SPRINTER & TRIKE
Contents
1. 16 5 7 Loading and unloading of goods ceccccccecccccccccccccccccccccccccccccccccccscccceccees 17 5 8 Use of the tow hook Prins Sprinter only ccceccecccccccccccccccccccccccccccccccccecs 20 6 MAINTENANCE THE FORKLIFT TRUCK ccccccccccccccccccccccccccccccccccccccccccccccces 21 6 1 DEVE Mal ioee550002012001020552000205210500923200202020002095223528922502 i 419590091085 10 9 2002 21 6 2 22 RAM MEE SIUE 22 Q 2 7 SEEUD nam naa 24 6 2 5 Cooling WALES VS CON k usa 24 6 2 4 Fuel filter for Sprinter and Trike with diesel engine eere eee 25 24 EE aliit a i 27 040 RECTE 28 A T OO HAAA AAA AA a a nnen ine 29 6 3 Miscellaneous maintenance tasks ccccccccccccccccccccccccccccccccccccccccccccccccccccccces 29 6 7 Electrical syster kaas ai 31 7 SUMMARY OF MAINTENANCE INTERVALS ccccccccccccccccccccccccccccccccccccccccccccccecs 32 8 TROUBLESHOOTING sestsrosberonosniooboronbsbhhbbevansdennsainnndennrrainnedsnrerntre ranks 33 Bet 505960520002 0548602902205 028 000 00900808 189 049 040 903 05 33 0 2 Jia TNR 33 9 SPRINTER amp TRIKE TECHNICAL SPECIFICATIONS cccccccccccccccccccccccccccccccccccccccccs 36 ELECTRICAL CIRCUIT DIAGRAM ccccccccccccccccccccccccccccccccccccc2. is possible to change the selected gear while moving at low speed Always release the accelerator during gear changes Changing gear can cause a minor jolt in the drive train This will not harm the machine but you must take account of possible effects on the load The two gears are indicated on the central dashboard using symbols depicting a hare and a tortoise 1 Brake pedal 2 Accelerator Figure 5 8 Pedals To bring the forklift truck to a stop release the accelerator pedal and apply the brake pedal in a controlled manner until the machine comes to a complete halt Once the machine is at a standstill place the gear lever in its neutral position The Prins Sprinter and Prins Trike with automatic gearbox come equipped with an inching pedal as standard The machine is provided with an electrically operated parking brake This is applied using a switch on the dashboard An indicator lamp on the central dashboard will indicate whether the parking brake is switched on When dismounting from the forklift truck the forks must always be fully lowered and the parking brake applied The machine can not be driven away with the parking brake applied 14 Prins Maasdijk Jan 12 Prins Maasdijk Sprinter amp Trike User Manual Operating the forklift truck Figure 5 9 Parking brake switch 5 4 Optional Figure 5 10 accumulator switch The machine can be fitted with an accumulator as an option This
3. Bn 8 4 R8 osooosi harmke 4 soon ces a mh ce m XE0800051 XE0801719 amp EO800051 11 NEGROS 11 D 57 58 56b seo L RI Iry cs2 E 1 0034 0773 l 1 5 OPTION 2 Ep 7H _ ROAD LIGHTS VERSION T INSTALLED FROM THE CUSTOMER Diagram 10 2 Dashboard electrical circuit diagram 3 O al FL 0005 0108 Electrical circuit diagram XEG8G0468 1 BATTERY WL HOURCOUNTER S61 2 FUEL LEVEL GAUGE CR 1 3 ENGINE OIL PRESS WL AwG1 4 WATER TEMPERATURE WL BGp1 5 LOW FUEL LEVEL WL VRei 6 RED WL LG61 FORWARD LIGHT BLUE WHITE ORANGE YELLOW GREY BLUE BROWN B C G H L M N R 3 y 0034 0631 My 1 E EE BRA MDC 0034 0631 RL1 0034 0592 1 HN 2 5 J2 XE0800448 Mad PREHEATING 2 5 START R46 412V IN 30 MOTE GEMERAL MATERIALE E LAVCRAZITIEO GERAL MITES MATERIAL DATA DATE 21 04 08 2 zin 1321 PRINS STEERING COLUMN ELECTRICAL SCHEME PROG CBO 1 2 REV m m VENUS 250 Prins Maasdijk Jan 12
4. Prins Maasdijk ad m Sprinter amp Trike User Manual Operating the forklift truck 5 1 2 Seat adjustment The standard seat allows for longitudinal adjustment and adjustment of the angle of the back support The various adjustment options are shown in Figure 5 2 Adjust the seat to provide a safe and comfortable sitting position Figure 5 2 Seat position Note A safety belt must be worn at all times when operating the forklift truck Prins Maasdijk Jan 12 rins Maasdijk p 4d Sprinter amp Trike User Manual Operating the forklift truck 5 2 Starting and stopping the engine 1 Before starting the engine ensure that the driving direction switch to the left of the steering column is in its neutral position see Figure 5 3 For lpg driven machines the valve above the tank must be rotated to open it 1 Forward 2 Neutral 3 Reverse Figure 5 3 Driving direction switch 2 Turn the ignition key to position I The oil pressure and charging current lamps will both illuminate 0 Off l Ignition on Il Pre glow IIl Start Figure 5 4 Ignition key 2 1 Fork lift truck with diesel engine Once both lamps are illuminated the ignition key should be further rotated to position The pre glow lamp will now illuminate Hold the ignition key in this position for around 5 seconds and then turn it on to position III The engine will now start If you now release the key it will re
5. USER MANUAL SPRINTER amp TRIKE Prins Maasdij Prins Maasdijk Prins Maasdijk 12 Prins Maasdijk CONTENTS le FOREWORD31 32023293233123293329 9932390 2 2 0 20 90 0 00 0 8 0 BUD UIN IN EIN EON EF SE CER EEEE EEEN 2 2 IMPORTANT ccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccecs 3 3 GENERAL SAFETY REQUIREMENTS ccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccs 4 4 OVERVIEW OF MACHINE AND CONTROLS cccccccccccccccccccccccccccccccccccccccccccccccccces 6 4 1 Overview of machine eeeeccccccccccccccccccccccccccccccccccccccccccececcecccccccccceccecceceeee 6 4 3 Overview of 7 4 4 Overview of central dashboard ccccccccccccccccccccccccccccccccccccccccccccccccccccccccccces 7 B OPERATING THE FORKLIFT TRUCK 8 Bel Ad ME 2 TNT 8 5 1 1 Steering column adjustment oes oase eso eene ensenvenvenvenvenvenvenven 8 SZ ku lst se aa eut dea 1 aa 9 5 2 Starting and stopping the engine ccccccecceccccccccccccccccccccccccccccccccccccccccccees 10 5 3 Moving off and stopping the forklift truck ccccccccecccccccccccccccccccccccccccccces 13 E OD ONAN AMMAS 15 5 9 MN OCU INE
6. see also Figure 5 12 on the machine Take careful note of the load diagram which is located on the forklift truck s engine cover If you are forced by circumstances to lift a load on a single fork take into account that the maximal permitted load will be halved However you must try to avoid doing this if at all possible Keep the speed low when travelling with a load never use top speed and keep the load as close as possible to the ground With a raised load keep the speed as low as possible and take account of the clearance height of the forklift truck Complete the required safety checks on the machine before starting to work with it You must never start work with the forklift truck without completing these checks Particular attention should be paid to the tyres the battery the brakes the steering system the fuel system and the electrical components This will help to prevent accidents Fuel must never be added while the engine is running No smoking is permitted while refuelling or while replacing or topping up the oil and no open flames or sparks may be present in the immediate vicinity Explosive gases are released during refuelling Hemove any spillages from the machine following refuelling or replenishment with oil Before refuelling or replenishing the oil check for any traces of leakage and establish where these are coming from If they are the result of a technical defect have this repaired before working with the f
7. Loads should be allowed to descend gradually with the forks horizontal or tilted slightly back Never lower the load with the forks tilted forwards There are numerous signs you can use to check the condition of the machine Unusual noises vibration or changes in the response to the controls may indicate defects If you suspect a fault take the machine out of use and stop the engine Check the cause of the defect and take the necessary measures to rectify it Table 3 1 Meaning of safety symbols Follow the safety Wear safety and operating instructions Smoking and open flames are prohibited Live electrics avoid contact Risk of explosion avoid short circuits eyewear and protective clothing Electrolyte is strongly corrosive Areas where batteries are stored or charged must be adequately ventilated Prins Maasdijk Jan 12 Ir i Prins Maasdijk A gt Overview of machine and controls Sprinter amp Trike User Manual 4 OVERVIEW OF MACHINE AND CONTROLS 4 1 Overview of machine q T Ballast plates separate Carriage load backrest oafety cage Tilting cylinder Fork carriage Forks Rear wheel steered Lifting mast Lifting cylinder Front wheel Counterweight 10 11 Figure 4 1 Overview NM ST LO OR O OD Jan 12 Prins Maasdijk Prins Maasdijk ad m E Sprinter amp Trike User Manual Overview of machine and controls 4 3 Overv
8. allows fully automatic driving The direction of travel is selected using a selector switch on the steering column 1 Forward 2 Neutral 3 Reverse Figure 5 6 Direction selector switch Lift the selector switch gently and move it forwards or backwards to select forward or reverse travel Operation of the accelerator will now move the machine in the desired direction Where a change of direction is required the machine must first be stopped and the switch can then be moved to the appropriate position Figure 5 7 Gear selector switch The machine is provided with two gear positions to allow a choice between additional speed and additional traction The choice between the two speeds is made using a rotary switch on the steering column It is not necessary to select first gear to drive away It is recommended that the desired gear should be identified and selected before moving off First gear can always be 13 Prins Maasdijk Jan 12 Prins Maasdijk A Sprinter Trike User Manual Operating the forklift truck selected by default The maximal traction is then available This will provide the best ride characteristics and the most constant speed of motion Where long distances are to be travelled and the load will not be at or close to maximum second gear may be selected The speed of travel will then be increased You must ensure that the conditions such as the state of the road surface will permit such higher speeds
9. be correctly connected to the battery possibly because of corrosion The battery posts should be smeared with Vaseline or similar to prevent this Another cause of failure is low level of electrolyte in the battery This is rectified by topping up the battery with distilled water The procedure is as follows Note Avoid contact with the battery electrolyte The dilute sulphuric acid solution can burn the skin and make holes in clothing In the case of accidental exposure flush immediately with flowing tap water Remove the protective cover from the battery The cable should then be disconnected from the negative pole The positive pole should then be disconnected Open the filler opening and check the fluid level Top up if necessary see Fout Verwijzingsbron niet gevonden and Fout Verwijzingsbron niet gevonden When reconnecting the battery the positive pole must be connected first followed by the negative pole a ea en Figure 6 8 The battery Figure 6 9 The battery acid level 1 filler cap 1 Level too low A Maximum level 2 Level okay B Minimum level 3 Level too high Prins Maasdijk Jan 12 28 Prins Maasdijk Sprinter amp TrikeUser Manual Maintaining the forklift truck 6 2 7 Fanbelt The fanbelt or V belt provides drive to the fan and the dynamo If it is not adequately tensioned it will slip This will impair the function of the fan which is responsible for cooling the engine bloc
10. engine 2 The engine should be checked regularly for oil leaks Following the running in period after 50 hours 1 Replace the oil filter 2 Replace the engine oil Replacing the oil filter o Remove the old filter see Figure with the aid of a filter wrench o Apply a film of oil to the new filter s oil seal o Screw in the filter hand tight o Once the filter is in place the oil level will usually drop slightly Check first that the filter is not leaking and if necessary top up the oil 1 Oil filter Figure 6 2 Oil filter Sprinter amp Trike with diesel engine 3 Replace the oil First allow the old oil to run out of the sump via the drainage point below the engine Periodically Every 200 service hours 1 Replace the oil filter 2 the oil Oil change data Capacity Sump 4 litres Oil ELF Multi performance 3C 15W40 or to MIL L 2104C or API classification CD class or above Prins Maasdijk Jan 12 23 i gt Prins Maasdijk p 13 ad Sprinter amp TrikeUser Manual Maintaining the forklift truck 6 2 2 Set up for towing If it is required to tow the vehicle the bolt above the hydraulic pump should be loosened a few turns so that hydraulic lines 2 and 3 are interconnected freeing the wheels This action must be carried out while the engine is running 2 pr 1 Bolt for towing set up 2 Hydraulic line 3 Hydraulic line Figure 6 3
11. pair of Prins Trike weights is equivalent to a single Prins Sprinter balance weight the stated numbers 0 10 in the load table relate to single balance plates in the case of the Prins Sprinter and pairs of balance weights in the case of the Prins Trike 5 When the correct plates are in place replace the securing components see figure 5 13 for the Sprinter and figure 5 14 for the Trike 18 Prins Maasdijk Jan 12 X i Prins Maasdijk 193 Sprinter amp Trike User Manual Operating the forklift truck Figure 5 13 Prins Sprinter ballast plate securing components Figure 5 14 Prins Trike ballast plate securing components Note It is extremely hazardous to work with the machine with insufficient ballast plates in place If there is any doubt ALWAYS install the full total of ballast plates on the truck and fit the securing components Prins Maasdijk 12 Prins Maasdijk Sprinter amp Trike User Manual Operating the forklift truck Note In the case of the Prins Trike the ballast plates are located below the rear engine cover both on the left and right The ballast weights must always be added or removed in pairs one from the left and one from the right The weight of a pair of Trike weights is equivalent to the weight of a single Sprinter weight See Table 5 12 In case of doubt ALWAYS fit the full number of ballast plates to the fork lift truck and secure these 5 8 Use of the
12. speed 8 2 Eng ne Engine will not start Starter fails to operate Possible cause Fuse burned out Direction selector switch not turned on Cable hangs up Hydraulic fluid level low Possible cause Lack of fuel Air in the fuel system Water in the fuel system Fuel line blocked Fuel filter blocked at low temperature Fuel cetane content too low Compression leak in cylinder Valve timing incorrect Worn piston rings and lining Excessive valve play Battery is discharged Starter fails to operate lgnition switch fails to operate Wiring not correctly connected Excessive fuel viscosity or engine oil Fuel leak due to loose injector lines Incorrect injection timing Worn fuel camshaft Atomiser blocked Malfunctioning injection pump 33 Solution Check fuse see Figure 6 13 Check if the drive direction selector switch is switched on Check that the inching pedal cable returns correctly Check that the hydraulic fluid level is correct Solution Top up fuel tank Bleed Replace fuel and repair or replace fuel system Clean fuel line Clean or replace filter Use specified fuel or engine oil Use specified fuel Tighten nut Adjust Replace Clean atomiser Repair or replace injection pump Replace head gasket tighten cylinder head bolts Rectify or replace timing gear Replace Adjust Charge battery Repair or replace Repair or
13. tow hook Pr ns Sprinter only The Sprinter is equipped as standard with a tow hook to allow other vehicles to be towed Ensure in all cases that the vehicle to be towed can be towed safely Always ensure that the securing pin is properly installed Note Ensure that the tow hook securing pin is properly installed at all times A towed vehicle which comes loose may cause injury and or damage The maximal load on the tow hook is 500kg If the hook is loaded beyond this there is a risk of it breaking which may result in damage to the vehicle Prins Maasdijk 12 20 Prins Maasdijk eee i Sprinter amp TrikeUser Manual Maintaining the forklift truck 6 MAINTENANCE THE FORKLIFT TRUCK Good maintenance is vital for the safe operation and long service life of your forklift truck Prins Maasdijk therefore strongly advise that the matters covered in this manual should be attended to stringently and with care The timing of the various operations is indicated in this manual The prescribed times indicated in hours relate to the service hours for the truck which are displayed on the counter on the dashboard The indicated times are based on operation in normal circumstances With heavy use or in extreme conditions certain maintenance operations may need to be carried out with greater frequency Note The operations specified in this manual should only be carried out by competent persons familiar with the working procedur
14. Bolt for towing set up 6 2 3 Cooling water system It is important to keep the coolant level topped up Failure to do so may lead to overheating causing damage The coolant level should therefore be topped up daily The procedure is as follows Note Always wait for the engine to cool down before opening the coolant reservoir 1 Open the cooling water system filler cap slightly to allow any over pressure to dissipate Figure 6 4 coolant filler opening Prins Maasdijk 12 24 Prins Maasdijk Sprinter amp TrikeUser Manual Maintaining the forklift truck 2 Now remove the filler cap completely and check that the coolant is at the indicated level roughly halfway up the reservoir 3 Topup as necessary 4 Replace the filler cap tightly after topping up Coolant We recommend ELF COOLELF The cooling water is cooled by air flowing through the radiator Check at least weekly that the airflow across the radiator is adequate The radiator may become blocked particularly when working in dirty or dusty conditions and cooling capacity will be seriously affected Contamination may be blown out of the radiator using compressed air 6 2 4 Fuel filter for Sprinter and Trike with diesel engine The fuel filter must be replaced every 200 hours as a minimum or at least once a year The fuel filter is located in the engine compartment Fuel filter replacement o Remove the old filter using a filter wrench Apply a sm
15. Dacron 118 Parking Brake 1 MA 118 gt Accumuinior 13 1 AV OUT 15 12V OUT 1205 421 5 a 4 23 E dE Ground 24 di 2 15 Gas Vaves d Carburetor Gow Plug L Start 42 43 4 zen Preheadng 1 gt 7 C 2 Engine Pressure 9 aen Eo PA Ec 5 Temperalure venen T WIRING DIAGRAM PRINS SPRINTER Diagram 10 1 Electrical circuit diagram cable loom 38 Prins Maasdijk Jan 12 Puppe roe 08910068 x4 xE0800254 EEL ilg edig eo en m U le x1 Hyd AE LR 0034 0651 DPTIDH 1 S SMTCHES LIGHT VERSION RS4 al INSTALLED FROM THE CUSTOMER r Nsi 9 l 1 test a CS2 3 Gp1 S XE9890051 2315 1 7 8 9 522 CEOLE CS2 1 XE0800017 J XEOBOO400 nnen L az d NDTM 5 1 5 4 3 4 1 1 16 0691 0500 13 Hi pr LI 9 TN og Ev EN 5 el 16 0691 0500 13 ES a 16 0691 0500 13 escam TT aeta 71 lt er Aen 11 bdo 4 nn mn Ee ee 2 HNH EFE pd 18 ZN91 st o
16. an or replace Tighten nut Repair or replace Adjust Repair or replace Repair Reduce to specified level Repair or replace Adjust Reduce loading Fill to specified level Clean or replace Clean or replace Adjust Repair or replace injection pump Repair or replace atomiser Replace head gasket tighten cylinder head bolt glow plug or atomiser mounting Change position Replace Replace piston Replace Replace pump element or entire pump Replace Replace Replace Top up Clean filter Replace Replace Replace Clean Use specified oil Prins Maasdijk Jan 12 Prins Maasdijk Sprinter amp Trike User Manual Fault analysis Excessive oil pressure Engine overheating Battery discharges rapidly Defective oil pump Incorrect oil type Insufficient engine oil V belt snapped or incorrectly tensioned Insufficient coolant Blocked radiator grille or radiator vanes Internal corrosion to radiator Corroded coolant line Defective radiator cap Excessive loading Head gasket defective Incorrect injection timing Unsuitable fuel used mixed with petrol Insufficient electrolyte Slipping V belt Wiring not correctly connected Voltage regulator defective Dynamo defective Battery defective 35 Repair or replace Use specified oil Top up engine oil Replace or tension correctly Top up coolant Clean Clean or replace Clean or rep
17. cccccccccccccccccccccscs 38 Prins Maasdijk Jan 12 Prins Maasdijk Sprinter amp Trike User Manual Prins Maasdijk 12 Prins Maasdijk Sprinter amp Trike User Manual Foreword 1 FOREWORD Congratulations on your purchase of a Prins Sprinter or Prins Trike forklift truck manufactured by Prins Maasdijk You will find all the important information you need to operate and maintain your forklift truck in this manual We recommend that you read through this manual carefully before taking the forklift truck into use Anyone using the machine is also recommended to read carefully through the manual Having read it keep the manual where it can readily be found so that essential information about maintenance defects and so on is always to hand If you need to order parts for your Prins forklift truck or if you have any questions or observations please contact Prins Maasdijk Please mention the machine s service and serial numbers in any correspondence with Prins Maasdijk These numbers appear on the plates mounted at top left and right of the steering column See Figure 1 1 Type plate colour black Make Type Serial number Capacity Deadweight Year of construction Ole du es Service plate colour grey 1 Service number Figure 1 1 Service number and serial number We trust you will enjoy many years of productive service from your new forklift truck Prins Maasdijk Prins Maasdi
18. e taken at all times of any load carried on the forks Anticipate any unevenness in the road surface in good time potholes and other obstacles may affect the Stability of the truck If stability is seriously affected the load may fall from the forks Note Unevenness of the road surface may interfere with the stability of the fork lift truck and give rise to a risk of the load falling from the forks Do not make sharp turns at high speed whether a load is carried or not The fork lift truck may lose its stability and overturn Note Making a sharp turn at high speed whether a load is carried or not may affect the stability of the fork lift truck Overturning the truck may cause damage and injury to yourself or others 16 Prins Maasdijk 12 Prins Maasdijk Sprinter amp Trike User Manual Operating the forklift truck 5 6 Operation of mast and forks The forklift truck is equipped with two hydraulic functions as standard the first to raise the load and the second to tilt the mast In most cases the machine will also be equipped with a side shift function to allow the load to be moved sideways The installation of a fourth and even a fifth hydraulic function is also possible The various functions are all controlled via a valve block located to the right of the driver Raising and lowering Adjusting angle of tilt Side shift Optional function 0 Figure 5 11 Hydraulic functions 5 7 Load
19. ear of fuel to the new filter s oil seal Fill the filter with clean fuel Screw in the filter hand tight Bleed the system in accordance with the following procedure O O X Bleeding the fuel system It is sometimes necessary to bleed air out of the system to prevent damage to the engine or its components Note The fuel system must not be bled while the engine is still warm Doing so may present a risk of fire or explosion The evaporating fuel may also give rise to toxic vapours When may bleeding be necessary If any of the fuel system pipework has been broken into o the fuel tank has been completely emptied o l fthe engine has been out of service for an extended period o the fuel filter has been replaced O The procedure for air bleeding is as follows 1 Fillthe fuel tank with diesel 2 Loosenthe air bleed screw see Figure 6 5 above the fuel filter 3 Start engine and wait until fuel trickles out through the bleed orifice then retighten the bleed screw 4 Start the engine It may run unevenly at first but this will stabilise after a short time 5 The starter motor must not be allowed to run continuously for more than 20 seconds during this bleeding period If the engine fails to start in this time wait for half a minute before operating the starter motor again Prins Maasdijk 12 25 Mex Prins Maasdijk p ig sir Sprinter amp TrikeUser Manual Maintaining the forklift t
20. es who are aware of the safety requirements and the hazards that may be created if these are ignored If you or your staff are not adequately aware of these requirements have the maintenance work carried out by your dealer or the Prins Maasdijk Technical Department 6 7 Drive tra n The Prins Sprinter and Prins Trike are provided with a so called hydrostatic drive This indicates that the drive is provided by means of hydraulic fluid using a motor and pump For proper operation and long service life it is crucial that the hydraulic fluid should be in top condition The following instructions should therefore be followed precisely Failure to follow the instructions correctly or contamination of the system may seriously reduce service life or lead to costly repairs You are expressly advised to have work on the hydraulic system carried out exclusively by Prins Maasdijk During the running in period the first 50 hours 1 Check the transmission oil level using the dipstick see no 1 in Figure 6 1 Top up the oil if necessary see no 1 in Figure 6 1 1 Dipstick 2 Oil filler opening 3 Oil filter Figure 6 1 Hydraulic fluid 21 Prins Maasdijk Jan 12 Prins Maasdijk ene Sprinter amp TrikeUser Manual Maintaining the forklift truck Note Carry out the check while the engine is running but the machine is Stationary with the oil at operating temperature 2 The transmission should be checked regularly for oil
21. harging current lamp remains illuminated Is the battery properly charged 15 the battery acid level correct there any short circuits or other defects in the wiring If you have checked these items and identified no defects please contact your dealer 5 Allow the engine to come up to temperature by running it at half speed without load 6 If you wish to stop the engine ensure that the gear lever to the left of the steering wheel is in its neutral position Also ensure that the forks are resting on the ground in order to remove any unnecessary loading from the lifting cylinders and prevent accidents Rotate the ignition key to the OFF position 11 Prins Maasdijk 12 Prins Maasdijk RE Sprinter amp Trike User Manual Operating the forklift truck Note Before dismounting from the truck the gear lever must be placed in its neutral position and the handbrake applied It is now safe to dismount from the forklift truck 7 If an lpg driven machine is not to be used for an extended period for example at the end of the working day the gas cylinder valve must be closed 1 Shut off valve 2 Level gauge Figure 5 5 Lpg tank 12 Prins Maasdijk 12 i Prins Maasdijk lt Sprinter amp Trike User Manual Operating the forklift truck 5 3 Moving off and stopping the forklift truck The Prins Sprinter and Prins Trike are provided with a hydrostatic drive which
22. iew of controls Figure 4 2 Control dashboard 4 4 Overview of central dashboard 5 Combination switch driving direction gear horn Battery switch optional Parking brake switch Front lighting switch optional Rear lighting switch optional Ignition switch The Prins Sprinter and Prins Trike feature a central dashboard which includes a number of warning signals The fuel gauge is located in the middle This shows the fuel tank level for diesel engines For lpg driven machines the level gauge is mounted on the tank Below the fuel gauge is a counter registering the service hours during which the machine has been in operation The following warning signals are displayed in figure 4 3 Figure 4 3 Signals QUO DI PI Parking brake lamp Low oil pressure lamp Charging current indicator High coolant temperature Pre glow indicator High gear indicator Low gear indicator Prins Maasdijk 12 Prins Maasdijk ad mE Sprinter amp Trike User Manual Operating the forklift truck 5 OPERATING THE FORKLIFT TRUCK 5 1 Adjustments Adopt the correct seating position before starting the machine 5 1 1 Steering column adjustment 1 Locked 2 Free Figure 5 1 Steering column operation Rotate the lever to loosen it as indicated in Figure 5 1and place the steering column in a comfortable position Then retighten the lever by moving it upwards Prins Maasdijk Jan 12
23. ing and unloading of goods Note Ensure that the load is correctly stacked and balanced at all times Falling loads may result in serious injury to the operator or others 1 Place the forklift truck directly in front of the goods to be carried Ensure that the load is evenly distributed between the forks 2 Ensurethat the mastis not tilted forwards or backwards then bring the forks to the appropriate height 3 Drive slowly forwards until the load comes up against the carriage backrest Now raise the load by 5 to 10 It may happen that the load is not completely at the edge of the trailer or storage racking In that case you should insert the forks as far as possible and then raise them slightly 17 Prins Maasdijk Jan 12 5 10 11 Prins Maasdijk rinter amp Trike User Manual Operating the forklift truck Note Ensure before raising the load that it is not tipping forwards You must therefore always ensure that the forks are inserted 2 3 to 3 4 of the way into the load depending on the weight of the load Now reverse a little until the load is so positioned that it can be taken entirely on the forks Lower the load again then insert the forks fully until the load comes up against the carriage backrest and raise the load some 5 to 10 cm Allow the forks to descend to just above the ground say 10 to 20 cm Tilt the mast completely back and reverse cautiously away Drive with the load to
24. is brought into operation using the switch shown in Figure 5 10 The accumulator acts as a shock damper for the load carried by the forklift truck For effective operation the accumulator must be set to the weight of the load being carried You should contact the Prins Maasdijk technical department or your dealer with any queries about this system The accumulator may be damaged beyond repair if it is overloaded The accumulator must be switched off if travelling without a load or where the load carried is substantially more than 25 above the accumulator setting The accumulator should also be switched off when precise positioning of the load is required In some cases the position used for the accumulator switch may be used for a different optional function Check what optional equipment is fitted to your truck before operating and using this control 15 Prins Maasdijk Jan 12 Prins Maasdijk eee Sprinter amp Trike User Manual Operating the forklift truck 5 5 Manoeuvring The Trike is equipped with twin pneumatic tyres as standard These provide stability in bends The Prins Sprinter and the Prins Trike are steered via the rear axle to provide the smallest possible turning circle Be aware when steering that the rear end will swing out Note The rear end will swing out during manoeuvres You must therefore always ensure that there is adequate space around the truck to allow safe manoeuvring When driving account must b
25. jk 12 Prins Maasdijk Sprinter amp Trike User Manual Important 2 IMPORTANT This manual includes important information on the correct and safe use of your forklift truck Follow the instructions set out in this manual at all times At various points in this manual you will see the following symbol Note Important information When you see this symbol read the adjacent text carefully before starting the relevant operation This information relates to the safety of yourself and others Stay alert and prevent hazardous situations developing Prins Maasdijk 12 Prins Maasdijk AA Sprinter amp Trike User Manual General safety requirements 3 GENERAL SAFETY REQUIREMENTS When working with or servicing the forklift truck you must be aware of the associated hazards Take full account of the safety rules Failure to do so may result in serious physical injury to yourself or others It is impossible for the manufacturer to foresee every hazardous situation that might arise You as the user therefore have a responsibility to look out for your own safety and that of others during the use and maintenance of the forklift truck Always use the tools and consumables recommended by the manufacturer Only original components should be used as replacements For your own safety and that of others Never overload the forklift truck above the maximum permitted load indicated on the load chart
26. k The engine may then overheat The same applies to the dynamo if the belt is loose it will not operate correctly and the battery will not be properly charged This may cause problems for example with starting The V belt must therefore always be correctly tensioned Checking this is fairly straightforward Note Ensure that the engine is switched off when checking the V belt 1 Press with a finger on the middle of the section of V belt between the dynamo and the crankshaft The deflection of the V belt from its original position must not be less than 7 mm or more than 9 mm 2 If itis outside these limits loosen the two dynamo securing bolts 3 Position the dynamo in such a way that the V belt is at the correct tension and retighten the bolts 1 Fan belt V belt 2 Adjusting bolts 3 Play 7 9 mm Figure 6 10 Tensioning the V belt 6 3 Miscellaneous maintenance tasks Lubrication The following components must be greased at least once monthly o Side shift cylinder o Steering cylinder o Axle tipping component o Tilting cylinders Tyres The tyre pressure must be checked weekly The correct tyre pressures are o Driven front wheels 3 0 bar o Steered rear wheels 2 5 bar Prins Maasdijk 12 29 rins Maasdijk 957 N Sprinter amp TrikeUser Manual Maintaining the forklift truck The tyre valves are located at the edge of the rims On machines fitted with double pneumatic tyres optio
27. lace Replace Reduce loading Replace Adjust Use specified fuel Top up with distilled water and charge battery Tension or replace V belt Connect wiring correctly Replace Replace Replace Prins Maasdijk Jan 12 Prins Maasdijk AA J Sprinter amp Trike User Manual Technical specifications 9 SPRINTER amp TRIKE TECHNICAL SPECIFICATIONS Table 9 1 Technical specifications Model Sprinter _ Trike Lifting capacit 1000 1000 1000 1000 2080 2080 1940 1940 500 Engline capacit Table 9 2 Dimensions Model Sprinter Trike 295 50R15 TE mm 1170 170 KEE _Mast inclination fron rear Fork carriage type Transmission SS gt gt m Prins Maasdijk 12 36 Prins Maasdijk Sprinter amp Trike User Manual Technical specifications Prins Maasdijk 12 37 dus i k Prins Maasdijk Sprinter amp Trike User Manual Electrical circuit diagram 10 ELECTRICAL CIRCUIT DIAGRAM Battery WL Hour counter 13 A Fuat Laval Gauge Water Temperatura 4 gt lt Law Fuel Level 5 veo DUM Rod Wl 5 3 pd i gt Forward 4 Slow Gear 9 gt Fast Goar 119 me Work Lamp Front 11 1 ed xm High Beams 12 KT Low 13 iro Work Fur 14 Let Owaction 15 AM Fight
28. leaks Following the running in period after 50 hours Replace oil filter see no 3 in Figure 6 1 Periodically Every 200 hours Check the oil level in the transmission and top up where necessary Every 500 hours Replace oil filter Every 1000 service hours Replace the oil in the transmission Note Where the annual service hours are less than 1000 hours on an annual basis the should be replaced every two years Note It is essential to prevent any contamination whatsoever entering the hydraulic system during level gauging or other work on the system The tiniest particle of dirt can cause damage Oil change data Capacity Tank 70 litres 6 2 Engine 6 2 1 Engine The engine of your new Prins forklift truck will also require a period of running in This will last around 50 hours We now detail the actions required to maintain your forklift truck in optimal condition and prevent problems On page 32 you will find a table setting out all the operations relating to the maintenance of the forklift truck During the running in period the first 50 hours 1 Check the oil level in the engine sump using the dipstick Top up the oil if necessary this also applies after the running in period Prins Maasdijk Jan 12 22 Prins Maasdijk Sprinter amp TrikeUser Manual Maintaining the forklift truck Note Carry out this check before starting the engine or wait at least 5 minutes after switching off the
29. nal on the Prins Sprinter mandatory on the Prins Trike the valve for the inner tyre is on the edge of the inner rim closest to the chassis Raise the mast to its maximum height and look from the front to see if the valve is accessible If necessary drive the machine a little forwards or backwards in order to gain access to the valve Figure 6 11 Valve on inner edge of rim Figure 6 12 Valve on outer edge of rim Note With double pneumatic tyres the pressure in the outer tyre should always be at least 0 5 bar higher than that in the inner tyre Prins Maasdijk 12 30 Prins Maasdijk A Sprinter amp TrikeUser Manual Maintaining the forklift truck 6 4 Electrical system The machine is provided with a 12V electrical system with an alternating current dynamo Apart from the procedures described in relation to the dynamo the electrical system is in principle maintenance free However dirt and moisture may affect the function of the system Avoid directing a stream of water onto electrical components when cleaning the machine Also avoid exposure of the electrical components to dirt and moisture as far as possible The electrical system includes a fusebox located to the right of the steering column In the event of a fault always check first that a fuse has not burned out Always engage a competent electrician to deal with any necessary repairs to the electrical system Connection 15 Dashboard Selecto
30. orklift truck Always apply the handbrake and place the gear lever in neutral when leaving the forklift truck An incorrect sitting position can lead to accidents You should therefore start by adjusting the seat so that you have good visibility and easy access to all controls The forklift truck must never be used without the safety cage or the roll bar fitted as standard A safety belt must be used when the forklift truck is in operation Prins Maasdijk Jan 12 Prins Maasdijk 5 rinter amp Trike User Manual General safety requirements Always drive at a speed where you have the forklift truck under proper control Excessive speed can be hazardous to you and your environment Sudden braking acceleration or turns can also result in a hazardous situation When driving the truck in and out of areas with limited headroom take account of the following points o Always check that there is sufficient space above and alongside the forklift truck o Keep all parts of your body within the safety cage at all times keep your hands on the steering wheel and your feet on or close to the pedals o Avoid hazardous situations when travelling Operate the controls gently This will appreciably extend the service life of your forklift truck and increase safety Never allow anyone to walk beneath the loaded forks This is extremely dangerous Never carry passengers on the forklift truck and do not use the forks to lift persons
31. r switch Parking brake high and low gears Battery Flashing indicators Connection 30 Horn Front working light parking lights Rear working light dipped beam Figure 6 13 Fuses 10 Dipped beam 11 Headlamp 31 Prins Maasdijk Jan 12 Prins Maasdijk AA Sprinter amp Trike User Manual Summary of maintenance intervals 7 SUMMARY OF MAINTENANCE INTERVALS In Table 7 1 and Table 7 2 below you will find a summary of the operations required for the maintenance of your fork lift truck Table 7 1 Hydraulic drive Running in Every Every Every Every 2 period 500 hours 1000 year years Operation First 50 hours hours Repaceol 3 3 J ok J X Replace filters LO X X j J X Daily checks on oil levels and for leaks Table 7 2 Engine Running in Before period each First 50 Operation hours A A Replace oil Replace oil filter Replace air filter 1 Check V belt tension Replace fan belt Check battery electrolyte level Check coolant and engine oil levels Replace fuel filters 2 Check oil level daily 1 Or earlier if necessary 2 Coarse and fine filter Prins Maasdijk 12 32 Prins Maasdijk Sprinter amp Trike User Manual Fault analysis 8 TROUBLESHOOTING 8 1 Vehicle Loss of front or rear lamps Forklift truck does not move off when inching pedal is depressed Truck does not come correctly up to
32. replace Connect wiring correctly Prins Maasdijk Jan 12 Prins Maasdijk AA Sprinter amp Trike User Manual Fault analysis Engine runs unevenly White or blue exhaust gases Grey or black exhaust gases Output capacity low Excessive oil consumption Fuel contaminated with engine oil Water contaminated with engine oil Low oil pressure Fuel filter blocked or dirty Air filter blocked correctly Excessive engine oil lining Incorrect injection timing Excessive loading Fuel level too low Fuel filter blocked Air filter blocked Incorrect injection timing Irregular fuel injection Atomiser pressure too low Compression leak side Oil seal worn or defective Piston ring groove worn Worn valve stem valve guide Worn injection pump piston Defective injection pump Defective head gasket Cracked cylinder block or cylinder head Insufficient engine oil Blocked oil filter Excessive play in crankshaft bearing Excessive play in connecting rod bearing bearing Oil channel blocked Incorrect oil type Fuel leak due to loose injector lines Injection pump fails to operate Incorrect atomiser opening pressure Atomiser defective or blocked Regulator fails to function correctly Worn or defective piston rings and Piston ring openings all on same Excessive play in rocker shaft 34 Clean or replace Cle
33. ruck bleed screw Figure 6 5 Fuel filter Prins Maasdijk 12 26 Prins Maasdijk Sprinter amp TrikeUser Manual Maintaining the forklift truck 6 2 5 Air filter The purpose of the air filter is to clean the air entering the engine This is a dry filter which is not suitable for use with oil The filter must be replaced once annually or every 600 service hours In dirty or dusty conditions it may be necessary to reduce this interval Where necessary the filter may be blown clean however this must always be done from the inside outwards with a maximum air pressure of 5 bar Note It is extremely important that the filter element is properly seated when it is replaced in the filter housing If it vibrates loose in operation dust will be able to enter the engine causing damage see Figure 6 6 and Figure 6 7 Figure 6 6 Air filter 1 Air filter housing 2 Air filter element 3 Fixing nut 4 Discharge valve for dirt Figure 6 7 Blowing air filter element clean Prins Maasdijk 12 27 Prins Maasdijk Sprinter amp TrikeUser Manual Maintaining the forklift truck 6 2 6 Battery Electrical energy is reguired for the starter motor and other functions of the vehicle This electrical power is delivered by a battery which is itself charged by a dynamo driven by the engine output shaft The battery may fail to operate correctly for a variety of reasons The cables may not
34. the desired location Note Brake and steer with extreme care when driving with a load on the forks Sudden changes of speed or direction may result in the loss of the load Having arrived at the desired location bring the forks back to their vertical position so that the load is level with the unloading location Allow the load to descend to around 5 cm above the unloading point Drive gently forwards and place the load some 10 to 20 in front of the final resting place Now reverse a similar distance 10 20 cm raise the load once again by some 5 cm and finally place it in its ultimate position This latter manoeuvre is intended to prevent damage from forks protruding from the load to any obstacle which is invisible to the driver because of the load The Prins fork lift truck is provided with removable counterweight plates Where lighter loads are being carried a number of plates may be removed so as to reduce the weight of the machine This may have advantages in dealing with difficult terrain and preventing tracks being created in the substrate Where these matters are not an issue ensure that all counterweight plates are in place Procedure 1 Establish the weight of the load to be carried 2 Consult the load table in Figure 5 12 to determine the minimal number of counterweight plates required Fit this number of plates The fitting and removal of plates must always be carried out by two persons 4 The weight of one
35. turn to position I and the engine will continue to run 10 Prins Maasdijk Jan 12 Prins Maasdijk Sprinter amp Trike User Manual Operating the forklift truck Note At very low ambient temperatures it may be necessary to pre glow for longer than 5 seconds Table 5 1 indicates how long pre glowing should continue after the lamp is extinguished Temperature Additional pre glow time Above 10 Not required Between 5 C and 10 C Below 5 C Maximal period of continuous pre glowing Table 5 1 Pre glow times 2 2 Fork lift truck with lpg engine Once both lamps have illuminated the ignition key should be rotated to position III the engine will then start The II position has no function in the lpg models 3 Ifthe engine does not start within 10 seconds then return the ignition key to the OFF position and wait 30 seconds before making a fresh attempt Every fresh attempt should start from step 1 Note The starter motor must not be allowed to operate continuously for longer than 20 seconds 4 Once the engine is running check that the oil pressure and charging lamps are extinguished Where this is notthe case switch off the engine and check the following possible causes Oil pressure lamp remains illuminated o Isthe V belt broken o Is oil filled to the correct level o Is the oil in the sump contaminated o there any short circuits or other defects in the wiring C
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