Linde H25D User manual

Operating Instructions
Diesel truck
H25D, H30D, H35D
393 807 1001 EN – 08/2008

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.
Thehighquali
ty 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: [e-mail]
Web: http://www.linde-mh.com
Operating Instructions – 393 807 1001 EN – 08/2008 I

Table of contents
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1 Introduction
Your forklift truck ..................................................... 2
Proper usage ........................................................ 3
Symbols used ....................................................... 3
Technical description .................................................. 4
Truck operation when using a shovel...................................... 5
Reception of forklift truck ............................................... 5
Service plan before initial start-up ......................................... 6
2Safety
Safety regulations .................................................... 8
In the case of tip-over .................................................. 9
Handling consumables ................................................ 10
Specialist .......................................................... 10
Operation of industrial trucks in plant area .................................. 10
Regulations ........................................................ 11
Determination and assessment of hazards from use of industrial trucks ............ 12
Instructions before fitting attachments ..................................... 13
3Overview
Identification plates .................................................. 16
Truck overview ..................................................... 18
Controls .......................................................... 19
Indicator unit ....................................................... 20
Switch panel ....................................................... 24
4 Operation
Running-in instructions ............................................... 26
Checks before starting work ............................................ 26
Standard equipment ................................................. 26
Adjustingthedriver’sseat .............................................. 26
Adjustingthesteeringcolumn ........................................... 29
Settingtheclock ..................................................... 30
Seatbelt .......................................................... 30
Operating Instructions – 393 807 1001 EN – 08/2008 III

Table of contents
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Drive engine (two-pedal operation) ....................................... 32
Driving (two-pedal operation) . .......................................... 35
Drive engine (single-pedal operation) ..................................... 38
Driving (single-pedal operation) ......................................... 42
Steeringsystem ..................................................... 45
Brakesystem ....................................................... 46
Horn ............................................................. 48
Liftingsystemandattachments(centralleveroperation) ....................... 49
Lifting system and attachments (singleleveroperation) ........................ 53
Special equipment ................................................... 56
Lifting system and attachments (single lever operation with toggle-switch-controlled
thirdauxiliaryhydraulics) .............................................. 56
Lifting system and attachments with 3rd auxiliary hydraulics without toggle switch .... 60
Adjustdriver’sseatwithswiveldevice ..................................... 63
Adjustthedriver’sair-sprungseat ........................................ 64
Liftmastpositioning .................................................. 67
Lighting ........................................................... 68
Windscreenwiper ................................................... 71
Window heater ...................................................... 73
Driver’scab ........................................................ 73
Heater,airconditioning ............................................... 74
Linde Forklift Data Management (LFM) .................................... 76
Working under load .................................................. 81
Beforetakingupaload ................................................ 81
Adjustingtheforkspread .............................................. 82
Takingupload ...................................................... 83
Travellingwithload .................................................. 84
Setting down loads ................................................... 85
Towcoupling ....................................................... 86
Loading / Transporting ................................................ 86
Securing the hose pulley against rolling up ................................. 86
Dismantlingtheliftmast ............................................... 87
Driving without lift mast ................................................ 88
Loading ........................................................... 89
Transportwithlorryorlow-bedtrailer ..................................... 91
Beforeleavingthetruck ............................................... 91
IV Operating Instructions – 393 807 1001 EN – 08/2008

Table of contents
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5 Maintenance
General remarks .................................................... 94
Working on Linde lift mast and at thefrontofthetruck ......................... 95
Inspection and maintenance data ........................................ 98
Consumables recommendations ........................................ 98
Inspection and maintenance overview ....................................101
50hServiceplan .................................................. . . 101
Serviceplanasrequired ...............................................102
1000hserviceplan ................................................ . . 103
3000hServiceplan ................................................ . . 105
6000hServiceplan ................................................ . . 108
9000hServiceplan ................................................ . . 111
Engine ............................................................114
Checking the engine oil level ...........................................114
Change engine oil ...................................................115
Engine oil filter change . ...............................................117
Fuel ............................................................ . . 119
Drainingwaterfromthefuelfilter. ........................................120
Exchanging the fuel filter ..............................................121
Cleaningthefueltankventilationhose ....................................121
Checkingthecoolantlevel .............................................122
Changing coolant ....................................................123
Checkcoolantconcentration ...........................................125
Cleaning the water cooler and hydraulic oil cooler,andcheckingthemforleaks ......127
Check the condition of the engine mountings and engine suspension; check that they
areattachedsecurely .................................................128
Check condition of the ribbed vee belt .....................................129
Replacing ribbed V-belt ...............................................130
Checking the condition and tension of toothed belt ............................130
Renew the toothed belt and idler pulley ....................................132
Change the water pump ...............................................133
Change air filter cartridge, check vacuum-operated switch ......................133
Exchange air filter safety cartridge .......................................134
Checkthedustdischargevalve .........................................135
Changing the breather for the charge air pressure regulator .....................135
Cleaningtheprefilter(specialequipment) ..................................136
Cleaning the oil bath air filter (special equipment) ............................1
37
Change the oil in the oil bath air cleaner (Optional) ............................137
Check suction and exhaust pipes for leaks . ................................138
Regenerating the particulate filter ........................................140
Operating Instructions – 393 807 1001 EN – 08/2008 V

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Regenerating the particulate filter (exchange filter system) .....................143
Checking the particulate filter system (special equipment) ......................145
Draining water from the water trap at the exchangeable soot filter (special equip-
ment) .............................................................146
Cleaning the water trap at the exchangeable particulate filter (special equipment) .....146
Cleaning the pressure control device at the exchangeable particulate filter (special
equipment) ........................................................147
Gearbox ..........................................................148
Checkingthefasteningsoftheaxleclampsandwheelmotors ...................148
Checkingandadjustingthesidestopsonthedriveaxle ........................148
Checking the drive axle bearings for wear ..................................149
Checkingthehydraulicpump’sattachmenttotheengine .......................149
Chassis, bodywork and fittings ..........................................150
Cleaning the truck ...................................................150
Bonnet . . .........................................................151
Floorplate .........................................................153
Servicing the air conditioning (special equipment) ............................154
Check the seat belt for condition and proper operation .........................155
Checking fastening for frame, tilt cylinders and steering axle ....................156
Checkandoilotherpivotsandjoints ......................................156
Chassis frame ......................................................157
Wheel change ......................................................157
Tighten the wheel bolts ................................................158
Checkthetyresfordamageandforeignobjects ..............................158
Checkingthetyrepressureandtyresizes ..................................159
Cleaning and greasing the steering axle ...................................160
Checkthesteeringcylinderandkingpinforsecurity ..........................161
Check the parking brake for correct operation ...............................162
Controls ..........................................................163
Checking the pedals ..................................................163
Checkingthebellowsattheactuatinglever .................................163
Electrics ..........................................................164
Check the condition and secure positioning of electric cables, cable connectors and
connections ........................................................164
Battery:checkcondition,acidlevelandaciddensity ..........................164
Hydraulics .........................................................167
Change hydraulic oil ..................................................167
Hydraulicsystem:Checkoillevel ........................................168
Hydraulic system: changing the filter ......................................169
Check correct operation of breather valve on the hydraulic oil tank ................172
Checkthehydraulicsystemforleaks .....................................173
VI Operating Instructions – 393 807 1001 EN – 08/2008

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Check tilt cylinder bearings for wear ......................................173
Check the tension of double hoses .......................................174
Checking the function and safety system of the third auxiliary hydraulics (special equip-
ment) ........................................................... . . 174
Load lift system .....................................................176
Cleaningtheliftmastchainandapplyingchainspray ..........................176
Mast, lift chains, lift cylinders and end stops: Check for security, condition and proper
operation ..........................................................177
Adjustliftmastchain .................................................177
Checktheforksandforkquick-releases ...................................179
Clean sideshift (special equipment) andgrease,checkfastening .................180
Checking the slide guides on the sideshift (special equipment) for wear . . ..........181
Cleaning and lubricating the fork positioner (special equipment), checking the fasten-
ing ............................................................. . . 181
Check fork arm adjustment device (special equipment) for wear and tear ...........183
Special equipment, accessories .........................................184
Topupthewashersystemwatertank ................................... . . 184
Troubleshooting .....................................................185
Openingthecovertotheelectricalsystem ..................................185
Fuses for basic and special equipment ....................................186
Main fuses in engine compartment .......................................186
Diagnosticconnector .................................................187
Jumpstart ....................................................... . . 187
Fork carriage emergency lowering .......................................189
Emergency exit for trucks with rear screen . ................................190
Towinginstructions ..................................................191
Placingtheforklifttruckintostorage ......................................193
Disposalofoldvehicles ...............................................193
Malfunctions during operation ...........................................195
Malfunctions, Causes and Remedies (diesel engine) ..........................197
Malfunctions,causes,remedies(hydraulicequipment) ........................201
Operating Instructions – 393 807 1001 EN – 08/2008 VII

Table of contents
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6 Technical data
Type sheet H 25, as at 05/2008 ..........................................204
Type sheet H 30, as at 05/2008 ..........................................207
Type sheet H 35, as at 05/2008 ..........................................210
Load diagrams and lift mast data as at 05/2008 ..............................213
Noise emission values ................................................215
Vibration characteristic values for bodily vibrations ...........................215
Annex
7 Circuit diagrams
Wiring diagram .....................................................230
Basic equipment for diesel with pump injection engine - sheet 1 ..................230
Basic equipment for diesel with pump injection engine - sheet 2 ..................232
Basic equipment for diesel with pump injectionengine - sheet 3 ..................234
Special equipment sheet 1 — working headlights, lighting, direction indicator system,
brakelight,interiorlighting .............................................23
6
Special equipment sheet 2 − Windscreen wiper, seat heater, radio ................238
Special equipment sheet 3 − Heater, air conditioning, rotating beacon, reversing sig-
nal ...............................................................240
Special equipment sheet 4 − Hazard warningsystemforreversing,higherlighting ....242
Special equipment sheet 5 − Lift mast positioning, hydraulic oil microfilter indicator,
vehicle deactivation, Forklift Data Management . . . ...........................244
Special equipment sheet 6 − Particulate filter, diesel filter water trap warning ........246
Special equipment sheet 7 − LPG volume display, 12 V socket, working headlights
pos. 5 and 6, coolant and engine oil levelmonitoring ..........................248
Special equipment sheet 8 − Battery main switch with indicator unit voltage supply,
exchangeable particulate filter, rear window heater, camera system . . . . ...........250
Special equipment sheet 9− Third auxiliary hydraulics with third joystick, centre rear
brake/taillight ......................................................252
Hydraulic circuit diagram ..............................................254
Traction,workingandsteeringhydraulics ..................................254
Accumulator .......................................................256
VIII Operating Instructions – 393 807 1001 EN – 08/2008