Linde Diesel Forklift Truck H-Series Type 396: H50D, H60D, H70D, H80D Operating Instructions (User Manual)

Diesel truck Original instructions Series 396-01 H50D, H60D, H70D, H80D 396 807 10 01 EN – 03/2013

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 – 396 807 10 01 EN – 03/2013 I

Table of contents g 1 Introduction Your forklift truck  ..................................................... 2 Intended use  ........................................................ 3 Impermissible use  .................................................... 4 Description of use and climatic conditions  ................................... 5 Symbols used  ....................................................... 5 Technical description  .................................................. 5 Taking delivery of the industrial truck  ....................................... 7 Legal requirements for placing on the market  ................................ 8 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 Fit attachments ..................................................... 14 Fork carriage emergency lowering ....................................... 17 Emergency exit with attached rear window ................................. 18 3 Overview Identiﬁcation plates .................................................. 22 Truck overview ..................................................... 24 Controls .......................................................... 25 Display unit ........................................................ 26 Switch panel ....................................................... 33 4 Operation Service plan before initial commissioning .................................. 36 Instructions for running-in .............................................. 36 Pre-shift checks ..................................................... 37 Operating Instructions – 396 807 10 01 EN – 03/2013 III

Table of contents g Standard equipment ................................................. 38 Entering and exiting the truck ........................................... 38 Adjusting the driver’s seat .............................................. 38 Adjusting the steering column ........................................... 42 Setting the clock ..................................................... 42 Seat belt .......................................................... 43 Starting and stopping the internal combustion engine (dual-pedal operation) ........ 45 Driving (dual-pedal operation) .......................................... 48 Starting and stopping the internal combustion engine (single-pedal operation) ....... 51 Driving (single-pedal operation) ......................................... 55 Steering system ..................................................... 58 Brake system ....................................................... 58 horn ............................................................. 60 Joystick with central lever operation ...................................... 61 Joystick with single lever operation ....................................... 66 Special equipment ................................................... 72 Joystick with central lever operation and 3rd auxiliary hydraulics without toggle switch .......................................................... 72 Depressurisation .................................................... 78 Adjust driver’s seat with swivel device ..................................... 78 Adjusting the driver’s seat equipped with air suspension ....................... 79 Mast positioning ..................................................... 81 Lighting ........................................................... 83 Windscreen wiper ................................................... 85 Window heater ...................................................... 88 Driver’s cab ........................................................ 89 Heating system, air conditioning ......................................... 90 Linde Forklift Data Management (LFM) .................................... 96 Working under load .................................................. 102 Before taking up load ................................................. 102 Adjusting the fork arm distance .......................................... 103 Taking up loads ..................................................... 104 Travelling with load .................................................. 105 Setting down loads ................................................... 106 Towing device ...................................................... 106 Before leaving the truck ............................................... 108 Loading / Transporting ................................................ 109 Removing the lift mast ................................................ 109 Securing the overhead guard against moving forwards or backwards .............. 109 Loading ........................................................... 109 Transportation by lorry or low-bed semi-trailer ............................... 111 IV Operating Instructions – 396 807 10 01 EN – 03/2013

Table of contents g 5 Maintenance General information .................................................. 114 Inspection and maintenance data ........................................ 115 Recommendations for consumables ...................................... 116 Inspection and maintenance overview .................................... 119 Service plan as required ............................................... 119 1000 h service plan .................................................. 120 2000-hour service plan ................................................ 122 3000 h service plan .................................................. 124 6000 h service plan .................................................. 126 Engine ............................................................ 129 Checking the engine oil level ........................................... 129 Changing the engine oil ............................................... 130 Changing the engine oil filter ............................................ 132 Fuel .............................................................. 133 Draining the fuel system water strainer .................................... 135 Changing the fuel filter ................................................ 136 Changing the fuel pre-filter ............................................. 137 Bleeding the fuel system ............................................... 139 Cleaning the fuel tank ventilation hose .................................... 140 Checking the coolant level ............................................. 141 Changing the coolant ................................................. 142 Checking the coolant concentration ...................................... 145 Clean the water cooler and hydraulic oil cooler and check for leaks ................ 146 Checking the condition and secure positioning of the engine support and engine mounting ........................................................ 148 Checking the condition and tension of the V-ribbed belt ........................ 149 Changing the V-ribbed belt ............................................. 150 Changing the air filter cartridge, checking the vacuum-operated switch ............ 152 Changing the air filter safety cartridge ..................................... 153 Checking the dust discharge valve ....................................... 154 Cleaning the prefilter (special equipment) .................................. 155 Cleaning the oil bath air filter (special equipment) ............................ 156 Changing the oil in the oil bath air filter (special equipment) ..................... 157 Checking the intake and exhaust pipes for leaks ............................. 158 Checking the valve clearance ........................................... 159 Changing the injection valves ........................................... 159 Draining water from the intercooler ....................................... 159 Regenerating the particle filter .......................................... 160 Checking the particle filter system (special equipment) ........................ 163 Regenerating the changing particle filter ................................... 164 Operating Instructions – 396 807 10 01 EN – 03/2013 V

Table of contents g Draining water from the water trap at the changing particle filter (special equipment) ........................................................... 166 Cleaning the water trap at the changing particle filter (special equipment) ........... 167 Cleaning the pressure control device at the changing particle filter (special equipment) ........................................................... 168 Gearbox .......................................................... 169 Planetary transmission: Checking the oil level and checking for leaks ............. 169 Planetary transmission: Changing the oil and cleaning the magnetic plug ........... 169 Checking the fastenings of the axle clamps ................................. 171 Checking the hydraulic pump’s mounting on the engine ........................ 171 Chassis, bodywork and fittings .......................................... 173 Cleaning the truck ................................................... 173 Bonnet ........................................................... 173 Floorplate ......................................................... 174 Maintaining the heating system and air conditioning (special equipment) ........... 176 Checking the condition and correct function of the seat belt ..................... 177 Checking the mounting of the chassis, tilt cylinders and steering axle .............. 179 Lubricating the overhead guard bearings and tilt cylinder bearings ................ 179 Checking and oiling other bearing points and joints ........................... 180 Washer system: Topping up the water tank ................................. 180 Chassis frame ...................................................... 182 Wheel change ...................................................... 182 Tightening the wheel fastenings ......................................... 182 Checking tyres for damage and foreign objects .............................. 183 Check the tyre pressure ............................................... 183 Checking the condition of the antistatic belt ................................. 185 Cleaning and greasing the steering axle ................................... 185 Checking the mountings of the steering cylinder and steering pivot pin ............. 186 Controls .......................................................... 187 Checking the parking brake for correct operation ............................. 187 Checking the pedal group .............................................. 187 Checking the bellows at the actuating lever ................................. 188 Electrics .......................................................... 189 Checking the condition and secure positioning of electric cables, cable connectors and connections ...................................................... 189 Battery: condition check, disposal ........................................ 189 Hydraulics ......................................................... 193 Changing the hydraulic oil ............................................. 193 Checking the oil level in the hydraulic system ............................... 195 Hydraulic system: changing the filter ...................................... 196 Check that the bleeder valve on the hydraulic tank is working correctly ............. 200 VI Operating Instructions – 396 807 10 01 EN – 03/2013

Table of contents g Checking the hydraulic system for leaks ................................... 201 Checking the pre-load of the double hoses ................................. 202 Load lift system ..................................................... 203 Working on the lift mast and at the front of the truck ........................... 203 Cleaning and spraying the lift mast chain ................................... 205 Checking the mounting, condition and function of the lift mast, lift mast chains, lift cylinders and end stops ............................................. 206 Adjusting the lift mast chain ............................................ 206 Checking fork arms and arm safety devices ................................. 208 Lubricating the mast ﬁxation ............................................ 209 Self-help .......................................................... 210 Opening the cover to the electrical system .................................. 210 Fuses for special electrical equipment ..................................... 210 Opening the central electrical system cover ................................. 212 Fuses for basic electrical equipment ...................................... 213 Fuses for air conditioning (special equipment) ............................... 213 Fuses for particle ﬁlter system (special equipment) ........................... 214 Diagnostic connector ................................................. 215 Malfunctions during operation ........................................... 216 Malfunctions, causes and remedies: diesel engine ........................... 218 Malfunctions, causes and remedies — hydraulic system ....................... 221 Jump start ......................................................... 223 Towing ........................................................... 224 Shutting down ...................................................... 229 Shutting down the truck ............................................... 229 Disposal of old trucks ................................................. 230 Operating Instructions – 396 807 10 01 EN – 03/2013 VII

Table of contents g 6 Technical data Overview of dimensions ............................................... 232 H 50 D type sheet .................................................... 233 H 60 D type sheet .................................................... 236 H 70 D type sheet .................................................... 239 H 80 D type sheet .................................................... 242 H 80 D/900 type sheet ................................................ 245 H 80 D/1100 type sheet ............................................... 248 Lift mast data type 195 ................................................ 251 Truck conﬁguration .................................................. 253 Tyre variants and rim sizes ............................................. 254 Load capacity diagrams ............................................... 256 Additional capacity rating plate for attachments .............................. 257 Noise emission values ................................................ 258 Vibration characteristic values for bodily vibrations ........................... 259 VIII Operating Instructions – 396 807 10 01 EN – 03/2013

1 Introduction

1 Introduction Your forklift truck Your forklift truck offers optimum economic efficiency, safety and driving comfort. It is primarily down to you to maintain these characteristics for a long time and take advantage of the resulting benefits. During manufacture: • all safety requirements of the relevant EC directives were observed • all conformity assessment procedures stipulated in the applicable directives were carried out This is attested by the CE mark shown on the nameplate. These operating instructions contain every- thing you need to know about commissioning, driving and maintenance. Carry out the specified work regularly, at the due times and using the consumables envisaged for this purpose in accordance with the inspection and maintenance overview. The designations used in the text (front, back, left, right) always refer to the installation position of the parts described, with forwards as the drive direction for the truck (fork arms forwards). Servicing work not described here will require specialist knowledge, measuring devices and frequently also special tools. Please ask your authorised dealer to carry out this work. Servicing should only be carried out by qual- ified personnel approved by Linde (special- ists). With orders for parts, please specify the following along with the parts numbers: Truck model: Chassis number/year of manufacture: Handover date: to be specified. The production number must also be specified for parts from the following units: engine, lift mast, hydraulic variable displacement pump, planetary transmission and steering axle. Engine number: Lift mast number: Lift mast lift: Hydraulic variable displacement pump number: Working hydraulics hydraulic pump number: Steering hydraulics hydraulic pump number: Planetary transmission number: Steering axle number: When taking over the truck, this data should be copied from the identification plates of the units into these operating instructions. NOTE In the event of repairs, only use genuine Linde spare parts. This is the only way to guarantee that your truck remains in the same technical condition as at the time of reception. Please address all queries and orders for spare parts relating to your truck only to your authorised dealer, stating your mailing address. Linde is constantly engaged in the further development of its products. We ask for your understanding that figures and technical data are subject to technical modification in terms of form, equipment and expertise in the interest of progress. For this reason, no claims can be asserted on the basis of the following data, figures and descriptions in these operating instructions. These operating instructions must not be reproduced, translated or made accessible to 2 Operating Instructions – 396 807 10 01 EN – 03/2013

Linde Diesel Forklift Truck H-Series Type 396: H50D, H60D, H70D, H80D Operating Instructions (User Manual)

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