TECHNICAL DATA TYPE 394 5 TORQUES Thread Nm

5.1 Drive - Engine:

H 40D / H 45D / H 50-500D
Engine mounting to engine M 10 46
1 SPEED SETTINGS min-1 min-1
Left, right, centre silentblocs to counterweight M 12 80
1.1 Engine (idle - driving) lower/upper 1000 2700 Right engine mount on spring element M 12 110
(idle - lifting) lower/upper 1000 2800
Left intermediate flange on spring element M 12 110
1.2 Wheels forwards/reverse 180-20 180-20 Rod to centre spring element A 20 110
2 PRESSURE SETTINGS bar bar Rod on intermediate flange M 10 46
2.1 Tyre pressure front /rear Flywheel on engine M 10x1 95
H 40 250-15/18 PR / 250-15/18 PR 10.0 6.0 Intermediate flange to engine M 12 80
250 R 15-XZM /250 R 15-XZM 10.0 6.0 Injection line union nuts 25
H 45/50-500 300-15/22 PR / 250-15/18 PR 10.0 6.0 Injector nozzle clamping bracket M8 20
300 R 15-XZM /250 R 15-XZM 10.0 6.0 Oil drain plug (with new oil seal) 30
H 40 Twin 250-15/18 PR / 250-15/18 PR 7.5 6.0
5.2 Drive - Gearbox:
250 R 15-XZM /250 R 15-XZM 7.5 6.0
H 45/50-500 Twin 8.25-15/18 PR /250-15/18 PR 7.5 6.0 Power unit HPV 105-02 R to intermediate flange M 12 110
8.25 R 15-XZM /250 R 15-XZM 7.5 6.0 Adjuster to power unit M8 32
Gear pump to power unit M 10 46
2.2 Pressure relief valve Mast type 189 Standard Duplex/
Slotted nut to wheel shaft (with Loctite Type 270) M 95x2 2200 +100
on control unit Triplex
Fixed displacement motor to axle housing M 16 275
H 40 250+5 250+5 Screw plug in fixed displacement motor cover BM 16x1.5 30
H 45/50-500 275+5 275+5
394 807 4001.1006

2.3 Max. working pressure / Boost pressure 425+20 21+0,5 5.3 Drive - Gearbox:
2.4 Nozzle injection pressure/wear limit 220-10 200 Bearing halves to frame M 20 540
3 SETTINGS mm Overhead guard to counterweight M 30 1350
3.1 Flyer chain, max. projection of lower guide roller Counterweight to frame M 30 1350
Fork carriage from inner channel 30.0
3.2 Double hose on mast (per referred metre) 5+5 5.4 Steering system and Wheels:
Steering axle to counterweight (with Loctite Type 243) M 16 195
3.3 Lateral stop of drive axle 1.0
Steering column to rotary valve M 10 46
3.4 Slider in the sideshift (minimum) 2.5
Steering wheel 40±5
4 FILLING QUANTITIES Litre Lubricant* King pin NM 18x1.5 310
4.1 Hydraulic tank 27.8 Hydraulic oil Mounting of steer cylinder M 16x1.5 295
4.2 Hydraulic oil level difference between min. and max. 3.0 Hydraulic oil Wheel hub to steering knuckle VM 20x1.5 470
4.3 Engine oil (diesel engine) 4.5 Engine oil Front wheel mounting M 18x1.5 425
4.4 Engine oil level difference between min. and max. 1.0 Engine oil Rear wheel mounting A 20 640
4.5 Fuel tank 60.0 Diesel
5.5 Hydraulic System:
4.6 Cooling system - 25° C with heater and air conditioning 10.0 Coolant
Bypass valve HPV - locknut M 12 50
w/o heater u. air conditioning 8.5 G 12
Set screw M 12 20 + 5
4.7 Air conditioning 1600 Refrigerant
Oil drain plug in hydraulic tank M 14x1.5 25
Gram R 134 a
4.8 Grease steer axle As Grease
5.6 Mast und tilt cylinders:
required
Mast to drive axle M 20 385
4.9 Flyer chain protection As Linde M 16 275
required chain spray Mounting of tilt cylinder front / rear M 16 275/275
* See recommended fuels and lubricants Clamping screw of eyebolt at tilt cylinder M 12 80

6 RECOMMENDED FUELS AND LUBRICANTS: 9 INSPECTION AND MAINTENANCE SCHEDULE

Maintenance as required
Engine oil - Oil change every 1000 service hours or 12 months - Clean the lift truck, clean and spray the lift chains
Longlife engine oils acc. to VW standard 506 00 and 506 01. - Clean the vent hose to the tank
These oils are only available in viscosity SAE 0W-30. - Replace the air filter safety element
The factory filling is a 1000-service-hour oil. - Check the dust discharge valve, clean the prefilter
Engine oil - Oil change every 500 service hours - Top up the washer system water tank
Engine oil acc. to VW standard 505 00 and. 505 01. - Drain the fuel filter, regenerate the soot filter
- Clean and check the radiator and hydraulic oil cooler for leaks
Engine oil for oil change every 300 service hours - Change the oil in the oil bath air cleaner
Also approved are engine oils of the quality class API CD or ACEA B2 / B3 and of higher - Tighten the wheel fasteners wheel fasteners (after each servicing or repair, every 100
API-C or ACEA-B quality classes. hours minimum)
ATTENTION - Check the tyres for damage and foreign objects
When refilling oil, different types of oil can be mixed; in this case the lowest quality oil - Lubricate the steering axle bearings
- Check the lap seat belt for condition and proper operation
determines the oil change interval. - Service the air conditioner
Do not add additives of any kind to the lubricating oils. Only use oils with a low ash Maintenance every 500 to 1000 service hours* or every year
content for trucks equipped with soot filter system. - Change engine oil (at least once a year), replace engine oil filter (at least once a year)
Diesel fuel: Use only Diesel fuel to EN 590 with a cetane number not lower than 51. The - Check coolant concentration, hydraulic system: Check oil level
- Check correct operation of breather valve on the hydraulic oil tank
sulphur content should not exceed 350mg/kg. If diesel fuel with a sulphur content higher - Replace fuel filter
than allowed by EN 590, the engine oil change intervals must be reduced as follows: - Replace breather of boost pressure control system
Change the engine oil every 300 service hours if the sulphur content is over 350 mg/kg - Check function of control unit
and under 2000 mg/kg. Change the engine oil every 150 service hours if the sulphur - Check the state of the ribbed V-belts
content is over 2000 mg/kg. - Check the state of the toothed belt, check tension
If the sulphur content of diesel fuel is higher than 350 mg/kg, an engine oil acc. to VW - Clean water and hydraulic oil cooler
- Check the condition and secure positioning of electric cables, cable connectors and
standard 505 00 / 505 01 / 506 01 must be used despite of reduced engine oil change connections
intervals. - Battery: Check condition, level and density of acid (even if battery is maintenance-free)
Hydraulic oil: Hydraulic oil recommendation for regular duty: Hydraulic oil - Replace the air filter cartridge, check the vacuum switch
ISO - L - HM 68 to ISO 6743 - 4 to. HLP ISO VG 68 to DIN 51524, T.2 (factory filling) - Check the condition of the engine mount and engine suspension; check that they are
attached securely
average oil temperature 60-80° C. Hydraulic oil recommendation for heavy duty: - Check suction and exhaust leads for leaks
Hydraulic oil ISO - L - HM 100 to ISO 6743 - 4 and HLP ISO VG 100 to DIN 51524, T.2 - Check hydraulic system for leaks
for heavy and multi-shift duty, operation in warm climate zones or at high ambient - Check how securely the frame, tilt cylinder und steering axle are attached
temperatures, average continuous oil temperature over 80° C. Hydraulic oil - Check the security of the axle clamps and drive motors
recommendation for regular and heavy duty: Hydraulic oil ISO - L - HV 68 to - Check the side stops on the drive axle
- Check pedals and oil them if necessary, check the soot filter system
ISO 6743 - 4 and HVLP ISO VG 68 to DIN 51524, T.3 (multigrade oil). - Check other bearings and joints and oil
Grease: Linde heavy duty grease with a lithium base and EP additives and MOS2. Desi- - Clean the steering axle, grease it
gnation to DIN 51825-KPF2N-20. Do not mix with other than lithium base greases. - Sideshift: Clean and grease, check fastening
Coolant: Use only coolant G12 A8D to VW specification TL-VW 774D (factory filling) or - Clean and grease the fork arm adjustment device, checkfastening
G 12 A8F to VW specification TL-VW- 774F. - Check fork arms and arm safety devices
- Lift mast chain, lift cylinders and end stops: check condition, secure fastening and
Refrigerant for air conditioning: R 134 a function
Chain spray: Linde chain spray - Adjust lift mast chain, apply chain spray to it
7 INITIAL OPERATION - Check the operation of the parking brake
- Check the engine oil level, check the hydraulic oil level, refuelling - Check the fastening on the steering cylinder and axle stub bolt
- Check the coolant level in the expansion reservoir, - Check the pre-tension of the double tubes
- Check condition, electrolyte level and acid density of the battery - Clean the oil bath air filter
Maintenance every 3000 service hours or every 2 years
- Tighten the wheel nuts, check the tyre inflation pressure - Change feed / pressure / suction filter and breather of hydraulic system
- Check the braking and steering system, check the lifting device and attachments - Change ribbed V-belt
- Regenerate the soot filter, check the third auxiliary hydraulic function and safety - Change safety cartridge of air filter
system - Check tilt cylinder bearing for wear
- Check drive axle bearing for wear
8 SERVICING AFTER THE FIRST 50 SERVICE HOURS - Hydraulic pump on engine: check fastening
- Check the parking brake for proper operation, tighten the wheel fasteners - Change toothed belt and tension pulley (at latest after 5 years)
- Check the hydraulic system, drive motors, hydraulic pumps and lines for leaks - Check slide guides on sideshift for wear
(visual inspection),drain water from the fuel filter - Check fork arm adjustment device for wear and tear
- Check the mast, lift chain, lift cylinders and stops for condition, security and proper Maintenance every 6000 service hours or every 3 years
- Renew the hydraulic oil
operation Maintenance every 9000 service hours or every 4 years
- Clean, adjust and lubricate the lift chain with chain spray - Renew the water pump, renew the G 12 coolant
- Check electric cables and connections for condition and security
* Depending on driving style and duty conditions, also see the fuel and lubricant recommendations.