Académique Documents
Professionnel Documents
Culture Documents
Container Handler
Preface
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Table of contents
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Introduction
Your Linde truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Technical description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Truck takeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Safety
Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Frequency characteristic for human body vibrations
Frequency characteristic for human body vibrations
. . . . . . . . . . . . . . . . . . . . . . . . . . 10
. . . . . . . . . . . . . . . . . . . . . . . . . . 10
Overview
General view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Type plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Composite instrument and light switches
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Operation
Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Beginning operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Opening the right hand side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Emergency exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Setting the clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Cab interior light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Hazard warning lights*, Turn indicators lights*, Horn . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Heater, Climate control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Adjusting the drivers seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Optional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
III
Table of contents
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To turn on the road lights* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Operating the windscreen wipers*
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Engine oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Checking the fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Checking the coolant level in the reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Tyres - check condition and pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Battery access - opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Isolating the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Working hydraulics filter panel - removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Hydraulic system: oil level check
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Installation of additional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Before lifting a load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Lifting a load
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
IV
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Towing
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Maintenance
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Work on the mast and the front part of the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
As required Service plan
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
50 h Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
500 h Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1000 h Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2000 h Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3000 h Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5000 h Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
6000 h Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Inspection and maintenance data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Inspection and maintenance as required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check the air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renew the safety element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clean the fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check seat belt for condition and correct operation* . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clean the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check the tyres for damage and foreign objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tighten the wheel nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clean the radiator and oil cooler, check for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic system: oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
91
91
92
92
93
95
97
97
98
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Tighten the wheel nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Tyres - check condition and pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Clean and lubricate the steer axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Check the parking brake for proper operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Check the batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Check the tension of double hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Lubricate the mast and tilt cylinder pivots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Check and adjust mast chains, lubricate with chain spray . . . . . . . . . . . . . . . . . . . . . . . 116
Inspection and maintenance every 500 hours or 6 months whichever comes first . . . . . 118
Change the engine oil (every 12 months minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Check coolant strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Change the fuel pre-filter with water monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Check the condition of the V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Check the condition of the drive belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Check the cab mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Brake control mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Check the security of the axle clamp and drive motors . . . . . . . . . . . . . . . . . . . . . . . . . 123
Check the hydraulic tank breather filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Lubricate the spreader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Inspection and maintenance every 1000 hours or 12 months, whichever comes first
...............................................................
Clean the radiator and hydraulic oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check the engine mounting for condition and security . . . . . . . . . . . . . . . . . . . . . . . . .
Check intake and exhaust systems for leaks and security . . . . . . . . . . . . . . . . . . . . . .
Check the cooling fan belt tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renew the air filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clean and lubricate the steer axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Final drive oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check the parking brake for proper operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check the batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check the tension of double hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubricate the mast and tilt cylinder pivots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check and adjust mast chains, lubricate with chain spray . . . . . . . . . . . . . . . . . . . . . . .
128
128
129
129
131
132
133
133
134
134
135
135
136
Inspection and maintenance every 2000 hours or 24 months, whichever comes first
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Renew engine coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Check the vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Check valve clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Renew the safety element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Checks - various . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Check the condition of structured components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
VI
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Change final drive hub oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Renew the main hydraulic system oil return line filters . . . . . . . . . . . . . . . . . . . . . . . . . 144
Renew the hydraulic tank breather filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Inspection and maintenance every 3000 hours or 36 months, whichever comes first
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Replace the toothed belt and idler pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Inspection and maintenance every 5000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Renewing the twistlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Inspection and maintenance every 6000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Renew hydraulic oil of working hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Renewing the lift chains (at least every 3 years and when 3% stretch has been attained) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Rated capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Filling capacity/rated values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Fuel and oil recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Fuel and oil recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Troubleshooting guide (Diesel engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Troubleshooting guide (Hydraulic system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Annex
6
Technical data
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Circuit diagrams
Cummins engine electrical circuit drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Cummins fault code list
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
VII
1
Introduction
1 Introduction
Your Linde truck
Your Linde truck
Linde lift trucks offer the best in economy,
safety and driving convenience. Therefore it
is mainly in the hands of the operator to preserve the qualities of the trucks for a long and
profitable service life and to make full use of
their benefits on the job. For attachments, the
proprietary operating instructions supplied
with them are applicable. Follow all hints for
operating the lift truck and carry out the maintenance and care prescribed in the inspection
and maintenance schedule regularly, on time
and with the specified lubricants. This manual
tells you all you need to know about starting, running, servicing and maintaining your
lift truck. The terms front, rear, left and
right refer to the position in which the item
concerned is installed in the truck, looking forward in the travel direction.
Approved applications Linde lift trucks are
designed for transporting and lifting the loads
stated in the load capacity diagram. In particular, we refer to the attached VDMA booklet
"Safety rules for industrial trucks" and accident prevention rules of your trade association
and the special measures required for driving
on public roads in accordance with the traffic
regulations. The safety rules for the use of
industrial trucks must be followed under all
circumstances by the responsible persons,
especially by the operator and service personnel. The user, and not Linde, is responsible
for any danger arising from applications not
authorised by the manufacturer. If you desire
to use the truck for applications not mentioned
in the manual and convert or supplement it for
this purpose, please first contact your authorised dealer. No changes, especially conversions or modifications, may be made on your
truck without the prior permission of the manufacturer. Only qualified persons authorised
by Linde are allowed to service the trucks. To
keep your warranty valid, keep a record of all
maintenance services.
Technical note These operating instructions
or excerpts thereof may only be copied, translated or transmitted to third parties after prior
Introduction 1
Technical description
1 Operating instructions
1 EC certificate of conformity (The manufacturer certifies that the industrial truck
conforms to EC guidelines for machines)
1 Safety rules for the use of industrial trucks
(VDMA)
Technical description
General
Series 318 empty container lift trucks allow the
transport and stacking of ISO type container
types up to 9.0 tonnes. The C90/5 can stack
empty containers up to 5 high, the C90/6 can
stack empty containers up to 6 high, the C90/7
can stack empty containers up to 7high and
the C90/8 can stack empty containers up to
8high at 1,295mm load centre.
Engine
A 6 cylinder, turbo charged, direct injection
diesel engine, providing 142 kW at 2300 rpm,
as a power unit, drives the truck hydraulic
pumps at load-dependent speed. The engine
is cooled by a closed-loop coolant circuit
with an expansion reservoir. The lubrication
system is a forced feed type lubrication with
the oil pump in the oil sump. A dry air filter with
a paper cartridge cleans the combustion air.
Diesel engines with state-of-the-art engine
technology are used for:
- high torque,
- low fuel consumption,
- low exhaust gas emissions,
- low soot emissions,
- low noise values.
Steering
The steering is a hydrostatic power system,
which operates the rear wheels with the
steering wheel via the steering cylinder. The
Brake system
The hydrostatic transmission is used proportionally as the service brake which provides
adequate braking performance under normal
operating conditions, therefore no brake servicing is required. The first 60% of brake pedal
movement actuates hydrostatic braking. Remaining pedal movement actuates the friction
brake system. When friction braking is being
applied the pedal effort is significantly higher
than for hydrostatic braking.
The disc brakes integrated in the axle are
utilised as the parking brake. When the
engine is stopped, the disc brakes are applied
automatically. When parking the truck, the
parking brake is applied by pulling the parking
brake handle.
Hydraulic system
The traction drive consists of a variable-displacement pump and two variable-displacement wheel motors installed as a unit in the
drive axle, and a variable displacement hydraulic pump for the working hydraulics and
power steering system. Travel direction and
speed are controlled by drive pedals via the
variable-displacement pump. The final drive
unit is supplied with oil from the variable-displacement pump, and is connected to the drive
wheel via a reduction gearbox.
1 Introduction
Technical description
Operation
The variable-displacement hydraulic pump
and engine speed are simultaneously controlled by one pedal each for forward and
reverse travel (twin-pedal control). With the
hydrostatic drive, truck speed can be controlled steplessly in both directions from zero
to maximum speed. The double-pedal control
permits easy, safe and quick operations of the
lift truck. Both hands are always free for steering and control of the mast operations. The
result is quick direction changes and efficient
stacking.
Another version allows control of the truck
speed with one accelerator pedal (singlepedal control) and the direction of travel with a
directional switch.
As standard, there is only one control lever
(joystick) for controlling the mast functions
lowering and tilting. Another joystick is
installed for the operation of sideshift and
forkspread functions.
Lift mast
The lift mast is equipped with two lift cylinders,
two tilt cylinders and chains mounted on each
side. Movement of the inner mast section
along the outer section is on heavy duty
bearings and sliding pads. The whole mast
assembly is mounted on two pivot pins to the
final drive unit casting.
Container spreader
The spreader is used to pick up empty containers. It is mounted directly on the outer upright
and it can handle ISO containers with a length
of 20 to 40 feet (6100 to 12200 mm) and a
height of 8 feet to 9 feet 6 inches (2438 to 2896
mm). The maximum container width can be
8 feet (2438 mm). The spreader is equipped
with two hydraulic cylinders for extending it to
the correct container length. When transporting empty containers two hydraulically operated twistlocks are engaged into the carrying
Electrical system
The electrical system is 24 volts direct current,
supplied by the alternator which is fitted with
a solid state rectifier and charge control
unit. Two 12 v 88AH heavy duty batteries
connected in series, are fitted.
Electronic/electrical installation
Linde Truck Control (LTC) The truck control
electronics allow:
- sensitive, smooth driving and reversing,
- automatic engine speed control to match the
hydraulic power requirements,
- fast service due to self-diagnostics,
- greatest possible operational reliability.
Driving cab
The driving cab frame forms the load guard;
it conforms to International safety standards
with cab glazing as an option.
Entry is on the left side of the truck. The large
opening window on the right can be used to
exit the cab in an emergency.
The cab and doors have large glazed areas
to allow the driver maximum visibility during
operations. Screen wiper and washers are
fitted to the front, top and rear screens with
screen demist functions as part of the cab
heater or climate control system.
An optional passenger seat can be fitted in the
left rear corner of the cab.
Introduction 1
Intended use
Truck takeover
Every container handler undergoes careful
inspection before leaving the factory in order
to make sure that it will be in satisfactory
condition and fully equipped as ordered
when delivered to the customer. Authorised
distributors are under obligation to reinspect
the truck before delivery and to hand it over in
good order.
In order to avoid later complaints and inconvenience to customers, you are requested to
ascertain that the truck is in satisfactory condition and fully equipped at the time of delivery
and to acknowledge orderly handing/taking
over of the truck in the manufacturers certificate of conformity.
Linde pursues a policy of continuous improvement in the design and manufacture of its
products. The illustrations and technical details referring to design, fittings and engineering of lift trucks are subject to change or modification as a result of technological progress
by Linde.
Linde is therefore unable to consider any
claims based on the specifications, illustrations and descriptions contained in this Operating Instructions manual.
Please submit all enquiries concerning Linde
container handling truck orders for spare parts
to your local Linde representative, making
sure to give the correct delivery address.
For repairs use only original Linde spare parts.
Only in this way can it be guaranteed that your
Linde truck maintains its original technical
standard.
These operating instructions or excerpts
thereof may only be copied, translated or
Engine number:
Mast / Boom number:
Mast lift:
Hydraulic pump number:
Drive pump number:
Drive motor number:
Spreader serial number:
Intended use
Linde trucks are designed for transporting and
stacking the loads stated in the load capacity
diagram. In particular;
1 Introduction
Commissioning
the special measures required for driving on
public roads in accordance with the C.U.R.,
other local regulations.
Symbols used
The precautions Danger, Warning, Caution,
Note und Environment Note in this manual
are provided to indicate special hazards
or unusual information requiring special
identification:
DANGER
indicates hazards that may result in personal injury
or death and/or substantial damage to the product.
WARNING
indicates hazards that may result in personal injury
and/or substantial damage to the product.
CAUTION
indicates hazards that may result in damage to or
destruction of the product.
NOTE
Commissioning
Check the engine oil level
The truck can be operated at full speed immediately. Avoid sustained high loads on
the working hydraulic system and transmission system in the first 50 hours of operation.
Re-tighten wheel nuts daily prior to starting
operation until they are seated firmly, i.e. until
no further tightening is possible.
2
Safety
2 Safety
Safety rules
Safety rules
Safety rules
WARNING
Exercise care when operating your machine in
wind velocities of 24 knots / 28 mph / 45 km h or
greater, handling characteristics may be affected,
specifically, high lifting and lowering operations.
Further information should be sought from the
manufacturer, or local statutory authorities.
!
WARNING
In case of tip-over
Follow these
Instructions
Stay
buckled up
Safety precautions
The precautions WARNING, CAUTION, ATTENTION and NOTE in this manual are provided to indicate special dangers or unusual
information requiring special identification:
DANGER
Indicates hazards that may result in personal injury
or death and/or substantial damage to the product
Don't jump
Hold on tight
Brace feet
lean away
WARNING
Indicates hazards that may result in personal injury
and/or substantial damage to the product
CAUTION
Indicates hazards that may result in damage to or
destruction of the product
Safety 2
Safety rules
CAUTION
CAUTION
This note is found on various
positions of the truck where special
attention is required. Read the
appropriate section of your operating
instructions.
The accident prevention rules in some countries prescribe that the forklift truck must be
checked at least once a year for proper working condition by trained personnel. Please
contact your authorised dealer in this regard.
Running-in Instructions
The truck can be operated at full speed immediately. Avoid sustained high loads on
the working hydraulic system and transmission system in the first 50 hours of operation.
Re-tighten wheel nuts daily prior to starting
operation until they are seated firmly, i.e. until
no further tightening is possible.
Tighten opposite wheel nuts to a torque of 680
Nm.
NOTE
Observe the tightening instructions on the tag
attached to the steering column.
2 Safety
Noise emission data
Daily checks*
NOTE
10
3
Overview
3 Overview
General view
General view
3
4
13
12
11
5
10
12
d3181001
Overview 3
General view
1
2
3
4
5
6
7
Lift mast
Lift chains
Hydraulic working system cover
Cab
Counterweight
Steer axle
Storage compartment
8
9
10
11
12
13
Battery compartment
Engine compartment
Drive axle
Tilt cylinders
Spreader attachment
Spreader twistlock
13
3 Overview
Type plates
Type plates
7
6
14
d3181002
Overview 3
Type plates
1
2
3
4
5
6
7
15
Typ
Type
Modele
14
10
Fabrik-Nr / Bj.
Serial no. / year
No.de serie / annee
..
Menn - Tragfahigk
Rated capacity
Capacite nominale
Batteriegew
Battery mass
Masse batterie
11
kg
kg
Leergew
Unladen mass
Masse a vide
Batt. - Sp
Batt. - volt
Tension batt
kg
12
V
13
d3591150
8
9
10
11
12
13
14
15
15
3 Overview
Composite instrument and light switches
Composite instrument and
light switches
The composite instrument (1) is clearly visible,
and located in the lower right-hand side of the
cabin. The composite instrument serves as a
warning and information display (12).
27
7
8
9
10
11
26
25
24
23
22
21
12
13
14
15
20
19
16
18
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
16
17
d3591006
Composite instrument
Hydraulic oil temperature warning light
Battery charge warning light
Engine oil pressure warning light
Electric controller malfunction light
Coolant temperature warning light
Overload warning light
Soot particulate filter warning* (* option)
Coolant level warning light
Hydraulic oil filter warning light
Fuel level indicator
Soot particulate filter symbol* (* option)
Hour meter
Hour meter run symbol
Clock
Service interval exceeded symbol
Function button
Reset button
Parking brake symbol
Do not start engine symbol
Service symbol
Mast position sensing symbol
Text field
Engine preheat indicator light
Air filter blocked warning light
Engine stop warning light (red)
Engine warning light (yellow)
Overview 3
Composite instrument and light switches
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
8
9
10
11
12
d3591007
Indicator element
Function
Illuminates in case of
malfunctions in the electrical
system.
17
3 Overview
Composite instrument and light switches
Engine oil pressure warning
light (4) (red)
Fuel level indicator (11) (either Shows the current fuel level.
green or red depending on fuel
level)
Soot particulate filter symbol*
(12)
18
Overview 3
Composite instrument and light switches
Hour meter (13)
NOTE
If a defective composite
instrument has to be replaced,
the elapsed operating hours
must be recorded. Affix
the information on durable
tape near the composite
instrument. It is also possible
to set the new instrument
to the actual elapsed
time. Please contact your
authorised dealer for this
service.
NOTE
If a defective composite
instrument has to be replaced,
the elapsed operating hours
must be recorded. Affix
the information on durable
tape near the composite
instrument. It is also possible
to set the new instrument
to the actually elapsed
time. Please contact your
authorised dealer for this
service.
Clock (15)
19
3 Overview
Composite instrument and light switches
Do not start engine symbol
(20)
20
NOTE
Leave ignition on until symbol
goes out (between 15 and 50
seconds depending upon oil
temperature). Then repeat the
start attempt.
Overview 3
Controls and indicators - single pedal cab
7
8
9
10
11
12
13
15
14
AUTO
ECON
OUT
d3181010
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
21
3 Overview
Controls and indicators - twin pedal cab
Controls and indicators - twin pedal cab
4
1
7
8
9
10
11
12
13
15
14
AUTO
ECON
OUT
d3181011
1
2
3
4
5
6
7
22
8
9
10
11
12
13
14
15
4
Operation
4 Operation
Beginning operation
Mirrors
CAUTION
Rear view mirrors should be cleaned and adjusted to suit the operator before commencement of
operation, and it should be noted that they are only
provided for checking the vicinity of the truck before moving off, and to monitor the rear traffic area.
Reversing is only allowed with a direct view in the
reverse direction of travel.
Beginning operation
Opening the cabin door from the outside
Pull handle (1) outwards.
d3591011
d3591012
24
Operation 4
Opening the right hand side window
Cab drivers door - closing
Depress switch (6). This will electrically
unlock the door open retainer.
d3591013
Lift handle up
3
Push window fully open and lock in position by
pushing handle down
To close the window, reverse actions (1 - 3).
d3591163
25
4 Operation
Emergency exit
To open the side window fully
Pull handle off retainers (1).
Push window open (2).
1
d3591164
Emergency exit
NOTE
26
1
d3591079
Operation 4
Cab interior light
d3591045
NOTE
1
2
d3591039
27
4 Operation
Hazard warning lights*, Turn indicators lights*, Horn
Hazard warning lights*, Turn
indicators lights*, Horn
To turn on the hazard lights*
1
2
3
4
5
6
7
8
9
10
11
12
d3181003
14
15
13
28
d3591054
Operation 4
Heater, Climate control
0-1
-2-
d3591148
29
4 Operation
Heater, Climate control
To operate the climate control
NOTE
1
2 3 4 5
AUTO
ECON
OUT
15
9 10 11 12
14
13
d3591057
Operating modes
Automatic mode. When automatic mode is
selected the system will independently control the cabin temperature by means of either
heating or cooling to within 1C of the display
Defog/demist mode. When defog/demist
mode is selected the system will independently control the cabin temperature while in
both heating and cooling mode.
NOTE
Operation 4
Heater, Climate control
Economy mode When economy mode is selected the ATC system will attempt to control
the cabin temperature by means of fresh air
and water valve and will not allow the air conditioning compressor to engage.
NOTE
31
4 Operation
Adjusting the drivers seat
(15) and either temperature up (13) or temperature down (14).
NOTE
Maximum driving comfort is obtained and vibrations are prevented if the seat is set to the
correct position of the driver.
Sit on the drivers seat.
d3591035
d3591036
Slide the seat forward or back until the desired position to the steering wheel, pedals
and control levers is obtained.
32
Operation 4
Optional equipment
Re-engage lever (3).
NOTE
Optional equipment
Adjusting the swivel seat
CAUTION
The drivers seat should not rotate while the truck is
being operated.
Ensure the swivel is locked before operating the
truck.
33
4 Operation
Operating the windscreen wipers*
To turn on the road lights*
Depress toggle switch (4) to the intermediate position to turn on the position lights and
license plate light*.
* option
1
2
3
4
5
6
7
8
9
10
11
12
d3181003
1
2
3
4
5
6
7
8
9
10
11
12
34
d3591007
Operation 4
Operating the windscreen wipers*
Move actuating lever (13) at the steering
wheel from the centre position downwards.
The front wiper operates intermittently.
Fully depress toggle switch (7).
14
15
13
d3591054
35
4 Operation
Control levers (joysticks)
Filling the windscreen washer
bottle
Open battery access door (1).
Open filler cap (2) top up if necessary.
d3181012
d3181006
Operation 4
Control levers (joysticks)
tilting is determined by how far the lever is
moved. The lever is designed to return to the
neutral position when released.
NOTE
37
4 Operation
Engine oil level check
Engine Access
Engine cover- opening
CAUTION
1
Insert key (1) into locks on the engine covers, and turn key anticlockwise to release.
Lift the engine cover.
d3181015
d3591025
38
Operation 4
Engine oil level check
NOTE
d3591162
2
d3591026
39
4 Operation
Checking the fuel
Checking the fuel
Checking the fuel
1
4
NOTE
d3591017
CAUTION
To prevent malfunctions in the fuel injection system
never operate the truck with an empty fuel tank.
Filling fuel
CAUTION
Stop the engine before filling fuel. No smoking or
naked lights when filling fuel. Do not spill fuel and
keep fuel away from hot parts. Follow the laws and
regulations regarding the handling of diesel fuel.
d3591028
40
Operation 4
Checking the coolant level in the reservoir
NOTE
When the indicator (1) in the composite instrument lights, the coolant level is too low and
coolant must be replenished.
Open cover (3), using key (2).
d3591024
d3591018
41
4 Operation
Battery access - opening
Tyres - check condition and
pressure
CAUTION
Low tyre inflation pressure reduces tyre service life
and the stability of the truck.
d3181013
d3591021
42
Operation 4
Fuses
d3591023
Fuses
The truck electrical circuits are protected by
fuses in the fuse box (1) located in the rear left
of the drivers cab.
WARNING
If fuses fail continuously, stop the truck, ground the
load and stop the engine.
Do not continue to operate with faulty electrical circuits. Danger of fire and severe damage to equipment.
NOTE
d3591059
NOTE
43
4 Operation
Fuses
44
Operation 4
Hydraulic system: oil level check
d3591016
d3181009
45
4 Operation
Starting the engine - double pedal models
Final drive oil level check
CAUTION
d3591034
NOTE
d3591037
46
Operation 4
Starting the engine - double pedal models
the zero position to position I. The electrical
system is turned on.
NOTE
13
12
11
10
7
9
8
d3591038
47
4 Operation
Driving - Double pedal models
The battery charge and engine oil pressure warning light symbols must extinguish
when the engine is running. Engine speed
is governed automatically, depending on
the load on the engine.
NOTE
CAUTION
Ensure that the cab door is secured in the open or
closed position before driving.
CAUTION
Rear view mirrors should be cleaned and adjusted to suit the operator before commencement of
operation, and it should be noted that they are only
provided for checking the vicinity of the truck before
moving off, and to monitor the rear traffic area.
Reversing is only allowed with a direct view in the
reverse direction of travel.
48
Operation 4
Driving - Double pedal models
CAUTION
Always look in the direction of travel and have an
adequate overview of the road ahead, including
to the sides when steering. When driving, ensure
that the road ahead is clear. If goods obstructing
vision are being transported, drive the truck with the
load trailing. If this is not possible, a second person shall walk in front of the truck as a guide. The
truck should then only be driven at walking speed
with particular caution being exercised. If visibility
aids are required (e.g. mirrors, camera/monitor),
to ensure adequate sight, then training should be
given for driving with these aids.
Reversing with a mirror for example, shall be exercised with particular care.
2
1
Forward travel
Ensure that the pedal area inside the cabin
is clear of obstruction and debris before
attempting to drive the truck.
Depress the right accelerator pedal (3) gently. Truck speed depends on how far the
pedal is depressed.
NOTE
d3591040
Reverse travel
Depress the left accelerator pedal (3). The
truck will reverse at a speed depending on the
position of the accelerator pedal.
49
4 Operation
Driving - Double pedal models
Depress the accelerator pedal for the opposite direction of travel. The truck will come
to rest before acceleration in the selected
direction.
During travel, keep both feet on the accelerator pedals in order to be able to control all
movements of the truck easily.
Stopping
Slowly release the depressed accelerator pedal. The hydrostatic travel drive will
act as service brake. If quicker stopping is
required depress the brake pedal (centre
pedal).
When stopping on gradients during upgrade
travel, leave both feet on the pedals and
equalise any drive slippage by depressing
the pedal slightly.
Or
Depress the brake pedal (4) for a long stop.
When dismounting from the truck with the
engine running, for example, in order to
briefly perform some action in close vicinity
to the truck (opening a gate, unhitching a
trailer, etc), always apply the parking brake
handle (1) and release the seat belt. Shut
down the engine and pull up the parking
brake handle (1) if making a longer stop.
When leaving the truck unattended, remove
the ignition key.
50
Operation 4
Starting the engine - Single pedal models
2
1
NOTE
2
1
d3591041
51
4 Operation
Starting the engine - Single pedal models
Insert ignition key (2) into the ignition switch
and turn it from the zero position to position
I.
The electrical system is turned on.
NOTE
13
12
11
10
7
9
8
d3591038
Operation 4
Driving - single pedals
to spare the battery. If the engine does not
start after the third attempt, refer to: Engine
Troubleshooting Guide.
The battery charge and engine oil pressure warning light symbols must extinguish
when the engine is running. Engine speed
is governed automatically, depending on
the load on the engine.
NOTE
d3591042
53
4 Operation
Driving - single pedals
Reverse travel
Pull directional control lever (4) back.
Depress accelerator pedal (5). Truck speed
depends on how far the pedal is depressed.
2
1
d3591041
Stopping
Slowly release the depressed accelerator pedal. The hydrostatic travel drive will
act as service brake. If quicker stopping is
required depress the brake pedal (centre
pedal).
When stopping on gradients during upgrade travel, equalise any drive slippage by
depressing accelerator pedal (5) slightly,
or
depress brake pedal (6) for a long stop
When dismounting from the truck with the
engine running, for example, in order to
briefly perform some action in close vicinity
to the truck (opening a gate, unhitching a
trailer, etc), always apply the parking brake
and release the seat belt. Shut down the
engine and pull up the parking brake if making a longer stop. When leaving the truck
unattended, remove the ignition key.
54
Operation 4
Malfunctions during operation
NOTE
d3591041
3 4
WARNING
If one of the following warning lights in the composite instrument illuminates and the buzzer sounds
during operation, the engine must be stopped immediately and the fault rectified. (see: Diesel Engine Troubleshooting Guide).
Do not operate the truck with any warning lights
illuminated.
11
6
9
7
8
d3591049
55
4 Operation
Malfunctions during operation
CAUTION
If warning light (4) flashes, there is a fault in the electric control. Depending on the adjustment and fault,
the truck can either only be driven slowly forward
or not at all. The fault in question is shown in the
text field (8) either as a number code or as symbols.
Please contact your authorised dealer.
CAUTION
If the indicator light (11) flashes, there is a malfunction in the engine or engine controller. Please
contact your authorised dealer.
NOTE
* option
10
d3591050
56
Operation 4
Steering
Steering
Start the engine and drive off.
Turn the steering wheel to the left and right
to full lock.
NOTE
d3591051
57
4 Operation
Braking system
Braking system
Service brake
Allow accelerator pedals (1) to return to
the neutral position. The hydrostatic drive
will act as a service brake. Braking can be
controlled from soft to hard braking with
sensitivity by releasing the accelerator pedals slowly or quickly.
CAUTION
For emergency braking depress brake pedal (2)
located between the accelerator pedals. The truck
will come to a full stop.
Brake pedal
CAUTION
d3591053
Because the hydrostatic transmission is used proportionally as the service brake, no brake servicing
is required. The first 60% of brake pedal movement
actuates the hydrostatic braking. Remaining pedal
movement (increased pressure will be felt on the
pedal), actuates the friction brake system. In unfavourable situations, the engine could stall following
a full stop using the friction brakes, in which case
about 30 seconds must elapse before the variable
pump of the power train returns to the zero position.
NOTE
Parking brake
The multiple disc brakes are used as a parking
brake.
To engage the parking brake:
Pull parking brake handle (3) up. The symbol
in the composite instrument illuminates.
To release the parking brake:
58
Operation 4
Installation of additional equipment
NOTE
CAUTION
1
2
3
4
5
6
7
8
9
10
11
12
d3591007
NOTE
59
4 Operation
Before lifting a load
Before lifting a load
Before lifting a load observe capacity diagram
(1) on the operators seat plinth.
WARNING
Exercise care when operating your machine in wind
velocities of 24 knots/28 mph or 45 km/ h or greater,
handling characteristics may be affected, specifically, high lifting and lowering operations. Further
information should be sought from the manufacturer, your authorised distributor, or local statutory
authorities.
Do not exceed figures stated in the capacity diagram.
d3591063
NOTE
Type plate
The maximum admissible weight of the container is given on the label located on the left
side of the spreader and on type plate (2).
WARNING
The values stated on the type plate and the handler
apply for standard containers and attached loads.
These values must not be exceeded as this will
reduce the stability of the truck and the strength of
the handler.
d3181040
60
Operation 4
Lifting a load
NOTE
d3181039
Lifting a load
WARNING
Do not stand under an elevated load.
d3181016
61
4 Operation
Lifting a load
NOTE
d3181028
NOTE
3 4 5
3
62
d3181037
Operation 4
Depositing the load
d3181018
Always travel with the load uphill on upgrades and down grades, never travel or
turn across a slope.
If visibility is reduced work with a guide.
Operate the truck in reverse if the load being
transported is stacked so high as to obstruct
forward vision.
NOTE
63
4 Operation
Depositing the load
Elevate the mast to the correct height.
Put the mast in the vertical position.
d3181020
d3181017
64
Operation 4
Trailer coupling
d3181007
Trailer coupling
NOTE
65
4 Operation
Locations for jacks when changing wheels
Locations for jacks when
changing wheels
CAUTION
Only use a jack with sufficient lifting capacity. The
capacity should be 25,000 kg minimum.
d3181029
CAUTION
The truck should only be jacked up at jacking points
(1&2). When jacking up the front of the truck, chock
the rear wheels. When working under the truck
secure the chassis with wooden blocks, do not rely
just on the jack.
2
d3181038
66
Operation 4
Wheel change
Wheel change
WARNING
Before removing a wheel on the steer or drive axle,
deflate the tyre to under 5 bar pressure.
Danger of damage or injury through wheel rims.
To remove a wheel
Drive axle outer wheels:
Remove wheel nuts (6) and lugs (5).
Release the outer wedge band (4) from
wheel (3) by striking the rim using a hammer
and drift.
Remove wheel.
56
d3181051
Wheel mounting
CAUTION
When a wheel has been removed and replaced, the
wheel nuts must be checked before use and daily
for two weeks.
67
4 Operation
Towing
Steer axle wheels:
Fit the wheel.
Fit the wheel lugs and nuts Tighten the nuts.
NOTE
Towing
If the truck must be towed:The hydraulic drive circuit must be short circuited with the bypass valve.
The multiple disc brakes in the drive axle can
be released by a diversion valve in the brake
valve and pressure applied by the steering
hand pump.
WARNING
The service friction brake can still be applied but will
not be re-released without further pumping with the
steering hand pump.
WARNING
The truck may only be towed with a rigid connection
(tow bar).
Only use a towing vehicle with sufficient tractive
and braking force for the un-braked trailing load.
Towing procedure
Ensure the truck cannot roll by either chocking
the wheels or connecting to the braked towing
vehicle with a rigid tow bar.
68
Operation 4
Towing
To bypass the hydrostatic transmission
Open the engine cover.
Loosen sealing collar nut (1) (19 mm) on top
of the drive pump.
Unscrew setscrew (2) (8 mm) 3 turns.
Lock setscrew (2) with sealing collar nut (1).
Tighten to 60 Nm.
2
d3591151
d3591152
After towing
Chock the wheels so that the truck cannot
roll.
Disconnect the rigid tow bar.
Operating Instructions 318 807 1001 EN 2008/10
69
4 Operation
Measures before taking the truck out of operation
Loosen sealing collar nut (1) (19 mm) on top
of the drive pump with a socket.
Tighten setscrew (2) (8 mm) to 20 Nm.
Lock setscrew (2) with sealing collar nut (1).
Tighten to 60 Nm.
The hydrostatic transmission is no longer bypassed.
CAUTION
Block up the truck so that all wheels are clear of the
ground. This will prevent tyre deformation.
NOTE
Operation 4
Putting the truck back into operation
NOTE
71
4 Operation
Putting the truck back into operation
72
5
Maintenance
5 Maintenance
General information
General information
Your truck will remain operational only if the
maintenance and checks are carried out
regularly and according to the information
and instructions in the operating manual.
This maintenance may only be performed
by qualified authorised personnel. This work
can be carried out by your authorised dealer
under a service contract.
If you wish to do the work yourself, we recommend that the first three customer service
checks be carried out by your distributors
mechanic in the presence of the responsible
mechanic in your workshop, so that your staff
can receive the appropriate instruction.
For all servicing, the truck must be placed
on a level surface and the wheels secured.
Stop the engine and remove the ignition key.
When working on the truck with the spreader
and mast elevated, secure them against
inadvertent lowering.
For work on the front end of the truck, secure
the mast against tilting back.
CAUTION
No changes, particularly no modifications and
additions, may be made to the truck without the
approval of the manufacturer.
74
CAUTION
Missing or damaged plates and/or adhesives must
be replaced. For location and or part number refer
to the Parts Catalogue.
Maintenance intervals
NOTE
Maintenance 5
Work on the mast and the front part of the truck
75
5 Maintenance
As required Service plan
As required Service plan
At operating hours
As
required
Carried
out
9
General
Clean the truck (if necessary)
Check the seat belt
Check and adjust mirrors
Check washer bottle level
Read out error log and delete
Enter the next maintenance interval
Engine
Check the air filter
Renew the safety element
Clean the fuel filter
Clean the radiator and check for leaks
Chassis, bodywork and fittings
Clean the truck
Check the seat belt
Steering and wheels
Check the wheel nuts for tightness
Check tyre pressure
Check tyres for damage and foreign objects
Hydraulics
Check hydraulic oil level
76
Maintenance 5
50 h Service plan
50 h Service plan
At operating hours
50h
Carried
out
9
General
Clean the truck (if necessary)
Check the seat belt
Check and adjust mirrors
Read out error log and delete
Enter the next maintenance interval
Engine
Change engine oil
Change engine oil filter
Change the fuel filter
Check engine mounting for security
Clean the radiator and check for leaks
Examine intake and exhaust pipes for tightness
Chassis, bodywork and fittings
Check cab mountings
Lubricate cab door hinges
Steering and wheels
Check the wheel nuts for tightness
Check tyre pressure
Check tyres for damage and foreign objects
Clean and lubricate steering axle
Check mounting of steering axle
Check mounting of steering cylinder and steering axle swivel pins
Controls
Check parking brake
Electrical equipment
Check the battery condition
Check the electrical system
Hydraulics
Operating Instructions 318 807 1001 EN 2008/10
77
5 Maintenance
50 h Service plan
Carried
out
At operating hours
50h
Check the hydraulic system, drive motors, pumps, valves and lines for leaks
Check the pre-tension of double hoses
Load lift system
Check mounting of mast
Lubricate mast and tilt cylinder bearings
Check and confirm mast and attachment adjusting and retaining screws remain tight
Mast and lift chains: check condition and mounting
Mast chain: adjust length and lubricate with chain spray
Subsequent tasks
Attach maintenance sticker
78
Maintenance 5
500 h Service plan
1500
2500
4500
5000
5500
3500
4000
Carried
out
9
General
Clean the truck (if necessary)
Check the seat belt
Check and adjust mirrors
Read out error log and delete
Enter the next maintenance interval
Engine
Change engine oil
Change engine oil filter
Change the fuel filter
Check condition of V-ribbed belt
Check the coolant concentration
Chassis
Check cab mountings
Check the condition of the overhead guard frame
Steering and wheels
Check the condition of the steer axle
Check the security of the axle clamp and drive motors
Controls
Check the parking brake for proper operation
Hydraulics
Hydraulic system: Check the oil level.
Check the hydraulic tank breather filter
Check the hydraulic system, drive motors, pumps, valves and lines for leaks
Mast assembly and auxiliary hydraulics
Check the condition of the tilt cylinders
Lubricate the spreader
79
5 Maintenance
500 h Service plan
At operating hours
500
1500
2500
4500
5000
5500
3500
4000
Carried
out
9
Subsequent tasks
Attach maintenance sticker
80
Maintenance 5
1000 h Service plan
At operating hours
1000
4000
General
Clean the truck (if necessary)
Check the seat belt
Check and adjust mirrors
Read out error log and delete
Enter the next maintenance interval
Engine
Change engine oil
Change engine oil filter
Change the fuel filter
Check condition of V-ribbed belt
Check condition and tension of drive belt
Check the coolant concentration
Check the engine mounting
Renew the air filter element
Check the vacuum switch
Check the intake and exhaust pipes for leaks
Check the cooling fan belt tensioner
Chassis
Check cab mountings
Check the condition of the overhead guard frame
Check and lubricate all pivots and joints
Steering and wheels
Check and lubricate the steer axle
Check the condition of the steer axle
Check the security of the axle clamp and drive motors
Controls
Check the parking brake for proper operation
Electrical equipment
Operating Instructions 318 807 1001 EN 2008/10
81
5 Maintenance
1000 h Service plan
Carried
out
At operating hours
1000
4000
Check electric cables, cable connectors and connections for condition and tightness
Check the batteries
Hydraulic equipment
Hydraulic system: Check the oil level.
Check the hydraulic tank breather filter
Check the hydraulic system, drive motors, pumps, valves and lines for leaks
Clean the radiator and hydraulic oil cooler
Check the tension of double hoses
Final drive oil level check
Mast assembly and auxiliary hydraulics
Check the condition of the tilt cylinders
Clean and lubricate the mast and tilt cylinder pivots
Check the mast roller bearings
Lubricate the spreader
Check and lubricate the slider pads on the spreader carriage and end beams
Check and adjust the lift chain length, lubricate with chain spray
Optional equipment
Check the soot filter system (part 1)
Subsequent tasks
Attach maintenance sticker
82
Maintenance 5
2000 h Service plan
At operating hours
2000
4000
General
Clean the truck (if necessary)
Check the seat belt
Check and adjust mirrors
Read out error log and delete
Enter the next maintenance interval
Engine
Check the engine mounting
Renew the air filter element
Check the vacuum switch
Check the intake and exhaust pipes for leaks
Check the cooling fan belt tensioner
Renew the engine coolant
Check the starter motor, alternator and injection pump
Check the vibration damper
Chassis
Check and lubricate all pivots and joints
Check the condition of structural components
Steering and wheels
Check and lubricate the steer axle
Renew final drive hub oil
Check and adjust hub bearings
Controls
Check the parking brake for proper operation
Electrical equipment
Check electric cables, cable connectors and connections for condition and tightness
Check the batteries
Hydraulic equipment
Clean the radiator and hydraulic oil cooler
Operating Instructions 318 807 1001 EN 2008/10
83
5 Maintenance
2000 h Service plan
Carried
out
At operating hours
2000
4000
84
Maintenance 5
3000 h Service plan
Carried
out
9
General
Clean the truck (if necessary)
Check the seat belt
Check and adjust mirrors
Read out error log and delete
Enter the next maintenance interval
Engine
Check the engine mounting
Renew the air filter element
Check the vacuum switch
Check the intake and exhaust pipes for leaks
Check the cooling fan belt tensioner
Renew the engine coolant
Check the starter motor, alternator and injection pump
Check the vibration damper
Renew the toothed belt and idler pulley
Chassis
Check and lubricate all pivots and joints
Check the condition of structural components
Steering and wheels
Check and lubricate the steer axle
Renew final drive hub oil
Check and adjust hub bearings
Controls
Check the parking brake for proper operation
Electrical equipment
Check electric cables, cable connectors and connections for condition and tightness
Check the batteries
Hydraulic equipment
Operating Instructions 318 807 1001 EN 2008/10
85
5 Maintenance
3000 h Service plan
Carried
out
At operating hours
3000
86
Maintenance 5
5000 h Service plan
Carried
out
9
General
Clean the truck (if necessary)
Check the seat belt
Check and adjust mirrors
Read out error log and delete
Enter the next maintenance interval
Engine
Check the engine mounting
Renew the air filter element
Check the vacuum switch
Check the intake and exhaust pipes for leaks
Check the cooling fan belt tensioner
Renew the engine coolant
Check the starter motor, alternator and injection pump
Check the vibration damper
Renew the toothed belt and idler pulley
Chassis
Check and lubricate all pivots and joints
Check the condition of structural components
Steering and wheels
Check and lubricate the steer axle
Renew final drive hub oil
Check and adjust hub bearings
Controls
Check the parking brake for proper operation
Electrical equipment
Check electric cables, cable connectors and connections for condition and tightness
Check the batteries
Hydraulic equipment
Operating Instructions 318 807 1001 EN 2008/10
87
5 Maintenance
5000 h Service plan
Carried
out
At operating hours
5000
88
Maintenance 5
6000 h Service plan
Carried
out
9
General
Clean the truck (if necessary)
Check the seat belt
Check and adjust mirrors
Read out error log and delete
Enter the next maintenance interval
Engine
Check the engine mounting
Renew the air filter element
Check the vacuum switch
Check the intake and exhaust pipes for leaks
Check the cooling fan belt tensioner
Renew the engine coolant
Check the starter motor, alternator and injection pump
Check the vibration damper
Renew the toothed belt and idler pulley
Chassis
Check and lubricate all pivots and joints
Check the condition of structural components
Steering and wheels
Check and lubricate the steer axle
Renew final drive hub oil
Check and adjust hub bearings
Controls
Check the parking brake for proper operation
Electrical equipment
Check electric cables, cable connectors and connections for condition and tightness
Check the batteries
Hydraulics
Operating Instructions 318 807 1001 EN 2008/10
89
5 Maintenance
Inspection and maintenance data
Carried
out
At operating hours
6000
1 Engine
Engine oil
approx. 15 lts
2 Fuel tank
Diesel
3 Cooling system
Antifreeze / water
approx. 20 lts
4 Hydraulic system
Hydraulic oil
5 Battery
Maintenance free
Maintenance free
6 Tyres
Air
10 bar
7 Wheel fasteners
8
90
680 Nm
Linde chain spray
As required
Maintenance 5
Inspection and maintenance as required
d3591083
CAUTION
A dirty filter element decreases engine performance.
Regular filter servicing is essential for the engine.
d3181042
91
5 Maintenance
Inspection and maintenance as required
Renew the safety element
The safety element (3) must be changed:
3
1
4
CAUTION
5
d3181043
2
2
d3591087
Maintenance 5
Inspection and maintenance as required
CAUTION
When closing drain valve (2), do not over tighten.
Overtightening can damage the threads.
NOTE
d3591093
To prevent accidents, check that all adjustments are properly engaged before operating
the truck.
Do not operate the seat adjusting devices
while operating the truck.
93
5 Maintenance
Inspection and maintenance as required
Seat belts must be applied before operation of
the truck.
After an accident, the seat belt must be renewed. In the case of seat belts attached to
the operator seat, the seat and mounting of
the seat must also be inspected by qualified
personnel.
Nuts and bolts should be checked regularly
for tightness. An unstable seat can indicate
loose bolts or other faults. If malfunctions in
the operation of the seat are detected (eg seat
cushioning), contact your authorised dealer
immediately to eliminate the cause.
If the seat belt is not checked, you put your
health in danger and there is a higher risk of
accidents.
94
Maintenance 5
Inspection and maintenance as required
CAUTION
Protect all electrical components and the air filter
intake from the ingress of steam, water etc., when
cleaning.
Protective clothing and eye protection must be
worn.
Clean the cabin floor and ensure that no debris is allowed to obstruct the operation of the
pedals.
Clean especially the oil filler areas and the
lubrication points prior to servicing.
When cleaning with compressed air, remove
sticking dirt with a cold cleaner.
When cleaning the truck with de-greasing
solutions, allow sufficient time for the cleaner
to soak in, then flush off with a strong water jet.
After cleaning the engine, allow it to run warm
to dry off and to ensure there are no malfunctions due to water ingress.
95
5 Maintenance
Inspection and maintenance as required
Clean and spray the lifting chains
NOTE
d3181025
NOTE
96
Maintenance 5
Inspection and maintenance as required
d3181029
2
d3181013
97
5 Maintenance
Inspection and maintenance as required
Clean the radiator and oil cooler,
check for leaks
CAUTION
NOTE
1
d3181014
98
Maintenance 5
Inspection and maintenance as required
d3591168
99
5 Maintenance
Inspection and maintenance as required
100
Maintenance 5
Inspection and maintenance after the first 50 hours
CAUTION
Protect all electrical components and the air filter
intake from the ingress of steam, water etc., when
cleaning.
Protective clothing and eye protection must be
worn.
Clean the cabin floor and ensure that no debris is allowed to obstruct the operation of the
pedals.
Clean especially the oil filler areas and the
lubrication points prior to servicing.
When cleaning with compressed air, remove
sticking dirt with a cold cleaner.
When cleaning the truck with de-greasing
solutions, allow sufficient time for the cleaner
to soak in, then flush off with a strong water jet.
After cleaning the engine, allow it to run warm
to dry off and to ensure there are no malfunctions due to water ingress.
101
5 Maintenance
Inspection and maintenance after the first 50 hours
Clean and spray the lifting chains
NOTE
d3181025
NOTE
102
Maintenance 5
Inspection and maintenance after the first 50 hours
NOTE
d3591093
To prevent accidents, check that all adjustments are properly engaged before operating
the truck.
Do not operate the seat adjusting devices
while operating the truck.
Seat belts must be applied before operation of
the truck.
After an accident, the seat belt must be renewed. In the case of seat belts attached to
the operator seat, the seat and mounting of
the seat must also be inspected by qualified
personnel.
Nuts and bolts should be checked regularly
for tightness. An unstable seat can indicate
Operating Instructions 318 807 1001 EN 2008/10
103
5 Maintenance
Inspection and maintenance after the first 50 hours
loose bolts or other faults. If malfunctions in
the operation of the seat are detected (eg seat
cushioning), contact your authorised dealer
immediately to eliminate the cause.
If the seat belt is not checked, you put your
health in danger and there is a higher risk of
accidents.
Mirrors
CAUTION
Rear view mirrors should be cleaned and adjusted to suit the operator before commencement of
operation, and it should be noted that they are only
provided for checking the vicinity of the truck before moving off, and to monitor the rear traffic area.
Reversing is only allowed with a direct view in the
reverse direction of travel.
104
Maintenance 5
Inspection and maintenance after the first 50 hours
CAUTION
Please observe lubricant recommendations. (Different types of oil/different maintenance intervals.)
3181044
DANGER
Risk of scalding when draining hot engine oil.
Wear protective clothing.
NOTE
2
3
d3591170
105
5 Maintenance
Inspection and maintenance after the first 50 hours
Renew the engine oil filter
DANGER
Risk of scalding when draining hot engine oil.
d3591096
d3591097
106
Maintenance 5
Inspection and maintenance after the first 50 hours
Top up the engine oil
Remove cap (1) on the filler opening.
Fill new engine oil as specified in the lubricant recommendations through the filler
opening.
Filling capacity with filter renewal: max. 17.5 L
After refilling, check the engine oil level with
the dipstick and add oil to the maximum
mark, if necessary.
Install and tighten engine oil cap (1).
3181044
107
5 Maintenance
Inspection and maintenance after the first 50 hours
Change the fuel pre-filter with water
monitor
1
2
1
d3591100
2
1
4
CAUTION
Do not clean or reuse the safety element.
5
6
d3181043
108
Maintenance 5
Inspection and maintenance after the first 50 hours
The dust ejection valve (6) must point downward.
Close the access door.
NOTE
109
5 Maintenance
Inspection and maintenance after the first 50 hours
Clean the radiator and oil cooler,
check for leaks
CAUTION
NOTE
1
d3181014
110
Maintenance 5
Inspection and maintenance after the first 50 hours
d3181033
CAUTION
Ensure the exhaust system is cool before servicing.
d3181032
111
5 Maintenance
Inspection and maintenance after the first 50 hours
Check the cab mountings
1
d3181030
2
d3181013
112
Maintenance 5
Inspection and maintenance after the first 50 hours
2
d3181013
NOTE
2
1
d3591107
113
5 Maintenance
Inspection and maintenance after the first 50 hours
Check the parking brake for proper
operation
Drive the lift truck with the maximum load
onto a 15 % slope.
Pull parking brake handle (1) up. The truck
should not move.
Release parking brake handle (1).
Stop the engine. The lift truck should not
move.
NOTE
d3591118
d3181027
114
Maintenance 5
Inspection and maintenance after the first 50 hours
d3181053
Take the weight off each pivot pin in turn using a suitable jack to ensure the optimum ingress of grease.
NOTE
d3181031
115
5 Maintenance
Inspection and maintenance after the first 50 hours
Lubricate the tilt cylinder pivots
NOTE
2
d3591109
d3591115
116
Maintenance 5
Inspection and maintenance after the first 50 hours
NOTE
117
5 Maintenance
Inspection and maintenance every 500 hours or 6 months whichever comes first
Inspection and maintenance every 500 hours or 6 months
whichever comes first
Change the engine oil (every 12
months minimum)
CAUTION
Please observe lubricant recommendations. (Different types of oil/different maintenance intervals.)
3181044
DANGER
Risk of scalding when draining hot engine oil.
Wear protective clothing.
NOTE
2
3
d3591170
118
Maintenance 5
Inspection and maintenance every 500 hours or 6 months whichever comes first
Renew the engine oil filter
DANGER
Risk of scalding when draining hot engine oil.
d3591096
d3591097
119
5 Maintenance
Inspection and maintenance every 500 hours or 6 months whichever comes first
Top up the engine oil
Remove cap (1) on the filler opening.
Fill new engine oil as specified in the lubricant recommendations through the filler
opening.
Filling capacity with filter renewal: max. 17.5 L
After refilling, check the engine oil level with
the dipstick and add oil to the maximum
mark, if necessary.
Install and tighten engine oil cap (1).
3181044
CAUTION
Risk of scalding.
Do not open the reservoir cap when the engine is
hot.
CAUTION
Follow the precautions for handling fuels and lubricants.
CAUTION
Too much antifreeze or use of high silicate antifreeze can cause damage to the engine.
d3591169
120
Maintenance 5
Inspection and maintenance every 500 hours or 6 months whichever comes first
2
1
d3591100
d3591156
121
5 Maintenance
Inspection and maintenance every 500 hours or 6 months whichever comes first
Check the condition of the drive belt
CAUTION
Stop the engine and remove the ignition key.
d3591157
d3181030
Maintenance 5
Inspection and maintenance every 500 hours or 6 months whichever comes first
Adjust the brake pedal floor plate screw
stops, to allow correct operation of the micro
switch.
Start the engine, and test the handbrake,
switch off the engine.
Start the engine, test the footbrake, switch
of the engine
NOTE
1
d3591102
123
5 Maintenance
Inspection and maintenance every 500 hours or 6 months whichever comes first
Check the hydraulic tank breather
filter
NOTE
The truck should be at normal operating temperature, and the oil level should be correct.
Raise and lower the mast twice in quick succession before performing this check.
d3181026
5
2
2
3
d3181045
NOTE
124
Maintenance 5
Inspection and maintenance every 500 hours or 6 months whichever comes first
Position 1 - Twistlocks
Apply grease at points (A) & (B).
A
d3181046
d3181052
125
5 Maintenance
Inspection and maintenance every 500 hours or 6 months whichever comes first
Position 2 - End beam slider pads
NOTE
No greasing is necessary.
Check the condition of slider pads.
CAUTION
Do not allow metal to metal contact.
d3181047
d3181048
d3181049
126
Maintenance 5
Inspection and maintenance every 500 hours or 6 months whichever comes first
Position 5 - Side shift slider pads
NOTE
No greasing is necessary.
Check the condition of slider pads.
CAUTION
Do not allow metal to metal contact.
d3181050
127
5 Maintenance
Inspection and maintenance every 1000 hours or 12 months, whichever comes first
Inspection and maintenance every 1000 hours or 12 months,
whichever comes first
Clean the radiator and hydraulic oil cooler
NOTE
NOTE
128
Maintenance 5
Inspection and maintenance every 1000 hours or 12 months, whichever comes first
d3181033
129
5 Maintenance
Inspection and maintenance every 1000 hours or 12 months, whichever comes first
CAUTION
Ensure the exhaust system is cool before servicing.
d3181032
130
Maintenance 5
Inspection and maintenance every 1000 hours or 12 months, whichever comes first
d3591153
d3591154
131
5 Maintenance
Inspection and maintenance every 1000 hours or 12 months, whichever comes first
Inspect the tensioner for evidence of the
pivoting tensioner arm contacting the stationary circular base. If there is evidence
of these two areas touching, the pivot tube
bushing has failed and the tensioner must
be replaced.
The worn tensioner that has play in it or
a belt that walks off its pulley possibly
indicates pulley misalignment.
NOTE
d3591155
NOTE
5
6
d3181043
132
Maintenance 5
Inspection and maintenance every 1000 hours or 12 months, whichever comes first
NOTE
2
1
d3591107
d3591034
133
5 Maintenance
Inspection and maintenance every 1000 hours or 12 months, whichever comes first
Check the parking brake for proper
operation
Drive the lift truck with the maximum load
onto a 15 % slope.
Pull parking brake handle (1) up. The truck
should not move.
Release parking brake handle (1).
Stop the engine. The lift truck should not
move.
NOTE
d3591118
d3181027
134
Maintenance 5
Inspection and maintenance every 1000 hours or 12 months, whichever comes first
d3181053
Take the weight off each pivot pin in turn using a suitable jack to ensure the optimum ingress of grease.
NOTE
d3181031
135
5 Maintenance
Inspection and maintenance every 1000 hours or 12 months, whichever comes first
Lubricate the tilt cylinder pivots
NOTE
2
d3591109
d3591115
136
Maintenance 5
Inspection and maintenance every 1000 hours or 12 months, whichever comes first
NOTE
137
5 Maintenance
Inspection and maintenance every 2000 hours or 24 months, whichever comes first
Inspection and maintenance every 2000 hours or 24 months,
whichever comes first
Renew engine coolant
CAUTION
Follow the precautions for fluids and lubricants.
CAUTION
Danger of scalds and burns.
Do not remove the radiator cap or drain plugs when
the radiator is hot or with the engine running.
CAUTION
Work on the truck on level ground. Centre and
lower the carriage, stop the engine and put the parking brake on when working.
d3591124
2
3
d3591170
138
Maintenance 5
Inspection and maintenance every 2000 hours or 24 months, whichever comes first
d3591142
139
5 Maintenance
Inspection and maintenance every 2000 hours or 24 months, whichever comes first
Check valve clearances
CAUTION
Lower the carriage, stop the engine and put the
parking brake on when working.
CAUTION
Engine and radiator may be at operating temperature. Danger of scalds and burns.
NOTE
The clearance is correct when some resistance is felt when the feeler gauge (1) is
slipped between the valve stem and the rocker
lever.
Intake clearance: 0.254 ...... 0.010
Exhaust clearance: 0.508 ...... 0.020
Set only valves ( indicated E = exhaust, I
= intake). Do not set valves that are not
indicated.
1
d3591134
140
Maintenance 5
Inspection and maintenance every 2000 hours or 24 months, whichever comes first
Holding the locknut steady with the wrench,
adjust the valve clearance with the screwdriver or Allen wrench. Tighten the locknut,
and measure the valve lash again.
Torque Value: 24 Nm (18 ft-lb)
Mark the pulley, and rotate the crankshaft
360 degrees.
EX
IN
EX
IN
EX
IN
EX
IN
EX
IN
EX
IN
d3591136
2
1
4
CAUTION
Do not clean or reuse the safety element.
5
6
d3181043
141
5 Maintenance
Inspection and maintenance every 2000 hours or 24 months, whichever comes first
NOTE
Checks - various
Check the starter motor, alternator and
injection pump
NOTE
CAUTION
This maintenance procedure requires to be carried
out at heights of more than 2 metres. Use suitable
access equipment. Danger of fall injuries.
142
Maintenance 5
Inspection and maintenance every 2000 hours or 24 months, whichever comes first
CAUTION
Work on the truck on level ground. Lower the carriage, stop the engine and put the parking brake on
when working.
d3591138
Fit filler plug (1) and drain plug (2) with new
seal rings.
Fit plugs (1) and (2).
2
d3591034
143
5 Maintenance
Inspection and maintenance every 2000 hours or 24 months, whichever comes first
Renew the main hydraulic system oil
return line filters
CAUTION
Danger of burns.
Follow the procedure for handling fluids and lubricants. The oil tank, filter and hydraulic oil may be at
operating temperature.
WARNING
The hydraulic tank accumulates stored pressure,
take care when removing the filler cap.
d3591123
144
Maintenance 5
Inspection and maintenance every 2000 hours or 24 months, whichever comes first
NOTE
2
d3591137
145
5 Maintenance
Inspection and maintenance every 2000 hours or 24 months, whichever comes first
146
Maintenance 5
Inspection and maintenance every 5000 hours
147
5 Maintenance
Inspection and maintenance every 5000 hours
148
Maintenance 5
Inspection and maintenance every 6000 hours
CAUTION
Hydraulic oil and oil tank may be at operating
temperature. Danger of scalds and burns.
CAUTION
NOTE
Renewing the lift chains (at least every 3 years and when 3% stretch has been
attained)
NOTE
149
5 Maintenance
Inspection and maintenance every 6000 hours
150
Maintenance 5
Rated capacities
Rated capacities
Filling capacity/rated values
No.
Assembly
Filling capacity/Rated
values
Engine
Engine oil
approx. 15 lts.
Fuel tank
Diesel
Cooling system
approx. 20 lts.
Hydraulic oil
approx.330 lts.
Gear oil
approx. 4 lts.
Lubricating grease
as required
Batteries
as required
Tyres
Air
10 bar
10
Lubricating grease
as required
11
Temperature switch
Oil
12
Valve clearances
13
Diesel
14
Belt deflection
approx. 10 mm
680 Nm
Inlet 0.254 mm
Exhaust 0.508 mm
151
5 Maintenance
Fuel and oil recommendations
Fuel and oil recommendations
Fuel and oil recommendations
Engine oil grades for H 100 / H 120 / H
140 / H 150 / H160 / H180
CAUTION
Used oil must be kept out of the reach of children
until disposed of in accordance with laws and
regulations.
Do not allow oil to get into the sewage system or
seep into the ground.
Viscosity of oil
d3591144
152
Maintenance 5
Fuel and oil recommendations
Too viscous oils lead to engine starting
problems. Therefore ambient temperatures
during engine starting determine the grade
of oil used in winter. Seasonal oil changes
can be avoided by using multigrade oils. The
specified oil change intervals also apply to
multigrade oils.
NOTE
Since the temperature changes of neighbouring SAE classifications overlap, the oil
does not need to be changed when short-term
changes in temperature occur.
NOTE
Shell Donax TX
Lubricating grease
Linde heavy duty grease with additives EP and
MOS2. Designation acc. to DIN 51825-KPF
2K-20 (see the Parts Catalogue for the order
number). Any mixing with grease types other
than lithium-based greases is not allowed.
Coolant
Only use coolants with a monoethylene glycol
base and containing a rust inhibitor. Do not
mix with antifreeze containing ethanolamine.
Hydraulic oil
Temperature Antifreeze
Water
-30 C
45 %
55 %
-35 C
50 %
50 %
Factory fill
50 %
50 %
Battery grease
Non-acidic grease (pole grease).
Chain spray
Linde chain spray (see the Parts Catalogue for
the order number).
153
5 Maintenance
Diesel fuel
Electrical contact grease
For use on all electrical connections.
Linde Part number: 7339500020
Diesel fuel
Diesel fuel
To get the correct power and performance
from your engine, use good quality fuel. The
recommended fuel specification is indicated
below:
Cetane number indicates ignition performance. A fuel with a low cetane number can
cause cold start problems and affect combustion
Viscosity is the resistance to flow and engine
performance can be affected if it is outside the
limits.
Density: A lower density reduces engine
power, a higher density increases engine
power and exhaust smoke.
Percentage of
sulphur in the fuel
(%)
<0.5
Normal
0.5 - 1.0
0.75 of normal
>1.0
0.5 of normal
154
Maintenance 5
Troubleshooting
Troubleshooting
Troubleshooting guide (Diesel engine)
Trouble
Possible cause
Correction
155
5 Maintenance
Troubleshooting
Engine running unevenly Fuel supply insufficient.
with poor performance
Restriction or air in fuel
system due to paraffin
deposits in winter.
Excessive exhaust
smoke
Engine overheating,
red warning light in
composite instrument
illuminated. Stop the
engine immediately.
156
Maintenance 5
Troubleshooting
Discharge indicator
light illuminated during
operation
157
5 Maintenance
Troubleshooting
158
Maintenance 5
Troubleshooting
No or too low
pressure in system
Oil pressure
fluctuating
Valves restricted.
159
Maintenance
Hydraulic oil
temperature too high
160
Index
g
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81
83
85
79
87
89
A
Accident prevention check . . . . . . . . . . . . 9
Adjusting the drivers seat . . . . . . . . . . . . 32
Adjusting the swivel seat . . . . . . . . . . . . 33
B
Battery access - closing . . . . . . . . . . . . . 42
Battery access - opening . . . . . . . . . . . . 42
Before leaving the truck unattended . . . . 65
Before lifting a load . . . . . . . . . . . . . . . . . 60
Beginning operation . . . . . . . . . . . . . . . . 24
Brake control mechanism . . . . . . . . . . . 122
Brake pedal . . . . . . . . . . . . . . . . . . . . . . 58
Braking system . . . . . . . . . . . . . . . . . . . 58
C
Cab interior light . . . . . . . . . . . . . . . . . . . 27
Change final drive hub oil . . . . . . . . . . . 143
Change the engine oil (every 12
months minimum) . . . . . . . 105, 118
Change the fuel pre-filter with water
monitor . . . . . . . . . . . . . . . 108, 121
Changing the travel direction . . . . . . . . . 49
Check and adjust mast chains, lubricate with chain spray . . . . . 116, 136
Check and adjust the hub bearings . . . . 142
Check and lubricate other pivots and
joints . . . . . . . . . . . . . . . . . . . . . 128
Check condition and mounting of mast
and lifting chain . . . . . . . . . . . . . 142
Check coolant strength . . . . . . . . . . . . . 120
Check electric cables, cable connectors and connections for condition and tightness . . . . . . . . . . . . 128
161
Index
g
Composite instrument and light
switches . . . . . . . . . . . . .
Control levers (joysticks) . . . . . .
Controls and indicators . . . . . . . .
Cummins engine electrical circuit
drawing . . . . . . . . . . . . . .
Cummins fault code list . . . . . . . .
. . . . . . 16
. . . . . . 36
. . . 21 22
. . . . . 176
. . . . . 178
D
Daily checks* . . . . . . . . . . . . . . . . . . . . . 10
Danger notices
Graduation . . . . . . . . . . . . . . . . . . . . . 6
Depositing the load . . . . . . . . . . . . . . . . 63
Diesel fuel . . . . . . . . . . . . . . . . . . . . . . 154
Drain the engine oil . . . . . . . . . . . 105, 118
Driving - double pedal models . . . . . . . . . 48
Driving - single pedals . . . . . . . . . . . . . . 53
E
Electrical Circuit . . . . .
Elme electrical circuit .
Elme hydraulic circuit .
Emergency exit . . . . .
Engine Access . . . . . .
Engine cover - closing
Engine cover - open . .
Engine oil level check .
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181
191
193
. 26
. 38
. 38
. 38
. 38
F
Filling capacity/rated values . . . . . .
Filling fuel . . . . . . . . . . . . . . . . . . .
Filling the windscreen washer bottle
Final drive oil level check . . . . . . . .
First 50 h . . . . . . . . . . . . . . . . . . . .
Forward travel . . . . . . . . . . . . . . . .
Frequency characteristic for human
body vibrations . . . . . . . . . . .
Fuel and oil recommendations . . . .
Fuses . . . . . . . . . . . . . . . . . . . . . .
. . . 151
. . . . 40
. . . . 36
46, 133
. . . . 77
. . . . 49
. . . . 10
. . . 152
. . . . 43
General view . . . . . . . . . . . . . . . . . . . . . 12
H
Handling Fuel, Lubricants and Coolant . . . 9
Hazard warning lights*, Turn indicators
lights*, Horn . . . . . . . . . . . . . . . . . 28
Heater, Climate control . . . . . . . . . . . . . . 29
Hydraulic system: oil level check . . . 45, 99
I
Inspection and maintenance data . . . . . . 90
Installation of additional equipment . . . . . 59
Isolating the battery . . . . . . . . . . . . . . . . 43
L
Lifting a load . . . . . . . . . . . . . . . . . . . . . 61
Locations for jacks when changing
wheels . . . . . . . . . . . . . . . . . . . . . 66
Lubricate the mast and tilt cylinder
pivots . . . . . . . . . . . . . . . . . 115, 135
Lubricate the spreader . . . . . . . . . . . . . 124
M
Malfunctions during operation . . . . . . . . . 55
Mast and load lifting device removal . . . . 71
Measures before taking the truck out of
operation . . . . . . . . . . . . . . . . . . . 70
Mirrors . . . . . . . . . . . . . . . . . . . . . . 24, 104
N
Noise emission data . . . . . . . . . . . . . . . . 10
O
Opening the right hand side window . . .
Operating the sideshift* . . . . . . . . . . . .
Operating the standard mast and
spreader controls . . . . . . . . . . . .
Operating the windscreen wipers* . . . . .
Operation of container handlers in the
plant area . . . . . . . . . . . . . . . . .
Optional equipment . . . . . . . . . . . . . . .
. 25
. 37
. 36
. 34
.. 9
. 33
General information . . . . . . . . . . . . . . . . 74
162
Index
g
P
Parking brake . . . . . . . . . . . . . . . . . . . . 58
Putting the truck back into operation . . . . 71
R
Renew engine coolant . . . . . . . . . . . . . 138
Renew hydraulic oil of working hydraulic system . . . . . . . . . . . . . . 149
Renew the air filter element . . . . . . . . . 132
Renew the engine oil filter . . . . . . . 106, 119
Renew the hydraulic tank breather filter . 145
Renew the main hydraulic system oil
return line filters . . . . . . . . . . . . . 144
Renew the safety element . . . . 92, 108, 141
Renewing the lift chains . . . . . . . . . . . . 149
Renewing the twistlocks . . . . . . . . . . . . 147
Replace the toothed belt and idler
pulley . . . . . . . . . . . . . . . . . . . . . 147
Reverse travel . . . . . . . . . . . . . . . . . . . . 49
Running-in Instructions . . . . . . . . . . . . . . 9
S
Safety Precautions . . . . . . . . . . . .
Service brake . . . . . . . . . . . . . . . .
Service plan . . . . . . . . . . . . . . . . .
Setting the clock . . . . . . . . . . . . . .
Starting the engine - double pedal
models . . . . . . . . . . . . . . .
Starting the engine - Single pedal
models . . . . . . . . . . . . . . .
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. 8
58
76
27
. . . . . 46
Steering . . . . . . . . . . . . . . . . . . . . .
Stopping . . . . . . . . . . . . . . . . . . . .
Stopping the engine - double pedal
models . . . . . . . . . . . . . . . .
Stopping the Engine - Single pedal
models . . . . . . . . . . . . . . . .
Symbols . . . . . . . . . . . . . . . . . . . .
. . . . 57
. . . . 50
. . . . 51
. . . . 55
..... 6
T
Technical data . . . . . . . . . . . . . . . . . . . 171
Tighten the wheel nuts . . . . . . . . . . 97, 112
To turn on the road lights* . . . . . . . . . . . . 34
Top up the engine oil . . . . . . . . . . 107, 120
Towing . . . . . . . . . . . . . . . . . . . . . . . . . 68
Trailer coupling . . . . . . . . . . . . . . . . . . . 65
Travelling with load . . . . . . . . . . . . . . . . 63
Troubleshooting guide (Diesel engine) . 155
Troubleshooting guide (Hydraulic
system) . . . . . . . . . . . . . . . . . . . 159
Tyres - check condition and pressure . . . . . . . . . . . . . . . . . . . 42, 113
W
Wheel change . . . . . . . . . . . . . . . . . . . .
Work on the mast and the front part of
the truck . . . . . . . . . . . . . . . . . . . .
Working hydraulics filter panel - fitting . . .
Working hydraulics filter panel - removal .
67
75
45
45
. . . . . 51
163
Operating Instructions
Container Handler
Annex
6
Technical data
170
Technical data
Technical data
Technical Data
a
2
a
2
171
Technical data
Manufacturer
Linde
Linde
Linde
Linde
Linde
Linde
Linde
Model
designation
C90/5
C90/6
C90/7
C90/5
C90/6
C90/7
C90/7
Power unit:
battery, diesel,
LP gas, mains
power
Diesel
Operation:
manual,pedestrian,standon,seated,order
picker
Rider
seated
Diesel
Diesel
Diesel
Diesel
Diesel
Diesel
Rider
seated
Rider
seated
Rider
seated
Rider
seated
Rider
seated
Rider
seated
Load centre
Q
9
(kg)
c
(mm) 1,295
1,295
1,295
1,295
1,295
1,295
1,295
Load centre
distance
x
(mm) 1,127
1,127
1,127
1,127
1,127
1,127
1,127
Wheelbase
y
(mm) 4,000
4,000
4,000
4,500
4,500
4,500
4,500
Load capacity
Service weight
kg
kg 34,217/9,161
35,315/9,341
35,466/9,462
33081/10007
33666/10210
33858/10351
35198/1211
kg 14,822/19,554
15,046/20,608
15,115/20,811
19908/14186
20691/14182
21027/14179
24190/15216
Tyres,
front/rear. SE =
(superelastic), P =
(pneumatic)
34,161
P/P
34,948
P/P
35,206
P/P
34,086
P/P
34,873
P/P
35,206
P/P
35,722
P/P
b11
2067
(mm)
Mast/fork
carriage/truck tilt, Grad
forward/backward
3/3.5
2067
2067
2067
2067
2067
2067
3/3.5
3/3.5
3/3.5
3/3.5
3/3.5
3/3.5
Height of mast
lowered
h1
9,283
(mm)
10,731
11,111
9,283
10,731
11,111
12,399
Lift
h3
12,678
(mm)
15,574
16,352
12,678
15,574
16,352
18,926
Height of mast
extended
h4
15,788
(mm)
18,384
19,244
15,788
18,384
19,244
21,818
Height of
overhead guard
(cabin)
h6
4,179
(mm)
4,179
4,179
4,179
4,179
4,179
4,179
Height, operators
seat/stand on
platform
h7
2,999
(mm)
2,999
2,999
2,999
2,999
2,999
2,999
Towing coupling
height
h10
(mm)
600
600
600
600
600
600
Twistlock height
lowered
h13
2,290
(mm)
2,290
2,290
2,290
2,290
2,290
2,290
Overall length
l1
6,177
(mm)
6,177
6,177
6,677
6,677
6,677
6,677
l2
6,009
(mm)
6,009
6,009
6,509
6,509
6,509
6,509
Overall width
b1/b2
3600/2545
3600/2545
3600/25454000/25454000/25454000/25454000/2545
(mm)
Width of
attachment
20/40
s/e/l
6050/12150
6050/12150
6050/12150
6050/12150
6050/12150
6050/12150
6050/12150
(mm)
Ground
clearance, mast
m1
(mm)
m2
(mm)
600
12.00
x 24 20
pr
12.00
x 24 20
pr
342
342
342
342
342
342
342
12.00
x 24 20
pr
12.00
x 24 20
pr
Ground
clearance, centre
of wheelbase
9702
9702
9702
9702
9702
9702
Wheels, number,
front/rear (x =
driven)
14232
14232
14232
14232
14232
14232
4x - 2
4x - 2
4x - 2
4x - 2
4x - 2
4x - 2
4x - 2
5,292
5,292
5,792
5,792
5,792
5,792
b10
2,900
(mm)
Wa
5,292
(mm)
2,900
2,900
2,900
2,900
2,900
2,900
172
Turning radius
Technical data
Minimum pivoting
point distance
b13
1,929
(mm)
1,929
1,929
2,129
2,129
2,129
2,129
Travel speed
with/without load
km/h 25/26
25/26
25/26
25/26
25/26
25/26
25/26
Lift speed
with/without load
Lowering speed
with/without load
Tractive force,
with/without load
kN
86.7
86.7
86.7
86.7
86.7
86.7
86.7
Climbing ability,
with/without load
17.6/-
17.6/-
17.6/-
17.6/-
17.6/-
17.6/-
17.6/-
Acceleration time,
with/without load
Wet
disc
Wet
disc
Wet
disc
Wet
disc
Wet
disc
Wet
disc
Wet
disc
Service brake
Battery voltage,
rated capacity
kW
Cummins
Cummins
Cummins
Cummins
Cummins
Cummins
Cummins
142
142
142
142
142
142
142
Rated speed
1/min 2,200
2,200
2,200
2,200
2,200
2,200
2,200
Number of cylinders/displacement
/
cm
6/6700
6/6700
6/6700
6/6700
6/6700
6/6700
6/6700
Hydrostatic
Hydrostatic
Hydrostatic
Hydrostatic
Hydrostatic
Hydrostatic
Hydrostatic
250
250
250
250
250
250
250
Fuel consumption
- average
l/h
Type of drive
control
Working pressure
for attachments
dB(A)
Trailer coupling,
design/type DIN
(mm)
50
50
50
50
50
50
50
Engine manufacturer/type
Engine
performance
according to ISO
1585
Noise level,
at operators
ear, overhead
guard/cab
bar
173
174
Technical data
7
Circuit diagrams
7 Circuit diagrams
Cummins engine electrical circuit drawing
Cummins engine electrical circuit drawing
176
Circuit diagrams 7
Cummins engine electrical circuit drawing
WARNING
Pressure
(kPa)
Pressure
(psi)
Voltage (V)
0.42 to 0.58
172.37
25
1.42 to 1.58
Solenoids
344.74
50
2.42 to 2.58
Electrical specifications
517.11
75
3.42 to 3.58
Data link
689.48
100
4.42 to 4.58
Priming pump
Temp F
Temp C
Resistance
(Ohms)
ECM connector
32
30k to 36k
25
77
9k to 11k
50
122
3k to 4k
75
167
1350 to 1500
100
212
600 to 675
Sensor specifications
75.35
2.44 to 2.56
2585.76
101.80
3.44 to 3.56
Torque = 14 Nm (30lb/ft)
1939.36
Pressure (in
Hg)
Voltage (V)
646.48
25.45
0.44 to 0.56
1292.88
50.90
1.44 to 1.56
177
7 Circuit diagrams
Cummins fault code list
Cummins fault code list
Fault code list page 1
178
Circuit diagrams 7
Cummins fault code list
Fault code list page 2
179
7 Circuit diagrams
Cummins fault code list
Fault code list page 3
180
Circuit diagrams 7
Electrical Circuit
Electrical Circuit
Page 1
181
7 Circuit diagrams
Electrical Circuit
Page 2
182
Circuit diagrams 7
Electrical Circuit
Page 3
183
7 Circuit diagrams
Electrical Circuit
Page 4
184
Circuit diagrams 7
Electrical Circuit
Page 5
185
7 Circuit diagrams
Electrical Circuit
Page 6
186
Circuit diagrams 7
Electrical Circuit
Page 7
187
7 Circuit diagrams
Electrical Circuit
Page 8
188
Circuit diagrams 7
Electrical Circuit
Page 9
189
7 Circuit diagrams
Electrical Circuit
Page 10
190
Circuit diagrams 7
Elme electrical circuit
191
7 Circuit diagrams
Elme electrical circuit
Page 2
192
Circuit diagrams 7
Elme hydraulic circuit
AA
AH
AB
AG
AD
AC
AA
AB
AC
AE
AF
AD
AG
AH
AE
AF
193