e324-02/08

Operating Instructions
Linde Fork Lift Truck

E 12 - 02 / E 15 - 02 / E 16 - 02
With Electric Motors

324 804 3001 GB

0702
Linde - Your Partner Linde AG Werksgruppe Flurförderzeuge und Hydraulik

Linde, an enterprise operating

worldwide in the investment
and service sector, is one of
the large industrial enterpris-
es in the EC with its four divi-
sions and over 80 associated
companies.

Fenwick-Linde, Châtellerault

Linde is a leading manufac-

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

Linde industrial trucks enjoy a

worldwide reputation - thanks
to their high quality in engin-
eering, performance and serv-
ice.

Werk I, Aschaffenburg Werk III, Kahl am Main Linde Heavy Truck Division Ltd., Merthyr Tydfil

Your Linde lift truck
offers the best in economy, safety and driving convenience.
Therefore it is mainly in the hands of the operator to preserve
the qualities of the truck for a long and profitable service life
and to make full use of their benefits on the job.
These operating instructions tell you all you need to know
about starting, operation, running and servicing the truck.
For maintenance and repair work not described in these
operating instructions special technical skill and knowledge,
measuring equipment and special workshop tools are often
required. Please contact your authorised Linde dealer for this
service.
Only qualified persons (experts) authorised by Linde are
allowed to service the trucks.
For some attachments, the proprietary operating instructions
supplied with them are applicable.
Follow all tips for operating the lift truck and carry out the
maintenance and care prescribed in the inspection and main-
tenance schedule regularly, on time and with the specified
lubricants.
To keep your warranty valid, all maintenance services must
be performed by qualified persons authorised by Linde.
The terms “front”, “rear”, “left” and “right” refer to the position
in which the item concerned is installed in the truck in relation
to the forward travel direction.
2
Description
Approved applications
Linde lift trucks are designed for transporting and lifting the
loads stated in the load capacity diagram.
In particular, we refer to the VDMA booklet “Rules for the
Normal and Proper Use of Industrial Trucks”, to the accident
prevention rules of your employer’s liability insurance and the
special measures for driving on public roads.
The rules for use of industrial trucks must be followed under
all circumstances by the responsible persons, especially by
the operating and service personnel.
The user, and not Linde, is responsible for any danger arising
from applications not authorised by the manufacturer.
If you desire to use the truck for applications not mentioned in
the manual and convert or supplement it for this purpose,
please first contact your authorised Linde dealer.
No changes, especially conversions or modifications, may be
made on your fork truck without the prior permission of the
manufacturer.
324 804 3001.0702

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 distributor, making
sure to state your correct shipping address.
For repairs, use only genuine Linde spare parts to ensure that
your Linde fork truck will maintain its original technical standard.
324 804 3001.0702
When ordering spare parts, it is important also to give the
following information:
Lift truck model: __________________________________
Manufacturer’s serial no./Year built: __________________
Handing-over date: ________________________________
Also specify the manufacturer’s number of the mast when
ordering parts.
Mast no.: ________________________________________
Mast lifting height: ____________________________ mm
When taking over the fork lift truck, transfer the data from the
assembly type plates into this operating manual.
Description
Truck takeover
Every fork truck undergoes careful inspection before leaving
the factory in order to make sure that it will be in satisfactory
condition and fully equipped as ordered when delivered to the
customer. Authorised distributors are under obligation to
reinspect the truck before delivery and to hand it over in good
order. In order to avoid later complaints and inconvenience to
customers, you are requested to ascertain that the truck is in
satisfactory condition and fully equipped at the time of delivery
and to acknowledge orderly handing/taking over of the truck
in the manufacturer’s certificate of conformity.
The following technical manuals are supplied with each fork
truck:
1 Operating manual
1 EC certificate of conformity
(The manufacturer certifies that the industrial truck con-
forms to EC guidelines for machines)
1 Rules for the normal and proper use of industrial trucks
(VDMA)
Wishing you satisfactory operation and much success,
Your
Linde AG
Linde Material Handling Division
Aschaffenburg
3
324 804 3001.0702

4
 Type plates Description
1 Mast number (stamped)
1 2 3 4 5 6
2 Working hydraulics pump motor (stamped)
3 Lift motor
4 Power steering pump
5 Traction motor, left
6 Reduction gearbox, left
7 Traction motor, right
8 Reduction gearbox, right
9 Vehicle identification plate
10 Manufacturer
11 CE symbol
(The symbol certifies that EC guidelines for machines
and all applicable guidelines are fulfilled.)
12 Serial no./year
13 Unladen mass
324 804 3001.0702

14 Battery voltage
15 Min. battery mass
8 7
16 Max. battery mass
17 Rated capacity
18 Type
19 Control valve number
20 Serial number (stamped)
10
9

18
11
20 19 9
17 e324-02/06
12
13

16 15 14
5
Fork lift truck E 12 / E 15 / E 16 Description
Advanced technology,
simple and ergonomic operation,
energy saving, environment-conscious and minimal mainte-
nance,
solid manufacture
and for availability of your lift truck
nearly all parts are available from Linde.
The success of a company
with about 9600 employees in eight plants.

324 804 3001.0702

The driver’s position and the controls are arranged in accord-
ance with state-of-the-art human engineering. The arrange-
ment and operation of each control is adapted to the driver so
that fatigue-free and therefore safe working is ensured. e324-02/08
Of course, this includes theeasily operated hydrostatic power
steering with non-return lock, the service-proved double-
pedal control - forward travel with the right accelerator pedal,
reverse travel with the left- and only one central control lever
for all lift mast functions.

6
 Table of contents
Page
Description ..................................................................... 2
Approved applications ......................................................... 2
Technical note ..................................................................... 3
Truck takeover ..................................................................... 3
Type plates .......................................................................... 5
Technical data ................................................................... 10
Technical description ......................................................... 12
Drive ............................................................................... 12
Steering .......................................................................... 12
Hydraulic system ............................................................ 12
Operation ........................................................................ 12
Brakes ............................................................................ 12
Handbrake ...................................................................... 12
Brush monitor ................................................................. 12
Electrical system ............................................................ 12
General view of truck ......................................................... 13
Controls and indicators ..................................................... 14
324 804 3001.0702
Composite instrument ....................................................... 15
Hour meter ..................................................................... 15
Battery discharge indicator ............................................ 15
Beginning operation ................................................ 17
Safety rules ........................................................................ 17
Important safety information .............................................. 17
Handling fluids and lubricants ........................................... 17
Accident prevention check ................................................ 18
Operation of industrial trucks in the plant area ................. 18
Noise emission level .......................................................... 18
Frequency characteristics for human body vibrations ...... 18
Running-in instructions ...................................................... 18
Checks and servicing prior to initial operation
of the truck ...................................................................... 18
Daily checks ....................................................................... 18
Daily checks and servicing before operation .................... 19
Tighten the wheel fasteners .............................................. 19
Check the tyre inflation pressure ...................................... 19
Push, pull the emergency isolator button ......................... 19
Checking the battery charge ............................................. 20
Charging the battery .......................................................... 20
Opening, closing the battery cover ................................... 21
Connecting the battery to a suitable external charger ...... 21
Battery: Check condition, electrolyte level
and specific gravity ........................................................ 21
Page
Battery change .................................................................. 22
Battery removal with a crane ......................................... 22
Adjusting the adjustable steering column ......................... 22
Adjusting the driver’s seat ................................................. 23
Applying, opening the seat belt ......................................... 23
Operation ...................................................................... 24
Driving ................................................................................ 24
Travel in the forward direction ....................................... 24
Travel in the reverse direction ....................................... 24
Reversing the direction of travel .................................... 25
Malfunctions during operation ........................................... 25
Single-pedal model ............................................................ 26
Steering system ................................................................. 28
Steering .......................................................................... 28
Braking system .................................................................. 29
Service brake, electric brake ......................................... 29
Foot brake ...................................................................... 29
Operating the electric motor brake (LBC) ...................... 29
Handbrake ...................................................................... 29
Engaging the handbrake ................................................ 29
Releasing the handbrake ............................................... 29
Central control lever operation of mast
and attachments ............................................................. 30
Tilting the mast forward ................................................. 30
Tilting the mast back ...................................................... 30
Raising the fork carriage ................................................ 30
Lowering the fork carriage ............................................. 30
Operating the attachments ............................................ 30
Operating the sideshift ................................................... 30
Operating the clamp ....................................................... 30
Single control lever operation of mast
and attachments ............................................................. 31
Operating the horn ............................................................ 32
Turning on the directional indicators ................................. 32
Switching on the hazard warning light .............................. 32
Switching on the lights ...................................................... 32
Turning on the working lights ............................................ 32
Turning on the windscreen wiper ...................................... 32
Fuses ................................................................................. 33
Checking, renewing the fuses ....................................... 33
Fuses (option) .................................................................... 34
Before loading ................................................................... 35
Positioning the forks .......................................................... 36
Description
Page
Loading .............................................................................. 36
Transporting the load ........................................................ 37
Unloading .......................................................................... 37
Before leaving the lift truck unattended ............................ 37
Tow coupling ..................................................................... 38
Lifting point for wheel jack ................................................. 38
Hoisting the truck ............................................................... 39
Hoisting the truck with a crane ...................................... 39
Hoisting the truck with lifting eyelets ............................. 40
Mast removal ..................................................................... 41
Towing instructions ............................................................ 41
Towing procedure .......................................................... 41
Emergency exit for trucks with rear windscreen ............... 42
Taking the truck out of operation ...................................... 43
Measures before taking the truck out of operation ........ 43
Putting the truck back into operation ............................. 43
Maintenance ................................................................ 43
General information ........................................................... 43
Mast versions ..................................................................... 44
Work on the mast and on the front part of the truck ......... 44
Securing the mast against tilting back .............................. 44
Standard mast ................................................................... 44
Securing the raised standard mast ................................... 44
Duplex mast ....................................................................... 44
Securing the raised duplex mast ....................................... 45
Triplex mast ....................................................................... 45
Securing the raised triplex mast ........................................ 45
Services after the first 50 hours of operation .................... 45
Inspection and maintenance chart .................................... 46
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324 804 3001.0702

8
 Table of contents Description
Page Page

attachments are fitted .................................................... 60

Inspection and maintenance as required ...... 48
Check seat belt for condition and operation ..................... 48
Clean the lift truck .............................................................. 49
Clean and spray the lift chain ............................................ 49
Tighten the wheel fasteners .............................................. 49
Check the tyres for damage and foreign objects .............. 50
Renew the motor brushes ................................................. 50
Lubricate the mast and tilt cylinder bearings .................... 51
Change contactor tips ....................................................... 51
Clean the traction Controller fan ....................................... 51
500-hour inspection and maintenance ........... 52
Clean the close-coupled steer axle ................................... 52
Check oil level in reduction gearboxes ............................. 52
Check reduction gearboxes for leaks ............................... 52
Check the hydraulic oil level ............................................. 53
324 804 3001.0702
Retighten the mast fastening bolts ................................... 61
1500-hour inspection and maintenance ........ 61
Renew the hydraulic system breather filter ...................... 61
3000-hour inspection and maintenance ........ 62
Renew the hydraulic oil and suction filter ......................... 62
Change the oil in the reduction gearboxes ....................... 62
Inspection and maintenance specifications ...................... 63
Lubricant recommendations .............................................. 64
Hydraulic oil .................................................................... 64
Bio hydraulic oil .............................................................. 64
Gear oil ........................................................................... 64
Lubricating grease ......................................................... 64
Battery grease ................................................................ 64

Clean the traction motor fan .............................................. 53 Chain spray .................................................................... 64

Clean the left and right wheel traction motors, Troubleshooting guide ....................................................... 65
the power steering and working hydraulics Wiring diagram for 24 Volt electrical system .................... 67
pump motor .................................................................... 54 Wiring diagram for 48 Volt electrical system .................... 71
Check the working and steering hydraulics for leaks ....... 54 Wiring diagram for E 12, E 15 electrical system
Lubricate the mast and tilt cylinder bearings .................... 55 (options) ......................................................................... 74
Sideshift: Clean, grease and check the mounting ............ 55 Wiring diagram for E 16 electrical system (options) ......... 76
Check the electric cables, cable connectors Hydraulic schematic for working and
and connections for condition and tightness ................. 56 steering hydraulics ......................................................... 78
Clean the digital control .................................................... 56 Index .................................................................................. 80
Check the contactors ......................................................... 56
Check the braking system ................................................. 57
Check the brake linings ..................................................... 57
Check the mounting of the counterweight,
electric motors, chassis, wheel drives,
overhead guard and close-coupled steer axle .............. 57
Check and lubricate other bearings and joints ................. 58
Check the motor brushes, renew if necessary .................. 58
Mast, lift chains and end stops: Check condition,
mounting and function ................................................... 59
Adjust the lift chains length, lubricate the lift chain
with chain spray ............................................................. 59
Check the fork quick-releases and fork stops ................... 60
Check and oil the pedal and travel control
linkage bearings ............................................................. 60
Check the pre-tension of double hoses if

9
Technical data Description
Forklift Trucks Data Sheet for EFG
Designation VDI 2198 VDI 2198
September 2001 Material Handling Equipment to VDI 3586
1.1
1.2
Manufacturer (see page 1)
Model designation
Notes:
Characteristics

E 12 E 15 E 16
1.3 Power unit: battery, diesel, petrol, LPG, mains power battery battery battery
1.4 Operation: manu., pedest., stand-on, seated, ord. pic. seated seated seated
1) See table for further masts.
1.5 Load capacity Q [t] 1,2 1,5 1,6
1.6 Load centre c [mm] 500 500 500 2) Figures in brackets refer to triplex masts.
1.8 Axle centre to fork face x [mm] 350 (375) 2) 350 (375) 2) 350 (375) 2)
1.9 Wheelbase y [mm] 1095 1275 1445
2.1 Service weight [kg] 3) With a free lift of 150 mm.
Wheels and Tyres Weight

2646 2860 2895

2.2 Axle load with load, front/rear [kg] 3405 / 441 3895 / 465 4003 / 492
2.3 Axle load without load, front/rear [kg] 1280 / 1370 1390 / 1470 1465 / 1430
4) Figures in brackets for trucks with 18x5x12 1/8 KS
3.1 Tyres, front/rear (SE = CS superelastic, L = pneum.) SE (L) / SE (L) 5) SE (L) / SE (L) 5) SE (L) / SE (L) 5)
3.2 Tyre size, front 18x7-8 SE 5) 18x7-8 SE 5) 18x7-8 SE 3)
solid rubber tyres on front wheels.
3.3 Tyre size, rear 15x4½-8 SE 6) 15x4½-8 SE 6) 15x4½-8 SE 6)
3.5 Wheels, number front/rear (x = driven) 2x/2 2x/2 2x/2 5) Optionally 18x7-8/16 PR pneumatic tyres or
3.6 Track width, front b10 [mm] 910 910 910
3.7 Track width, rear b11 [mm] 168 168 168
18x5x12 1/8 solid rubber tyres.
4.1 Mast/fork carriage tilt, forward/backward degrees 5/8 5/8 5/8
4.2 Height of mast, lowered h1 [mm] 2137 3) (2080) 1) 8) 2137 3) (2080) 1) 8) 2137 3) (2080) 1) 8) 6) Optionally 15x4½-8/12 PR pneumatic tyres.
4.3 Free lift h2 [mm] 150 150 150
4.4 Lift h3 [mm] 3250 (4675) 1) 2) 3250 (4675) 1) 2) 3250 (4675) 1) 2)
4.5 Height of mast, extended h4 [mm] 3813 (5238) 1) 2) 3813 (5238) 1) 2) 3813 (5238) 1) 2)
7) Other battery capacity available

324 804 3001.0702

4.7 Height of overhead guard (cabin) h6 [mm] 1953 1953 1953
4.8 Height of seat/stand-on platform h7 [mm] 923 923 923 8) Figures in brackets refer to duplex and triplex
4.12 Tow coupling height h10 [mm] - - -
masts
Dimensions

4.19 Overall length l1 [mm] 2515 2695 2865

4.20 Length to fork face l2 [mm] 1615 (1640) 2) 1795 (1820) 2) 1965 (1990) 2)
4.21 Overall width b1/b2 [mm] 1083 (1000) 4) 1083 (1000) 4) 1083 (1000) 4) 9) Values for triplex mast on request
4.22 Fork dimensions s/e/l [mm] 40x80x900 40x80x900 40x80x900
4.23 Fork carriage to DIN 15173, class/form A, B 2A 2A 2A
4.24 Width of fork carriage b3 [mm] 1040 1040 1040
4.31 Ground clearance, mast m1 [mm] 95 95 95
4.32 Ground clearance, centre of wheel base m2 [mm] 110 110 110
4.33 Aisle width with pallet 1000x1200 across Ast [mm] 2942 (2965) 2) 3122 (3145) 2) 3292 (3315) 2)
4.34 Aisle width with pallet 800x1200 lengthwise Ast [mm] 3065 (3090) 2) 3245 (3270) 2) 3415 (3440) 2)
4.35 Turning radius Wa [mm] 1265 1445 1615
4.36 Min. distance between the centres of rotation b13 [mm] - - -
5.1 Travel speed, with/without load km/h 11 / 12,5 10,6 / 12,5 13,4 / 15,8
5.2 Lifting speed, with/without load m/s 0,27 / 0,48 0,25 / 0,48 0,41 / 0,62
5.3 Lowering speed, with/without load m/s 0,56 / 0,47 0,58 / 0,47 0,58 / 0,47
5.5 Tractive force, with/without load N 2050 / 2226 1860 / 2189 1900 / 2147
Performance

5.6 Max tractive force, with/without load N 5768 / 5894 5678 / 5857 7383 / 7557
5.7 Climbing ability with/without load % 7,4 / 11,5 6,3 / 10,5 5,7 / 9,7
5.8 Max. climbing ability with/without load % 15,5 / 23,3 13,4 / 21,4 17 / 27,7
5.9 Acceleration time with/without load s 6,2 / 5,4 6,5 / 5,6 4,9 / 4,3
5.10 Service brake mechanical / electric mechanical / electric mechanical / electric
6.1 Traction motor, rating kW 2x3 2x3 2x4
Electr. Motor

6.2 Lift motor, rating kW 5 5 9,5

6.3 Battery according to IEC 254-2 254-2 254-2
6.4 Battery voltage, rated capacity K 5 V/Ah 24 / 550 7) 24 / 880 7) 48 / 660 7)
6.5 Battery weight kg 445 676 1013
6.6 Power consumption, VDI cycle kWh/h - - -
8.1 Type of control digital control digital control digital control
8.2 Working pressure for attachments bar 170 200 210
Others

8.3 Oil quantity for attachments l/min - - -

8.4 Mean noise level at driver's ear dB (A) - - -
8.5 Tow coupling, design/type DIN, no. - - -

10
 Technical data Description

Load capacity diagram for standard and duplex masts:

E 12

E 15
324 804 3001.0702

E 16

Values for triplex mast on request.

Heights and lift height (mm) 9)

Lift height h3 2950 3250 3950 4250 4950
Heights, min. lift h1 # 1987 2137 2487 2637 2987
(with 150 mm free lift for standard)
Heights, min. lift (for duplex) h1 1930 2080 2430 2580
Heights, max. lift h4 3513 3813 4513 4813 5513
Safety distance a = 200 mm Special lift height h2 1367 1517 1867 2017

11
Technical description
With the series 324 trucks it is possible to transport and stack
loads up 1.2 tonnes with the E 12, 1.5 t with the E 15 and
1.6 t with the E 16.
Two stable half-frames, a driver’s station with the latest
ergonomic design and an energy-saving pulse control with
the Digital Control (LDC) as standard equipment make this
fork truck a valuable work tool. Compact design, good visibil-
ity, greatest possible stability when stacking and in curves due
to the long wheelbase are its distinguishing features.
The fork truck is equipped with a close-coupled steer axle and
is thus suited for operation in halls.
The close-coupled steer axle results in a particularly low
energy consumption and tyre wear due to the off-set of the
rear twin wheels against each other. The truck can be turned
very tightly and, due to its manoeuvrability and narrow width,
it is also suited for confined work areas.
Drive
The fork truck is electrically driven and has separate hydraulic
pumps for steering and working hydraulics.
Drive power is provided by two electric motors which drive the
appropriate reduction gearbox for the right or left drive wheels.
The required energy is supplied by the battery installed in the
machine.
The digital control (LDC) provides stepless forward and
reverse travel via the double accelerator pedals.
Steering
The kickback-free, sensitive and nearly play-free manual
steering is operated via the small steering wheel actuating the
steer cylinder of the steer axle. The steering column is
adjustable, so that a comfortable working position is assured.
12
Description
Hydraulic system Brush monitor
The hydraulic system consists of an electric motor with a For the service life of the DC motors, it is important to replace
hydraulic pump for the power steering, an electric motor with worn motor brushes in time.
a hydraulic pump for the working hydraulics and a hydraulic
The replacement of the brushes is indicated optically by the
oil reservoir with a breather filter, a dipstick and a suction filter.
illumination of a warning lamp and LED display for the motor
in question in the composite instrument.
Operation
The traction motors are controlled by a separate accelerator Electrical system
pedal for forward and reverse travel. Infinitely variable control
The electrical system is located in and is well protected by the
is possible in both directions from truck standstill to maximum
counterweight. The required energy is supplied by a 24 V or
speed. Both hands are always free for steering and for
48 V battery mounted in the chassis.
controlling the work operations. The result is fast reversing
and fatigue-free stacking. Only one control lever is provided
ATTENTION
for the control of the lift, lower and tilt functions (central control
Connect to 24 V supply (E12/15).
lever). Additional control levers are fitted for attachments.
Ensure correct polarity.
Length of battery cable max. 5m.
Brakes
324 804 3001.0702
In addition to electrical braking, the fork truck can also be
braked mechanically with two disc brakes by depressing the
STOP pedal. Releasing the accelerator pedal brakes the
truck with the Linde Brake Control (LBC). The LBC can be
disabled with the diagnostic unit (Universal Calibration Box),
if desired.
CAUTION
After having suppressed the electric brake con-
trol (LBC) a label with the information “Without
electric brake control” must be placed so that the driver
can see it well. Contact your Linde distributor.
As standard equipment, this truck model is provided with an
energy recovery system. When braking, or the driving direc-
tion changes, the resulting generator energy is used to charge
the battery.
Handbrake
The handbrake acts on the disc brakes fitted at both traction
motors via a cable. When the handbrake is applied, the
electric power is reduced by a microswitch.
 General view of truck Description
1 Overhead guard
2 Steering wheel
3 Mast (Duplex)
4 Mast chains 1 2 3 4
5 Lift cylinders
6 Fork quick-releases
7 Fork carriage
8 Reduction gearbox, left
9 Traction motor, left
18
10 Forks
11 Traction motor, right
12 Tilt cylinder
17
13 Battery compartment
14 Counterweight 5
324 804 3001.0702

15 Emergency isolator button 16

16 Cover, electrical system
17 Battery cover 15
18 Driver’s seat
6
14

9 e324-02/09

13 12 11 10

13
Controls and indicators Description
1 Handbrake
2 Signal horn
1 2 3 4 5 67 8
3 Composite instrument
4 Steering wheel
5 Switch key in key switch
6 Label for pedal operation
7 Load capacity diagram
8 Label for tyre pressure
9 Control lever for auxiliary hydraulics (attachments)*
10 Control lever for working hydraulics
11 Emergency isolator button
12 Symbol label for auxiliary hydraulics*
13 Notice plate “Without electric brake control”**
14 Load capacity plate (attachments)*

324 804 3001.0702

15 Notice plate 9
16 Symbol label for working hydraulics
17 Forward accelerator pedal
18 Brake pedal
19 Reverse accelerator pedal 10
20 Locking lever for adjustable steering column

11

20 19 18 17 16 15 14 13 12 e324-02/10

* Option
** Only with LBC disabled

14
 Composite instrument
The composite instrument contains the following control
elements and indicator elements:
1 Battery discharge indicator
2 Hour meter (LCD display)
3 Motor brush warning light
4 Service interval exceeded
5 Motor temperature warning light
324 804 3001.0702
3 4
6 7
2 8
1
12 11
Hour meter
Indicates the operating time of the truck in hours. It operates
only when the key switch is turned on, the emergency isolator
button pulled out and the seat switch activated.
The hour meter serves as proof of the operating time of the
truck and for scheduling inspections and maintenance serv-
ices.
The flashing ”h“ (8) and flashing decimal point (9) show that
the hour meter is on.
The left row of figures (6) displays the full hours of operation,
the right figure (7) indicates tenths of an hour.
NOTE
When replacing a defective hour meter, the number of
effective service hours has to be noted. Affix this infor-
mation near the new hour meter on durable tape.
It is also possible to set the replacement hour meter so
that the actual aggregate service hours are displayed.
Please contact your authorised dealer in this regard.
5
9
10
e324-02/11
Description
Battery discharge indicator
Indicates the charging state of the battery when the key switch
is turned on and the emergency isolator button is pulled out.
It reduces the speed of the working hydraulics when the
battery discharge reaches 80 %.
The battery is fully charged when the right LED (10) is
illuminated. As the battery discharges, the illuminated bar
(10) moves from right to left.
If only the orange LED (11) is illuminated, the battery dis-
charge is up to 70 % and the battery must be recharged.
If the orange LED (11) also extinguishes, the two red LEDs
(12) begin to flash. The battery discharge is up to approx.
80 % and recharging or changing of the battery is required.
15
Composite instrument Description
Instrument Purpose Possible cause

Motor brush warning light (3) indicates motor brushes are worn. The motor no.*** appears Truck does not operate
in the LCD display (1).

Service intervall exceeded indicator light (4) indicates inspection and service is due Perform the correct inspection and service**

Left and right traction motor temperature warning light (5) indicates right and left motor temperatures are too high. The Electric fan is faulty
LCD display (1) displays motor number 1.

324 804 3001.0702

4 *** 1 = Traction motor, right and left ** A reset and setting the intervals is only possible with the
3 5 2 = Lift motor diagnostic unit designed for this purpose.
3 = Steering pump motor Please contact your authorized distributor.

e324-02/22

16
 Safety rules
The responsible persons, particularly the truck operator and
servicing personnel, must be instructed in the rules for the
normal and proper use of industrial trucks included with these
operating instructions.
The employer must ensure that the driver has understood all
of the safety information.
Please observe the guidelines and safety rules 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.
The operator (employer) or the responsible person must
324 804 3001.0702
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 (joystick), brake pedal)
- optional attachments
- special operating characteristics,
by training and practicing driving, shifting and steering oper-
ations until they are completely mastered.
Only then start to practice shelf-stacking.
ATTENTION
Later modifications of drive or brake parameters
of the LDC control make it necessary to inform
and train again the truck driver.
In case of tip-over
Follow these Stay
WARNING instructions buckled up
The stability of the truck in the work area is ensured if
employed properly. Should the truck tip over during an
unauthorised application or due to incorrect operation, al-
ways follow the instructions depicted below.
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.
Other warning symbols are also used for your
safety. Please observe the various symbols.
NOTE
identifies technical information requiring special atten-
tion because the connection may not even be obvious to
skilled personnel.
Don't jump Hold on tight Brace feet Lean away
Beginning operation
Handling fluids and lubricants
Always handle fluids and lubricants as required and
as specified by the manufacturer.
Only store fluids and lubricants in approved containers at
specified storage places. As they could be inflammable, do
not contact them with hot objects or a naked flame.
Follow the manufacturer’s safety and disposal instructions
when using fluids and lubricants and cleaning compounds.
Avoid spilling fluids and lubricants. Remove any spillage
immediately with a suitable binding agent and dispose of as
specified.
Also dispose of used or contaminated fluids and lubricants as
specified.
Follow laws and regulations.
Clean the area surrounding the part in question before
lubrication, filter renewal or repairs in the hydraulic system.
Only use clean containers when replenishing fluids and
lubricants.
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.
Please note that the battery cover must be open during the
entire charging period.
17
Beginning operation
Accident prevention check
The accident prevention regulations require that the forklift
truck must be checked at least once a year for proper working
condition by trained personnel. Please contact your author-
ised distributor in this regard.
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 insur-
ance covers any damages occurring with your fork truck
against third parties on "limited" public traffic areas.
Noise emission value
Frequency characteristic for human body Checks and servicing prior to initial opera-
vibrations (preliminary values as only a draft standard tion of the truck*
is available)
- Check the tyre inflation pressure
The values are determined in conformance with prEN 13059
on trucks with standard equipment according to the technical - Tighten wheel fasteners
data sheet (driving over test course with bumps). - Check the battery condition, level and specific gravity of
Frequency characteristic acc. to EN 12096 electrolyte
Measured frequency characteristic aw.zs = 0.7 m/s² - Check the hydraulic oil level
Uncertainty K = 0.2 m/s² - Check the braking system
Frequency characteristic given for hand and arm vibrations - Check the steering system
Frequency characteristic < 2.5 m/s²
- Check the mast and attachments
NOTE - Check oil level in reduction gearboxes
The frequency characteristic for the human body can not
be used to determine the actual frequency load during Daily checks*
operation. This load depends on the working conditions
(condition of roadway, type of operation, etc.) and must - Check the battery state of charge

324 804 3001.0702

Determined in a test cycle in accordance with EN 12053 from therefore be determined at the site, if necessary. - Check the tyre inflation pressure
the weighted values in the operating modes DRIVING, LIFT- The specification of hand and arm vibrations is required
ING, IDLING. by law, even if the values, as in this case, do not signal
any danger.
Noise level at driver’s station
E 12 - E 16 LPAZ = 76 dB (A) Running-in instructions
Uncertainty KPA = 4 dB (A)
The truck can be operated at full speed directly. Avoid
sustained high loads on the working hydraulic system and the * The description of the services can also be located in the
NOTE index.
travel drive in the first 50 hours of operation.
Higher or lower noise emissions can exist during opera-
Tighten wheel fasteners daily prior to starting operation or
tion of the truck, e.g. due to different operation, influence
after a wheel change until they are seated firmly, i.e. until no
of the surroundings and additional noise emission sourc-
further tightening is possible.
es.
Tighten opposite wheel fasteners
on the front wheels to: .............................................. 210 Nm
Tighten opposite wheel fasteners
on the rear wheels to: ............................................... 195 Nm

NOTE
Refer to the tightening instructions on the tag attached to
the steering column.

18
 Daily checks and servicing before operation Beginning operation
Tighten the wheel fasteners Push the emergency isolator button
- Check all wheel fasteners (2). - Depress the emergency isolator button(1) and release it.
This shuts off the truck completely.
- Torque opposite wheel fasteners:
front wheels ......................................................... 210 Nm Pull the emergency isolator button
rear wheels ......................................................... 195 Nm
- Pull out the emergency isolator button (1).
Check the tyre inflation pressure This makes the truck ready for operation.

ATTENTION
A low inflation pressure reduces tyre service life
and truck stability.

- Check the tyres for the specified inflation pressure.

- If necessary, inflate according to the specifications on the
label (1).
Drive axle 18x7-8 (16 PR) .............. 10 bar
Steering axle 15x4½-8 (12 PR) ........... 10 bar
324 804 3001.0702

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19
Daily checks and servicing before operation
Checking the battery charge
- Apply the handbrake (1).
- Pull up the emergency isolator button (4).
- Insert the key (3) into the key switch and turn clockwise as
far as possible.
- Check the battery charge at discharge indicator (5) in the
composite instrument (2).
Charging the battery
ATTENTION
For the safe operation and maintenance of the
batteries, follow the following instructions.
ATTENTION
The electrolyte in the batteries is a sulphuric
acid and water solution, which is poisonous and
caustic. Therefore, wear protective clothing and
protective glasses when working around the
batteries.
If the battery electrolyte should nevertheless contact
clothing, the skin or eyes, immediately flush the affected
parts with water. Seek medical aid at once if the eyes are
affected!
Neutralize spilled battery electrolyte without delay.
Gases are released when batteries are being charged. Do
not expose the battery to sparks or open flames, as an
Beginning operation
NOTE
Check that the specific gravity of the electrolyte is at least
1.14. Always charge and service the battery according to
the manufacturer’s instructions.
If you are not in possession of these instructions, please
contact your distributor. Also follow the operating in-
structions for the optional battery charger. If a battery
charger is already available, follow the instructions
supplied with it.
CAUTION
Do not place any metal parts on the battery - risk
of a short!
Do not top up electrolyte before charging.
Please note that the battery cover must be open during the
entire charging period.

324 804 3001.0702

explosion could result. Rooms in which batteries are
charged or stored must be ventilated accordingly.

1 2 3 2

5
4

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20
 Daily checks and servicing before operation
Opening the battery cover
- Lower the forks.
- Tilt the mast slightly forward. The forks must rest on the
ground.
- Apply the handbrake.
- Press the emergency isolator button.
- Reach through the opening in the battery cover and push
the lever (1) of the latch cover in the direction of the arrow,
holding it in place until the cover lifts.
- Lift the battery cover to the stop position.
NOTE
The battery cover is held in the open position by two gas
springs.
Closing the battery cover
- Close the battery cover against the pressure of the two gas
324 804 3001.0702
springs.
It automatically locks into place.
1 e324-02/07
Connecting the battery to a suitable exter-
nal charger
CAUTION
The charging current of the battery charger used
for the battery charge should not be higher than
160 A. If your battery charger has a higher charging rate,
ask your authorized dealer beforehand.
- Open the battery cover.
- Disconnect the battery socket (1) from the battery plug (2).
- Insert the charger plug into the battery socket.
- Switch the charger on.
Always recharge batteries without delay. Never leave batter-
ies in a discharged state. This also applies to partially
discharged batteries.
1 2
e324-02/04
Beginning operation
Battery: Check condition, electrolyte level
and specific gravity
- Check the battery for casing cracks, lifted plates and
electrolyte leakage.
- Unscrew the caps (3) and check the electrolyte level.
On batteries with check tubes, the fluid should be at the
bottom of the tubes. On batteries without tubes, the fluid
should be 10 - 15 mm above the plates.
- If the electrolyte level is low, top up with distilled water
only.
- Refit all caps (3).
- Remove corrosion on battery poles and coat with non-
acidic grease.
- Retighten pole clamps firmly.
- Check the specific gravity using a hydrometer. The specif-
ic gravity of the electrolyte should be between 1.24 and
1.28.
NOTE
Discharges which are under 20 % of the rated capacity are
deep discharges. Deep discharges shorten the service
life of the battery.
3
21
Daily checks and servicing before operation
Battery change
When changing the battery, at least 6 minutes must elapse
between the disconnection and connection of the batteries.
Otherwise the battery discharge indicator will display a false
reading and reduce the speed of the working hydraulic system.
ATTENTION
The replacement battery must correspond to the
standard battery both in size and weight.
Deviations in weight must be compensated by additional
weights. The battery must be secured against sliding.
Please consult your authorised distributor.
1 2
e325-02/16
22
Beginning operation
Battery removal with a crane Adjusting the adjustable steering column
Use a crane and a lifting gear with a sufficient load capacity - Loosen the locking lever (1).
(see technical data for battery weight).
- Swing the steering column into suitable driver position.
- Lower the forks completely.
- Tighten the locking lever (2).
- Unlock and lift the battery cover.
- Drive the crane, from the right, into position in the cut-out
on the driver’s overhead guard.
- Remove the side cover (1).
- Pull out the battery socket (2) from the battery plug (3)
- Connect the lifting gear to the battery.
- Lift the battery up and out of the battery compartment and
remove it to the side (observe the driver’s overhead
324 804 3001.0702
guard).
2 3
e324-02/83 e324-02/17
 Daily checks and servicing before operation
Adjusting the driver’s seat
- For a horizontal adjustment of the seat, pull the lever (1)
up.
- Slide the driver’s seat forward or back in the rails until the
optimum position for operating the steering wheel, pedals
and control levers is obtained.
- Re-engage the lever (1).
- Depress the lever (3) to adjust the backrest.
- Swing the backrest forwards or backwards until a comfort-
able seating position is achieved.
- Engage lever (3) again.
- Fold out the crank (2) and rotate to adjust the seat spring
to the driver’s weight. The adjustment ange from 50 kg to
130 kg is readable on the indicator (4).
NOTE
324 804 3001.0702
Beginning operation
Applying the seat belt
DANGER - Pull the seat belt (9) out of the retractor (7) with a smooth
The seat belt must always be applied during movement.
the operation of the truck! The seat belt is only
for securing one person. - Place the seat belt over the loin area, not over the belly.
NOTE - Engage the tongue (8) in the lock (5).
Driver cabs with closed, solid doors or bar-type doors
comply with the safety requirements for driver retaining - Check seat belt tension. The belt should be snug on the
systems. We recommend the additional use of the seat body.
belt. The seat belt must be used if the truck is operated
with the doors open or removed. CAUTION
The webbing should not be twisted, stuck or
NOTE knotted.
The automatic lock blocks the belt when the truck is Protect the lock (5) and retractor (7) against foreign
tilting heavily. The belt can then not be pulled out of the particles and dirt.
retractor.
To unlock the automatic lock, carefully drive the truck off NOTE

Prolonged sitting puts a great strain on the spinal
column. Do light exercises regularly to prevent back
problems.
the side slope. 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 opera-
tion of the truck.

2 5 Opening the seat belt

6 - Press the red button (6) on the lock (5) to disengage the
belt.

- Return the tongue (8) back to the retractor (7) by hand.

3
NOTE
A belt which returns too fast can trigger the automatic
1 2 lock when the tongue hits the enclosure. The belt can
then not be pulled out with the usual force.

8
9
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23
Driving
Driving
CAUTION
Travel on long slopes over 15 % is generally not
allowed due to the prescribed minimum brake
applications and truck stability characteristics. Before
driving on steeper slopes, you should consult your
distributor. The climbing ability rates given in the data
sheet were derived from the tractive force of the truck
and they apply only for the crossing of obstacles and for
short differences in level.
NOTE
Always adapt your driving style to suit the conditions of
the roadway (rough surfaces, etc.), especially hazardous
work areas and the load.
ATTENTION
The electric motor for the power steering pump
is turned on, at base rpm, when the keyswitch is
- Sit down on the driver’s seat (only this will actuate the seat
switch beneath the driver’s seat).
- Apply the seat belt.
- Pull out the emergency isolator button (4).
- Insert the switch key (3) into the key switch and turn the
key clockwise as far as possible.
- The symbol ”h“ (7) and the decimal point (8) will flash and
the hour meter (10) is turned on.
- The battery discharge indicator (9) in the composite
instrument (2) illuminates.
- Raise the forks slightly and tilt the mast back.
- Release the handbrake (1).
Operation
Travel in the forward direction
- Depress the right accelerator pedal (5) smoothly. Truck
speed depends on how far the pedal is depressed.
NOTE
Depressing the accelerator pedal fully will not increase
the rate of acceleration as maximum acceleration is
controlled automatically.
Travel in the reverse direction
- Depress the left accelerator pedal (6) smoothly.
Truck speed depends on how far the pedal is depressed.
Truck speed depends on how far the pedal is depressed.

324 804 3001.0702

activated. When the power steering is operated, the
electric motor switches to maximum rpm.
When the hydraulic oil temperature is low, the steering
pump motor operates at maximum rpm until the oil has
reached operating temperature.
1 2 3 2
NOTE
All 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. There-
fore only persons with a headroom of 30 mm between the
head and overhead guard should operate this truck.

10 7
4 8

9
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24
 Reversing direction Operation
Reversing the direction of travel Malfunctions during operation
- Release the depressed accelerator pedal. ATTENTION
If one of the following warning lights in the
- Depress the accelerator pedal for the opposite direction of composite instrument illuminates during opera-
travel. The truck will be braked to a standstill electrically tion, stop the truck and remedy the fault without delay.
and then accelerated in the selected direction. (Refer to: Troubleshooting guide)

- Keep both feet on the accelerator pedals for easy control 1 Motor brush warning light
of the truck during travel.
3 Motor temperature warning light
- The accelerator pedals can be operated directly from one
direction to the other. NOTE
If the service interval exceeded indicator light (2) is
NOTE illuminated, various services are required. To reset the
Depressing the accelerator pedal fully does not increase indicator with the diagnostic unit, contact your author-
the rate of acceleration as maximum acceleration is ised dealer.
controlled automatically.
324 804 3001.0702

2
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e324-02/21 e324-02/88

25
Single-pedal model
Driving
CAUTION
Travel on long slopes over 15 % is generally not
allowed due to the prescribed minimum brake
applications and truck stability characteristics. Consult
your distributor before driving on steeper slopes. The
climbing ability rates given in the data sheet were derived
from the tractive force of the truck and they apply only for
crossing obstacles and for small differences in level.
NOTE
Always drive consistent with road conditions (rough
surfaces, etc.), hazardous work areas and the truck load.
ATTENTION
The electric motor for the power steering pump
is turned on, at base rpm, when the keyswitch is
activated. When the power steering is operated, the electric
motor switches to maximum rpm.
- Sit down on the driver’s seat (only this will actuate the seat
switch beneath the driver’s seat).
- Apply the seat belt.
- Pull out the emergency isolator button (5).
- Insert the switch key (4) into the key switch and turn the
key clockwise as far as possible.
- The symbol ”h“ (7) and the decimal point (8) will flash and
the hour meter (10) is turned on.
- The battery discharge indicator (9) in the composite
instrument (3) illuminates.
- Raise the forks slightly and tilt the mast back.
- Release the handbrake (1).
Operation
Travel in the forward direction
- Push the directional control lever (2) forward.
- Depress the accelerator pedal (6) smoothly. Truck speed
depends on how far the pedal is depressed.
NOTE
Depressing the accelerator pedal fully does not increase
the rate of acceleration as maximum acceleration is
controlled automatically.
Travel in the reverse direction
- Pull the directional control lever (2) back.
- Depress the accelerator pedal (6). The reversing speed of
the truck depends on how far the pedal is depressed.

324 804 3001.0702

When the hydraulic oil temperature is low, the steering
pump motor operates at maximum rpm until the oil has
reached operating temperature.

NOTE
The directional control lever (2) must be in the neutral
1 2 3 4 3
position.
All control levers must be in the neutral position.

NOTE
On certain Linde fork trucks (eg with container overhead 0

guard, swivel seat) the torso clearance is reduced. There-

fore only persons with a headroom of 30 mm between the
head and overhead guard should operate this truck.

5 10 7
8

9
6 e324-02/24 e324-02/25

26
 Single-pedal model Operation
Reversing the direction of travel Malfunctions during operation
- Release the accelerator pedal (6). ATTENTION
If one of the following warning lights in the
- Shift the directional control lever (1) to the opposite composite instrument illuminates during opera-
direction of travel. tion, stop the truck and remedy the fault without delay.
(Refer to: Troubleshooting guide)
- Depressing the accelerator pedal (6) will accelerate the
truck in the new direction. 1 Motor brush warning light

The directional control lever can be shifted directly to the
opposite direction of travel. Without releasing the accelerator
pedal, the truck will be braked to a standstill electrically and
accelerated in the desired direction.
324 804 3001.0702
3 Motor temperature warning light
NOTE
If the service interval exceeded indicator light (2) is
illuminated, various services are required. To reset the
indicator with the diagnostic unit, contact your author-
ised dealer.

2
1 3

6
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27
Steering system Operation
Steering
Due to the hydrostatic power steering, only minimal effort is
required for turning the steering wheel. This feature is partic-
ularly of benefit when working in narrow aisles.

- Take the truck into operation, drive and turn the steering
wheel left and right through the full cycle.

WARNING
Contact your authorised distributor if the steer-
ing is hard or has too much play. Your truck may
not be operated with a faulty steering system.

Turning radii:
- E 12 .................................................................. 1265 mm
- E 15 .................................................................. 1445 mm
- E 16 .................................................................. 1615 mm

324 804 3001.0702

e324-02/27

28
 Braking system Operation
Service brake, electric brake Handbrake
- Release the depressed accelerator pedal and depress the ATTENTION Use the mechanical handbrake to park the fork truck. Both
pedal for the opposite direction of travel until the truck is After cleaning the truck, the braking power may disc brakes are applied by means of a cable.
electrically braked. be reduced due to wetness. Before driving the NOTE
truck perform a brake test and, if necessary, dry the When the hand brake is operated, the drive current is
NOTE
brakes by operating them several times while driving reduced at the same time with an electric switch.
Please ask for a demonstration of electrical braking when
slowly.
taking over the truck.
Engaging the handbrake:
Foot brake
- Pull the handbrake lever (2) back firmly.
- Release the accelerator pedals (1, 3) so that they can Operating the electric motor brake (LBC)
return to neutral position.
- Depress the brake pedal (2). The two disc brakes will be
- Release the accelerator pedal (1 or 3) when driving. The Releasing the handbrake:
pedal will return automatically to the neutral position and
applied mechanically. - Press the release button (1) on the brake lever and push
the truck will come to a standstill.
ATTENTION the lever forward.
For emergency stops, depress the brake pedal NOTE
located between the accelerator pedals. This feature can be disabled with the diagnostic unit. WARNING
It is recommended that the driver acquaint himself with Please contact your authorised distributor if
signs of wear or faults become evident in the
324 804 3001.0702

the operation and effect of the emergency brake without

carrying a load. This should be done on a road stretch braking system.
without traffic and at low speed. Do not operate the truck with a faulty braking system.

1
2

1 2 3 e324-02/23 e324-02/30

29
Central control lever operation of mast and attachments
CAUTION
Use the lifting device and attachments only for
authorised applications. The driver 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; do not jerk.
The speed of lifting, lowering and tilting is determined by how
far the lever is moved.
The lever is designed to return to the neutral position when
released.
NOTE
Note the operating symbols with arrows.
Tilting the mast forward
- Push the control lever (1) forward.
Tilting the mast back
- Pull the control lever (1) back.
1 2 3
e324-02/28
30
Operation
Raising the fork carriage Operating the sideshift
- Push control lever (1) to the right. - Push control lever (2) to the left (this will move the sideshift
to the left).
Lowering the fork carriage
- Push control lever (2) to the right (this will move the
- Push control lever (1) to the left. sideshift to the right).
CAUTION Operating the clamp
The mast and fork carriage can be lowered even
when the electrical system is shut off. - Push control lever (3) forward (this will open the clamp).
Operating the attachments - Pull control lever (3) back (this will close the clamp).
Attachments (e.g. sideshift, clamp, etc.) can be fitted on the lift ATTENTION
truck as optional equipment. Observe the operating pressure Attachments not supplied with the truck may
and instructions for the attachment. only be employed if an authorised distributor
One additional control lever is fitted for its operation. ascertains that a safe operation is assured in respect to
load capacity and stability.
NOTE
324 804 3001.0702
For each attachment, affix a load capacity label for the
truck with attachment to the battery cover and affix a
symbol label at the rear of the appropriate control lever.
 Single control lever operation of mast and attachments
CAUTION
Use the lifting device and attachments only for
authorised applications. The driver 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 lever smoothly; do not jerk.
The speed of lifting, lowering and tilting is determined by how
far the lever is moved.
The lever is designed to return to the neutral position when
released.
NOTE
Note the operating symbols with arrows.
Raising the fork carriage
324 804 3001.0702
Lowering the fork carriage
- Push the control lever (1) forward.
CAUTION
The mast and fork carriage can be lowered even
when the electrical system is shut off.
Tilting the mast forward
- Push the control lever (2) forward.
Tilting the mast back
- Pull the control lever (2) back.
Operating the attachments
Attachments (e.g. sideshift, clamp, etc.) can be fitted on the lift
truck as optional equipment. Observe the operating pressure
Operation
NOTE
For each attachment, affix a load capacity label for the
truck with attachment and a symbol label for the respec-
tive attachment to the battery cover.
Operating the sideshift
- Push control lever (3) forward (this will move the sideshift
to the left).
- Pull control lever (3) back (this will move the sideshift to
the right).
Operating the clamp
- Push control lever (4) forward (This will open the clamp).
- Pull back on control lever (4) (This will close the clamp).
ATTENTION
Attachments not supplied with the truck may
only be employed if an authorised distributor

- Pull the control lever (1) back. and instructions for the attachment. ascertains that a safe operation is assured in respect to
One or two additional control levers are fitted for its operation. load capacity and stability.

1 2 3 4

e324-02/29

33a 31
Horn, directional indicators*, lights*, wipers* Operation
Operating the horn NOTE Turning on the working lights
The switches can be arranged in a different order, de-
The horn serves as a warning signal, for example, on stretches pending on the model. - Operate the toggle switches (5 or 6).
with reduced visibility and at junctions. Please observe the switch symbol. The working lights are turned on.

- Pressing the horn button will sound the horn. Turning on the directional indicators Turning on the windscreen wiper
- Move the directional indicator switch (1) forward or back. - Operate the toggle switch (7).
The left or right directional indicator will flash, and the The wiper operates.
indicator light (4) lights up.

Switching on the hazard warning light

- Operate the toggle switch (2).
The hazard warning lights will flash.

Switching on the lights

- Operate the toggle switch (3).
The low beams are on.

324 804 3001.0702

* Option

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32
 Fuses
Checking, renewing the fuses
NOTE
The electrical system and fuses are located in the coun-
terweight under the cover (16).
The fuse box (7) can be accessed easily after removing
the electric compartment cover on the counterweight.
- Unscrew the emercency isolator button (15).
- Remove the screws (14) and lift off the cover (16).
- Remove the cover (8) from the fuse box (7).
The fuses protect the following circuits:
Note the numbers and letters on the fuse box or in the cover.
1 Battery discharge indicator (6F1) .............................. 5 A
2 Control current (F2) ................................................. 15 A
3 Regenerative current contactor*, bridging contactor*,
horn, fan traction motor (F3) ...................................... 5 A
4 Steering and traction electronics,
fan electronic controller (F4) ...................................... 5 A
5 Lifting electronics (2F5) ............................................. 5 A
6 Hour meter, brake relay (F6) ..................................... 5 A
Operation
ATTENTION
Only use genuine Linde replacement fuses with
a higher voltage rating.
Two other fuses protect the following main circuits:
11 Regenerative current contactor* (1F3) .................. 160 A
12 Lifting (2F1) ............................................................ 250 A
13 Driving (1F1) .......................................................... 355 A

Another MTA fuse (3F1) (9) protects the steering

pump motor ..................................................... 40 A* / 50 A**
First remove the cover (10).
324 804 3001.0702

* for 48 V only
** for 24 V only

14 7
15 10
654321
8

F E D C B A
9 11
16 12
13

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33
Fuses (option) Operation
NOTE
The electrical system for the auxiliary equipment is located Fuse box A: 12 V (Lighting E 16) Fuse box A: 24 V (Lighting E 12, E 15)
under the cover (2) of the control valve block.
1 Dip beam, left (5F5). ................................................ 10 A 1 Dip beam, left (5F5) ................................................... 5 A
- Unscrew the control levers (3) and remove the rubber 2 Dip beam, right (5F6) ............................................... 10 A 2 Dip beam, right (5F6) ................................................. 5 A
protectors (4). 3 Position light, left (5F7) .............................................. 5 A 3 Position light, left (5F7) .............................................. 5 A
4 Position light, right (5F8) ........................................... 5 A 4 Position light, right (5F8). .......................................... 5 A
- Unscrew screws (1) (each 4) and remove the cover (2) 5 Lighting (5F9) ........................................................... 15 A 5 Lighting (5F9) ........................................................... 15 A
upwards. 6 Direction indicator/wiper (5F10) .............................. 15 A 6 Direction indicator/wiper (5F10) .............................. 15 A

- Remove the cover from the appropriate fuse box. Observe
the number sequence on the cover and on the fuse box.
Fuse box B: 48 V/12 V (Working lights, voltage converter E Fuse box B: 24 V (Working lights E 12, E 15)
16)
1 Not used
1 Voltage converter (9F1) ............................................. 5 A 2 Not used
2 Working light (9F2) .................................................. 10 A 3 Working light (9F3) .................................... 10 A / 15 A**
3 Working light (9F3) ...................................... 15 A / 20 A* 4 Working light (9F4) .................................... 10 A / 15 A**
4 Working light (9F4) ...................................... 15 A / 20 A* 5 Working light (9F5) ....................................... 5 A / 10 A**
5 Working light (9F5) ...................................... 10 A / 15 A* 6 Working light (9F6) ....................................... 5 A / 10 A**
6 Working light (9F6) ...................................... 10 A / 15 A*

324 804 3001.0702

* Fuses for working lights see wiring diagram page 76 ** Fuses for working lights see wiring diagram page 74

4
3 A

A
2

B
1 2 3 4 5 6
1 B

1 2 3 4 5 6
e324-02/90 e324-02/91

34
 Before loading Operation
Check the load capacity diagram (1) before picking up a load. Example: E 16
If attachments are fitted, first check the respective load
Load centre distance: .............................................. 600 mm 1 Maximum load capacity in kg
capacity plate (2).
Height of lift: ........................................................... 4750 mm 2 Height of lift
WARNING
The weights given in the load capacity diagram
- Follow the vertical line for a load centre distance of 3 Mast type
and plate are only applicable to compact and
600 mm to the point where it intersects the line for a lift
homogeneous loads. Never exceed the load capacity of
height of 4750 mm. 4 Fork truck model with maximum load capacity
the lift truck. Overloading will reduce truck stability and
the strength of forks and mast.
- Follow the horizontal line at the point of intersection to the 5 Load centre distance from fork-face in mm
left to read the maximum load capacity.
The maximum load capacity is governed by the height of lift
and the load centre distance.
- In this case the maximum load is 1400 kg.
NOTE
Proceed in the same manner for other heights and load centre
- Before transporting off-centre or swinging loads,
distances. The values in the diagram apply to both forks and
- before transporting loads with the mast tilted forward
even distribution of loads.
or the load not near the ground,
- loads with a large load centre distance,
324 804 3001.0702

- before operating attachments and additional devices,

- with wind force 6
check the load limits and contact your authorised distrib-
utor.

1 1 2

4
2
e324-02/92
5 4 3
e324-02/33

35
Loading
Positioning the forks
- Pull up on the quick-release lever (1).
- Position the forks as required by the width of the load by
sliding the forks to the right or left. Make sure that both
forks are equally far from the centre of the truck.
Operation
Loading
- Approach the load carefully and as accurately as possible. CAUTION
Do not stand under the elevated load. When
- Set the mast to the vertical position. travelling, the load should be carried as low as
possible and the mast should be tilted back.
- Elevate or lower the forks to the proper height.

- Allow the fork quick-releases (1) to seat in the notch.
NOTE
The load centre should be midway between the forks.
- Carefully move the truck forward into the centre of the load
until the load contacts the fork-face. Take care not to
contact adjacent loads.
- Raise the fork carriage until the load rests freely on the
forks.

- Reverse the truck until the load is clear.

- Tilt the mast back.

324 804 3001.0702

1

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36
 Transporting the load, unloading Operation
NOTE Unloading Before leaving the lift truck unattended
Pick up the load so that it is within the truck loading area
and so that it does not slide, tip over, or fall off. - Carefully drive the truck up to the racking. - Deposit the load and lower the fork carriage.

Transporting the load - Elevate the fork carriage to the proper height. - Tilt the mast forward until the forks touch the ground.

- Do not transport an off-centre load (e.g. if a sideshift is - Set the mast to the vertical position. - Engage the handbrake (1).
fitted).
- Drive carefully into the rack. - Depress the emergency isolator button (3).
- Transport the load near the ground.
- Lower the load slowly until the forks are clear. - Turn the switch key (2) anti-clockwise as far as possible
- When travelling on slopes, always drive the truck with the and remove it.
forks facing uphill when carrying a load. Never drive or turn - Reverse the truck.
across the slope. - Remove the seat belt.
WARNING
- If you do not have a clear view, work with a guide. Never park and leave the lift truck unattended
with the load elevated.
- If your load obstructs forward vision, you must travel with
the load trailing, except when travelling uphill.
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37
Tow coupling
Tow coupling
NOTE
Only use the tow coupling for towing light trailers in the
plant area.
(Please observe the valid accident prevention and VDI
regulations.)
- Turn the tow pin (1) 90o degrees and pull it up.
- Insert the tow bar eye into the coupling.
- Press the tow pin down against the pressure of the spring,
turn the pin 90° and allow it to engage in the retainer.
Operation
Lifting point for wheel jack
ATTENTION
Use only a jack with sufficient lifting capacity.
Capacity minimum 3600 kg.
- Apply the jack at the front only on the frame (1) point
behind the fender.
- Apply the jack at the rear under the counterweight (2).
- For E 12/16 in front of the tipping supports (3)
- For E 15 beside the tipping supports (3), inside.

CAUTION
The truck can only be jacked at these lifting
points on the left and right side of the truck.

324 804 3001.0702

1
1 3

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38
 Transport, Hoisting the truck
Transporting the truck on a lorry or low-bed
trailer
- Lower the mast.
- Apply the parking brake.
- Chock the truck.
- Lash down the truck.
WARNING
When hoisting the truck with a
crane make sure that no persons are within
the working range of the crane!
Do not step under the elevated load!
324 804 3001.0702
Operation
Hoisting the truck with a crane
ATTENTION - Sling lifting slings (3) (2000 kg load capacity minimum)
Only use a lifting sling and crane with a sufficient around the cross member on the outer upright of the mast.
load capacity.
For the truck weight incl. battery see the technical data. - Hook the ends of the slings into the crane hook (1).
To hoist with a crane, attach the lifting slings at the points
provided. ATTENTION
The safety lock (4) must close after inserting the
ATTENTION slings into the crane hook.
Tilt the mast fully back.
When the truck is being hoisted, the slings must not rub
against the sides of the overhead guard, rear cover and
- Turn the tow pin 90° and raise it. any attachments fitted.
Insert a lifting sling (2) (2000 kg load capacity minimum)
into the tow coupling.
- Press the tow pin down against the force of the spring, turn
90° and let it engage in the lock.
4
1
2
3
2 3
e324-02/40
39
Hoisting the truck Operation
Transporting the truck on a lorry or low-bed Hoisting the truck with lifting eyelets*
trailer ATTENTION ATTENTION
- Lower the mast. Only use a lifting gear and crane with a sufficient The safety lock (5) must close after inserting the
- Apply the parking brake. load capacity. chains into the crane hook (4).
- Chock the truck. For the truck weight incl. battery see the technical data.
- Lash down the truck. ATTENTION
ATTENTION When the truck is being hoisted, the chains must
To hoist with a crane when using the lifting not rub against the sides of the driver’s overhead
WARNING eyelets (1), an appropriate lifting gear (3), with guard, mast or any fitted attachments.
When hoisting the truck with a the lifting chains (2, 6) positioned vertically above the
crane make sure that no persons are within eyelets (1), must be used.

the working range of the crane! - Attach the chains (2) (min. 2000 kg load capacity) at the
Do not step under the elevated load! eyelets (1) on the counterweight

- Attach the chains (6) (min. 2000 kg load capacity) at the

eyelets (1) on the mast.

324 804 3001.0702

*Option

5
4
3
6

2
1

e324-02/102

40
 Mast removal, towing instructions
Mast removal
ATTENTION
Attach the lifting gear to the upper cross mem-
ber (1) on the outer upright of the mast.
This work may only be performed by the qualified staff of
your authorised distributor.
WARNING
Do not step under the elevated load!
Operation
Towing instructions Towing procedure
If, in exceptional cases, the lift truck needs to be towed, a tow NOTE
bar or rope can be attached to the tow pin in the tow coupling. The power steering is inoperative when the emergency
A rope can also be attached at the bottom of the mast. isolator button is depressed.
CAUTION - Depress the emergency isolator button.
When being towed, the truck can only be braked - Lower the load, but only so far that the forks will not contact
mechanically with the brake pedal or the hand- the ground when towing.
brake.
- Remove the load.
- Attach the tow bar to the tow pin or a rope at the bottom of
the mast.
- Release the handbrake.
- One driver must steer the truck being towed and operate
the brake when needed.

Tow the fork truck and do not exceed the maximum operating
speed of the truck.
324 804 3001.0702

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41
Emergency exit 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 swing open the rear window
backwards.

- For opening, push the lower part the rear window

backwards and swing the pane upwards.

- Carefully dismount from the truck through the rear window.

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42
 Taking the truck out of operation
If the truck is taken out of operation for over 2 months, it must
be parked in a well ventilated, frost-free, clean and dry room
and the following measures must be carried out.
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.
- Apply a thin film of oil or grease on all unpainted mechan-
ical parts.
- Lubricate the truck.
- Check the condition and electrolyte level of the battery.
324 804 3001.0702
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 of
the ground. This will prevent tyre deformation.
NOTE
Do not use a plastic foil to cover the truck as this
enhances the formation and collection of condensation
water.
If the vehicle is to be taken out of operation for over
6 months, contact your authorised dealer for further
measures.
Putting the truck back into operation
- Thoroughly clean the truck.
- Lubricate the truck.
- Coat the battery terminals with non-acidic grease.
- Check the condition and electrolyte level of the battery.
- Check the hydraulic oil for condensation water and change
the oil, if necessary.
- Perform the same services as for commissioning.
- Take the truck into operation.
Maintenance
General information
Your truck will remain operational only if the maintenance and
checks are carried out regularly and according to the informa-
tion and instructions in the operating manual. The mainte-
nance may only be performed by qualified authorised person-
nel. This work can be carried out by your authorised distributor
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
distributor’s mechanic in the presence of the responsible
mechanic in your workshop, so that your staff can receive the
appropriate instruction.
For all servicing, the truck must be placed on a level surface
and the wheels secured.
Lower the fork carriage, tilt the mast slightly forward until the
forks rest on the ground. Apply the parking brake. Depress the
emergency isolator button and remove the key switch.
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.
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 the 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 fluids and
lubricants.
43
Mast versions Maintenance
Work on the mast and on the front part of the Standard mast Duplex mast
truck FUNCTION NOTE
CAUTION When the inner mast is lifted, the chain pulleys and chains The advantage of this version is that the special free lift
Do not carry out any services on the mast and also go up so that the fork carriage is raised twice as fast due height can be used even in spaces with a low ceiling
the front part of the truck when the mast or fork to the chain pulleys. (cellars, wagons, ships).
carriage is raised before performing the following safety
procedures. Securing the raised standard mast FUNCTION
These safety precautions are only limited to the general The fork carriage is raised to the special free lift height by the
servicing of your truck (checks and lubrication). For WARNING centre cylinder via the chain guide roller.
repairs (e.g. chain replacement, lift cylinder removal) Use a chain of sufficient lifting capacity for each
Then the inner mast is lifted by the two exterior cylinders,
further safety precautions are necessary. Please contact mast. Do not exceed the maximum height of lift.
taking the fork carriage with it.
your authorised distributor.
- Raise the mast. The centre cylinder is fitted to the extendible inner mast.

Securing the mast against tilting back - Fasten the chain around the cross member of the outer
To prevent the lifting mast from tilting back accidentally, insert upright (1) and the cross member of the inner upright (2).
a hardwood block of dimensions 120 x 120 x 800 mm (1)
between the mast and chassis. - Lower the inner mast until it is held by the chain.

324 804 3001.0702

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|
1

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44
 Mast versions
Securing the raised duplex mast
WARNING
Use a suitable chain for each type of 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.
- Lower the fork carriage completely.
324 804 3001.0702
1 1
2 2
e324-02/46
Triplex mast
FUNCTION
The fork carriage is raised to the special free lift height by the
centre cylinder via the chain guide roller. Both exterior cylinders
then raise the inner mast. Due to the chain guide roller, the
inner mast is raised twice as fast. The centre cylinder is
mounted within the extendible inner mast.
Securing the raised triplex mast
WARNING
Use a suitable chain for the particular lifting
mast. Do not exceed the minimum height of lift.
- Raise the mast.
- Fasten the chain around the cross member of the outer
mast (1) and the intermediate mast (2).
- Lower the mast until it is held by the chain.
- Fully lower the fork carriage.
e324-02/47
Maintenance
Services after the first 50 hours of operation
NOTE
A description of the services can also be found in the
index.
- Check the tyre inflation pressure
- Check the braking system
- Tighten the wheel fasteners
- Check the tyres for damage and foreign objects
- Working and steering hydraulics: Renew the suction filter
and check the hydraulic oil level
- Change the reduction gearboxes oil
- Check the reduction gearboxes for leaks
- Check the mounting of the close-coupled steer axle,
electric motors, reduction gearboxes, counterweight and
overhead guard
- Lubricate the mast and tilt cylinder bearings
- Mast, lift chain and end stops: Check condition, mounting
and function, lubricate with chain spray
- Check the electric cables, connectors and connections for
condition and tightness
- Check the working and steering hydraulics for leaks
- Check the pre-tension of double hoses if attachments are
fitted
- Retighten the mast fastening bolts
- Check the motor brush connections for security
45
Inspection and maintenance chart Maintenance
Services Before initial After first Daily As
(A description of the service can also be located in the index.) operation 50 hours checks required

See page 18 for the services ..................................................................................................................................... ●

See page 45 for the services ....................................................................................................................................................................... ●

Check the battery charge ............................................................................................................................................................................................................... ●

Check tyre inflation pressure .......................................................................................................................................................................................................... ●

324 804 3001.0702

Check seat belt for condition and operation .................................................................................................................................................................................................................... ●

Clean the lift truck ............................................................................................................................................................................................................................................................. ●

Clean and spray the lift chain ........................................................................................................................................................................................................................................... ●

Tighten the wheel fasteners (every 100 hours minimum) ............................................................................................................................................................................................... ●

Check the tyres for damage and foreign objects ............................................................................................................................................................................................................. ●

Renew the motor brushes ................................................................................................................................................................................................................................................ ●

Lubricate the mast and tilt cylinder bearings ................................................................................................................................................................................................................... ●

Change contactor tips ...................................................................................................................................................................................................................................................... ●

46
 Inspection and maintenance chart Maintenance
Services Every Every Every
(A description of the service can also be located in the index.) 500 hours 1500 hours 3000 hours

Clean the close-coupled steer axle .............................................................................................................................................................. ●

Check oil level in reduction gearboxes ........................................................................................................................................................ ●
Check reduction gearboxes for leaks .......................................................................................................................................................... ●
Check the hydraulic oil level ........................................................................................................................................................................ ●
Clean the traction motor fan ......................................................................................................................................................................... ●
Clean the left and right wheel traction motors, the power steering and working hydraulics pump motor .................................................. ●
Check the working and steering hydraulics for leaks .................................................................................................................................. ●
Lubricate the mast and tilt cylinder bearings ............................................................................................................................................... ●
Sideshift: Clean, grease and check the mounting ....................................................................................................................................... ●
Check the electric cables, cable connectors and connections for condition and tightness ........................................................................ ●
Clean the digital control ............................................................................................................................................................................... ●
Check the contactors .................................................................................................................................................................................... ●
324 804 3001.0702

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

Check the brake linings ................................................................................................................................................................................ ●
Check the mounting of the counterweight, electric motors, chassis, wheel drives, overhead guard
and close-coupled steer axle .................................................................................................................................................................... ●
Check and lubricate other bearings and joints ............................................................................................................................................ ●
Check the motor brushes, renew if necessary ............................................................................................................................................. ●
Mast, lift chains and end stops: Check condition, mounting and function .................................................................................................. ●
Adjust the lift chain length and lubricate the lift chain with chain spray ...................................................................................................... ●
Check the fork quick-releases and fork stops .............................................................................................................................................. ●
Check and oil the pedal and travel control linkage bearings ...................................................................................................................... ●
Check the pre-tension of double hoses if attachments are fitted ................................................................................................................ ●
Retighten the mast fastening bolts .............................................................................................................................................................. ●

Renew the hydraulic system breather filter ................................................................................................................................................................................... ●

Renew the hydraulic oil and suction filter ........................................................................................................................................................................................................................ ●

Change the oil in the reduction gearboxes ...................................................................................................................................................................................................................... ●

47
Inspection and maintenance as required
Check seat belt for condition and operation
NOTE
For safety reasons the condition and operation of the
retention system should be inspected regularly (month-
ly). Under extreme operating conditions this check is
required daily before taking the truck into operation.
- Pull the belt (2) 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 (1).
Maintenance
- Unlock the battery cover (4), open approx. 30° and hold in CAUTION
place. To prevent back injury, the weight setting should
The automatic lock should prevent the belt from unrolling be set to the individual weight of the driver.To
from the retractor (1). prevent injuries, do not store any objects in the tilting
range of the seat.
NOTE To prevent accidents, check that all adjustments are
When opening the battery cover, observe if a rear win- properly engaged before operating the truck.
dow* is mounted on the truck. Do not operate the seat adjusting devices while operating
the truck.
CAUTION Seat belts must be applied before operation of the truck.
Do not operate the truck with a faulty seat belt. After an accident, the seat belt must be renewed. In the
Have a defective seat belt replaced immediately case of seat belts attached to the operator seat, the seat
by your authorised dealer. 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

324 804 3001.0702

dealer immediately to eliminate the cause. In case of non-
observance, you put your health in danger and there is a
* Option
higher risk of accidents.

4
3

1
30o

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48
 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,
fertiliser, chemicals, cement, etc., clean the truck thor-
oughly after every application.
Hot steam or intensive degreasing solutions should be
used with utmost care! The grease in the lubricated-for-
life bearings will dissolve and leak out. As regreasing is
not possible, the bearings will be damaged.
- Depress the emergency isolator button.
Danger
For safety reasons the front axle and the area of
the front axle of the truck should never be cleaned
with a high pressure cleaning device.
This may substantially reduce the braking effect during
324 804 3001.0702
the first braking attempts after cleaning.
e324-02/50
ATTENTION
When washing with a cleaning device, do not
directly expose the electrical system, front axle
area, electric motors and insulating material to the jet,
cover them first.
Clean the oil filler openings along with the surrounding
area and the grease nipples prior to lubrication.
When cleaning with compressed air, first remove stick-
ing dirt with a cold cleaner.
Clean and spray the lift chain
NOTE
The lift chain must be cleaned if dust on the chain
prevents penetration of the lubricant.
- Place a container under the mast.
- Clean the chain using paraffin derivatives such as wash-
ing petrol (follow manufacturer’s notes on safety).
- When using a steam jet, clean without additives.
e324-02/51
Maintenance
- After cleaning, blow dry the chain at once to remove any
water in the chain links and on the chain surface. During
this procedure the chain should be moved several times.
- Spray the chain at once with Linde chain spray. Also move
the chain when spraying.
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.
Tighten the wheel fasteners
ATTENTION
Every 100 hours minimum.
- Check wheel fasteners (1) for the proper torque:
front wheels ......................................................... 210 Nm
rear wheels ......................................................... 195 Nm
1
e324-02/52
49
Inspection and maintenance as required Maintenance
Check the tyres for damage and foreign Renew the motor brushes
objects ATTENTION
- Secure the truck against rolling (apply the parking brake). For the service life of the motors it is important
to renew the motor brushes in time.
- Chock a wheel that is not to be raised.
NOTE
- Jack up the truck until the wheels are clear of the ground. When the motor brushes must be changed, the warning
light (5) in the composite instrument (6) will go on. The
- Secure the truck with wooden blocks. number of the motor in question appears in the LCD
display (4):
- Check the wheels for ease of movement and remove
anything hindering their movement. 1 = Traction motor
2 = Lift motor
- Renew worn or damaged tyres. 3 = Steering pump motor

(See page 58 for repair procedure)

324 804 3001.0702

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3 2

1
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50
 Inspection and maintenance as required
Lubricate the mast and tilt cylinder bear-
ings
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.
(See page 55 for repair procedure)
324 804 3001.0702
Maintenance
Change contactor tips Clean the traction Controller fan
Contact your authorised distributor in order to change the - Press down and unscrew the emergency isolator button
contactor tips. (2).
NOTE - Loosen the screws (1).
The regenerative current and bridging contactors can
only be renewed as a kit. - Lift the cover (3) and pull the connector out of the fan (4).
- Dismount the fan (4) from the cover (3).
- Clean the fan motor with compressed air.
- Mount the fan (4) to the cover (3) and plug in the connector.
- Fasten the cover (3) with the screws (1).
- Refit the emergency isolator button (2).

1
2

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51
500-hour inspection and maintenance Maintenance
Clean the close-coupled steer axle Check oil level in reduction gearboxes Check reduction gearboxes for leaks
- Lower the mast completely. - Raise and secure mast against inadvertent lowering.
CAUTION
Depress the emergency isolator button and
- Screw out the oil dipstick (1) with breather filter on the left - Check the right and left gearbox for leaks at dipstick, at
protect the electrical system (digital control)
and right reduction gearbox. axle seal and at motor fastenings.
against spray water.
- Wipe the dipstick with a clean cloth.
- Clean the close-coupled steer axle with water or a cold
cleaner.
- Screw the dipstick completely in place and screw out
again.

- The gearbox oil level should be between the marks on the

dipstick.

- If needed, top up gear oil as far as the top mark.

Max. capacity per side ............................... approx. 1.2 litres

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52
 500-hour inspection and maintenance
Check the hydraulic oil level
ATTENTION
Follow the instructions for handling fluids and
lubricants.
Maintenance
Clean the traction motor fan
- Pull out the breather filter (1) and oil dipstick (2). CAUTION
If the traction motors are warm, the fan motor
- Wipe the oil dipstick with a clean cloth. can operate when the truck is shut off.

ATTENTION
Check the hydraulic oil level only with the mast
tilted back and the fork carriage lowered.
- Apply the handbrake.
- Depress the emergency isolator button.
- Loosen the floor plate (3) and swing to the rear.
- Fully re-insert the breather filter and dipstick and pull it out - Depress the emergency isolator button.
again. - Remove the plug from the accelerator switch.
- The oil level should be between the marks on the dipstick. - Remove the floor plate.
- Remove the fan.
- If needed, top up the hydraulic oil as far as the top mark.
- Use compressed air to clean the protective screen, fan
motor and air passage.
- Refit the breather filter.
- Install the fan.
- Mount the floor plate and reconnect the plug.

ATTENTION
The truck braking only operates when the floor
324 804 3001.0702

plate is screwed in place.

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53
500-hour inspection and maintenance
Clean the left and right wheel traction mo-
tors, the power steering and working hy-
draulics pump motor
- Set the mast to the vertical position.
- Raise and secure the fork carriage against inadvertent
lowering.
- Depress the emergency isolator button.
- Unscrew the floor plate and swing back.
- Clean the travel traction motors and the power steering
and working hydraulics pump motor with compressed air.
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54
Maintenance
Check the working and steering hydraulics
for leaks
- Check the pump for the working hydraulics and power
steering, valves and pipes for leaks.
NOTE
Protect the electrical system and connections against
- Replace any porous hoses.
moisture. Take care not to let water penetrate the electric
motors. Should moisture nevertheless penetrate, either
- Examine the pipes and hoses for chafe marks, replace if
operate the lift truck (drying with own heat) or dry the
required.
motors with heat, air jet, etc. in order to avoid damage
through corrosion.
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e325-02/54 e325-02/69
 500-hour inspection and maintenance
Lubricate the mast and tilt cylinder bearings
NOTE
Use lubricating grease for greasing.
- Fully lower the fork carriage.
- Lubricate the grease nipples (2) on the left and right mast
bearings.
- Lubricate with a grease gun until fresh grease emerges at
the bearings.
- Using lubricating grease, lubricate the grease nipples (1)
on the tilt cylinder bearings.
- Using lubricating grease, lubricate the grease nipples (3)
on the left and right tilt cylinder bearings at the chassis
from the inside.
- Lubricate with a grease gun until fresh grease emerges at
the bearings.
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.
NOTE
Use lubricating grease for greasing.
- Lubricate at the roller grease nipples (1) on the carriage
and grease nipples (2) at the fork carriage with lubricating
grease, until new grease appears at the side.

NOTE
The sideshift must be greased each time the truck is
cleaned.
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* Option

3
1

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55
500-hour inspection and maintenance Maintenance
Check the electric cables, cable connectors Clean the digital control Check the contactors
and connections for condition and tight- NOTE - Check contactor tips for pitting and have them replaced, if
ness Apply the handbrake and depress the emergency isolator required.
button before every servicing. Please contact your authorised distributor.
NOTE
Apply the handbrake and depress the emergency isolator - Clean the pulse control with an air jet. - Refit the electrical system cover.
button before every servicing.
NOTE
- Electric motor terminals: Check the connectors for secu- Protect the electrical system and digital control against
rity and traces of oxidation. moisture.
- Check the battery cables for security.
- Remove the electrical system cover.
- Check the wiring for chafing and security.

NOTE
Oxidized connections and broken cables lead to drops in
voltage causing malfunctions.

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- Eliminate any traces of oxidation and renew any broken
cables.

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56
 500-hour inspection and maintenance
Check the braking system
WARNING
The proper operation of the handbrake (1) and
the brake pedal (2) must always be ensured. If
faults due to mechanical wear become evident (e.g. worn
brake pads or scored brake discs), please contact your
authorised distributor.
Maintenance
Check the brake linings Check the mounting of the counterweight,
ATTENTION electric motors, chassis, wheel drives, over-
Raise the fork carriage and secure it against head guard and close-coupled steer axle
inadvertent lowering.
- Check the mounting elements of motor drive units, power
- Depress the emergency isolator button. steering and working hydraulics motor, counterweight,
chassis, wheel drives, overhead guard and close-coupled
- Brake pad thickness ...................................... min. 2 mm steer axle for security and wear.

- Check the surfaces of the brake pads and discs. - Tighten any loose nuts and bolts.

ATTENTION - Renew any damaged parts.

If the braking system shows signs of defects or
wear, contact your authorised distributor. - Touch up the paint, if required.
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57
500-hour inspection and maintenance
Check and lubricate other bearings and
joints
Inspect and oil the bearings and joints of:
- seat guide
Maintenance
Check the motor brushes, renew if neces-
sary
ATTENTION - Check the springs and brushes for ease of movement in
Elevate the fork carriage and secure it against the guides and visually inspect the brushes for condition
inadvertent lowering. and length, renewing them if necessary.

- battery cover lock and hinges
- wiper system*
- cabin* door locks and hinges
- Depress the emergency isolator button.
- Remove the brush cover (1) on the steering pump motor.
- Remove the brush cover (2) on the lift motor and the brush
covers (3) on both traction motors.
- Pull up the brush springs (4) of the brushes (5).
- Withdraw the brushes (5) out of their guides.
- Insert the brushes into the guide again, tension the brush-
es and check the brush connections for security.
NOTE
Only replace carbon brushes in sets.
Brush lengths:
Traction motors .................. original 32.0 mm, min. 15.0 mm
Lift motor ............................ original 32.0 mm, min. 15.0 mm
Steering pump motor ........... original 17.5 mm, min. 7.0 mm

- Install the brush covers on the motors.

324 804 3001.0702

- Close the floor plate and screw tight.
* Option

1 2

5 4
5

3 4
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58
 500-hour inspection and maintenance
Mast, lift chains and end stops:
Check condition, mounting and function
- Clean the mast channels and chains.
- Examine the chains for condition and wear, particularly in
the area of the pulleys.
- Check the mounting of the chains at the chain anchors.
- Renew damaged chains.
Adjust the lift chain length*
NOTE
As the lift chain stretches with use, it must be checked
and adjusted as necessary on the right and left sides.
- Completely lower mast.
- 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.
Maintenance
Adjust the lift chains length*
NOTE
The lift chains must be adjusted as they stretch with use.
- Completely lower mast.
- Loosen the locknuts (1) at the right and left.
- Adjust chain lengths with the adjusting nut (2) on the chain
anchors. The lower guide roller of fork carriage may
project a maximum of 25 mm from inner mast channel.
- Tighten the locknuts (1) left and right firmly.

- Inspect the mast, channel surfaces and rollers for condi- Lubricate the lift chain with chain spray Lubricate the lift chain with chain spray
tion and security.
- Spray the guiding surfaces and chain with Linde chain - Spray the guiding surfaces and chains with Linde chain
- Check condition and function of end stops. spray. spray.

NOTE NOTE
Trucks in service in the food industry must be lubricated Trucks in service in the food industry must be lubricated
with a thin oil approved for the food industry instead of with a thin oil approved for the food industry instead of
324 804 3001.0702

chain spray. chain spray.

* for standard and triplex masts only * for duplex and triplex masts only

2
2

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59
500-hour inspection and maintenance
Check the fork quick-releases and fork stops
- Examine the forks for visible deformation and damage.
- Check the bolts of the fork quick-releases (2) and fork
stops (1) for proper seating and damage.
- Renew any defective parts.
Check and oil the pedal and travel control
linkage bearings
ATTENTION
The accelerator sensor (1) must only be adjust-
ed by trained skilled personnel.
Please contact your authorised distributor.
- Unscrew the floor plate and swing back.
Maintenance
Check the pre-tension of double hoses if
attachments are fitted
- The pre-tension of the double hoses should be 5 to 10 mm
per meter referred to initial length.
- Adjust the pre-tension to the specified value by shifting the
hoses in the clamps.

- Check the pin and joint retainers for security.

- Lightly oil the lever bearings and clevises as required.

- Check leaf spring (2) and tension spring (3) for proper
operation.

- Refit floor plate and screw tight.

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60
 500-hour inspection and maintenance 1500-hour inspection and maintenance

Retighten the mast fastening bolts Renew the hydraulic system breather filter
- Elevate the fork carriage and secure against inadvertent ATTENTION
lowering. Follow the instructions for handling fluids and
lubricants.
- Check the fastening bolts (1) (2 on each side) of the mast
bearings for tightness. - Unscrew the floor plate (3) and swing to the rear.

Torque: ..................................................................... 570 Nm - Pull the breather filter (1) and dipstick out of the filler neck.

- Tighten the left and right mast fastening bolt (2) on the - Pull the dipstick (2) out of the filter and install in the new
chassis. breather filter.

Torque: ..................................................................... 210 Nm - Install the breather filter in the filler neck.

- Unlock and lower the fork carriage. - Close the floor plate and screw tight.

NOTE
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In a dusty environment, the filter may need more frequent

renewal.

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61
3000-hour inspection and maintenance Maintenance
Renew the hydraulic oil and suction filter Change the oil in the reduction gearboxes
ATTENTION - Pump out the hydraulic oil with the appropriate hand ATTENTION
Follow the instructions for handling fluids and pump. Follow the instructions for handling fluids and
lubricants. - Fill new hydraulic oil into the hydraulic oil tank. lubricants.

NOTE
The hydraulic oil can only be pumped out with the
appropriate aid (hand pump).
- Lower the fork carriage completely.
- Loosen the floor plate and swing back.
- Loosen the fastening screw of the clamping band (2) on
the suction filter cover.
- Remove the suction filter cover (1) with the clamping
band.
- Withdraw the suction filter (3) slowly so that the oil can flow
back into the tank.
Hydraulic oil tank capacity ....................... approx. 14.0 litres
- Carefully install the new suction filter in the oil tank.
- Clean the sealing ring on the filter cover, apply a thin film
of oil to the ring and refit it.
- Refit the filter cover with the clamping band and secure it
with the fastening screw.
- Check the filter for leaks in a trial run.
- Pull out the breather filter (4) and check the oil level with
the dipstick. Add oil as required through the filler neck up
to the top mark on the dipstick.
- Drive the truck until the reduction gearboxes are warm.
- Elevate the mast and secure against inadvertent lowering.
- Place a catch tray under the reduction gearbox.
- Screw out the oil dipstick (1) with breather filter
- Screw out the drain plug (2) allow oil to drain completely.
- Screw in the drain plug again.
- Fill oil into the opening for the dipstick.
NOTE
Fill oil in small amounts to reduce air pockets
- Check the oil level with the dipstick and add oil as required
up to the top mark on the dipstick.
Max. capacity per reduction gearbox ........ approx. 1.2 litres

324 804 3001.0702

- Install the breather filter tightly.
- Screw in the oil dipstick again.
- Close the floor plate and screw tight.
- Repeat the procedure for the second reduction gearbox.

1
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62
 Inspection and maintenance specifications Maintenance
No. Aids/ Capacity/
Lubricants Settings

1 Reduction gearboxes Gear oil Each gearbox 1.2 litres

2 Hydraulic system Hydraulic oil Approx. 14.0 litres

3 Hydraulic system Filter element Mesh = 25 mm

4 Tyres Air Front 10 bar, rear 10 bar

5 Wheels Traction wheel Torque 210 Nm

Rear wheel Torque 195 Nm

6 Electrical system:
Traction motors Fuse 355 A
Lift motor Fuse 250 A
Regenerative current contactor Fuse (for 48 V only) 160 A
Steering pump motor MTA Fuse (for 24 V only) 50 A
324 804 3001.0702

Steering pump motor MTA Fuse (for 48 V only) 40 A

Discharge indicator Fuse 15 A
Control current Fuse 5A
Regenerative current and bridging
contactors, horn Fuse 5A
Steering and traction electronics, fan Fuse 5A
Lifting electronics Fuse 5A
Hour meter, brake relay Fuse 5A

7 Electric motors:
Traction motors Motor brushes Original 32 mm, min. 15 mm
Lift motor Motor brushes Original 32 mm, min. 15 mm
Steering pump motor Motor brushes Original 17.5 mm, min. 7 mm

8 Battery Distilled water As required

9 Mast/tilt cylinder bearings Lubricating grease As required

10 Sideshift Lubricating grease As required

11 Mast channels and chain guides Linde chain spray As required

63
Lubricant recommendations
Hydraulic oil Gear oil
Recommendation for regular duty: Preferably SAE 80 W - 90 API GL5, also suitable is SAE 85 W
Hydraulic oil HLP ISO VG 46 to DIN 51524 T.2 (factory filling), - 90 API GL4 (to DIN 51512).
average continuous oil temperature 40 °C to 60 °C.
Lubricating grease
Recommendation for heavy duty:
Linde lithium-based heavy duty grease with EP additives and
Hydraulic oil HLP ISO VG 68 to DIN 51524 T.2, average MOS2.
continuous oil temperature over 60 °C.
Designation to DIN 51825 KPF 2N-20, (see Parts Catalogue
for Order No.).
Recommendation for light duty at low ambient temperatures:
Do not mix with greases having another base than lithium.
Hydraulic oil HLP ISO VG 32 to DIN 51524 T.2, average
continuous oil temperature under 40 °C.
Battery grease
Recommendation for strongly varying operating conditions: Non-acidic lubricating grease (terminal grease).
All the above applications can be covered with an hydraulic oil
HVLP ISO VG 46 to DIN 51524 T.3. Chain spray
Such hydraulic oils have a high viscosity index (multigrade

324 804 3001.0702

oils). Linde chain spray (see Parts Catalogue for Order No.).

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 manufacturers cannot be recommand-
ed.

NOTE
The above oil recommendations are only guidelines.
If case of doubt we recommend contacting your author-
ised distributor.
Recommendations of representatives of the oil industry
should also be checked with your authorised truck dealer.
Only the above-mentioned oils are approved by the man-
ufacturer. Costly damage can result if other hydraulic oils
are used or mixed.

64
 Troubleshooting guide
Trouble Possible Cause Remedy See Page
Abnormal noise Suction filter restricted. Clean or replace filter. 62
Suction hoses leak, oil foams. Tighten hose connections. Check oil level, top up if 53, 54
necessary.

Hydraulic pump damaged, seals faulty, Have inspected by your authorised distributor.
causing air intake.

Oil of wrong viscosity, low oil level in tank. Change oil, use specified viscosity. Top up oil. 53, 62, 64

No or too low pressure in Pump suction faulty, noises. Add oil, change oil. 53, 62
system Pump failure, pressure valves do not close, Have repaired by distributor’s mechanic.
valve seat damage.
Pipeline broken or leaky. Replace pipe or tighten connections. 54
Oil of low viscosity, causing high leakage losses. Change oil, use specified viscosity. 62, 64

Oil pressure fluctuates Causes as under abnormal noise. See under abnormal noise.
324 804 3001.0702

Lift and tilt cylinders have tight spots. Have seal rings replaced by a workshop.
Mast does not extend completely or retracts Top up oil. 53
slightly after being extended.

Hydraulic oil temperature Pump failure, valves leaking. Have repaired by a workshop.
too high Oil level too low. Check oil level; if necessary, top up oil. 53

Failure of the working Faulty fuse. Renew the fuse. 33, 34

hydraulic system

Reduced performance of Battery discharge at 80 %. Check, charge or replace the battery. 20, 21, 22
the hydraulic system

Truck does not drive Battery is discharged. Check, charge or replace the battery. 20, 21, 22

Loose electrical connections. Tighten battery terminals, coat with 21

non-acidic grease.
Check electric motor cable connections. 56

Seat switch not operated properly, or faulty. Sit on the seat properly, or renew the seat switch. 24

65
324 804 3001.0702

66
 Wiring diagram for 24 Volt electrical system
1A1 Traction control power module 3M1 Steering motor 3X3 Connector, 4 way
1A2 Traction control 9M1 Traction motor fan 4X1 Connector, 2 way
1A4 Accelerator transmitter 9M2 Fan electronic controller 6X1 Motor brush plug 2M1, 4 way
2A1 Lift control power module 6X5 Motor brush plug 3M1, 1 way
6P2 Composite instrument
3A1 Steering control 6X6 Connector, 12 way
2A2 Lift control S1 Key switch 6X8 Connector, composite instrument, 16 way
6A2 Motor brush monitor S2 Emergency isolator switch 6X9 Diagnostic plug, composite instrument, 4 way
1B1 Accelerator transmitter 1S1 Curve switch, right 6X10 Hour meter, pump motor, 3 way
1S2 Curve switch, left 9X1 Connector, 2 way
1B2 RPM sensor 1M1 (traction motor, right) 1S4 Handbrake switch 9X2 Connector, 2 way
1B3 Actual current sensor 1S5 Foot brake switch
1B4 Temperature switch 80°C (closer in 1M2) 1S12 Accelerator switch 1Z11 Quencher, traction contactor, right
1B5 Temperature switch 80°C (closer in 1M1) 1S13 Direction switch, one pedal/SRTN 1Z12 Quencher, traction contactor, right
1B6 Temperature switch 160 °C (opener in 1M2) 1S50 Reed switch, driver’s seat 1Z21 Quencher, traction contactor, right
1B7 Temperature switch 160 °C (opener in 1M1) 1Z22 Quencher, traction contactor, right
1B8 RPM sensor 1M2 (traction motor, left) 4S1 Horn button 9Z1 Quencher, fan motor
2B7 Temperature switch
2B11 Sensor, lift U1 Voltage converter
2B12 Sensor, tilt Cable colour codes
2B13 Sensor, auxiliary hydraulics 1 1V6 Freewheel diode, traction
1V51 Armature diode 1M1
324 804 3001.0702

2B14 Sensor, auxiliary hydraulics 2 BK black

3B1 Sensor Steering 1V52 Armature diode 1M2 WH white
4B1 Signal horn 2V6 Freewheel diode, lift BU blue
6B1 Motor brush wear switch, traction motor 1M1, A1 3V6 Freewheel diode, steering OGorange
6B3 Motor brush wear switch, traction motor 1M2, A2 BN brown
6B5 Motor brush wear switch, lift motor 2M1, A X1 Connector, 10 way
X2 Connector, 6 way GN green
6B7 Motor brush wear switch, steering motor 3M1, A1
X6 Connector, curve switch, 3 way VT violet
4C1 Suppresser capacitor, horn, 470 nF/400 V X8 Connector, voltage converter, 6 way RD red
X10 Battery plug YE yellow
F2 Fuse, control 15 A
1X1 Connector, 4 way GY grey
F3 Fuse, horn, fan traction motor 5 A
1X2 Connector, 4 way
F4 Fuse, steering and traction electronics,
1X4 Connector, 3 way The number in front of the wire colour indicates the wire cross-
fan electronic controller 5 A
1X6 Connector, 4 way section.
F6 Fuse, composite instrument 5 A
1X7 Connector, 4 way On wires with no number, the cross-section = 0.5 mm2
1F1 Fuse, traction 355 A
1X8 Connector, 6 way Main voltage wires without colour = BK
2F1 Fuse, lift 250 A
1X9 Connector, 4 way
2F5 Fuse, lift electronics 5 A
1X10 Connector, 6 way 1) The switch is operated when the hand brake is not pulled.
3F1 MTA Fuse, steering 50 A
1X12 Connector, traction control power module, 6 way
6F1 Fuse, battery discharge indicator 5 A 2) The switch is operated when the foot brake is in the neutral
1X13 Connector, 42 way
position
G1 Battery 1X14 Connector, 3 way
1X15 Diagnostic plug, 4 way Ý Indicates operated position.
1K11 Traction contactor, rear right 2X1 Connector, 25 way
1K12 Traction contactor, front right 2X2 Connector, 3 way
1K21 Traction contactor, rear left 2X5 RPM sensor, lift impulse, 3 way
1K22 Traction contractor, front left
2X6 Connector, 3 way
1M1 Traction motor, right 2X7 Connector, 3 way
1M2 Traction motor, left 2X10 Connector, lift control module, 6 way
2M1 Pump motor 3X1 Connector, 25 way
3X2 Connector, 1 way
67
Wiring diagram for 24 Volt electrical system

324 804 3001.0702

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68
324 804 3001.0702
Wiring diagram for 24 Volt electrical system

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69
324 804 3001.0702

70
 Wiring diagram for 48 Volt electrical system
1A1 Traction control power module 1K21 Traction contactor, rear left 2X7 Connector, 3 way
1A2 Traction control 1K22 Traction contractor, front left 2X10 Connector, lift control module, 6 way
1A4 Accelerator transmitter 1M1 Traction motor, right 3X1 Connector, 25 way
2A1 Lift control power module 1M2 Traction motor, left 3X2 Connector, 1 way
3A1 Steering control 2M1 Pump motor 3X3 Connector, 4 way
2A2 Lift control 3M1 Steering motor 4X1 Connector, 2 way
6A2 Motor brush monitor 9M1 Traction motor fan 6X1 Motor brush plug 2M1, 4 way
9M2 Fan electronic controller 6X5 Motor brush plug 3M1, 1 way
1B1 Accelerator transmitter 6P2 Composite instrument 6X6 Connector, 12 way
1B2 RPM sensor 1M1 (traction motor, right) S1 Key switch 6X8 Connector, composite instrument, 16 way
1B3 Current value sensor S2 Emergency stop switch 6X9 Diagnostic plug, composite instrument, 4 way
1B4 Temperature switch 80°C (closer in 1M2) 1S1 Curve switch, right 6X10 Hour meter, pump motor, 3 way
1B5 Temperature switch 80°C (closer in 1M1) 1S2 Curve switch, left 9X1 Connector, 2 way
1B6 Temperature switch 160 °C (opener in 1M2) 1S4 Handbrake switch 9X2 Connector, 2 way
1B7 Temperature switch 160 °C (opener in 1M1) 1S5 Foot brake switch 1Z5 Quencher, regenerative current contactor
1B8 RPM sensor 1M2 (traction motor, left) 1S12 Accelerator switch 1Z6 Quencher, bridging contactor
2B7 Temperature switch 1S13 Direction switch, one pedal/SRTN 1Z11 Quencher, traction contactor, right
2B11 Sensor, lift 1S50 Reed switch, driver’s seat 1Z12 Quencher, traction contactor, right
2B12 Sensor, tilt 4S1 Horn button 1Z21 Quencher, traction contactor, right
2B13 Sensor, auxiliary hydraulics 1 U1 Voltage converter 1Z22 Quencher, traction contactor, right
2B14 Sensor, auxiliary hydraulics 2 1V1 Diode
324 804 3001.0702

9Z1 Quencher, fan motor

3B1 Sensor Steering 1V6 Freewheel diode, traction
4B1 Signal horn 1V51 Armature diode 1M1
6B1 Motor brush wear switch, traction motor 1M1, A1 1V52 Armature diode 1M2 Cable colour codes
6B3 Motor brush wear switch, traction motor 1M2, A2 1V53 Regenerative current diode BK black
6B5 Motor brush wear switch, lift motor 2M1, A 2V6 Freewheel diode, lift WH white
6B7 Motor brush wear switch, steering motor 3M1, A1 3V6 Freewheel diode, steering
BU blue
X1 Connector, 10 way
OGorange
4C1 Suppresser capacitor, horn, 470 nF/400 V X2 Connector, 6 way
X3 Connector, 4 way BN brown
F2 Fuse, control 15 A X6 Connector, curve switch, 3 way GN green
F3 Fuse, regenerative current contactor, bridging con- X8 Connector, voltage converter, 6 way VT violet
tactor, horn, fan traction motor 5 A X10 Battery plug RD red
F4 Fuse, steering and traction electronics, 1X1 Connector, 4 way YE yellow
fan electronic controller 5 A 1X2 Connector, 4 way GY grey
F6 Fuse, composite instrument 5 A 1X4 Connector, 3 way
1F1 Fuse, traction 355 A 1X6 Connector, 4 way The number in front of the wire colour indicates the wire cross-
1F3 Fuse, regenerative current contactor 160 A 1X7 Connector, 4 way section.
2F1 Fuse, lift 250 A 1X8 Connector, 6 way On wires with no number, the cross-section = 0.5 mm2
2F5 Fuse, lift electronics 5 A 1X9 Connector, 4 way Main voltage wires without colour = BK
3F1 MTA Fuse, steering 40 A 1X10 Connector, 6 way
6F1 Fuse, battery discharge indicator 5 A 1X12 Connector, traction control module, 6 way 1) The switch is operated when the hand brake is not pulled.
1X13 Connector, 42 way 2) The switch is operated when the foot brake is in the neutral
G1 Battery 1X14 Connector, 3 way position
1X15 Diagnostic plug, 4 way
Ý Indicates operated position.
1K5 Regenerative current contactor 2X1 Connector, 25 way
1K6 Bridging contactor 2X2 Connector 3 way
1K11 Traction contactor, rear right 2X5 rpm sensor, lift impulse 3 way
1K12 Traction contactor, front right 2X6 Connector, 3 way

71
Wiring diagram for 48 Volt electrical system

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72
324 804 3001.0702
Wiring diagram for 48 Volt electrical system

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73
Wiring diagram for E 12, E 15 electrical system (options)
5E2 Left dip beam 55 W 9M1 Wiper motor, front 30 W * Fuses for working lights
5E3 Right dip beam 55 W
5E4 Left parking light 5 W 5S11 Light switch Number of working lights
5E5 Right parking light 5 W 5S12 Hazard light switch
1 2 3 4
5E6 Left rear position light 10 W 5S13 Direction light switch
5E7 Right rear position light 10 W 9S1 Switch, working light 9F3 - - 10 A 15 A
5E8 License plate light 5 W 9S2 Switch, working light 9F4 10 A 15 A 15 A 15 A
9E1 Working light 70 W 9S3 Switch, front windshield wiper 9F5 5A 10 A 10 A 10 A
9E2 Working light 70 W
9F6 - - 5A 10 A
9E3 Working light 70 W 1X13 Connector 42 way
9E4 Working light 70 W 4X3 Connector 3 way
5X1 Connector 9 way
F6 Fuse, Buzzer 5 A 5X2 Terminal board
5F5 Fuse, left dip beam 5 A 5X3 Terminal board
5F6 Fuse, right dip beam 5 A 9X1 Connector, 6 way
5F7 Fuse, left position lights 5 A
5F8 Fuse, right position lights 5 A
5F9 Fuse, lighting 15 A
Cable colour codes
5F10 Fuse, direction indicator system/wiper 15 A BK black

324 804 3001.0702

9F3 Fuse, working light 10 A / 15 A* WH white
9F4 Fuse, working light 10 A / 15 A* BU blue
9F5 Fuse, working light 5 A / 10 A* OG orange
9F6 Fuse, working light 5 A / 10 A* BN brown
GN green
4H15 Strobe light VT violet
4H16 Buzzer RD red
5H8 Direction indicator light, left front 21 W YE yellow
5H9 Direction indicator light, left rear 21 W GY grey
5H10 Direction indicator light, right front 21 W
5H11 Direction indicator light, right rear 21 W (I) Working light
5H12 Direction indicator control light 2.4 W
5H18 Switch lighting 1.2 W (II) Lighting
5H19 Switch lighting 1.2 W
5H20 Brake light, left 21 W (III) Windshield wiper
5H21 Brake light, right 21 W
9H1 Switch lighting 1.2 W (IV) Buzzer and Strobe light
9H2 Switch lighting 1.2 W
9H3 Switch lighting 1.2 W The number in front of the wire colour indicates the wire cross-
section.
4K1 Buzzer relay 24 V On wires with no number, the cross-section = 0.75 mm2
5K1 Flasher unit
5K2 Stop light relay

74
 Wiring diagram for E 12, E 15 electrical system (options)

(I) (II) (III) (IV)

324 804 3001.0702

324 802 0152c

75
Wiring diagram for E 16 electrical system (options)
5E2 Left dip beam 55 W 9H1 Switch lighting 1.2 W Cable colour codes
5E3 Right dip beam 55 W 9H2 Switch lighting 1.2 W
5E4 Left parking light 5 W 9H3 Switch lighting 1.2 W BK black
5E5 Right parking light 5 W WH white
5E6 Left rear position light 5 W 4K1 Buzzer relay 24 V BU blue
5E7 Right rear position light 5 W 5K1 Flasher unit OGorange
5E8 License plate lights 5 W 5K2 Stop light relay BN brown
9E1 Working light 55 W
GN green
9E2 Working light 55 W 9M1 Wiper motor, front 30 W
9E3 Working light 55 W VT violet
9E4 Working light 55 W 5S11 Light switch RD red
5S12 Hazard light switch YE yellow
F6 Fuse, Buzzer 5 A 5S13 Direction light switch GY grey
5F5 Fuse, left dip beam 10 A 9S1 Switch, working light
5F6 Fuse, right dip beam 10 A 9S2 Switch, working light (I) Lighting
5F7 Fuse, left position lights 5 A 9S3 Switch, front windshield wiper
5F8 Fuse, right position lights 5 A (II) Windshield wiper
5F9 Fuse, lighting 15 A
9U1 Voltage converter, lighting
5F10 Fuse, direction indicator system/wiper 15 A
9U2 Voltage converter, working light* (III) Buzzer and Strobe light

324 804 3001.0702

9F1 Fuse, voltage converter/working light* 5 A/10 A
9U3 Voltage converter, working light*
9F2 Fuse, voltage converter/lighting 10 A
9F3 Fuse, working light 15 A / 20 A* (IV) 1-2 working lights
1X13 Connector 42 way
9F4 Fuse, working light 15 A / 20 A*
4X3 Connector, 3 way
9F5 Fuse, working light 10 A / 15 A* (V) 3-4 working lights
5X1 Connector 9 way
9F6 Fuse, working light 10 A / 15 A*
5X2 Terminal board U-
5X3 Terminal board L- (VI) 1-4 working lights and wipers
4H15 Strobe light
9X1 Connector, 6 way
4H16 Buzzer
9X3 Connector, 4 way The number in front of the wire colour indicates the wire cross-
5H8 Direction indicator light, left front 21 W
9X4 Connector, 3 way section.
5H9 Direction indicator light, left rear 21 W
9X5 Connector, 3 way On wires with no number, the cross-section = 0.75 mm2
5H10 Direction indicator light, right front 21 W
9X6 Connector, 3 way
5H11 Direction indicator light, right rear 21 W
9X7 Connector, 3 way * Fuses for working lights
5H12 Direction indicator control light 2.4 W
5H18 Switch lighting 1.2 W
5H19 Switch lighting 1.2 W Number of working lights
5H20 Brake light left 21 W 1 2 3 4
5H21 Brake light right 21 W
9F1 5A 5A 10 A 10 A
9F3 - - 15 A 20 A
9F4 15 A 20 A 20 A 20 A
9F5 10 A 15 A 15 A 15 A
9F6 - - 10 A 15 A

76
 Wiring diagram for E 16 electrical system (options)
(I) (II) (III)
324 804 3001.0702

(IV) (V) (VI)

324 802 0153d

77
Hydraulic schematic for working and steering hydraulics
A Working hydraulics D Steering cylinder
1 Tilt cylinder
2 Lift cylinder, standard BR 160 E Lift hydraulic
3 Hose safety valve 25 Hydraulic pump
4 Lift cylinder, duplex BR 161 E 12 – 15 8 cm3/rev
5 Lift cylinder, triplex BR 162 E 16 11 cm3/rev
6 Slow lowering valve 26 Electric motor
7 Control valve block, assy. consisting of:
8 Way valve, auxiliary hydraulics 1
F Steering hydraulics
9 Way valve, auxiliary hydraulics 2 27 Electric motor
10 Check valve, releasable 28 Hydraulic pump
11 Way valve, tilting 24 V 1.7 cm3/rev
12 Check valve 48 V 2.2 cm3/rev
13 Way valve, lifting 24 V (36) 2.8 cm3/rev
14 Pressure relief valve
Standard Duplex Triplex G Hydraulic oil reservoir
E 12 170 +5 bar 170 +5 bar 190 +5 bar 29 Suction filter with by pass valve 0.3 - 0.1 bar
E 15 200 +5 bar 200 +5 bar 210 +5 bar
E 16 210 +5 bar 210 +5 bar 225 +5 bar H Breather filter

324 804 3001.0702

15 Check valve
16 Pressure switch
17 Restrictor

B Electronic control

C Steering control valve

18 Hydraulic pump/motor with two flow directions
19 6/3 way valve
20 Check valve
21 Pressure relief valve 130 +20 bar
22 Check valve
23 Restrictor
24 Pressure relief valve 70 +5 bar

78
 Hydraulic schematic for working and steering hydraulics

4 5
1 2

3 3
V

3 3
3
3

6
A
10
B4 A4 B3 A3 B2 A2 12 A1 R

8 9 11 13
7

14
D
17
15 15 15

16 16 16 16 P
324 804 3001.0702

19 20
C 21
R B
Controller 18 L
22
22

23
R

EL
22 21
T 24 P

27
E F
M M
25
28

26

G H

29

324 802 02 11C

79
Index
Page
A
Accident prevention check ................................................ 18
Approved applications ......................................................... 2
Attachments, operating ..................................................... 30
B
Battery change .................................................................. 22
Battery charge, checking ................................................... 20
Battery cover, opening, closing ......................................... 21
Battery discharge indicator ................................................ 15
Battery grease ................................................................... 64
Battery removal with a crane ............................................. 22
Battery, charging ............................................................... 20
Battery, connecting to a suitable external charger ........... 21
Battery: check condition, electrolyte level and
specific gravity ................................................................ 21
Bearings and joints, check and lubricate other ................. 58
Before leaving the lift truck unattended ............................ 37
Before loading ................................................................... 35
Beginning operation .......................................................... 17
Bio-hydraulic oil ................................................................. 64
Brake linings, check .......................................................... 57
Brakes ................................................................................ 12
Braking system .................................................................. 29
Braking system, check ....................................................... 57
Brush monitor .................................................................... 12
C
Central control lever operation of mast
and attachments ............................................................. 30
Chain spray ........................................................................ 64
Checks and servicing prior to initial operation
of the truck ...................................................................... 18
Clamp, operating ............................................................... 30
Composite instrument ....................................................... 15
Contactor tips, change ...................................................... 51
Contactor tips, check ......................................................... 56
Controls and indicators ..................................................... 14
80
Page
D
Daily checks and servicing before operation .................... 19
Daily checks ....................................................................... 18
Description ........................................................................... 2
Digital control, clean .......................................................... 56
Directional indicators, turning on ...................................... 32
Double hoses, check pre-tension ...................................... 60
Drive ................................................................................... 12
Driver’s seat, adjusting ...................................................... 23
Driving ................................................................................ 24
E
Electric cables, cable connectors and connections,
check for condition and tightness .................................. 56
Electric motor brake (LBC) , operating ............................. 29
Electrical system ................................................................ 12
Emergency stop button, push, pull .................................... 19
Emergency exit for trucks with rear windscreen ............... 42
F
Fan, traction LDC Controler, clean ................................... 51
Foot brake .......................................................................... 29
Fork carriage, lowering ...................................................... 30
Fork carriage, raising ......................................................... 30
Fork quick-releases and fork stops, check ....................... 60
Forks, positioning .............................................................. 36
Frequency characteristics for human body vibrations ...... 18
Fuses (option) .................................................................... 34
Fuses ................................................................................. 33
Fuses, checking, renewing ................................................ 33
G
Gear oil .............................................................................. 64
General information ........................................................... 43
General view of truck ......................................................... 13
Page
H
Handbrake ................................................................... 12, 29
Handbrake, engaging ........................................................ 29
Handbrake, releasing ........................................................ 29
Handling fluids and lubricants ........................................... 17
Hazard warning light, switching on ................................... 32
Hoisting the truck with a crane .......................................... 39
Hoisting the truck with lifting eyelets ................................. 40
Hoisting the truck ............................................................... 39
Horn, operating .................................................................. 32
Hour meter ......................................................................... 15
Hydraulic oil and suction filter, renew ............................... 62
Hydraulic oil level, check ................................................... 53
Hydraulic oil ....................................................................... 64
Hydraulic schematic for working and
steering hydraulics ......................................................... 78
324 804 3001.0702
Hydraulic system breather filter, renew ............................ 61
Hydraulic system ............................................................... 12
I
Inspection and maintenance as required .......................... 48
500-hour inspection and maintenance .......................... 52
1500-hour inspection and maintenance ........................ 61
3000-hour inspection and maintenance ........................ 62
Inspection and maintenance chart .................................... 46
Inspection and maintenance specifications ...................... 63
L
Lift chain, adjust length, lubricate with chain spray .......... 59
Lift chain, clean and spray ................................................ 49
Lift truck, clean .................................................................. 49
Lifting point for wheel jack ................................................. 38
Lights, switching on ........................................................... 32
Loading .............................................................................. 36
Lubricant recommendations .............................................. 64
Lubricating grease ............................................................. 64
 Index
Page
M
Maintenance ...................................................................... 43
Malfunctions during operation ........................................... 25
Mast and tilt cylinder bearings, lubricate .................... 51, 55
Mast fastening bolts, retighten .......................................... 61
Mast removal ..................................................................... 41
Mast versions ..................................................................... 44
Mast, duplex ...................................................................... 44
Mast, lift chains and end stops: check condition,
mounting and function ................................................... 59
Mast, securing against tilting back .................................... 44
Mast, securing the raised duplex ...................................... 45
Mast, securing the raised standard ................................... 44
Mast, securing the raised triplex ....................................... 45
Mast, standard ................................................................... 44
Mast, tilting back ................................................................ 30
324 804 3001.0702
Mast, tilting forward ........................................................... 30
Mast, triplex ....................................................................... 45
Measures before taking the truck out of operation ........... 43
Motor brushes, check, renew if necessary ....................... 58
Motor brushes, renew ........................................................ 50
Mounting of the counterweight, electric motors,
chassis, wheel drives, overhead guard
and close-coupled steer axle, check ............................. 57
N T
Noise emission level .......................................................... 18
O
Oil in the reduction gearboxes, change ............................ 62
Oil level in reduction gearboxes, check ............................ 52
Operation of industrial trucks in the plant area ................. 18
Operation ..................................................................... 12, 24
P
Pedal and travel control linkage bearings, check and oil ..... 60
Page Page
R
Reduction gearboxes, check for leaks .............................. 52
Travel in the reverse direction ........................................... 24
Troubleshooting guide ....................................................... 65
Truck takeover ..................................................................... 3
Truck, putting back into operation ..................................... 43
Reversing the direction of travel ....................................... 25
Truck, taking out of operation ........................................... 43
Running-in instructions ...................................................... 18
Type plates .......................................................................... 5
Tyre inflation pressure, check ........................................... 19
S
Safety information, important ............................................ 17
Tyres, check for damage and foreign objects ................... 50
Safety rules ........................................................................ 17
Seat belt, applying, opening .............................................. 23
Seat belt, check for condition and operation .................... 48
U
Unloading .......................................................................... 37
Service brake, electric brake ............................................. 29
Services after the first 50 hours of operation .................... 45
Sideshift, operating ............................................................ 30
Sideshift: clean, grease and check the mounting ............. 55
W
Wheel fasteners, tighten ............................................. 19, 49
Single control lever operation of mast and attachments .. 31
Windscreen wiper, turning on ........................................... 32
Single-pedal model ............................................................ 26
Wiring diagram for 24 Volt electrical system .................... 67
Steer axle, clean close-coupled ........................................ 52
Wiring diagram for 48 Volt electrical system .................... 71
Steering column, adjusting the adjustable ........................ 22
Wiring diagram for E 12, E 15 electrical system
Steering system ................................................................. 28
(options) ......................................................................... 74
Steering ....................................................................... 12, 28
Wiring diagram for E 16 electrical system (options) ......... 76
Work on the mast and on the front part of the truck ......... 44
Table of contents ................................................................. 7
Working and steering hydraulics, check for leaks ............ 54
Working lights, turning on .................................................. 32
Technical data ................................................................... 10
Technical description ......................................................... 12
Technical note ..................................................................... 3
Tow coupling ..................................................................... 38
Towing instructions ............................................................ 41
Towing procedure .............................................................. 41
Traction motor fan, clean .................................................. 53
Traction motors, the power steering and
working hydraulics pump motor, clean .......................... 54
Transporting the load ........................................................ 37
Transport ........................................................................... 39
Transporting the truck on a lorry or low-bed trailer ....... 39
Travel in the forward direction ........................................... 24
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