Linde Diesel Forklift Truck 351-02 series: H20, H25, H30 Operating manual (User Manual)

TABLE OF CONTENTS Page Description 2 Approved applications 2 Technical note 2 Truck takeover 2 Type plates 3 Technical data 7 Technical description 8 Engine 8 Hydraulic system 8 Operation 8 Brakes 8 Steering 8 Electrical system 8 General view 9 Controls and indicators 10 Composite instrument 11 Beginning operation 12 Safty rules 12 Important safety information 12 Handling fuels and lubricants 12 Accident prevention check 13 Particle filter inspection 13 Running-in instructions 13 Checks and services before initial operation 13 Daily checks 13 Daily pre-operational checks and services 14 Opening the engine cover 14 Checking the engine oil level 14 Checking the fuel level 14 Filling fuel 15 Hydraulic system: Checking the oil level 15 Checking the fluid level in coolant reservoir 16 Adjusting the driver's seat 17 Checking the typre pressure 18 Starting the engine 19 Cold start 19 Stopping the engine 20 Malfunctions during operation 20 Operation 21 Travel 21 Forward travel 21 Page Reverse travel 21 Changing the travel direction 21 Single-pedal model 22 Steering system, Braking system 25 Steering 25 Service brake 25 Parking brake 25 Applying the parking brake 25 Releasing the parking brake 25 Lifting device and attachments 26 Tilting the mast forward 26 Tilting the mast back 26 Lifting the fork carriage 26 Lowering the fork carriage 26 Operating the attachments 26 Operating the sideshift 26 Operating the clamp 26 Single-lever operation of lifting device and attachments 27 Turning on the windscreen wipers 28 Switching on the lights 28 Switching on the hazard warning light 28 Turning on the ventilation 28 Front working lights 28 Rear working lights 28 Heater 29 Heater controls 29 Fan motor fuse 29 Operating the horn 30 Fuses 30 Before lifting a load 31 Adjusting the fork spread 32 Loading 32 Travel with a load 33 Unloading 33 Before leaving the lift truck unattended 33 Hoisting the truck with a crane 34 Hoisting the truck with a crane using the lifting eyes 34 Jack locations when changing wheels 34 Trailer coupling 35 Mast removal 35 Towing instructions 36 Towing 36 Page Towing procedure 36 Releasing the wheel drive brake pressure 36 Opening the hydraulic by-pass valve 36 After towing 36 Re-establishing braking power 36 Taking the truck out of operation 37 Measures before taking the truck out of operation 37 Putting the truck back into operation 37 Maintenance 37 General information 37 Work on the mast and on the front part of the truck 38 Securing the mast against tilting back 38 Standard mast 38 Securing the raised standard mast 38 Duplex mast 38 Securing the raised duplex mast 39 Triplex mast 39 Securing the raised triplex mast 39 Checks and services after the first 50 service hours 39 Inspection and maintenance chart 40 Inspection and maintenance as required 42 Cleaning the lift truck 42 Cleaning and spraying the mast chain 42 Cleaning the air filter 42 Cleaning with compressed air 43 Wet cleaning 43 Replacing the safety element 43 Checking the dust discharge valve 44 Cleaning the prefilter 44 Checking the mounting of the steering cylinder and king pin at the steering axle 44 Regenerating the particle filter 45 Cleaning and checking radiator and hydraulic oil cooler for leaks 46 Drain the fuel system water preseparator 46 Tightening the wheel nuts 47 Check the tyres for damage and foreign objects 47 5

TABLE OF CONTENTS Page 250-hour inspection and maintenance .. 48 Clean and grease the steering axle 48 Grease the mast and tilt cylinder pivots 48 Check electric cables, cable connectors and con¬ nections for condition and tightness 49 Drain the fuel system water preseparator 49 Sideshift: clean and grease, check the mounting 50 Battery: Check condition, electrolyte level 50 and specific gravity 50 500-hour inspection and maintenance . 51 Check the mast and mast chains for condition and security 51 Adjust the mast chain length and lubricate with chain spray 51 Change the engine oil (every 12 months minimum) . 52 Drain the engine oil 52 Renew the engine oil filter 52 Top up engine oil 53 Check coolant strength 53 Check the mounting of the compact axle at the engine 54 Check the engine mounting, counterweight, overhead guard, steering axle and wheel drives for tightness 54 Check and oil the pedals, travel control and engine control linkages 54 Check the tension and condition of the alternator and fan V-belt 55 Tighten the alternator and fan V-belt 55 Renew the fuel filter (every 12 months minimum) .... 56 Clean the radiator and hydraulic oil cooler 56 Checking the particle filter system 56 Check and oil other pivots and joints 57 Check the fork stops and fork quick-releases 57 Check the pre-tension of double hoses if attachments are fitted 57 Page 1000-hour inspection and maintenance 58 Renew the air filter element, check the vacuum switch 58 Check the engine mounting for condition and tightness 58 Check the air intake and exhaust pipes for leaks 59 Check the hydraulic system, compact axle, pumps, valves and lines for leaks 59 Hydraulic system: Renew the pressure, suction and breather filters 60 Renew the pressure filter 60 Renew the suction filter 60 Renew the breather filter 61 Check the wheel drive oil level 61 Check the particle filter system 62 Check the parking brake 62 2000-hour inspection and maintenance 63 Renew the alternator and fan V-belt 63 Tighten the V-belt 63 Check the injection nozzles 63 Check, adjust valve clearance 64 Check the particle filter system 64 Page 3000-hour inspection and maintenance 65 Renew the hydraulic oil 65 Check the mounting of the compact axle on engine 65 Inspection and maintenance data 66 Fuel and recommendations 67 Engine oils 67 Oil grades 67 Oil viscosity 67 Diesel fuel 68 Hydraulic oil 69 Lubricating grease 69 Coolant 69 Battery grease 69 Chain spray 69 Engine Troubleshooting guide (diesel engine) 70 Troubleshooting guide (hydraulic system) 73 Wiring diagram 74 Hydraulic circuit schematic 76 Index 78 6