Linde Forklift Truck Type 359: H100, H120, H140, H160, H180 Operating Instructions (User Manual)

Linde Forklift Truck Original instructions H100-600, H120-1200, H120-600, H140-1200, H140-600, H160-1200, H160-600, H180-600 3598011501 EN – 0110

Preface g Linde - Your Partner Linde, an enterprise operating worldwide in the investment and service sector, is one of the large industrial enterprises in the EC with its three business segments and six divisions. The Linde Material Handling division is a lead- ing manufacturer of industrial trucks and hydraulics. It includes eight manufacturing plants in the Federal Republic of Germany, France and Great Britain, as well as sub- sidiaries and branches in all economically important countries. Linde industrial trucks enjoy a worldwide reputation - thanks to their high quality in engineering, performance and service. Wishing you satisfactory operation, Linde Heavy Truck Division Limited Linde Industrial Park Merthyr Tydﬁl South Wales, UK CF48 4LA Tel: +44 (0)1443 624300 Fax: +44 (0) 1443 624302 Operating Instructions – 3598011501 EN – 0110 I

Table of contents g 1 Introduction Your 359 Forklift Truck ................................................. 2 Technical Description .................................................. 3 Intended use ........................................................ 5 Improper use ........................................................ 5 Symbols Used ....................................................... 6 Commissioning ...................................................... 6 Truck takeover ....................................................... 7 EC declaration of conformity ............................................. 9 2 Safety Safety Rules ....................................................... 12 Do not operate with guards removed ...................................... 14 Park Brake ......................................................... 14 Malfunctions ....................................................... 14 Handling Fuel, Lubricants and Coolant .................................... 15 Residual risks ...................................................... 16 Stability ........................................................... 16 3 Overview General view of Truck ................................................. 18 Type Plates ........................................................ 19 Composite instrument and light switches .................................. 21 Controls and indicators - single pedal cab .................................. 25 Controls and indicators - twin pedal cab ................................... 26 4 Operation Mirrors ............................................................ 28 Beginning operation .................................................. 28 Opening the right hand side window ...................................... 29 Setting the clock ..................................................... 30 Cab interior light ..................................................... 31 Hazard warning lights*, Turn indicators lights*, Horn .......................... 31 Operating Instructions – 3598011501 EN – 0110 III

Table of contents g Heater, Climate control ................................................ 32 Adjusting the driver’s seat .............................................. 35 Optional equipment .................................................. 36 To turn on the road lights* .............................................. 40 Operating the windscreen wipers* ....................................... 41 Filling the windscreen washer bottle ...................................... 43 Programmable mast positioning* ........................................ 43 Control levers (joysticks) .............................................. 44 Engine Access ...................................................... 47 Engine oil level check ................................................. 47 Checking the fuel .................................................... 49 Checking the coolant level in the reservoir .................................. 50 Tyres - check condition and pressure ..................................... 51 Battery access - opening .............................................. 52 Isolating the battery .................................................. 52 Opening the fuse box cover ............................................ 53 Fuses ............................................................ 53 Working hydraulics ﬁlter panel - removal ................................... 55 Hydraulic system: oil level check ........................................ 55 Final drive oil level check .............................................. 56 Starting the engine - double pedal models .................................. 56 Stopping the engine - double pedal models ................................. 58 Driving - double pedal models ........................................... 58 Starting the engine - Single pedal models .................................. 61 Stopping the Engine - Single pedal models ................................. 63 Driving - single pedals ................................................ 64 Tilting the cabin ..................................................... 66 Malfunctions during operation .......................................... 67 Steering .......................................................... 68 Braking system ..................................................... 69 Installation of additional equipment ....................................... 70 Mast, lifting device and attachment controls ................................ 71 Operating optional attachments ......................................... 71 IV Operating Instructions – 3598011501 EN – 0110

Table of contents g Before lifting a load ................................................... 72 Lifting a load ....................................................... 73 Travelling with load .................................................. 74 Depositing the load .................................................. 75 Before leaving the truck unattended ...................................... 76 Loading ........................................................... 77 Trailer coupling ..................................................... 78 Locations for jacks when changing wheels ................................. 78 Wheel change ...................................................... 79 Towing ........................................................... 80 Hoisting the truck .................................................... 83 Emergency exit ..................................................... 83 Measures before taking the truck out of operation ............................ 84 Putting the truck back into operation ...................................... 85 5 Maintenance General remarks .................................................... 88 General information .................................................. 88 Filling capacity/Rated values ........................................... 89 Fuel and oil recommendations .......................................... 90 Diesel fuel ......................................................... 92 Check the condition of structured components .............................. 92 Truck welds inspection ................................................ 94 Checks - various .................................................... 94 Inspection and maintenance schedule .................................... 95 Service plan as required ............................................... 95 50 h Service plan .................................................... 96 500 h Service plan ................................................... 97 1000 h Service plan .................................................. 98 2000 h Service plan .................................................. 99 3000 h Service plan .................................................. 101 6000 h Service plan .................................................. 102 Rated capacities .................................................... 105 Engine ............................................................ 105 Engine oil level check ................................................. 105 Change the engine oil (every 12 months minimum) ........................... 108 Clean the fuel ﬁlter ................................................... 110 Operating Instructions – 3598011501 EN – 0110 V

Table of contents g Change the fuel pre-filter with water monitor ................................ 111 Check the condition of the V-belt ......................................... 111 Check the condition of the drive belt ...................................... 112 Replace the toothed belt and idler pulley ................................... 113 Check the cooling fan belt tensioner ...................................... 114 Check the engine mounting for condition and security ......................... 115 Check the air filter ................................................... 116 Renew the air filter element ............................................ 116 Replacing the air filter safety element ..................................... 117 Checking the coolant level in the reservoir .................................. 118 Check coolant strength ................................................ 119 Renew engine coolant ................................................ 120 Check the vibration damper ............................................ 121 Clean the radiator and oil cooler, check for leaks ............................. 122 Check intake and exhaust systems for leaks and security ...................... 123 Check valve clearances ............................................... 124 Gearbox .......................................................... 125 Final drive oil level check .............................................. 125 Change final drive hub oil .............................................. 126 Chassis bodywork and fittings .......................................... 127 Clean the truck ...................................................... 127 Mirrors ............................................................ 128 Check seat belt for condition and correct operation* ........................... 129 Check the tyres for damage and foreign objects .............................. 130 Tighten the wheel nuts ................................................ 130 Tyres - check condition and pressure ..................................... 131 Check the cab mountings .............................................. 131 Chassis frame ...................................................... 132 Check the security of the axle clamp and drive motors ......................... 132 Clean and lubricate the steer axle ........................................ 132 Check the condition of structured components .............................. 133 Controls .......................................................... 133 Check the parking brake for proper operation ............................... 133 Brake control mechanism .............................................. 133 Electrics .......................................................... 134 Check the battery / batteries. ........................................... 134 Hydraulics ......................................................... 135 Hydraulic system: oil level check ........................................ 135 Check the hydraulic tank breather filter .................................... 136 Renew the main hydraulic system oil return line filters ......................... 136 VI Operating Instructions – 3598011501 EN – 0110

Table of contents g Renew hydraulic oil of working hydraulic system ............................. 139 Load lift system ..................................................... 139 Lubricate the mast and tilt cylinder pivots ................................... 139 Lubricate fork carriage cylinder bearings ................................... 140 Check the tension of double hoses ....................................... 142 Check and adjust mast chains, lubricate with chain spray ....................... 142 Renewing the lift chains (at least every 3 years and when 3% stretch has been at- tained) .......................................................... 143 Troubleshooting ..................................................... 145 Troubleshooting guide (Diesel engine) .................................... 145 Troubleshooting guide (Hydraulic system) ................................. 149 User manual feedback ................................................ 150 User manual improvement record. ....................................... 150 Troubleshooting ..................................................... 151 Troubleshooting guide (Diesel engine) .................................... 151 Troubleshooting guide (Hydraulic system) ................................. 155 Annex 6 Technical data Datasheet ......................................................... 167 359 Datasheet ...................................................... 167 359 Datasheet ...................................................... 171 Mast variations ..................................................... 174 Technical Data ...................................................... 174 7 Circuit diagrams Electrical circuit diagrams .............................................. 176 Cummins fault code list ............................................... 176 Hydraulic circuit diagrams ............................................. 181 Hydraulic circuit ..................................................... 181 Operating Instructions – 3598011501 EN – 0110 VII

1 Introduction

1 Introduction Your 359 Forklift Truck Your 359 Forklift Truck Linde lift trucks offer the best in economy, safety and driving convenience. Therefore it is mainly in the hands of the operator to pre- serve the qualities of the trucks for a long and profitable service life and to make full use of their benefits on the job. For attachments, the proprietary operating instructions supplied with them are applicable. Follow all hints for operating the lift truck and carry out the maintenance and care prescribed in the inspection and maintenance schedule regularly, on time and with the specified lubricants. This manual tells you all you need to know about starting, running, servicing and maintaining your lift truck. The terms “front”, “rear”, “left” and “right” refer to the position in which the item concerned is installed in the truck, looking for- ward in the travel direction. Approved applications Linde lift trucks are designed for transporting and lifting the loads stated in the load capacity diagram. In partic- ular, we refer to the attached VDMA booklet "Safety rules for industrial trucks" and acci- dent prevention rules of your trade association and the special measures required for driving on public roads in accordance with the traffic regulations. The safety rules for the use of industrial trucks must be followed under all circumstances by the responsible persons, especially by the operator and service person- nel. 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 dealer. No changes, especially conversions or modifications, may be made on your fork truck without the prior permission of the manufacturer. Only qualified persons authorised by Linde are allowed to service the trucks. To keep your warranty valid, keep a record of all maintenance services. 2 Operating Instructions – 3598011501 EN – 0110

Introduction 1 Technical Description Technical note These operating instructions or excerpts thereof may only be copied, trans- lated 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 re- ferring to design, fittings and engineering of lift trucks are subject to change if progress war- rants 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 authorized 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. • Lift truck model:...................................... • Serial no./year built:............................... • Handing-over date:................................ When ordering parts for the engine, mast, drive axle, steer axle, hydraulic pump and transmission, also state the serial number of the assembly. When taking over the lift truck, transfer the details from the assembly type plates into this operating manual. 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 re-inspect 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 documents are supplied with each fork truck: • 1 Operating instructions • 1 EC certificate of conformity (The manufacturer certifies that the industrial truck conforms to EC guidelines for machines) • 1 Safety rules for the use of industrial trucks (VDMA) We wish you satisfactory operation. Linde Material Handling Aschaffenburg Technical Description General Series 359 fork lift trucks are designed for loading and stacking loads up to: 12.0 tonnes with the H120, 14 tonnes with the H140, and 16.0 tonnes with the H160 at 1200 mm load centre. 10.0 tonnes with the H100/600, 12.0 tonnes with the H120/ 600, 14.0 tonnes with the H140/600, 16.0 tonnes with the H160/600 and 18.0 tonnes with the H180/600, at 600 mm load centre The low centre of gravity and optimum weight distribution ensure maximum stability in all operating conditions. Engine A 6 cylinder, turbo charged, direct injection diesel engine, providing 142 kW at 2200 rpm, as a power unit, drives the truck hydraulic pumps at load-dependent speed. The engine is cooled by a closed-loop coolant circuit with an expansion reservoir. The lubrication system is a forced feed type lubrication with the oil pump in the oil sump. A dry air filter with a paper cartridge cleans the combustion air. Diesel engines with state-of-the-art engine technology are used for: - high torque, - low fuel consumption, - low exhaust gas emissions, - low soot emissions, - low noise values. Operating Instructions – 3598011501 EN – 0110 3

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Linde Forklift Truck Type 359: H100, H120, H140, H160, H180 Operating Instructions (User Manual)

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