unit Relay for UPAs (customer specific) 4S15 5S11 5S12 5S13 9S1 9S2 9S10 9S11 5X1 5X2 5X3 9X7 9X8 9X10 (I) (II) (III) (a) (b) (IV) (a) (V) (a) (c) (d) Revolving light switch Light switch Hazard warning light switch Turn signal switch Switch, front working lights Switch, rear working light Seat switch Switch speed increase for option Connector Connector Connector Connector Connector Connector 8 6 3 6 6 6 way way way way way way (VII) (a) (c) (d) Steady 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 Seat switch Wiring diagram for stndard equipment Speed increase for option Wiring diagram for stndard equipment

(VIII) (a) (IX) (a)

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

350 804 3351.0705

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.

(VI) (a) (c) (d)

96

Electric circuit diagram (Options)

350 804 3351.0705

97

Electric circuit diagram (Options)


7A1 7A2 7B1 7F1 7F2 9F4 9F5 4H23 9H3 9H4 9K5 9K6 9M1 9M2 7S1 9S3 9S4 7X1 7X2 7X4 7X5 9X1 9X2 Controller Actuator Lambda probe Fuse 5 A Fuse 1 A Fuse 10 A Fuse 10 A Switch illumination 1.2 W Switch illumination 1.2 W Switch illumination 1.2 W Relay, front windscreen wiper Relay, rear windscreen wiper Wiper motor, front 30 W Wiper, rear 30 W Vacuum switch Switch, front wiper Switch, rear wiper Connector 2 way Connector 2 way Connector 2 way Diagnostic connector 6 way Connector 6 way Connector 3 way (I) (II) (a) (III) (b) (c) Windscreen wiper, front Windscreen wiper, rear 9F4, 9F5 in fuse strip III, cavity 5 + 6 Lambda control Ignition coil T1:1, wiring diagram for standard equipment 9F16:1 (terminal 30) wiring diagram for standard equipment

Colour code
BU BN YE GN GY RD BK WH VT OG blue brown yellow green grey red black white violet orange

350 804 3351.0705

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

Electric circuit diagram (Options)

350 804 3351.0705

99

Electric circuit diagram (Options)


7A1 7B1 7B2 F1 F3 7F15 7F16 7F17 9F13 9F14 H26 4H14 4H15 7H22 7H23 K2 7K9 7M1 7M5 9M6 7R2 Soot filter control unit** Buzzer** Thermo-element** Fuse MTA (standard equipment)** Fuse (standard equipment)** Fuse 5 A** Fuse 30 A** Fuse 20 A** Fuse 15 A Fuse 10 A Indictor light** Revolving light Flashing light Warning lamp regeneration** Fault warning lamp regeneration** Starting relay** Glow plug relay** Fan** Metering pump** Heater fan 35 W Glow plug** (I) (a) (b) (c) (d) (e) (II) (III) Soot filter system** To alternator** To ignition switch** To starter** To brake pedal switch** ISO interface** Heater Rotating/flashing light connected to key switch

350 804 3351.0705

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.

Cut-off valve** **no function on LP gas engine models

100

Electric circuit diagram (Options)

350 804 3351.0705

101

Electric circuit diagram (Options)


6B10 Tank sending unit (ultrasonic) F3 F5 6H7 Fuse Fuse Instrument lighting (I) (a) (II) Engine and load cut-out after 0.5 to 5.0 min. To wiring diagram for stndard equipment LP gas gauge with ultrasonic sensor

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

350 804 3351.0705

Cables without specification of diameter = 0.75 mm2 The number before the cable colour corresponds to the cable cross section.

102

Electric circuit diagram (Options)

350 804 3351.0705

103

Electric circuit diagram Truck Data Management (LFM)


6A3 6A4 6B1 6B2 6B3 Data-Logger with key pad (LFM) LFM on-line module Traction sensor Lift sensor Shock sensor

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

(a) (b) (c)

Particle filter**
350 804 3351.0705

Electric circuit diagram for options For particulate filter warning buzzer 7B1:30 optional equipment wiring diagram**

**no function on LP gas engine models 104

Electric circuit diagram Truck Data Management (LFM)

350 804 3351.0705

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

Steering control valve consisting of:


Metering valve 45 cm3/rev. Hose safety valve 190 10 bar Makeup valve Pressure relief valve 120 +5 bar

O
55 56

Hydraulic drive axle AH-20 assembly consisting of:


Multiple disc brake Hydraulic motors 25 cm3/rev.

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

Oil cooler Hydraulic oil tank


Suction filter 25 m

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

Pressure sensor 0 - 20 bar Electronic controller


Not used Not used Speed increase Not used Actual speed Brake applied IC engine Brake released Forwards Forwards Emergency stop Reverse Reverse Brake

49 50

J
51 52 53 54

Tandem pump assembly consisting of:


Check valve Flow regulator 15.5 to 17.0 litres Gear pump 14 cm3/rev. Gear pump 11 cm3/rev.

K L M N

Damper Brake valve Pressure filter 6 m absolute Check valve 1 bar

106

Hydraulic schematic

350 804 3351.0705

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

350 804 3351.0705

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

Noise emission levels ........................................................ 12

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

109

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

Visual, olfactory inspection of LPG system ....................... 21

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

Safety rules for LP gas (excerpt)


Observe the accident prevention rules of your national Industrial Trade Association. Liquefied petrol gases are BUTANE, PROPANE and butanepropane mixtures. They are supplied in LPG cylinders or gas tanks for the operation of IC engines. The operating pressure of these gases depends on the ambient temperature and it may reach 25 bar or more. WARNING Released LP gas becomes gaseous instantly so that the formation of a hazardous and explosive atmosphere is immediately given. WARNING No naked flame (stoves, storm lanterns, spark generating activities, etc.), no smoking in garages or when carrying out work on the LP gas system!
350 804 3351.0705

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.

Responsibility of employer and employees


The employer must ensure that the industrial trucks must be operated and serviced by persons instructed in the operation and servicing of these trucks and who can be relied on to perform their tasks reliably. LPG systems on trucks may only be taken into operation if they are in the proper working condition. The employer must prepare operating instructions for the industrial truck in an understandable form and language, which contains all the information required for safe operation. The operating and service staff must be acquainted with the operating instructions. The operating instructions must be available for and observed by the operating and service staff at all times.

111

Safety rules for LP gas (excerpt)


B. In garages, storehouses and repair shops
1. Close the cylinder and main shut off valves immediately after parking the vehicle. 2. LPG powered industrial trucks may only be parked in wellventilated rooms above ground level. They may not be parked near openings to rooms below ground level. Keep a safe area around parked trucks in which there are no cellar openings and doors, pits and similar hollows, uncovered sewer openings, air and light shafts, and inflammable materials. 3. Removable gas cylinders may only be changed in garages in which the formation of an explosive atmosphere has been prevented. 4. Follow the special regulations related to the storage of gas cylinders or national regulations. For example, gas cylinders may not be stored in rooms under ground level, in staircases, in hallways of houses and multiple-story buildings, small yards and passages and gates or in their immediate vicinity, at stairs of open-air facilities, at specially marked rescue routes, in garages, in workrooms. 5. Electric lights installed in these rooms must have a tightly fitting sealed protective cover with a strong basket protector. 6. Close the cylinder and main shutoff valves during work in repair shops and protect the LPG cylinders from the influence of heat. A responsible person must check if all valves, especially cylinder valves, are closed before work breaks or at the end of the day's work. Do not perform any work involving fire, in particular welding and cutting jobs, near the LPG cylinders. Do not store LPG cylinders in workshops, even if they are empty. 7. Garages, storehouses and repair shops must be well ventilated. Do not forget that LP gases are heavier than air. They accumulate over the floor, in inspection pits and other low spots and there they can form a dangerous and explosive air-gas mixture. WARNING Exhaust gases are poisonous. Ensure adequate ventilation of garages!

Safety precautions for transistorised ignition systems


To prevent injuries to persons and/or destruction of the contactless transistorised ignition system, observe the following points when working on components of the transistorised ignition system: Disconnect and connect ignition system cables - also high-voltage cables and test leads - only with the ignition turned off. If the engine is to be operated at starting speed without firing (e.g. when testing compression), pull the highvoltage cable (terminal 4) from the distributor and earth it. Use a rapid charging system as a starting aid only for 1 minute and with max. 16.5 Volt.
350 804 3351.0705

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