Linde H40D 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 oper-
ating 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 [phone]
Fax [phone]
Mail: [email protected]
Web: http://www.linde-mh.com
Operating Instructions – 394 807 10 01 EN – 07/2011 I

Table of contents
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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
2Safety
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
3Overview
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
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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
Adjustingtheheight-adjustablecomfortdriver’sseat .......................... 34
Adjusting the luxury driver’sseat ......................................... 36
Adjustingthearmrest ................................................. 39
Adjustingthesteeringcolumn ........................................... 40
Settingtheclock ..................................................... 40
Seatbelt .......................................................... 41
Drive engine (dual-pedal operation) ...................................... 43
Driving (dual-pedal operation) .......................................... 46
Drive engine (single-pedal operation) ..................................... 49
Driving (single-pedal operation) ......................................... 53
Steeringsystem ..................................................... 56
Brakesystem ....................................................... 56
Signal horn ........................................................ 58
Joystick with central lever operation ...................................... 59
Joystickwithsingleleveroperation ....................................... 65
Special equipment ................................................... 71
Depressurisation .................................................... 71
Driver’scab ........................................................ 72
Lighting ........................................................... 72
Windscreenwiper ................................................... 74
Window heater ...................................................... 77
Heating system, air conditioning ......................................... 78
Linde Forklift Data Management (LFM) .................................... 81
Adjustingthedriver’sseatwithrotatingdevice ............................... 88
Liftmastpositioning .................................................. 89
Working under load .................................................. 91
Beforetakingupaload ................................................ 91
Adjustingtheforkspread .............................................. 93
Takingupload ...................................................... 94
Travellingwithload .................................................. 95
Setting down loads ................................................... 96
Towcoupling ....................................................... 96
Before leaving the lift truck unattended .................................... 97
Beforeleavingthetruck ............................................... 97
Loading / Transporting ................................................ 98
Securing the hose pulley against rolling up ................................. 98
Removingtheliftmast ................................................ 99
IV Operating Instructions – 394 807 10 01 EN – 07/2011

Table of contents
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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
Serviceplanasrequired ...............................................108
1000hserviceplan ................................................ . . 109
3000hserviceplan ................................................ . . 111
6000hserviceplan ................................................ . . 114
9000hServiceplan ................................................ . . 117
Engine ............................................................120
Checking the engine oil level ...........................................120
Change engine oil ...................................................121
Changing the engine oil filter ............................................123
Fuel ............................................................ . . 124
Draining water from thefuelfilter. ........................................126
Changing the fuel filter . ...............................................126
Cleanthefueltankventilationhose .......................................127
Checking the coolant level .............................................128
Changing the coolant . . ...............................................129
Checkingthecoolantconcentration ......................................131
Cleaning the water coolerandhydraulicoilcooler,andcheckingthemforleaks ......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 dischargevalve .........................................141
Changing the breather filter for the charge air pressure regulator .................142
Cleaningtheprefilter(specialequipment) ..................................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
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Check suction and exhaust pipes for leaks .................................145
Regenerating the particle filter ..........................................146
Regenerating the changing particlefilter ...................................149
Checkingtheparticlefiltersystem(specialequipment) ........................151
Draining water from the water trap at the changing particle filter (special equip-
ment) ........................................................... 152
Cleaning the water trap at the changing particle filter (special equipment) ...........152
Cleaning the pressure control device at the changing particle filter (special equip-
ment) ........................................................... 153
Gearbox ..........................................................154
Axle clamps and wheel motors: checking the mountings .......................154
Checkingandadjustingthesidestopsonthedriveaxle ........................154
Checkingthedriveaxlebearingsforwear ..................................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 andcorrectfunctionoftheseatbelt .....................160
Check fastening for frame, tilt cylinders and steering axle .......................162
Checking and oiling other bearing points and joints ...........................162
Topping up the washer systemwatertank(specialequipment) ..................163
Chassis frame ......................................................164
Changing a wheel ...................................................164
Tighten the wheel nuts ................................................165
Checkthetyresfordamageandforeignobjects ..............................165
Checkingthetyrepressure .............................................166
Checking the conditionoftheantistaticbelt .................................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 bellowsattheactuatinglever .................................170
Electrics ..........................................................171
Check the condition and secure positioning of electric cables, cable connectors and
connections ..................................................... . 171
Battery: Check condition,levelanddensityofacid ............................171
Hydraulics .........................................................174
Change hydraulic oil ..................................................174
VI Operating Instructions – 394 807 10 01 EN – 07/2011

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Hydraulicsystem:Checktheoillevel. .....................................175
Hydraulic system: changing the filter ......................................176
Check the bleeder valve on the hydraulicoiltankforcorrectoperation .............179
Checkthehydraulicsystemforleaks .....................................180
Check tilt cylinder bearings for wear ......................................180
Check the tension of double hoses .......................................181
Load lift system .....................................................182
Workingontheliftmastandatthefrontofthetruck ...........................182
Cleaning and spraying the liftmastchain ...................................185
Lift mast, lift mast chains, lift cylinder and end stops: Check mounting, condition and
function ........................................................ . 186
Adjustingtheliftmastchain ............................................186
Check the forks and fork quick-releases ...................................188
Cleansideshift(specialequipment)andgrease,checkfastening .................189
Checking the slide guides on the sideshift (special equipment) for wear . . ..........190
Self-help ..........................................................191
Openingthecovertotheelectricalsystem ..................................191
Fuses for basic and special equipment ....................................192
Main fuses in engine compartment .......................................192
Diagnosticconnector .................................................193
Malfunctions during operation ...........................................194
Malfunctions, Causes andRemedies(dieselengine) ..........................196
Malfunctions,causesandremedies(hydraulicsystem) ........................199
Jumpstart ....................................................... . . 201
Towing .......................................................... . 202
Shutting down ......................................................205
Shuttingdownthetruck ...............................................205
Disposal of old trucks .................................................206
Operating Instructions – 394 807 10 01 EN – 07/2011 VII

Table of contents
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6 Technical data
Type sheet H 40, as at 07/2011 ..........................................208
Type sheet H 45, as at 07/2011 ..........................................21
1
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,mastpositioning .............................................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