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Maintenance

When acquiring a battery for the truck, pay attention to the following sections of the standard EN 1175-1:

• 5.1 Traction batteries (includes the requirements for the protective cover of the battery case, ventilation and interior surface treatment) • 7.4 Minimum markings (includes the requirements specified on the truck battery plate)

The battery plate should provide at least the following information:

• Manufacturer • Type • Serial number • Rated voltage • Capacity (Ah/5h) • Service weight

Only adequately trained people are allowed to carry out daily and weekly maintenance. The terms of the warranty prescribe appropriate maintenance of the truck. All spare parts must be original ones. It is recommended that you sign a maintenance agreement with the truck dealer, who can also supply spare parts. Only professional service ensures long-term, trouble-free truck operation. Service program monitoring becomes easier if you enter the service dates in a service logbook. Contact our maintenance department or your truck dealer for qualified, authorized and efficient maintenance service.

Safety instructions for maintenance

• Keep the service area clean; oil, grease, and water make the floor slippery. • Remove all rings, watches and other metal jewellery. Short-circuits and burns may occur if a metal object touches a charged electrical connection when working with the truck's electrical system. • Switch off the truck's power before opening the cover of the drive unit or the electrical system. • Release the hydraulic pressure before opening the system. • Do not use your hands to check for oil leaks. • Remember that the surfaces of the hydraulic system and the motors may be hot. • Only use clean oil in the hydraulic system. • Always disconnect the battery when welding. Remove paint from a 10 cm radius from the welding point to avoid creating toxic gases during welding. • The truck must always be supported on jacks if someone needs to work underneath it.

WARNING!

Do not make any alterations or repairs that can weaken the truck’s structure or endanger safety.

Daily checks

• Check the truck externally to see that there are no oil leaks. • Check all wheels for damage or wear. • Check the battery fluid in each battery cell. Top up with battery water if needed. The fluid surface should be about 15 mm above the plates (this does not apply to maintenance-free batteries). • Check the gearbox for leaks. Also check the hydraulic pipes, hoses and connectors. No leaks or damage should be found. • Switch on the power and test the operation of the lifting hydraulics by raising and lowering the forks. • Check the operation of the accelerator and steering by driving slowly forward and backward. • Also check the operation of the other electrical functions. • Check that the batteries are charged and locked in place. • Check the operation of the horn. • Check that the safety pedal and parking brake functions properly. • Check that the emergency stop operates properly. • Check the fastenings of the lifting chain.

Weekly maintenance

• Check and clean the battery cable fastenings. • Ensure that the air holes of the battery cell plugs are not plugged up (this does not apply to maintenance-free batteries). • Clean the batteries with a dry rag. If necessary, you can wash the batteries with warm water or a mild soda solution, which neutralises the battery acid. Dry the battery carefully after the wash. • Check that the hydraulic system has no leaks. • Check the hydraulic oil in the oil tank. Add if necessary. • Check that the machine plates and labels are securely fastened and fully legible. • Clean the truck if necessary. • Check that all the screws, nuts, and pipe connections are tight. • Check that the fastening bolts of the drive wheel are tight. • Check the length of the lifting chains. When the mast is upright and the top of the mast bars is on the same level with the mast, the chains should be loose. Adjust if necessary. • Lubricate lightly the grooves of the mast, reach carriage, and the lift carriage.

NOTE

Do not let water onto the electrical devices.

Quarterly maintenance (300 hours)

Check and adjust or repair, if necessary:

• Contactors, microswitches, and solenoids and their cables • Brake air gap: correct dimension 0.3-0.8 mm • Accelerator operation • Speed limiter operation • Anchoring of the lifting cylinder • Play of the forks and their slope and condition • Collectors, carbon brushes, and electric cables of the drive and pump motors

Semi-annual maintenance (600 hours)

Check and, if necessary, adjust or repair:

• Operation of the hydraulics and pressure limit valves • Drive wheel for wear. • Clean the oil filter • Fasten the gearbox • Condition of the side stabilizer wheels

Annual maintenance (1200 hours)

• Change the hydraulic oil once a year. • Change the transmission oil once a year.

Monthly hydraulics maintenance

The truck's lubricating points should be lubricated once a month:

• Turning bearings of the side wheels • Bearings of the side stabilizer wheels • Suspension rail of the drive unit

Lubricant recommendation

Filling hole for hydraulic oil

Hydraulic oil: ISO 11158 HM/HV/HR - VG 32 In freezer warehouses: ISO 11158 HM/HV/HR - VG 15 Fill the tank to ¾ volume. Transmission oil: EP 80/90 Fill to the volume of 2 l. Lubricating grease: NLGI No. 2, containing molybdenumdisulfide In freezer warehouses: NLGI No. 1 or No. 0

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