Linde Diesel Forklift Truck H-Series Type 394: H40D, H45D, H50D Operating Instructions (User Manual)

Diesel truck Original instructions H40D, H45D, H50D 394 807 10 01 EN – 07/2011

Preface g Linde − Your Partner With over 100,000 fork lift trucks and ware- house machines sold annually, Linde is one of the world’s leading manufacturers of material handling equipment. There are many reasons for this success: Linde products are renowned not only for their innovative, cutting-edge tech- nology, but also for their low energy and operating costs, which are up to 40 per cent lower than those of their competitors. The high quality of Linde products is also matched by the quality of our service. With ten production plants worldwide and an extensive network of sales partners, we are at your service round the clock and around the world. Your local Linde partner can offer you a complete package from a single source; ranging from expert advice on all aspects of sales and service through, of course, to appropriate ﬁnance options. Our leasing, hire or lease-purchase agreements provide you with the ﬂexibility to tailor decision-making to your individual business requirements. Linde Material Handling GmbH Carl-von-Linde-Platz 63743 Aschaffenburg Telephone +49 (0) 6021 99-0 Fax +49 (0) 6021 99-1570 Mail: info@linde-mh.com Web: http://www.linde-mh.com Operating Instructions – 394 807 10 01 EN – 07/2011 I

Table of contents g 1 Introduction Your forklift truck ..................................................... 2 Proper use .......................................................... 3 Impermissible use .................................................... 3 Description of use and climatic conditions ................................... 3 Symbols used ....................................................... 4 Technical description .................................................. 4 Truck operation when using a shovel ...................................... 6 Receiving the industrial truck ............................................ 6 Legal requirements for marketing ......................................... 7 2 Safety Safety guidelines .................................................... 10 Residual risks ...................................................... 11 Stability ........................................................... 12 In the case of tip-over ................................................. 12 Handling consumables ................................................ 12 Competent person ................................................... 13 Regulations ........................................................ 13 Instructions for ﬁtting attachments ....................................... 14 Fork carriage emergency lowering ....................................... 15 Emergency exit with attached rear window ................................. 16 3 Overview Identiﬁcation plates .................................................. 18 General view ....................................................... 20 Operating devices ................................................... 21 Display unit ........................................................ 22 Switch panel ....................................................... 28 4 Operation Service plan before initial commissioning .................................. 30 Running-in instructions ............................................... 30 Operating Instructions – 394 807 10 01 EN – 07/2011 III

Table of contents g Pre-shift-checks ..................................................... 31 Standard equipment ................................................. 32 Entering and exiting the truck ........................................... 32 Adjusting the standard driver’s seat and comfort driver’s seat .................... 32 Adjusting the height-adjustable comfort driver’s seat .......................... 34 Adjusting the luxury driver’s seat ......................................... 36 Adjusting the armrest ................................................. 39 Adjusting the steering column ........................................... 40 Setting the clock ..................................................... 40 Seat belt .......................................................... 41 Drive engine (dual-pedal operation) ...................................... 43 Driving (dual-pedal operation) .......................................... 46 Drive engine (single-pedal operation) ..................................... 49 Driving (single-pedal operation) ......................................... 53 Steering system ..................................................... 56 Brake system ....................................................... 56 Signal horn ........................................................ 58 Joystick with central lever operation ...................................... 59 Joystick with single lever operation ....................................... 65 Special equipment ................................................... 71 Depressurisation .................................................... 71 Driver’s cab ........................................................ 72 Lighting ........................................................... 72 Windscreen wiper ................................................... 74 Window heater ...................................................... 77 Heating system, air conditioning ......................................... 78 Linde Forklift Data Management (LFM) .................................... 81 Adjusting the driver’s seat with rotating device ............................... 88 Lift mast positioning .................................................. 89 Working under load .................................................. 91 Before taking up a load ................................................ 91 Adjusting the fork spread .............................................. 93 Taking up load ...................................................... 94 Travelling with load .................................................. 95 Setting down loads ................................................... 96 Tow coupling ....................................................... 96 Before leaving the lift truck unattended .................................... 97 Before leaving the truck ............................................... 97 Loading / Transporting ................................................ 98 Securing the hose pulley against rolling up ................................. 98 Removing the lift mast ................................................ 99 IV Operating Instructions – 394 807 10 01 EN – 07/2011

Table of contents g Driving without the lift mast ............................................. 100 Loading ........................................................... 100 Transportation by lorry or low loading trucks ................................ 102 5 Maintenance General information .................................................. 104 Inspection and maintenance data ........................................ 105 Recommendations for consumables ...................................... 105 Inspection and maintenance overview .................................... 108 Service plan as required ............................................... 108 1000 h service plan .................................................. 109 3000 h service plan .................................................. 111 6000 h service plan .................................................. 114 9000 h Service plan .................................................. 117 Engine ............................................................ 120 Checking the engine oil level ........................................... 120 Change engine oil ................................................... 121 Changing the engine oil filter ............................................ 123 Fuel .............................................................. 124 Draining water from the fuel filter. ........................................ 126 Changing the fuel filter ................................................ 126 Clean the fuel tank ventilation hose ....................................... 127 Checking the coolant level ............................................. 128 Changing the coolant ................................................. 129 Checking the coolant concentration ...................................... 131 Cleaning the water cooler and hydraulic oil cooler, and checking them for leaks ...... 133 Checking the condition and secure positioning of the engine support and engine mounting ........................................................ 134 Check condition of the ribbed vee belt ..................................... 135 Replacing ribbed V-belt ............................................... 136 Checking the condition and tension of toothed belt ............................ 137 Renew the toothed belt and idler pulley .................................... 139 Change the water pump ............................................... 139 Changing the air filter cartridge, checking the vacuum-operated switch ............ 139 Changing the air filter safety cartridge ..................................... 141 Check the dust discharge valve ......................................... 141 Changing the breather filter for the charge air pressure regulator ................. 142 Cleaning the prefilter (special equipment) .................................. 143 Cleaning the oil bath air filter (special equipment) ............................ 143 Change the oil in the oil bath air cleaner (Optional) ............................ 144 Operating Instructions – 394 807 10 01 EN – 07/2011 V

Table of contents g Check suction and exhaust pipes for leaks ................................. 145 Regenerating the particle filter .......................................... 146 Regenerating the changing particle filter ................................... 149 Checking the particle filter system (special equipment) ........................ 151 Draining water from the water trap at the changing particle filter (special equipment) ........................................................... 152 Cleaning the water trap at the changing particle filter (special equipment) ........... 152 Cleaning the pressure control device at the changing particle filter (special equipment) ........................................................... 153 Gearbox .......................................................... 154 Axle clamps and wheel motors: checking the mountings ....................... 154 Checking and adjusting the side stops on the drive axle ........................ 154 Checking the drive axle bearings for wear .................................. 155 Checking the hydraulic pump’s mounting on the engine ........................ 155 Chassis, bodywork and fittings .......................................... 156 Cleaning the truck ................................................... 156 Bonnet ........................................................... 156 Floorplate ......................................................... 158 Maintaining the heating system and air conditioning (special equipment) ........... 159 Checking the condition and correct function of the seat belt ..................... 160 Check fastening for frame, tilt cylinders and steering axle ....................... 162 Checking and oiling other bearing points and joints ........................... 162 Topping up the washer system water tank (special equipment) .................. 163 Chassis frame ...................................................... 164 Changing a wheel ................................................... 164 Tighten the wheel nuts ................................................ 165 Check the tyres for damage and foreign objects .............................. 165 Checking the tyre pressure ............................................. 166 Checking the condition of the antistatic belt ................................. 167 Cleaning and greasing the steering axle ................................... 167 Checking the mountings of the steering cylinder and steering pivot pin ............. 168 Controls .......................................................... 169 Checking the parking brake for correct operation ............................. 169 Checking the pedals .................................................. 169 Checking the bellows at the actuating lever ................................. 170 Electrics .......................................................... 171 Check the condition and secure positioning of electric cables, cable connectors and connections ...................................................... 171 Battery: Check condition, level and density of acid ............................ 171 Hydraulics ......................................................... 174 Change hydraulic oil .................................................. 174 VI Operating Instructions – 394 807 10 01 EN – 07/2011

Table of contents g Hydraulic system: Check the oil level. ..................................... 175 Hydraulic system: changing the ﬁlter ...................................... 176 Check the bleeder valve on the hydraulic oil tank for correct operation ............. 179 Check the hydraulic system for leaks ..................................... 180 Check tilt cylinder bearings for wear ...................................... 180 Check the tension of double hoses ....................................... 181 Load lift system ..................................................... 182 Working on the lift mast and at the front of the truck ........................... 182 Cleaning and spraying the lift mast chain ................................... 185 Lift mast, lift mast chains, lift cylinder and end stops: Check mounting, condition and function ......................................................... 186 Adjusting the lift mast chain ............................................ 186 Check the forks and fork quick-releases ................................... 188 Clean sideshift (special equipment) and grease, check fastening ................. 189 Checking the slide guides on the sideshift (special equipment) for wear ............ 190 Self-help .......................................................... 191 Opening the cover to the electrical system .................................. 191 Fuses for basic and special equipment .................................... 192 Main fuses in engine compartment ....................................... 192 Diagnostic connector ................................................. 193 Malfunctions during operation ........................................... 194 Malfunctions, Causes and Remedies (diesel engine) .......................... 196 Malfunctions, causes and remedies (hydraulic system) ........................ 199 Jump start ......................................................... 201 Towing ........................................................... 202 Shutting down ...................................................... 205 Shutting down the truck ............................................... 205 Disposal of old trucks ................................................. 206 Operating Instructions – 394 807 10 01 EN – 07/2011 VII

Table of contents g 6 Technical data Type sheet H 40, as at 07/2011 .......................................... 208 Type sheet H 45, as at 07/2011 .......................................... 211 Type sheet H 50/500, as at 07/2011 ...................................... 214 Type sheet H 50/600, as at 07/2011 ...................................... 217 Type sheet H 40 elevated driver’s compartment, as at 07/2011 .................. 220 Type sheet H 45 elevated driver’s compartment, as at 07/2011 .................. 223 Type sheet H 50/500 elevated driver’s compartment, as at 07/2011 ............... 226 Type sheet H 40 container, as at 07/2011 .................................. 229 Type sheet H 45 container, as at 07/2011 .................................. 232 Type sheet H 50/500 container, as at 07/2011 ............................... 235 Type sheet H 50/600 container, as at 07/2011 ............................... 238 Truck configuration .................................................. 241 Tyre variants and rim sizes ............................................. 242 Load capacity diagrams and lift mast data as at 07/2011 ....................... 244 Additional capacity rating plate for attachments .............................. 247 Noise emission values ................................................ 248 Vibration characteristic values for bodily vibrations ........................... 249 Annex 7 Circuit diagrams Wiring diagram ..................................................... 264 Basic equipment for diesel with pump injection engine — Sheet 01 ................ 264 Basic equipment for diesel with pump injection engine — sheet 02 ................ 266 Basic equipment for diesel with pump injection engine — sheet 03 ................ 268 Special equipment sheet 01 — working spotlight ............................. 270 Special equipment sheet 02 — Windscreen wipers, seat heater, seat with air suspen- sion ............................................................ 272 Special equipment sheet 03 — Heating system, air conditioning, flashing/rotating beacon, reversing signal, interior lighting/clipboard lighting ................... 274 Special equipment sheet 04 — hazard warning system for reverse travel, truck deacti- vation, mast positioning ............................................. 276 Special equipment sheet 05 — particle filter, radio ............................ 278 Special equipment sheet 06 — Higher lighting, 12 V socket, diesel filter water trap warning ......................................................... 280 VIII Operating Instructions – 394 807 10 01 EN – 07/2011

Table of contents g Special equipment sheet 07 – Truck data management, LPG volume display ........ 282 Special equipment sheet 08 – LPG volume display for volumetric ﬁlling with shut-off valve, changing particle ﬁlter, camera system ............................. 284 Special equipment sheet 09 — battery main switch with display unit power supply, rear centre brake/tail light ............................................... 286 Special equipment sheet 10 — third auxiliary hydraulics with third joystick .......... 288 Special equipment sheet 11 — Lighting, direction indicator and hazard warning system, brake light .................................................... 290 Special equipment sheet 12 — single lever for lifting/lowering, tilting, single auxiliary hydraulics and double auxiliary hydraulics ................................ 292 Hydraulic circuit diagram .............................................. 294 Traction, working and steering hydraulics .................................. 294 Accumulator ....................................................... 296 Operating Instructions – 394 807 10 01 EN – 07/2011 IX

1 Introduction

Linde Diesel Forklift Truck H-Series Type 394: H40D, H45D, H50D Operating Instructions (User Manual)

You're Reading a Preview

Recently Viewed