Руководство по эксплуатации linde h80d

Brand: Linde
|
Category: Forklifts
|
Size: 9.14 MB

• Table of Contents

  3

• IC-Engined Fork Truck H 50/60/70/80, Type

  9

• Engine Drive

  9

• Engine Model BF6M 1012 E

  9

• Engine Specifications

  9

• Explanation of the Engine Number

  10

• Changing and Tightening the Drivebelt

  11

• Adjusting Valve Clearance

  12

• Adjusting the Injection Valve

  15

• Checking the Compression Pressure

  17

• Cylinder Head

  18

• Adjusting the Begin of Delivery

  20

• Special Tools

  24

• Engine Model BF6M 2012

  26

• Overview of Engine Components

  26

• Engine Specifications

  28

• Explanation of the Engine Number

  29

• Replacement of V-Ripped Belt

  30

• Adjusting Valve Clearance

  31

• Checking and Adjusting Leak-Fuel-Free Injection Nozzles

  32

• Thermostat

  38

• Checking the Compression Pressure

  40

• Cylinder Head

  41

• Injection Pump

  43

• Adjusting the Begin of Delivery

  43

• Replacement of the Injection Pump

  45

• Heater Flange

  51

• Special Tools

  54

• Transmission

  59

• Hydrostatic Transmission

  60

• Schematic Diagram of the Drive

  61

• Transmission Specifications

  62

• Hydraulic Circuit Diagram

  64

• Operation of the Hydrostatic Transmission

  78

• Travel Control Unit P

  78

• Operation of Control Valve Block N = Power Limiter

  81

• Braking

  82

• Auxiliary Brake

  82

• Lock-Out Logic — Reversing Lock

  84

• Flushing of the Circuit and Housing

  86

• Hydraulic Remote Control

  88

• Adjustments

  89

• Hydraulic Neutral Position

  89

• Primary Adjustment of Start of Control

  89

• Mechanical Limitation of the Swashplate Angle

  89

• Hydraulic Remote Control HPV

  90

• Reversal Lock (Logic Lock Out)

  92

• Reducing the Truck Speed

  92

• Wheel Drive

  93

• Reduction Gearbox with Disc Brake (GR 80 -02/-03/-04)

  94

• Servicing the Reduction Gearbox (GR 80 -02/-03/-04)

  96

• Disc Brake Repairs

  97

• Reduction Gearbox GR 80 -06 with Multiple Disc Brake

  98

• Repair on the Reducing Gear GR

  99

• Troubleshooting

  106

• Connecting Diagram for Troubleshooting

  106

• Tools and Aids for Measurements

  108

• Explanations to Troubleshooting

  110

• Hydraulic Speed Control for the Engine

  111

• Functional Test

  111

• Troubleshooting

  111

• Hydraulic Braking System

  116

• Functional Test

  116

• Troubleshooting

  116

• Pressure Equality and Start of Control

  119

• Functional Test

  119

• Troubleshooting

  119

• Hydrostatic Travel Drive

  123

• Test and Adjustment Instructions for Hydraulic Primary and Secondary Control

  135

• Q Max

  136

• Of Variable Displacement Pump BPV

  136

• Qmax

  138

• Of Hydraulic Motors Hmv 105

  138

• Qmin

  139

• Of Hydraulic Motors Hmv 105

  139

• Chassis

  141

• Overhead Guard — Torsion Mounting

  142

• Work on the Overhead Guard

  143

• Steering System

  145

• Power Steering Circuit Diagram

  146

• Series 304 Steering Axle

  148

• Description

  148

• Steering Axle Removal

  149

• Steering Axle Installation

  150

• Steering Axle Repairs

  150

• Renewing the Wheel Bearings

  151

• Steering Knuckle Removal and Installation

  152

• Steering Cylinder Removal and Installation

  154

• Replacing the Steering Cylinder Seals

  156

• Steering Stop Adjustment

  157

• Controls

  159

• Accelerator and Brake Pedal Adjustment

  160

• Speed Control

  163

• Speed Control up to 10/95

  163

• Speed Control from 11/95

  165

• Medium Wheel Speed

  166

• Start of Drive Wheel Rotation

  167

• Brake Shaft Stop Screws

  168

• Symmetry of the Travel Control

  169

• Drive Wheel Start of Rotation

  169

• Engine Speed Increase

  170

• Pressure Difference Δp

  171

• Modification of Engine Acceleration

  172

• Electrical System

  173

• Wiring Diagram

  174

• Wiring Diagram for Options

  178

• Wiring Diagram

  178

• Wiring Diagram for Options

  185

• Wiring Diagram, 353 -03 Diesel

  189

• Wiring Diagram for Options

  193

• Electrical System Circuit Diagram, Type 353 -03 LPG

  197

• Wiring Diagram for Options

  201

• Central Electrical System

  206

• Central Electrics of Series

  208

• Relay and Fuses of 353 -03 Diesel

  208

• Relay and Fuses of 353 -03 LPG

  210

• Relay and Fuses for 353 -03 Particulate Trap

  212

  • Working Hydraulics

    213

• Working Hydraulics Circuit Diagram

  214

• Explanation of the Working Hydraulics

  215

• Tilt Cylinder

  216

• Tilt Cylinder Removal, Installation, Adjustment, Sealing

  217

  • Mast

    221

• Mast Removal

  222

• Lift Cylinder Removal, Installation

  223

• Sealing the Lift Cylinder

  224

  • LP Gas Model H 50/60/70/0, Type

    227

• Drive Engine

  227

• Technical Data on Engine

  227

• Technical Data on Engine up to 12/2004

  227

• Technical Data on Engine from 01/2005

  228

• Note on the Engine Number

  229

• Changing and Tensing V-Belt

  230

• Checking and Setting Valve Clearance

  231

• Removing and Installing the Cylinder Head

  232

• Electrical System

  235

• Electronic Ignition System

  235

• Electronic Ignition System up to 12/2004

  235

• Electronic Ignition System from 01/2005

  240

• 4.9.2.1.2.1 Mechanical Ignition Timing

  245

• Electronic Engine-Speed Control

  249

• Electrical System Circuit Diagram up to 12/2004

  252

• Electrical System Circuit Diagram from 01/2005

  256

• Propellant Gas System

  259

• Diagram

  259

• Functional Description of the Propellant Gas System

  260

• Inspections and Adjustments

  268

• Ignition System

  268

• Installation of the Engine Speed Control System

  272

• Inspection of the Engine Speed Control System

  274

• Adjustment of the Propellant Gas Mixers

  279

• Data Plate

  23

• Capacity Plate

  24

• Description

  36

  • Authorised Applications

    36

  • Technical Note

    37

  • Takeover Inspection

    37

  • Type Plates

    39

  • Table of Contents

    41

  • Technical Data

    44

  • Noise Emission Levels

    46

  • Frequency Characteristic for Human Body Vibrations

    46

  • Technical Description

    47

    • Engine

      47

    • Hydraulic System

      47

    • Operation

      47

    • Lift Mast

      47

    • Brakes

      47

    • Steering

      47

    • Electrical System

      47

  • General View of Truck

    48

  • Controls and Indicators

    49

  • Composite Instrument

    51

• Beginning Operation

  52

  • Safety Rules

    52

  • Important Safety Information

    52

  • Handling Fuels and Lubricants

    52

  • Accident Prevention Check

    53

  • Operation of Industrial Trucks in the Plant Area

    53

  • Diesel Engine Emissions

    53

  • Particle Filter System Inspection (Option)

    53

  • Running-In Instructions

    53

  • Services Prior to First Operation

    53

  • Daily Checks

    53

  • Daily Checks and Servicing before Operation

    54

  • Opening the Bonnet

    54

  • Closing the Bonnet

    54

  • Check the Fuel Level

    54

  • Refuelling

    55

  • Check the Engine Oil Level

    55

  • Check the Header Tank Coolant Level

    55

  • Check the Tyre Inflation Pressure

    56

  • Applying the Seat Belt

    57

  • Opening the Seat Belt

    57

  • Adjusting the Operator Seat

    57

  • Starting the Engine

    58

  • Cold Start

    59

  • Stopping the Engine

    59

  • Malfunctions During Operation

    59

• Operation

  60

  • Driving

    60

    • Driving Forward

      60

    • Reversing

      60

    • Reversing the Direction of Travel

      60

    • Stopping

      60

  • Single-Pedal Model

    61

  • Steering

    64

  • Brakes

    64

    • Service Brake

      64

    • Parking Brake

      64

    • Applying the Parking Brake

      64

    • Releasing the Parking Brake

      64

  • Central-Lever Control of Lifting Device and Attachments

    65

    • Tilting the Mast Forward

      65

    • Tilting the Mast Back

      65

    • Lifting the Fork Carriage

      65

    • Lowering the Fork Carriage

      65

    • Operating the Attachments

      65

    • Operating the Sideshift

      65

    • Operating the Clamp

      65

  • Single-Lever Control of Lifting Device and Attachments

    66

  • Installation of Additional Equipment

    67

  • Turning on the Lighting

    67

  • Turning on the Hazard Warning Light

    67

  • Turning on the Front Working Lights

    67

  • Turning on the Working Light (at Rear)

    67

  • Operating the Intermittent Front Windscreen Wiper

    67

  • Operating the Front Windscreen Wiper

    67

  • Operating the Front Windscreen Washer

    67

  • Intermittent Switch for Rear and Top Windscreen Wiper

    67

  • Operating the Rear Windscreen and Top Screen Wipers

    67

  • Heater

    68

    • Controls

      68

    • Fan Motor Fuse

      68

  • Operating the Horn

    68

  • Check Fuses, Renew if Required

    69

  • Before Lifting a Load

    70

  • Loading

    71

  • Adjusting the Fork Spread

    71

  • Transporting a Load

    72

  • Depositing a Load

    72

  • Before Leaving the Lift Truck Unattended

    72

  • Transport

    73

    • Transport with Lorry or Low-Bed Semi-Trailer

      73

  • Hoisting the Truck

    73

  • Hoisting the Truck with a Crane

    73

  • Hoisting the Truck, Wheel Change

    74

  • Hoisting the Truck with Lifting Eyes

    74

  • Wheel Change

    74

  • Mast Removal, Trailer Coupling

    75

  • Mast Removal

    75

  • Securing the Moveable Overhead Guard

    75

  • Trailer Coupling

    75

  • Towing Instructions

    76

    • Towing

      76

    • Towing Procedure

      76

    • Releasing the Disc Brake

      76

    • Opening the Hydraulic By-Pass Valve

      76

    • After Towing

      76

    • Making the Brakes Operational Again

      76

  • Emergency Exit for Trucks with Rear Windscreen

    77

  • Taking the Truck out of Operation

    78

  • Measures before Taking the Truck out of Operation

    78

  • Putting the Truck Back into Operation

    78

• Maintenance

  78

  • General Information

    78

  • Servicing the Mast and the Front Part of the Truck

    79

  • Securing the Mast against Tilting Back

    79

  • Standard Mast

    79

  • Securing the Raised Standard Mast

    79

  • Maintenance after the First 50 Service Hours

    79

  • Inspection and Maintenance Schedule

    80

    • Inspection and Maintenance as Required

      82

    • Cleaning the Lift Truck

      82

    • Cleaning and Spraying the Mast Chain

      82

    • Cleaning the Air Filter

      83

    • Cleaning with Compressed Air

      83

    • Emptying the Dust Bowl in the Air Filter Cover

      84

    • Replacing the Safety Element

      84

    • Clean the Pre-Filter

      84

    • Regenerate the Particle Filter

      85

    • Check Wheel Fastener for Tightness

      86

    • Check the Tyres for Damage and Foreign Objects

      86

    • Clean the Radiator and Engine Oil, Hydraulic Oil and Fuel Cooler, Check for Leaks

      87

    • Clean with Compressed Air

      87

    • Clean with a Cold Cleaner

      87

    • Drain the Water Separator in the Fuel System

      88

    • Check Seat Belt for Condition and Operation

      89

    • 500-Hour Inspection and Maintenance

      90

    • Clean and Lubricate the Steer Axle

      90

    • Grease the Mast Pivots

      90

    • Grease the Tilt Cylinder and Overhead Guard Pivots

      90

    • Check the Engine Mounting, Movable Overhead Guard, Steer Axle and Drive Axle Hub Differentials for Tightness

      91

    • Check the Forks and Fork Quick-Releases

      91

    • Check the Mast, Lift Chains and Stops for Condition, Operation and Security

      91

    • Adjust the Lift Chains

      92

    • Lubricate with Chain Spray

      92

    • Check the Pre-Tension of Double Hoses if Attachments Are Fitted

      92

    • Check and Oil Other Pivots and Joints

      92

    • Check the Engine Cooling System for Leaks

      93

    • Check and Oil the Pedals, Accelerator and Engine Control Linkage

      93

    • Renew the Engine Oil (at Least Every 12 Months)

      94

    • Drain the Engine Oil

      94

    • Renew the Engine Oil Filter

      94

    • Add Engine Oil

      95

    • Check the Hydraulic Oil Level

      95

    • Check the Coolant Concentration

      96

    • Check the Particle Filter System

      96

    • Check and Tension V-Belt Drives

      97

    • Tighten V-Belt Drives

      97

    • Drain the Water Separator in the Fuel System

      97

    • Clean the Radiator, Hydraulic Oil and Fuel Cooler

      98

    • Clean with Compressed Air

      98

    • Clean with a Cold Cleaner

      98

    • Renew the Drive Axle Hub Differential Oil and Clean the Magnetic Plug

      98

    • Check the Condition and Security of Electric Cables, Connectors and Cable Connections

      99

    • Check the Condition, Electrolyte Level and Specific Gravity of the Battery

      99

    • 1000-Hour Inspection and Maintenance

      100

    • Renew the Hydraulic Pressure, Suction and Breather Filters

      100

    • Renew the Pressure Filter

      100

    • Renew the Suction Filter

      100

    • Renew the Breather Filter

      101

    • Renew the Fuel Filter Canister

      101

    • Check the Engine Mounting for Condition and Tightness

      101

    • Renew and Tension the V-Belt Drive

      102

    • Check the Exhaust System for Leaks and Tightness

      103

    • Check the Hydraulic System, Hydraulic Pumps, Valves and Lines for Leaks

      103

    • Renew the Air Filter Element, Check the Vacuum Switch

      104

    • Check the Parking Brake

      104

    • Check the Drive Axle Hub Differential Oil Level and for Leaks

      105

    • Check the Particle Filter System

      105

    • 2000-Hour Inspection and Maintenance

      106

    • Check the Particle Filter System

      106

    • Check Valve Tip Clearances

      106

    • Renew the Safety Element

      107

    • 3000-Hour Inspection and Maintenance

      108

    • Renew the Hydraulic Oil

      108

    • Drive Axle Hub Differential: Renew Oil and Clean the Magnetic Plug

      109

    • Renew the Coolant

      110

    • Inspection and Maintenance Data

      111

    • Fuel and Oil Recommendations

      112

    • Engine Oils

      112

    • Diesel Fuel

      113

    • Hydraulic Oil

      113

    • Gear Oil

      113

    • Grease

      113

    • Coolant

      113

    • Battery Grease

      113

    • Chain Spray

      113

    • Troubleshooting Guide (Diesel Engine)

      114

    • Troubleshooting Guide (Hydraulic System)

      117

    • Electric Circuit Diagram

      118

    • Electric Circuit Diagram (Options)

      121

    • Particle Filter Wiring Diagram

      124

    • Hydraulic Circuit Diagram

      126

    • Index

      128