Linde H35D - Annex

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Operating Instructions

Diesel truck

H25D, H30D, H35D

Annex

3 807 1001 EN – 08/2008

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Table of Contents5
Introduction11
Your Forklift Truck12
Proper Usage13
Symbols Used13
Technical Description14
Truck Operation When Using a Shovel15
Reception of Forklift Truck15
Service Plan before Initial Start-Up16
Safety17
Safety Regulations18
In the Case of Tip-Over19
Handling Consumables20
Specialist20
Operation of Industrial Trucks in Plant Area20
Regulations21
Determination and Assessment of Hazards from Use of Industrial Trucks22
Instructions before Fitting Attachments23
Overview25
Identification Plates26
Truck Overview28
Controls29
Indicator Unit30
Switch Panel34
Operation35
Running-In Instructions36
Checks before Starting Work36
Standard Equipment36
Adjusting the Driver's Seat36
Adjusting the Steering Column39
Setting the Clock40
Seat Belt40
Drive Engine (Two-Pedal Operation)42
Driving (Two-Pedal Operation)45
Drive Engine (Single-Pedal Operation)48
Driving (Single-Pedal Operation)52
Steering System55
Brake System56
Horn58
Lifting System and Attachments (Central Lever Operation)59
Lifting System and Attachments (Single Lever Operation)63
Special Equipment66
Lifting System and Attachments66
Third Auxiliary Hydraulics)66
Lifting System and Attachments with 3Rd Auxiliary Hydraulics Without Toggle Switch70
Adjust Driver's Seat with Swivel Device73
Adjust the Driver's Air-Sprung Seat74
Lift Mast Positioning77
Lighting78
Windscreen Wiper81
Window Heater83
Driver's Cab83
Heater, Air Conditioning84
Linde Forklift Data Management (LFM)86
Working under Load91
Before Taking up a Load91
Adjusting the Fork Spread92
Taking up Load93
Travelling with Load94
Setting down Loads95
Tow Coupling96
Loading / Transporting96
Securing the Hose Pulley against Rolling up96
Dismantling the Lift Mast97
Driving Without Lift Mast98
Loading99
Transport with Lorry or Low-Bed Trailer101
Before Leaving the Truck101
Maintenance103
General Remarks104
Working on Linde Lift Mast and at the Front of the Truck105
Inspection and Maintenance Data108
Consumables Recommendations108
Inspection and Maintenance Overview111
50 H Service Plan111
Service Plan as Required112
1000 H Service Plan113
3000 H Service Plan115
6000 H Service Plan118
9000 H Service Plan121
Engine124
Checking the Engine Oil Level124
Change Engine Oil125
Engine Oil Filter Change127
Fuel129
Draining Waterfrom the Fuel Filter130
Exchanging the Fuel Filter131
Cleaning the Fuel Tank Ventilation Hose131
Checking the Coolant Level132
Changing Coolant133
Check Coolant Concentration135
Cleaning the Water Cooler and Hydraulic Oil Cooler, and Checking Them for Leaks137
Check the Condition of the Engine Mountings and Engine Suspension; Check that They Are Attached Securely138
Check Condition of the Ribbed Vee Belt139
Replacing Ribbed V-Belt140
Checking the Condition and Tension of Toothed Belt140
Renew the Toothed Belt and Idler Pulley142
Change the Water Pump143
Change Air Filter Cartridge, Check Vacuum-Operated Switch143
Exchange Air Filter Safety Cartridge144
Check the Dust Discharge Valve145
Changing the Breather for the Charge Air Pressure Regulator145
Cleaning the Prefilter (Special Equipment)146
Cleaning the Oil Bath Air Filter (Special Equipment)147
Change the Oil in the Oil Bath Air Cleaner (Optional)147
Check Suction and Exhaust Pipes for Leaks148
Regenerating the Particulate Filter150
Regenerating the Particulate Filter (Exchange Filter System)153
Checking the Particulate Filter System (Special Equipment)155
Draining Water from the Water Trap at the Exchangeable Soot Filter (Special Equipment)156
Cleaning the Water Trap at the Exchangeable Particulate Filter (Special Equipment)156
Cleaning the Pressure Control Device at the Exchangeable Particulate Filter (Special Equipment)157
Gearbox158
Checking the Fastenings of the Axle Clamps and Wheel Motors158
Checking and Adjusting the Side Stops on the Drive Axle158
Checking the Drive Axle Bearings for Wear159
Checking the Hydraulic Pump's Attachment to the Engine159
Chassis, Bodywork and Fittings160
Cleaning the Truck160
Bonnet161
Floorplate163
Servicing the Air Conditioning (Special Equipment)164
Check the Seat Belt for Condition and Proper Operation165
Checking Fastening for Frame, Tilt Cylinders and Steering Axle166
Check and Oil Other Pivots and Joints166
Chassis Frame167
Wheel Change167
Tighten the Wheel Bolts168
Check the Tyres for Damage and Foreign Objects168
Checking the Tyre Pressure and Tyre Sizes169
Cleaning and Greasing the Steering Axle170
Check the Steering Cylinder and King Pin for Security171
Check the Parking Brake for Correct Operation172
Controls173
Checking the Pedals173
Checking the Bellows at the Actuating Lever173
Electrics174
Check the Condition and Secure Positioning of Electric Cables, Cable Connectors and Connections174
Battery: Check Condition, Acid Level and Acid Density174
Hydraulics177
Change Hydraulic Oil177
Hydraulic System: Check Oil Level178
Hydraulic System: Changing the Filter179
Check Correct Operation of Breather Valve on the Hydraulic Oil Tank182
Check the Hydraulic System for Leaks183
Check Tilt Cylinder Bearings for Wear183
Check the Tension of Double Hoses184
Checking the Function and Safety System of the Third Auxiliary Hydraulics (Special Equip- Ment)184
Load Lift System186
Cleaning the Lift Mast Chain and Applying Chain Spray186
Mast, Lift Chains, Lift Cylinders and End Stops: Check for Security, Condition and Proper Operation187
Adjust Lift Mast Chain187
Check the Forks and Fork Quick-Releases189
Clean Sideshift (Special Equipment) and Grease, Check Fastening190
Checking the Slide Guides on the Sideshift (Special Equipment) for Wear191
Ing191
Check Fork Arm Adjustment Device (Special Equipment) for Wear and Tear193
Special Equipment, Accessories194
Top up the Washer System Water Tank194
Troubleshooting195
Opening the Cover to the Electrical System195
Fuses for Basic and Special Equipment196
Main Fuses in Engine Compartment196
Diagnostic Connector197
Jump Start197
Fork Carriage Emergency Lowering199
Emergency Exit for Trucks with Rear Screen200
Towing Instructions201
Placing the Forklift Truck into Storage203
Disposal of Old Vehicles203
Malfunctions During Operation205
Malfunctions, Causes and Remedies (Diesel Engine)207
Malfunctions, Causes, Remedies (Hydraulic Equipment)211
Technical Data213
Type Sheet H 25, as at 05/2008214
Type Sheet H 30, as at 05/2008217
Type Sheet H 35, as at 05/2008220
Load Diagrams and Lift Mast Data as at 05/2008223
Noise Emission Values225
Vibration Characteristic Values for Bodily Vibrations225
Annex237
Circuit Diagrams239
Wiring Diagram240
Basic Equipment for Diesel with Pump Injection Engine - Sheet 1240
Basic Equipment for Diesel with Pump Injection Engine - Sheet 2242
Basic Equipment for Diesel with Pump Injectionengine - Sheet 3244
Special Equipment Sheet 1 - Working Headlights, Lighting, Direction Indicator System246
Brake Light, Interior Lighting246
Special Equipment Sheet 2 − Windscreen Wiper, Seat Heater, Radio248
Special Equipment Sheet 3 − Heater, Air Conditioning, Rotating Beacon, Reversing Sig250
Nal250
Special Equipment Sheet 4 − Hazard Warning System for Reversing, Higher Lighting252
Special Equipment Sheet 5 − Lift Mast Positioning, Hydraulic Oil Microfilter Indicator, Vehicle Deactivation, Forklift Data Management254
Special Equipment Sheet 6 − Particulate Filter, Diesel Filter Water Trap Warning256
Special Equipment Sheet 7 − LPG Volume Display, 12 V Socket, Working Headlights Pos. 5 and 6, Coolant and Engine Oil Level Monitoring258
Special Equipment Sheet 8 − Battery Main Switch with Indicator Unit Voltage Supply, Exchangeable Particulate Filter, Rear Window Heater, Camera System260
Special Equipment Sheet 9− Third Auxiliary Hydraulics with Third Joystick, Centre Rear Brake/Tail Light262
Hydraulic Circuit Diagram264
Traction, Working and Steering Hydraulics264
Accumulator266

Linde H35D - Annex

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