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Operating Instructions

Container Handler

318, C-90-5, C-90-6,C-90-7


318 807 1001 EN 2008/10

Preface
g

Linde - Your Partner


Linde, an enterprise operating worldwide in
the investment and service sector, is one of
the large industrial enterprises in the EC with
its three business segments and six divisions.
The Linde Material Handling division is a leading manufacturer of industrial trucks and
hydraulics. It includes eight manufacturing
plants in the Federal Republic of Germany,
France and Great Britain, as well as subsidiaries and branches in all economically
important countries.

Wishing you satisfactory operation,


Linde Heavy Truck Division Limited
Linde Industrial Park
Merthyr Tydfil
South Wales, UK
CF48 4LA
Tel: +44 (0)1443 624300
Fax: +44 (0) 1443 624302

Linde industrial trucks enjoy a worldwide


reputation - thanks to their high quality in
engineering, performance and service.

Operating Instructions 318 807 1001 EN 2008/10

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

Noise emission data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10


Noise emission data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Overview
General view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Type plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Composite instrument and light switches

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Controls and indicators - single pedal cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21


Controls and indicators - twin pedal cab

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

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To turn on the road lights* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Operating the windscreen wipers*

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Filling the windscreen washer bottle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36


Control levers (joysticks)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

Final drive oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46


Starting the engine - double pedal models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Driving - Double pedal models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Stopping the engine - double pedal models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Starting the engine - Single pedal models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Driving - single pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Stopping the Engine - Single pedal models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Malfunctions during operation
Steering

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Installation of additional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Before lifting a load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Lifting a load

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Travelling with load

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Depositing the load

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Before leaving the truck unattended . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65


Trailer coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Locations for jacks when changing wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Wheel change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

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Towing

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Measures before taking the truck out of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70


Putting the truck back into operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

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
99

Inspection and maintenance after the first 50 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . 101


Clean the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Check seat belt for condition and correct operation* . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Change the engine oil (every 12 months minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Change the fuel pre-filter with water monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Renew the safety element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Check the engine mounting for condition and security . . . . . . . . . . . . . . . . . . . . . . . . . 109
Clean the radiator and oil cooler, check for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Check intake and exhaust systems for leaks and security . . . . . . . . . . . . . . . . . . . . . . 111
Check the cab mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
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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

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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

Electrical Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181


Elme electrical circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Elme hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

Operating Instructions 318 807 1001 EN 2008/10

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

written approval by the manufacturer. Linde


pursues a policy of continuous progress in the
design and construction of its products. As a
result, the illustrations and technical details
referring to design, fittings and engineering
of lift trucks are subject to change if progress
warrants it. Therefore, the manufacturer will
not accept any claims based on the specifications, illustrations and descriptions contained
in this operating manual. Please submit all
enquiries concerning your truck and all orders
for spare parts to your authorized distributor,
making sure to state your correct shipping
address. For repairs, use only genuine Linde
spare parts to ensure that your Linde truck will
maintain its original technical standard.
Lift truck model:......................................
Serial no./year built:...............................
Handing-over date:................................
When ordering parts for the engine, mast,
drive motors, drive pumps, steer axle, hydraulic pump and transmission, also state the
serial number of the assembly. When taking
over the lift truck, transfer the details from the
assembly type plates into this operating manual.
Truck takeover Every truck 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 re-inspect
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.
The following technical documents are supplied with each truck:

Operating Instructions 318 807 1001 EN 2008/10

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)

We wish you satisfactory operation.


Linde Material Handling

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

Operating Instructions 318 807 1001 EN 2008/10

steering system can also be operated when


the engine is stopped, but a greater effort is
required to turn the steering wheel.

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

corner castings on the container and locked.


When the container is lifted, it hangs on these
twistlocks. With a hydraulic cylinder as integrated sideshift, the spreader can be adjusted
laterally 300 mm to the left and right side. The
functions of the twistlocks are indicated by indicator lights on the spreader and in the cabin.
Orange-coloured flags on the twistlocks also
indicate the position of the twistlocks.

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.

Operating Instructions 318 807 1001 EN 2008/10

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

transmitted to third parties after prior written


approval by the manufacturer.
When ordering spare parts, please specify the
part number and state the following truck data:
Truck model:
Serial number/year of manufacture:
Hand over date:
Additionally, specify the serial number of the
engine, mast, hydrostatic hydraulic pump,
drive pump and drive motors when ordering
parts for these assemblies.

Engine number:
Mast / Boom number:
Mast lift:
Hydraulic pump number:
Drive pump number:
Drive motor number:
Spreader serial number:

This information can be found on the type


plates on the truck. We recommend that you
transfer this information to this manual for
ease of future reference.
The following technical documents are supplied with each fork truck:
1 Operating Instructions
1 EC certificate of conformity (The manufacturer certifies that the industrial truck
conforms to EC guidelines for machines)
Safety rules for the use of industrial trucks
(VDMA)
We wish you satisfactory operation.
Linde Material Handling

Intended use
Linde trucks are designed for transporting and
stacking the loads stated in the load capacity
diagram. In particular;

Operating Instructions 318 807 1001 EN 2008/10

we refer to the VDMA Guidelines for the


normal and proper use of industrial trucks
(or BITA for UK market),
the safety rules of your trade association,

1 Introduction
Commissioning
the special measures required for driving on
public roads in accordance with the C.U.R.,
other local regulations.

The user, and not Linde, is responsible for


any danger arising from applications not
authorised by the manufacturer.

The rules for the intended and approved


use of industrial trucks must be followed
under all circumstances by the responsible
persons, especially by the operator and
service personnel.

If you desire to use the truck for applications


not mentioned in this manual, please first
contact your authorised dealer.
No changes, particularly no modifications and
additions, may be made to the truck without
the approval of the manufacturer.

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

Identifies technical information requiring


special attention because the connection may
not even be obvious to skilled personnel.
ENVIRONMENT NOTE

The information contained herein must be


observed, otherwise environmental damage
may occur.
For your safety other symbols are also used.
Please note the different symbols.

Commissioning
Check the engine oil level

Check the steering system

Check coolant level in expansion reservoir

Check the lifting device and attachments

Refuel the truck

Regenerate the soot filter (option)

Check the condition of the battery

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.

Check the tyre inflation pressure


Tighten the wheel nuts
Working hydraulic system: Check the oil
level
Check the braking system

Tighten opposite wheel nuts to a torque of


680 Nm.
Operating Instructions 318 807 1001 EN 2008/10

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.

The responsible persons, particularly the truck


operator and servicing personnel, must be
instructed in the safety rules for the normal
and proper use of the trucks included with
these operating instructions.
The employer must ensure that the operator
has understood all safety information.
Please observe the guidelines and safety
rules therein for example:
information on the operation of container
handling trucks
rules for roadways and work areas
rights, duties and safety rules for the
operator
operation in special areas
information related to starting, driving and
braking

!
WARNING

The operator (employer) or the responsible


person must ensure that all the guidelines
and safety rules applicable for your truck
are observed. When instructing a trained
operator, acquaint him with the:
special features of the truck
optional attachments
special operating and working area characteristics, by training and practice driving,
shifting and steering operations until they
are completely mastered.
Only then start to train for stacking operations.
The stability of the truck in the work is ensured
if employed properly. Should the truck tip
over during unauthorised application or due
to incorrect operation, always follow the
instructions depicted below.

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

service and repair information


recurrent inspections, accident prevention
check
disposal of grease, oil and batteries
remaining risks

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

Operating Instructions 318 807 1001 EN 2008/10

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.

Improper handling of coolant and coolant additives


puts your health and the environment at risk.
Always handle fuel, lubricants and coolant as
required and as specified by the manufacturer.

Accident prevention check


NOTE

Identifies technical information requiring


special attention because the connection may
not even be obvious to skilled personnel.

Handling fuel, lubricants and coolant


Always handle fuel, lubricants and coolant as
required and as specified by the manufacturer.
Only store fluids and lubricants in approved
containers at specified storage places, as they
could be inflammable. Do not allow them to
come into contact with hot objects or naked
flame.
Only use clean containers when replenishing
fluids and lubricants.
Follow the manufacturers safety and disposal
instructions when using fluids, lubricants and
cleaning compounds. Avoid spilling fluids and
lubricants.
Remove any spillage immediately with a suitable binding agent and dispose of as specified.
Also dispose of used or contaminated fluids
and lubricants as specified.
Follow laws and regulations.
Clean the area surrounding the part in question before lubrication, filter renewal or repairs
in the hydraulic system. Discard parts in an
environmentally friendly way.
CAUTION
Medical aid is required if such an injury occurs.
Do not allow hydraulic oil under pressure, for
example at a leak, to penetrate the skin.

Operating Instructions 318 807 1001 EN 2008/10

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.

Operation of container handlers in the


plant area
WARNING
Many plant areas are so-called limited public traffic
areas. We advise you to check if your company
liability insurance covers any damages occurring
with your truck against third parties on limited
public traffic areas.

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.

Checks prior to first operation*

Coolant level in reservoir


Engine oil level
Fuel level
Working hydraulic system oil level
Tightness of wheel nuts
Tyre pressure

2 Safety
Noise emission data

Drive motors oil volume


Battery terminals
Mast and attachments
Function of braking system
Function of steering system
Regenerate the soot filter (option)

Daily checks*

Coolant level in reservoir


Engine oil level
Hydraulic system oil level
Tyre pressure
Windscreen washer fluid level
Clean, check and adjust mirrors

*A description of the services can also be


located in the alphabetical index.

Frequency characteristic for human body vibrations


Frequency characteristic for human body vibrations
The values are determined in conformance
with EN 13059 on trucks with standard equipment according to the technical data sheet
(driving over test course with bumps).
Frequency characteristics acc. to EN 12096
Measured frequency characteristic aw, ZS =
0.5 m/s Uncertainty K = 0.2 m/s
Frequency characteristic for hand arm vibrations
Frequency characteristic <2.5 m/s

NOTE

The frequency characteristic for the human


body cannot be used to determine the actual
frequency load during operation. This load
depends on the working conditions (conditions of roadway, type of operation, etc) and
must therefore be determined at the site, if
necessary. The specification of hand and arm
vibration is required by law, even if the values,
as in this case, do not indicate any danger.

Noise emission data


Noise emission data
Determined in the test cycle according to EN
12053 from the weighted data in the operating
modes DRIVING, LIFTING, IDLE.

While Idling LPb = 60 dB(A)


While driving LPc = 77dB(A)
Uncertainty KPA = 4 dB(A)

Noise level at the drivers station


318 LPAZ = 71 dB(A)
While lifting Lpa = 66dB(A)

10

Operating Instructions 318 807 1001 EN 2008/10

3
Overview

3 Overview
General view
General view

3
4
13
12
11
5

10

12

d3181001

Operating Instructions 318 807 1001 EN 2008/10

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

Operating Instructions 318 807 1001 EN 2008/10

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

Operating Instructions 318 807 1001 EN 2008/10

Overview 3
Type plates
1
2
3
4

Load capacity plate


Steer axle number
Engine number
Hydraulic pump and transmission number

5
6
7

Drive axle number


Spreader attachment number
Mast number

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

s. Betriebsant. / See Operating Instructions / voir Mode d'employ

d3591150

8
9
10
11
12
13
14
15

Operating Instructions 318 807 1001 EN 2008/10

Lift truck type plate (on left side of seat)


Chassis number (stamped)
CE symbol (The symbol certifies that EC
guidelines for machines and all applicable
guidelines are fulfilled).
Serial number
Unladen mass
Battery voltage
Rated capacity
Type

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)

Operating Instructions 318 807 1001 EN 2008/10

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

Programmable mast positioning switch


Twist locks switch
Hazard warning lights switch
Reverse lights
Road lights
Working lights
Front wipers switch
Rear wipers switch
Top wipers switch
Heated seat switch
Working lights
Central lubrication warning light

Indicator element

Function

Possible fault(s) / Remedy

Hydraulic oil temperature


warning light (2) (red)

Illuminates if the specified


temperature limit is reached.
If the admissible temperature
limit is reached, a buzzer also
sounds.

- Oil level in hydraulic circuit is


low
- Incorrect oil specification
- Oil filter blocked
- Accumulation of debris on oil
cooler
- Turn off buzzer with reset
button (19).

Battery charge warning light


(3) (red)

Illuminates in case of
malfunctions in the electrical
system.

- Ribbed V-belt broken or


tension too low, tensioner
defective.
- Cables defective
- Alternator defective
- Charging regulator or
regulator switch defective

Operating Instructions 318 807 1001 EN 2008/10

17

3 Overview
Composite instrument and light switches
Engine oil pressure warning
light (4) (red)

Illuminates if oil pressure of


- Oil level is too low
engine lubrication is too low. A - Engine overheated
buzzer also sounds.
- Incorrect oil specification
- Internal leak in lubricating oil
circuit
- Turn off buzzer with reset
button (19).

Fault in electric controller


malfunction light (5) (red)

Illuminates in case of faults


in the electric controller and
indicates an error code in the
text field (24).

Please contact your authorised dealer

Coolant temperature warning


light (6) (red)

Illuminates if the specified


temperature limit is reached.
If the admissible temperature
limit is reached, a buzzer also
sounds.

- Fan motor defective


- Thermal switch defective
- Radiator blocked
- Leak in cooling circuit
- Low coolant level
- Turn off buzzer with reset
button (19).

Overload warning light (7)

Illuminated orange for a


WARNING
normal load. Illuminated red in The load must be put down
case of overload.
immediately.
- Check the load capacity
diagram.

Soot particulate filter warning*


(8) (red)

Illuminates if the soot filter


must be regenerated.

- Regenerate the soot filter.

Coolant level warning light


(9)(orange)

Illuminates if coolant level is


below the minimum level.

- Low coolant level, replenish


coolant

Hydraulic oil filter warning light Illuminates if the filter requires


(10) (orange)
replacements.

- Filter restricted, change filter

Fuel level indicator (11) (either Shows the current fuel level.
green or red depending on fuel
level)
Soot particulate filter symbol*
(12)

18

Illuminates or flashes and


shows the residual capacity
in the text field (24) via 4
symbols.

Soot particulate filter


restricted, regenerate filter.

Operating Instructions 318 807 1001 EN 2008/10

Overview 3
Composite instrument and light switches
Hour meter (13)

Indicates the operating hours


of the truck. The readout
serves as proof of the elapsed
service time of the truck
and for the inspection and
maintenance services to be
carried out.

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.

Hour meter run symbol (14)

Flashes if hour meter is


running (only if ignition is on
and engine speed is over 500
r.p.m).

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)

The time is displayed in the 24


hour format. The time is set
with the function buttons ((18)
and (19)).

Change to 12 hour format with


diagnostic unit.
Please contact your authorised dealer for this service.

Service interval exceeded


symbol (16)

If the number of service hours


to the service interval is < 0,
the symbol first blinks for 10
sec after each start before
burning steadily.

A reset and adjustment of the


intervals is only possible with
the appropriate diagnostic
unit.
Please contact your authorised dealer for this service.

Function button (17)

Function depending on model.

Reset button (18)

For setting the time, turning


off the buzzer and other
functions, depending upon
the version.

Parking brake symbol (19)

Illuminates when the parking


brake is applied.

Operating Instructions 318 807 1001 EN 2008/10

19

3 Overview
Composite instrument and light switches
Do not start engine symbol
(20)

Illuminates if the engine


has stalled or pre-heat is in
process.

Symbol for time until next


service (21)

After the ignition is turned


on, the operating hours until
the next service are shown
in display field (14) (counting
backwards). Symbol (22)
illuminates. After 4 seconds
the readout (14) changes
automatically to the truck run
hours and the service hours
symbol (15) flashes.

Mast position sensing symbol


(22)

Illuminates if the admissible tilt


angle is exceeded.

Text field (23)

Serves as display field.

Engine preheat indicator light


(24) (orange)

Illuminates during the


preheating period and then
extinguishes. Flashes if there
is a malfunction in the engine
or engine controller.

Please contact your authorised dealer.

Air filter blocked warning light


(25)) (orange)

Illuminates if the air filter is


blocked.

Air filter is blocked; clean or


change the filter.

Engine stop warning light (red) Illuminates if the engine


(26)
malfunctions, and will shut
down or function at low idle.
Engine warning light (yellow)
(27)

20

Reduced engine power.

NOTE
Leave ignition on until symbol
goes out (between 15 and 50
seconds depending upon oil
temperature). Then repeat the
start attempt.

Please contact your authorised dealer.


Please contact your authorised dealer.

Operating Instructions 318 807 1001 EN 2008/10

Overview 3
Controls and indicators - single pedal cab

Controls and indicators - single pedal cab


4
1

7
8
9
10

11

12

13
15

14
AUTO

ECON

OUT

d3181010

1
2
3
4
5
6
7

Parking brake handle


Clamping screw for steering column adjustment
Multiple function electrical control lever
Horn
Steering wheel
Ignition key switch
Composite instrument

Operating Instructions 318 807 1001 EN 2008/10

8
9
10
11
12
13
14
15

Direction control lever


Central control lever (joystick)
Armrest
Switches panel
Accelerator pedal
Brake pedals
Heater control (Climate Control)
Drivers seat

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

Parking brake handle


Clamping screw for steering column adjustment
Multiple function electrical control lever
Horn
Steering wheel
Ignition key switch
Composite instrument

8
9
10
11
12
13
14
15

Central control lever (joystick)


Armrest
Switches panel
Forward accelerator pedal
Brake pedal
Reverse accelerator pedal
Heater control (Climate Control)
Drivers seat

Operating Instructions 318 807 1001 EN 2008/10

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.

Open the door.

Opening the cabin door from the inside


Squeeze handle (2) to release door lock.
Open the door.

d3591011

Securing the open cabin door


Open the cab door.

Swing door fully rearward until retainer (3)


locks into retaining catch (4).

d3591012

24

Operating Instructions 318 807 1001 EN 2008/10

Operation 4
Opening the right hand side window
Cab drivers door - closing
Depress switch (6). This will electrically
unlock the door open retainer.

Close the door until it closes securely.


NOTE
Lock the cabin door with the key when leaving
the truck unattended.
NOTE
If switch (6) fails to operate, press lever (5) on
door open retaining catch (4) to release the
retainer (3).
6

d3591013

Opening the right hand side


window
1
Pull lower part of window handle back
2

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

Operating Instructions 318 807 1001 EN 2008/10

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

If it is not possible to exit the cab using the door


the driver can leave the truck through the side
window on the right side of the cab.
Remove retaining strut (1) from mounting
(2) to the right of the drivers seat.
Open the window as wide as possible, and
exit the cab.
CAUTION
Risk of injury.
Only use in an emergency.

26

1
d3591079

Operating Instructions 318 807 1001 EN 2008/10

Operation 4
Cab interior light

Setting the clock


Depress both buttons (2) and (3) simultaneously for 3 seconds; the hour readout in the
time display (1) blinks.
Depress button (2) to set the hours.
Depress button (3) to confirm the hour setting. Now the minute readout blinks.

Depress button (2) to set the minutes.


Depress button (3) to confirm the setting of
the minutes.
NOTE

The setting of the hours or minutes can be


adjusted slowly with button (2) by tapping it
quickly, or keeping it depressed.

d3591045

NOTE

Change to 12 hour format with diagnostic unit.


Please contact your authorised dealer for this
service.

Cab interior light


Depress switches (2) to turn interior lights
on. One switch operates the directional
map light (1), the other operates the diffused
cab light (3).

1
2

d3591039

Operating Instructions 318 807 1001 EN 2008/10

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

Depress toggle switch (3).

d3181003

To operate turn indicators*


To operate the right turn indicators, push
the control lever (13) at the steering wheel
forward. Indicator light (15) will blink.

14

To operate the left turn indicators, pull the


control lever (13) at the steering wheel back.
Indicator light (15) will blink.

Operating the horn

15
13

When operating at blind corners and junctions,


a horn serves as warning signal.
Press the horn button (14) on the steering
wheel to sound the horn.
*option

28

d3591054

Operating Instructions 318 807 1001 EN 2008/10

Operation 4
Heater, Climate control

Heater, Climate control


To operate the cab heater
NOTE

Do not operate the system with all vents


closed. Heating and cooling systems will
operate only while the engine is running.

0-1
-2-

Blower speed switch. Rotate blower speed


control knob (1) to select speeds 1, 2 or 3.
Temperature control switch. Rotate temperature control knob (2) to select either hot
(red) or cold (blue).
Cab re-circulation switch. Rotate recirculated air control knob (3) to select either
fresh or re-circulated air.

d3591148

Selecting optimum performance


Maximum ventilation mode (no heating)
Rotate temperature control (2) anti-clockwise to minimum heating.
Rotate blower speed control (1) clockwise
to position 3.
Rotate recirculation control (3) anti-clockwise to minimum.
Maximum Heating Mode
Rotate temperature control (2) clockwise to
maximum heating.
Rotate blower speed control (1) clockwise
to position 3. .
Rotate recirculation control (3) clockwise to
maximum

Operating Instructions 318 807 1001 EN 2008/10

29

4 Operation
Heater, Climate control
To operate the climate control
NOTE

Do not operate the system with all vents


closed. Heating and cooling systems will
operate only while the engine is running.

(1) Climate control unit


(2) Manually increase blower speed
(3) Manually decrease blower speed
(4) Automatic preset
(5) Blower speed leds
(6) Status led
(7) LCD display power switch
(8) Power switch
(9) Status leds
(10) Windscreen demist switch
(11) Cab re-circulation switch
(12) Economy mode switch
(13) Temperature up switch
(14) Temperature down switch
(15) Outside temperature reading

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

To maximise this mode do not select the recirculating air function


Recirculating air mode When recirculating air
mode is selected the ATC system will reduce
the fresh air drawn into the cabin to a predefined minimum.
NOTE

Recirculating air mode will disengage after 45


minutes.
30

Operating Instructions 318 807 1001 EN 2008/10

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

Air vents are situated at the base of the front


and rear windscreens and also alongside and
below the drivers seat.
Selecting optimum performance, Maximum
cooling mode Close the doors, windows and
foot vents. Decrease the temperature until 13
is displayed. Manually increase the blower
speed to maximum to disengage the automatic function. Select recirculating air mode.
NOTE

Recirculating air mode will disengage after 45


minutes.
Maximum heating mode Increase the temperature until 32 is displayed. Manually increase
the blower speed to maximum to disengage
the automatic function.
Maximum defog/demist mode Increase the
temperature until 32 is displayed. Manually
increase the blower speed to maximum to
disengage the automatic function. Select the
defog/demist mode.
NOTE

In very cold conditions there will be a delay


between the time the ATC system is turned on
and when the compressor will engage. This is
to eliminate the freezing of the evaporator coil.
Useful tips In winter always operate the AC
system at least once a month. This will ensure
the components in the system will stay lubricated and increase the service life.
Regular cleaning/replacement of the fresh air
and recirculation filter will aid maximum HVAC
performance.
To toggle display (7) between F and C, depress and hold outside temperature button

Operating Instructions 318 807 1001 EN 2008/10

31

4 Operation
Adjusting the drivers seat
(15) and either temperature up (13) or temperature down (14).
NOTE

Do not wash the filters.


If the cabin has been subjected to direct sunlight, open the doors and windows on system
start up for 1 minute to rapidly reduce the inside temperature.

Adjusting the drivers seat


Adjusting the lumbar support
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.

Set the lumbar support with adjusting knob


(1).

d3591035

Adjusting the backrest


Push latch (2) down.
Push the backrest into the desired position
and release the latch.
NOTE

Adjust the seat so you are comfortable and


you can rest both feet on the bottom of the
cab without strain. Ensure you have the best
visibility possible.

Adjusting the seat position


For a horizontal adjustment of the seat pull
lever (3) up.

d3591036

Slide the seat forward or back until the desired position to the steering wheel, pedals
and control levers is obtained.
32

Operating Instructions 318 807 1001 EN 2008/10

Operation 4
Optional equipment
Re-engage lever (3).
NOTE

Sitting for a long time puts excessive strain on


the spinal column. Prevent strain with regular,
light exercise.

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.

The swivel seat allows better view to the rear


when reversing for long periods. It is recommended to set the seat to the straight-ahead
position for long periods of travel in the forward
direction. The swivel is maintenance free.
Pull up locking lever (1).
This releases the swivel and allows the seat to
be swivelled 17 to the right, lockable in the 0
and 17 positions.
Engage locking bolt (1) audibly.

Operating Instructions 318 807 1001 EN 2008/10

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

Operating the windscreen


wipers*
To operate the front windscreen wiper *
* option
Depress toggle switch (7) to its first position.

1
2
3
4
5
6
7
8
9
10
11
12

34

d3591007

Operating Instructions 318 807 1001 EN 2008/10

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

Move actuating lever (13) at the steering


wheel from the centre position downwards.
The front wiper operates continuously.

To operate the rear screen wiper

15
13

Depress toggle switch (8) to the desired


intermediate position, (this function has five
speed control settings).
Move actuating lever (13) at the steering
wheel from the centre position downwards.
The rear wiper operates intermittently.

d3591054

Fully depress toggle switch (8).


Move actuating lever (13) at the steering
wheel from the centre position downwards.
The rear wiper operates continuously.

To operate the top windscreen wiper


Depress toggle switch (9) to the intermediate position, (this function has five intermittent speed control settings).
Move actuating lever (13) at the steering
wheel from the centre position downwards.
The roof screen wiper operates intermittently.
Fully depress toggle switch (9).
Move actuating lever (13) at the steering
wheel from the centre position downwards.
The roof screen wiper operates continuously.

To operate the washers


To operate the front screen washer, pull up
control lever (13) as far as possible.
To operate the rear screen washer, depress
the wash symbol on toggle switch (8).
To operate the top screen washer, depress
the wash symbol on toggle switch (9).

Operating Instructions 318 807 1001 EN 2008/10

35

4 Operation
Control levers (joysticks)
Filling the windscreen washer
bottle
Open battery access door (1).
Open filler cap (2) top up if necessary.

Replace filler cap (2).


Close battery access door (1).
2

d3181012

Control levers (joysticks)


CAUTION

Use the truck only for authorised applications. The


operator must be trained in the handling of the lifting
device and attachments.

Control levers (1) are mounted on the drivers


control centre (2) to the right of the seat. Always shift control levers gently and slowly.
Control levers return to their initial positions
automatically when released.

Operating the standard mast and


spreader controls

d3181006

The movements of the standard mast and


spreader attachment with the central control
lever are shown on labels in front of the joysticks.
CAUTION
Use the lifting device and attachments only for
authorised applications. The operator must be instructed in the handling of the lifting device and
attachments. Observe the maximum lift height.
Do not put your hands or any other part of the body
into the lift mast or the space between the mast and
truck.

Always operate the control levers gently; do


not jerk. The speed of lifting, lowering and
36

Operating Instructions 318 807 1001 EN 2008/10

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

Note the operating symbols with arrows.


Lifting the spreader attachment
Push control lever (1) to the right.
Lowering the spreader attachment
Push control lever (1) to the left.
Tilting the mast back
Pull control lever(1) back.
Tilting the mast forward
Push control lever (1) forward.

Operating the sideshift*


CAUTION
Danger of severe damage to equipment.
Do not operate the sideshift when the load or the
forks are grounded.

Raise the fork carriage and/or load from the


ground and then move the sideshift.
To sideshift left*
Push control lever (2) to the left (to move the
fork carriage to the left).
To sideshift right*
Push control lever (2) to the right (to move
the fork carriage to the right).
NOTE

The sideshift is switched off when the fork


spread is at the minimum or maximum value.
* option

Operating Instructions 318 807 1001 EN 2008/10

37

4 Operation
Engine oil level check
Engine Access
Engine cover- opening
CAUTION
1

Pressurised gas springs are fitted which may cause


the engine cover to rise immediately.

Insert key (1) into locks on the engine covers, and turn key anticlockwise to release.
Lift the engine cover.

Engine cover - closing


Lower the engine cover.
Insert key (1) into locks on the covers, turn
key clockwise to lock.

d3181015

Engine oil level check


CAUTION
Follow the precautions for handling fluids and lubricants.

Open the battery access door.


Remove dipstick (1) and wipe with a clean
cloth.
1

d3591025

38

Operating Instructions 318 807 1001 EN 2008/10

Operation 4
Engine oil level check
NOTE

There are two available versions of dipstick


(1) fitted, for the type shown here, rotate the
dipstick before pulling it out. Similarly, rotate
dipstick after replacing, to lock in position.

Fully re-insert dipstick (1) and remove it


again.
The oil level should be between the Min.
and Max. markings.
Add oil if required.

d3591162

If necessary, remove oil filler cap (2) and


add oil to the Max mark on the dipstick.
(Difference between Max. and Min. = 2.0 L)
Maximum oil capacity ..... 16.4 L

2
d3591026

Operating Instructions 318 807 1001 EN 2008/10

39

4 Operation
Checking the fuel
Checking the fuel
Checking the fuel

1
4

NOTE

The current fuel level is displayed by fuel level


warning lights in composite instrument (4).
The tank is full if all 6 LEDs (2) and fuel pump
symbol (1) are illuminated green. As fuel level
drops, the LEDs extinguish from right to left.
When fuel level is low, petrol pump symbol (1)
illuminates red and LED (3) green. At this time
approximately 5.0 litres of fuel remain in the
tank and fuel must be added. If only the red
petrol pump symbol (1) is illuminated, the fuel
tank is empty.

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.

Turn the ignition off. Open fuel tank filler cap


(5) on the left-hand side and fill with clean
diesel fuel.
NOTE

Maximum fuel capacity ..................190 L


CAUTION
Never drive the truck until the tank is empty to prevent air from entering the fuel injection system
through suction.

d3591028

Refit fuel tank filler cap (5).

40

Operating Instructions 318 807 1001 EN 2008/10

Operation 4
Checking the coolant level in the reservoir

Checking the coolant level in


the reservoir
Checking the coolant level in the reservoir
CAUTION
Follow the instructions for handling fluids and lubricants.
Do not remove the filler cap if the reservoir is hot or
when the engine is running. Risk of scalding!

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

Remove the filler cap (4).


NOTE

The expansion reservoir is pressurised.


The coolant level must reach to just under
the filler neck.
Fill coolant if necessary. Max. coolant capacity ............. 20 L

Refit filler cap (4).

Refit and secure cover (3).

d3591018

Operating Instructions 318 807 1001 EN 2008/10

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.

Check tyres for damage and excessive


wear.
Remove any foreign objects from the
treads.

Check the tyres for specified pressure.

Inflate tyres according to stickers on the


chassis.

d3181013

If necessary, add air at filler valves for drive


axle (1) and steer axle (2).
Tyre specification:
Drive axle:
Front ......................................... 10.0 bar
Steer axle:
Rear ......................................... 10.0 bar

Battery access - opening


Check that door swing area (2)is free from
obstruction.

Insert flat head screw driver into lock (1) and


turn anti-clockwise to open door (2).
Open door (2).

Battery access - closing


Close door (2), and turn lock (1) fully clockwise.

d3591021

42

Operating Instructions 318 807 1001 EN 2008/10

Operation 4
Fuses

Isolating the battery


Access to the battery isolator is through
battery access door (1).
Rotate handle (2) 90 clockwise. The battery is now isolated.

To restore battery power, return handle (2)


to original position.

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

There are also high power fuses (2), located in


the battery compartment.

d3591059

NOTE

The fuse box door is hinged on the lower edge,


and should be supported until in contact with
the cab side wall. A layout panel is provided
for identification of fuses and relays.
Fuses in fuse box (1) protect the following
circuits:

F1 Fuse, cab roof light 20 A


F2 Chassis light 20 A
F3 Progr lights 20 A
F4 Fuse, reverse light relay 10 A
F5 Fuse, brake lights 15 A

Operating Instructions 318 807 1001 EN 2008/10

43

4 Operation
Fuses

F6 Fuse, head/side lights 10 A


F7 Fuse, rotating beacon 7.5 A
F8 Fuse, spare 5 A
F9 Fuse, spare 10 A
F10 Fuse, Indicator 10 A
F11 Fuse, engine ignition 5 A
F12 Fuse, spare ignition
F13 Fuse, rear wiper 10 A
F14 Fuse, top wiper 10 A
F15 Fuse, front wiper 15 A
F16 Fuse, parking brake 5 A
F17 Fuse, display (12V) 12 A
F18 Fuse LHOM bat+ 15 A
F19 Fuse LHSS bat + 15 A
F20 Fuse, spare 12V batt + 10 A
F21 Fuse, AC 5 10 A
F22 Fuse, AC 6 20 A
F23 Fuse, AC 7 20 A
F24 Fuse, heated seat 15 A
F25 Fuse, 24V/12V converter 20 A
F26 Fuse, spare ignition
F27 Fuse, spare ignition
F28 Fuse, rocker switch, lights 15 A
F29 Fuse, display ignition 2 A
F30 Fuse, LHCM ignition 2 A
F31 Fuse, LHCS ignition 2 A
F32 Fuse, spare 12V ignition 10 A
F33 Fuse, ignition switch 5 A
F34 Fuse, elect. door release 5 A
F35 Fuse, cab lift safety 7.5 A
F36 Fuse, horn 15 A
F37 Fuse, main side lights 15 A
F38 Fuse, spare batt + 5 A
F39 Fuse, cab interior light 15 A
F40 Fuse, indicator batt+ 15 A
F41 Fuse, road lights left 10 A
F42 Fuse, road lights right 10 A
F43 Fuse side lights left 15 A
F44 Fuse, side lights right 10 A

Fuses in battery compartment (2) protect the


following circuits:

44

Operating Instructions 318 807 1001 EN 2008/10

Operation 4
Hydraulic system: oil level check

F50 Fuse, engine management 7.5 A


F51 Fuse, engine management 7.5 A
F52 Fuse, engine management 7.5 A
F53 Fuse, engine management 10 A
F54 Fuse, engine management 10 A
F55 Fuse, radio (option) 5 A
F60 Fuse, (blue) grid heater 60 A
F61 Fuse, (blue) grid heater 60 A
F62 Fuse, (green) tilting cab 30 A
F63 Fuse, (orange) main cab supply 40 A
F64 Fuse, starter

Working hydraulics filter panel


- removal
Insert flathead screwdriver (1) into slots
(2) of panel (3), turn slots anti-clockwise to
release.

Lift panel (3) clear.


3

Working hydraulics filter panel - fitting


Place panel (3) in position.
Insert flathead screwdriver (1) into slots (2)
of panel (3), turn slots clockwise to lock.

d3591016

Hydraulic system: oil level


check
Park the truck on level ground, fully lower
the spreader.
Check sight glass (1) on the right side of the
chassis, add oil if necessary (see maintenance).

d3181009

Operating Instructions 318 807 1001 EN 2008/10

45

4 Operation
Starting the engine - double pedal models
Final drive oil level check
CAUTION

Perform the check with the engine running.


Follow the instructions for handling fluids and lubricants.

Ensure that filler plug (1), is at the 12 o clock


position, and drain plug (2) is at the 5 o clock
position.
Remove plugs (1&2).

Check oil is visible at the base of drain hole


(2).
If required, replenish oil to the base of drain
hole (2).

d3591034

Replace plugs (1&2).

Starting the engine - double


pedal models
WARNING
Risk of carbon monoxide poisoning!
Do not let the engine run in unventilated enclosed
spaces.

NOTE

If at all possible, avoid frequent engine starts


and short periods of duty so that the engine
can reach its operating temperature. Frequent
cold starts lead to increased wear.
NOTE

The control lever (joystick) must be in the neutral position.


Sit on the operators seat.
Apply the seat belt.

d3591037

Place both feet on accelerator pedals (4).


With parking brake handle (1) pulled out
(engine will start only with the parking brake
handle pulled out). Insert the ignition key
(2) into the ignition switch and turn it from

46

Operating Instructions 318 807 1001 EN 2008/10

Operation 4
Starting the engine - double pedal models
the zero position to position I. The electrical
system is turned on.
NOTE

After the ignition is turned on, the operating


hours until the next service are shown for 4
seconds in the display field (11) of the composite instrument (3). During this time symbol
(12) is illuminated. After 4 seconds the display
reverts automatically back to the operating
hours.
NOTE

When buzzer* sounds (fault in soot particulate


filter system), conduct a lamp test (see Troubleshooting Guide (Diesel engine), Possible
Cause, Correction). If the buzzer continues to
sound contact your Linde dealer.

13
12
11
10

7
9

8
d3591038

Parking brake on warning light (9), engine


oil pressure warning light (6), battery charge
warning light (5) and preheating indicator
light (13) illuminate.
After the preheating indicator light (13) extinguishes, turn the ignition key to position
II. Release the key as soon as the engine
has started. Symbol (7) flashes.
* Only if equipped with a soot filter
CAUTION
Watch the mouth of the exhaust pipe whenever the
engine is started. In case of heavy and persistent
smoke in the exhaust gas, take the truck out of operation. Please contact your authorised dealer.

If the engine does not start, interrupt the


starting procedure and reattempt starting
after a short pause.
If the engine is stalled, the symbol Do not
start engine(10) comes on. Leave ignition
on until symbol goes out (between 15 and
50 seconds depending upon oil temperature). Then repeat the start attempt. Wait
at least 1 minute between starting attempts
to spare the battery. If the engine does not
start after the third attempt, refer to: Engine
Troubleshooting Guide.

Operating Instructions 318 807 1001 EN 2008/10

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

Do not warm up the engine at idle speed. Drive


the truck briskly with a load. The engine will be
at operating temperature in a short time.

Driving - Double pedal models


CAUTION
Travel on long slopes over 15 % is not allowed as a
rule due to the prescribed minimum brake applications and truck stability characteristics. The climbing
ability rates given in the data sheet were derived
from the tractive force of the truck and they apply
only for crossing obstacles and for short differences
in level. Always accommodate your driving style to
suit the conditions of the roadway (rough surfaces,
etc), especially hazardous work areas and the load.
Before driving on steeper slopes, you should consult your authorised dealer.

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

Operating Instructions 318 807 1001 EN 2008/10

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.

Start the engine.


Elevate the spreader slightly and tilt the
mast back.
Push parking brake handle (1) down.

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

Quick flooring of the accelerator pedal is not


recommended as the maximum acceleration
rate is controlled automatically.

Reverse travel
Depress the left accelerator pedal (3). The
truck will reverse at a speed depending on the
position of the accelerator pedal.

Changing the travel direction


Release the actuated accelerator pedal.
The hydrostatic drive will act as service
brake. If quicker stopping is required depress the brake pedal (centre pedal). The
truck will come to rest.

Operating Instructions 318 807 1001 EN 2008/10

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

Operating Instructions 318 807 1001 EN 2008/10

Operation 4
Starting the engine - Single pedal models

Stopping the engine - double


pedal models
NOTE

2
1

Do not stop the engine at full speed.


Release pedal (3). If quicker stopping is
required depress brake pedal (4).
Turn ignition key (2) to the zero position
NOTE

The brake engages automatically when the


engine is stopped.
d3591040

Pull parking brake handle (1) up.


Remove ignition key (2) when leaving the
truck unattended.

Starting the engine - Single


pedal models
WARNING
Risk of carbon monoxide poisoning!
Do not let the engine run in unventilated enclosed
spaces.

NOTE

2
1

If at all possible, avoid frequent engine starts


and short periods of duty so that the engine
can reach its operating temperature. Frequent
cold starts lead to increased wear.
NOTE

Control levers (hydraulics and directional lever


(5)) must be in the neutral position.
Sit on the drivers seat.
Apply the seat belt.

d3591041

With parking brake handle (1) pulled out


(engine will start only with the parking brake
handle pulled out).

Operating Instructions 318 807 1001 EN 2008/10

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

After the ignition is turned on, the operating


hours until the next service are shown for 4
seconds in the display field (12) of the composite instrument (3). During this time symbol
(13) is illuminated. After 4 seconds the display
reverts automatically back to the operating
hours.
NOTE

When buzzer* sounds (fault in soot particulate


filter system), conduct a lamp test (see Troubleshooting Guide (Diesel engine), Possible
Cause, Correction). If the buzzer continues to
sound contact your Linde dealer.

13
12
11
10

7
9

8
d3591038

Parking brake on warning light (10), engine


oil pressure warning light (7), battery charge
warning light (6) and preheating indicator
light (14) illuminate.
After the preheating indicator light (14) extinguishes, turn the ignition key to position
II. Release the key as soon as the engine
has started. Symbol (8) flashes.
* Only if equipped with a soot filter system
CAUTION
Watch the nozzle of the exhaust about 5 seconds
whenever the engine is started. In case of heavy
and persistent smoke in the exhaust gas, take the
truck out of operation. Please contact your authorised dealer.

If the engine does not start, interrupt the


starting procedure and reattempt starting
after a short pause.
If the engine is stalled, the symbol Do not
start engine (10) comes on. Leave ignition
on until symbol goes out (between 15 and
50 seconds depending upon oil temperature). Then repeat the start attempt. Wait
at least 1 minute between starting attempts
52

Operating Instructions 318 807 1001 EN 2008/10

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

Do not warm up the engine at idle speed. Drive


the truck briskly with a load. The engine will be
at operating temperature in a short time.

Driving - single pedals


Forward travel
NOTE

Ensure that the pedal area inside the cabin is


clear of obstruction and debris before attempting to drive the truck.
Push directional control lever (4) forward.
Depress accelerator pedal (5) gently. Truck
speed depends on how far the pedal is depressed.

d3591042

Operating Instructions 318 807 1001 EN 2008/10

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

Changing the travel direction


Release the accelerator pedal. The hydrostatic drive will act as service brake. If
quicker stopping is required depress the
brake pedal (centre pedal). The truck will
come to rest.
Directional control lever (4) can be moved
whilst travelling. If it is moved to the opposite direction than the current travel direction, then full hydrostatic braking will be
applied.

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

Operating Instructions 318 807 1001 EN 2008/10

Operation 4
Malfunctions during operation

Stopping the Engine - Single


pedal models
NOTE

Do not stop the engine at full speed.


Release accelerator pedal (5). If quicker
stopping is required depress brake pedal
(6).
Turn ignition key (2) to the zero position.
6

NOTE

The brake engages automatically when the


engine is stopped.

d3591041

Pull parking brake handle (1) up.


Remove ignition key (2) when leaving the
truck unattended.

Malfunctions during operation

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.

Hydraulic oil temperature warning light (1)


and buzzer
Battery charge warning light (2)
Engine oil pressure warning light (3) and
buzzer
Electric control malfunction indicator (4)
Coolant temperature warning light (5) and
buzzer
Coolant level warning light (6)
Hydraulic filter (7)

Operating Instructions 318 807 1001 EN 2008/10

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

The air filter must be serviced if the air filter


blocked warning light (9) comes on during
operation.
CAUTION
If the orange soot filter warning light (10) comes on
when a particle filter* is installed, the filter must be
regenerated within the next 30 minutes.
Do not operate the truck for longer than 30 minutes
after the soot filter warning light has illuminated.

* option

10
d3591050

56

Operating Instructions 318 807 1001 EN 2008/10

Operation 4
Steering

Steering
Start the engine and drive off.
Turn the steering wheel to the left and right
to full lock.
NOTE

Very little effort is required to turn the steering


wheel due to the power-assisted steering system. This is especially advantageous when
operating in narrow aisles. To avoid unnecessary tyre wear, turn the steering only when the
truck is moving.
Turning Radii:
Short wheelbase C90/5, C90/6 & C90/7 .........
5292 mm

d3591051

Long wheelbase C90/5, C90/6, C90/7 & C90/8


......... 5792 mm
WARNING
Contact your authorized dealer if steering requires
too much effort or there is excess play in the steering.
Do not drive the truck if the steering is defective.

Operating Instructions 318 807 1001 EN 2008/10

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

It is recommended that the operator acquaint


himself with the function and effect of these
brakes without a load on the truck. Drive on a
roadway without traffic at a slow speed.
CAUTION
Use of the friction braking system other than for
emergency braking is not recommended as the life
of the braking components will be greatly reduced.

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

Operating Instructions 318 807 1001 EN 2008/10

Operation 4
Installation of additional equipment
NOTE

The multiple disc brakes are only released if


the engine is running.
Push parking brake handle (3) down. The
symbol in the composite instrument goes
off.
WARNING
Contact your authorised dealer if faults or signs of
wear become evident in the braking system.
Do not drive the truck with a faulty braking system.

Installation of additional equipment


CAUTION
Electrical additional equipment (lights, seat heaters, etc) should be connected to the free cable loom connections provided for this purpose.
Further connections beyond this anticipated range
are only permitted after contacting your local Linde
representative. Only qualified skilled persons who
observe the applicable rules and use the appropriate material should carry out this work.
Contact your local Linde representative before
attempting to connect any additional equipment.

CAUTION

1
2
3
4
5
6
7
8
9
10
11
12

d3591007

Do not drill a hole into or weld on the overhead guard.

NOTE

Switches on the console on the right of the


drivers seat can be arranged in a different
order, depending on the model. Please note
the switch symbols.

Operating Instructions 318 807 1001 EN 2008/10

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.

Before lifting a load, check type plate (1) on left


of the seat in the cabin.

d3591063

NOTE

Check the load capacity limits and contact


your authorised dealer;

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

Operating Instructions 318 807 1001 EN 2008/10

Operation 4
Lifting a load
NOTE

Check the load capacity limits and contact


your authorised dealer
before lifting off-centre or swinging loads,
before transporting loads with the mast

tilted forward or raised above the driving


height (3),
before operating attachments and auxiliary
equipment.

d3181039

Lifting a load
WARNING
Do not stand under an elevated load.

The twistlocks must be unlocked and the


red indicator lights (5) must be illuminated.
Approach the container to be lifted as carefully and accurately as possible.
Tilt the mast to vertical position.
NOTE

Observe the marking* on the left tilt cylinder


for this.

d3181016

Raise or lower the spreader to the correct


height.
Operate the spreader sideshift and align to
the container.
Approach the container to be lifted carefully
and at the centre until both pillars contact
the container.
Apply the parking brake.
Lower the spreader until twistlocks are
seated in the corner castings.

Operating Instructions 318 807 1001 EN 2008/10

61

4 Operation
Lifting a load
NOTE

The yellow and red indicator lights (4 & 5) must


be illuminated to indicate that the twistlocks
are inserted and not locked.
Lock the twistlocks.
NOTE

The green and yellow indicator lights (3 & 4)


must illuminate to indicate that the twistlocks
are inserted and locked.
Raise the spreader until the container
hangs on the twistlocks and is clear of the
ground.

d3181028

NOTE

The yellow indicator light (4) will extinguish.


Tilt the mast slightly back.
Release the parking brake.

3 4 5
3

Reverse the truck.


Tilt the mast fully back.
Raise or lower the spreader to the driving
height.
NOTE

The driving height is the point at which it is


possible to look through the mast under the
container onto the roadway.

62

d3181037

Operating Instructions 318 807 1001 EN 2008/10

Operation 4
Depositing the load

Travelling with load


Do not travel with the load laterally displaced (e.g. with a sideshift).
Transport the load near the ground.

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

When the mast is fully lowered, or raised


above normal travel position, truck speed
is restricted and braking performance is adjusted accordingly. Normal speeds and functions
are restored when the mast is raised.
d3181019

Depositing the load


Approach the stack or device receiving the
load as carefully and as accurately as possible.

Operating Instructions 318 807 1001 EN 2008/10

63

4 Operation
Depositing the load
Elevate the mast to the correct height.
Put the mast in the vertical position.

d3181020

Carefully move into the stack.


Lower the load on to the stack.
Unlock the twistlocks and raise the mast
until the twistlocks are clear of the load.
Reverse the truck away from the stack until
clear.
Lower the mast to the travel position.
WARNING
Never leave the truck unattended with the load elevated.

d3181017

64

Operating Instructions 318 807 1001 EN 2008/10

Operation 4
Trailer coupling

Before leaving the truck unattended


Deposit the load and lower the spreader .
Tilt the mast slightly forward, the spreader
must touch the ground.
Apply the parking brake.
Stop the engine and remove the key.
Lock the cabin doors and remove the key.

d3181007

Trailer coupling
NOTE

The trailer coupling should only be used to


tow light trailers inside the plant working area.
Refer to the technical data for rated towing
capacity.

Lift tow pin (1).


Place towbar in coupling recess.
Push tow pin (1) down to engage the drawbar and the lower retaining hole.
d3591077

Operating Instructions 318 807 1001 EN 2008/10

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.

To jack up front of truck, place jack under


final drive unit (1).

To jack up rear of truck, place jack under the


main plate of steer axle (2).

2
d3181038

66

Operating Instructions 318 807 1001 EN 2008/10

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

Drive axle inner wheels:


Release the inner wedge band (2) from the
hub.
Remove wheel (1) from hub.
Steer axle wheels
Remove the wheel nuts and lugs.
Remove the wheel.

Wheel mounting
CAUTION
When a wheel has been removed and replaced, the
wheel nuts must be checked before use and daily
for two weeks.

Drive axle inner wheels:


Fit wheel (1) to the hub. Ensure that the
tyre inflation valve extension is positioned
correctly in the hub cutaway.
Fit centre wedge band (2).
Drive axle outer wheels:
Fit wheel (3). Ensure the tyre inflation valve
is correctly located in the hub cutaway.
Fit outer wedge band (4).
Fit wheel lugs (5) and nuts (6).
Tighten the nuts.
Operating Instructions 318 807 1001 EN 2008/10

67

4 Operation
Towing
Steer axle wheels:
Fit the wheel.
Fit the wheel lugs and nuts Tighten the nuts.
NOTE

The steer axle wheels fit directly to the hub.


Wheel nut torque = 680 Nm.
Inflate tyres to 10 bar (145 psi)

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 speed should not exceed 5 km/hour


and a maximum towing distance of 2 km must
be observed.

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

Operating Instructions 318 807 1001 EN 2008/10

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

To disengage the brake


Rotate control (3) on brake valve to stop (4).
Rotate the steering wheel until increased
resistance is felt (when the brakes are fully
released).

Connect to the braked towing vehicle with


a rigid draw bar and remove any wheel
chocks.
Close the engine cover.
The truck may now be towed. Braking should
be achieved by application of the towing vehicle brakes.
Due to hydraulic leakage the brakes will re-engage after a short period.

d3591152

Towing should be stopped and the brakes


disengaged again by rotating the steering
wheel until increased resistance is felt (when
the brakes are fully released).
WARNING
Steering efforts will be high as the power assistance
for the steering is not available without the engine
running.

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.

Re-establishing braking power


Turn control (3) on brake valve from stop (4) to
its original position.
The brakes are no longer disengaged.
Apply the parking brake.
Remove the wheel chocks.
WARNING
Check brake function after completing repairs. If
deficiencies should occur in the braking system,
please contact your authorised dealer.
Do not drive the truck with a faulty braking system.

Measures before taking the truck out of operation


If the truck is taken out of operation for over 2
months, it must be parked in a well ventilated,
frost-free, clean and dry room and the following measures must be carried out.

Check the condition and electrolyte level of


the battery. Coat the battery terminals with
non-acidic grease. (Follow the instructions
of the battery manufacturer.)

Thoroughly clean the truck.

Spray all open electrical contacts with a


suitable contact spray.

Operate the spreader several times.


Tilt the mast forward and back several
times.
Lower the spreader on a support until the
chains are slack.
Check the hydraulic oil level and add oil, if
needed.
Add diesel fuel.
Apply a thin film of oil or grease on all
unpainted mechanical parts.

CAUTION
Block up the truck so that all wheels are clear of the
ground. This will prevent tyre deformation.

NOTE

Do not use plastic foil to cover the truck as


this enhances the formation and collection of
condensation water.

Lubricate the truck as described in the


maintenance section of this manual.
70

Operating Instructions 318 807 1001 EN 2008/10

Operation 4
Putting the truck back into operation
NOTE

If the vehicle is to be taken out of operation for


over 6 months, contact your authorised dealer
for further measures.

Mast and load lifting device removal


DANGER
This work must only be carried out by the trained
personnel of your authorised dealer.
Do not attempt to remove the mast or lifting device.

Putting the truck back into operation


Thoroughly clean the truck as described in
the maintenance section of this manual.

Check the engine oil for condensation water


and change the oil, if necessary.

Lubricate the truck.

Check the hydraulic oil for condensation


water and change the oil, if necessary.

Coat the battery terminals with non-acidic


grease.
Check the condition and electrolyte level of
the battery.

Operating Instructions 318 807 1001 EN 2008/10

Perform the same services as for commissioning.


Take the truck into service.

71

4 Operation
Putting the truck back into operation

72

Operating Instructions 318 807 1001 EN 2008/10

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.

Perform a functional check and trial run after


every servicing.

Maintenance intervals
NOTE

When operating the truck under extreme


conditions (i.e. extreme heat or cold, intensive
dust concentration, etc.), the intervals given in
the maintenance schedule should be reduced
accordingly.
Use only the specified engine oil and coolant
when servicing. The required qualities are
described in the recommended lubricants
section. The inspection and maintenance intervals depend on the operating and service
conditions of the truck. For heavy duty conditions we recommend shorter intervals. Please
contact your authorised dealer in this regard.

Operating Instructions 318 807 1001 EN 2008/10

Maintenance 5
Work on the mast and the front part of the truck

Work on the mast and the front


part of the truck
CAUTION
Do not carry out any work on the mast or the front
part of the truck with the mast or spreader raised
without securing the mast as described below.

These safety precautions are only sufficient


for the general servicing of the truck (inspections and lubrication).
When carrying out repairs (e.g. changing
chains, cylinder removal), additional safety
precautions are required. Please contact your
authorised distributor.

Securing the mast against tilting back


Apply the parking brake.
Fully lower the mast.
Stop the engine and remove the ignition
key.
Lock the cabin doors and remove the key.

Securing the raised mast


CAUTION
The mast and carriage must be secured with a suitable chain if working on the mast or the front of the
truck with the carriage raised. Be sure not to exceed the maximum height of lift.

Raise the spreader fully.


Fasten the chain around the cross member
of the outer mast (1) and inner mast (2).
Lower the inner mast until it is held by the
chain.
d3181041

Operating Instructions 318 807 1001 EN 2008/10

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

Operating Instructions 318 807 1001 EN 2008/10

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

Operating Instructions 318 807 1001 EN 2008/10

Maintenance 5
500 h Service plan

500 h Service plan


At operating hours
500

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

Operating Instructions 318 807 1001 EN 2008/10

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

Operating Instructions 318 807 1001 EN 2008/10

Maintenance 5
1000 h Service plan

1000 h Service plan


Carried
out

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

Operating Instructions 318 807 1001 EN 2008/10

Maintenance 5
2000 h Service plan

2000 h Service plan


Carried
out

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

Check the tension of double hoses


Final drive oil level check
Renew the feed, pressure, suction and breather filter
Mast assembly and auxiliary hydraulics
Clean and lubricate the mast and tilt cylinder pivots
Check the mast roller bearings
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 2)
Subsequent tasks
Attach maintenance sticker

84

Operating Instructions 318 807 1001 EN 2008/10

Maintenance 5
3000 h Service plan

3000 h Service plan


At operating hours
3000

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

Clean the radiator and hydraulic oil cooler


Check the tension of double hoses
Final drive oil level check
Renew the feed, pressure, suction and breather filter
Mast assembly and auxiliary hydraulics
Clean and lubricate the mast and tilt cylinder pivots
Check the mast roller bearings
Check and lubricate the slider pads on the spreader carriage and end beams
Check and adjust the lift chain length, lubricate with chain spray
Subsequent tasks
Attach maintenance sticker

86

Operating Instructions 318 807 1001 EN 2008/10

Maintenance 5
5000 h Service plan

5000 h Service plan


At operating hours
5000

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

Clean the radiator and hydraulic oil cooler


Check the tension of double hoses
Final drive oil level check
Renew the feed, pressure, suction and breather filter
Mast assembly and auxiliary hydraulics
Clean and lubricate the mast and tilt cylinder pivots
Check the mast roller bearings
Check and lubricate the slider pads on the spreader carriage and end beams
Check and adjust the lift chain length, lubricate with chain spray
Renew the twistlocks
Subsequent tasks
Attach maintenance sticker

88

Operating Instructions 318 807 1001 EN 2008/10

Maintenance 5
6000 h Service plan

6000 h Service plan


At operating hours
6000

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

Clean the radiator and hydraulic oil cooler


Check the tension of double hoses
Final drive oil level check
Renew the feed, pressure, suction and breather filter
Renew the hydraulic oil
Mast assembly and auxiliary hydraulics
Clean and lubricate the mast and tilt cylinder pivots
Check the mast roller bearings
Check and lubricate the slider pads on the spreader carriage and end beams
Check and adjust the lift chain length, lubricate with chain spray
Renew the twistlocks
Renew the lift chains (or whenever 2% stretch has been attained).
Subsequent tasks
Attach maintenance sticker

Inspection and maintenance data


No Assembly

Aids Fluids and lubricants

Filling capacity / Settings

1 Engine

Engine oil

approx. 15 lts

2 Fuel tank

Diesel

approx. 190 lts

3 Cooling system

Antifreeze / water

approx. 20 lts

4 Hydraulic system

Hydraulic oil

approx. 330 lts

5 Battery

Maintenance free

Maintenance free

6 Tyres

Air

10 bar

7 Wheel fasteners
8

90

Lift chains / mast


channels

680 Nm
Linde chain spray

As required

Operating Instructions 318 807 1001 EN 2008/10

Maintenance 5
Inspection and maintenance as required

Inspection and maintenance as required


Check the air filter
WARNING
Stop the engine before servicing the air intake system.
Do not start the engine with the filter element removed.

Wear a protective mask for all services on the


air intake system.
CAUTION
Clean the filter casing with a damp cloth.
Do not clean the filter element.

The use of wet cleaning agents will destroy


the filter element. Follow the precautions for
handling fluids and lubricants. If the air filter
restriction indicator (1) illuminates, stop the
engine at once and renew the air filter.

d3591083

CAUTION
A dirty filter element decreases engine performance.
Regular filter servicing is essential for the engine.

Open the engine cover.


Lift catch (2) and remove filter end cover (3).
2

Empty the dust collected in cover (3), and


wipe it with a clean damp cloth.
Clean dust valve (4) to remove any collected dust. If necessary use a damp cloth.

Replace dust valve (4) if split or torn.

d3181042

Operating Instructions 318 807 1001 EN 2008/10

91

5 Maintenance
Inspection and maintenance as required
Renew the safety element
The safety element (3) must be changed:
3

After 2000 hours of service.


If the element is defective:

Depress catch (1) remove cover (5) and


withdraw filter element (2) and safety element (3). Before installing a new safety
element, ensure it is not damaged.
Insert new safety element (3).

1
4

CAUTION
5

Do not clean or reuse the safety element.

Install filter element (2) in filter housing (4).


Take care not to damage safety element (3)
when installing it and be sure that the seal
sits correctly in the filter casing.

d3181043

Refit cover (5) and secure with catch (1).


The dust ejection valve (6) must point downward.
Close the access door.
NOTE

Use only genuine parts as incorrect parts may


reduce the service life of the engine and affect
its performance.

Clean the fuel filter


CAUTION
Follow the instructions for handling fluids and lubricants.

Place a container underneath filter (1) to


catch any fluid running out.
Open drain valve (2) by turning it anti-clockwise approximately 3 turns until valve (2)
drops down 25 mm (1 inch), and draining
occurs.

2
2

Allow fuel to drain until clear fuel emerges.


Close drain valve (2), hand tight only, as
soon as clean fuel emerges.
92

d3591087

Operating Instructions 318 807 1001 EN 2008/10

Maintenance 5
Inspection and maintenance as required
CAUTION
When closing drain valve (2), do not over tighten.
Overtightening can damage the threads.

Dispose of drained fuel in a way that is


friendly to the environment.

Check seat belt for condition and


correct operation*

NOTE

For safety reasons the condition and proper


operation of the retention system should be
inspected regularly (monthly).
Under extreme operating conditions this
check is required daily before taking the truck
into operation.

Pull belt (1) out fully and inspect for fraying.


Check lock (2) for correct operation and the
retractor for proper return of the belt.
Check covers for damage.

d3591093

Check the automatic lock.


Park the truck on level ground.
Pull out the belt with a jerk. The automatic
lock should prevent the belt from unrolling
from retractor (3).
Slide the seat fully forward.
Tilt the backrest fully forward.
* option
CAUTION
Have a defective seat belt replaced immediately by
your authorised dealer.
Do not operate the truck with a faulty seat belt.

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.

Operating Instructions 318 807 1001 EN 2008/10

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

Operating Instructions 318 807 1001 EN 2008/10

Maintenance 5
Inspection and maintenance as required

Clean the truck


NOTE

How often the truck needs cleaning depends


on its use. If used with very aggressive media
like salt water, fertilizer, chemicals, cement,
etc., the truck should be cleaned carefully and
more often.
WARNING
Hot steam or intensive degreasing solutions should
be used with utmost care. The grease in sealed
for life bearings may dissolve and leak out. Since
re-greasing is not possible, this will result in damage to the bearing.

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.

Operating Instructions 318 807 1001 EN 2008/10

95

5 Maintenance
Inspection and maintenance as required
Clean and spray the lifting chains
NOTE

The lifting chains must be cleaned if the dust


covering the chain prevents penetration of the
lubricant.
Place a container under the mast.
Clean the chain using paraffin derivatives
such as washing petrol, wear protective
clothing and observe the manufacturers
safety notes.
When using a steam jet, use without using
additives.
After cleaning, blow dry the chain at once
to remove any water in the chain links and
on the surface. During this procedure the
chain should be moved several times.

d3181025

Spray Linde chain spray immediately, move


the chain while spraying by raising and lowering the fork carriage.
CAUTION
Lifting chains are safety components. The use
of cold cleaners, chemical cleaning agents and
caustic or acidic and chlorinated fluids can be a direct cause of damage to the chain.

NOTE

Trucks in service in the food industry must be


lubricated with an oil approved for the food
industry instead of chain spray.

96

Operating Instructions 318 807 1001 EN 2008/10

Maintenance 5
Inspection and maintenance as required

Check the tyres for damage and


foreign objects
Secure the truck against rolling (apply parking brake).
Chock a wheel that will not be raised.
Raise the truck with a jack at the locating points until the wheels are clear of the
ground.
Secure the truck with squared timbers.
Check the wheels for ease of movement
and remove any debris hindering their free
rotation.
Renew worn or damaged tyres.

d3181029

Tighten the wheel nuts


CAUTION
During initial operation and after each wheel
change, the wheel fasteners must be tightened
before starting work and thereafter every 10 service
hours until they have settled, i.e. until no further
tightening is possible.

Thereafter check wheel nuts (1) every 100


hours.

Torque all wheel nuts to 680 Nm.


A socket with an extension bar is needed to
tighten the front wheel nuts.

2
d3181013

Operating Instructions 318 807 1001 EN 2008/10

97

5 Maintenance
Inspection and maintenance as required
Clean the radiator and oil cooler,
check for leaks
CAUTION

Clean the radiator only when the engine is stopped


and cool.
Do not touch the hot radiator.

NOTE

Do not open the engine cover.

Remove cover plates (1 & 2).


Remove any debris from the radiator and oil
cooler.

1
d3181014

Clean the radiator and oil cooler fins with


compressed air.
A cold cleaner or steam jet can be used if
the accumulation of dirt is excessive.
If a cold cleaner is used, allow sufficient time
for the cleaner to soak in before spraying
clean with a water jet.
NOTE

On trucks with a particle filter system* clean


the exhaust duct thoroughly.
Run the engine warm to evaporate any
residual water and to prevent the formation
of corrosion.
Check all fittings, hoses and pipes at the
radiator and oil cooler for leaks.
Change porous hoses, tighten the hose
clamps if required.
Inspect for leaks in the cooling system with
the engine running and at operating temperature.
CAUTION
When using compressed air, observe the safety
precautions.

Refit cover plates (1 & 2).


* option

98

Operating Instructions 318 807 1001 EN 2008/10

Maintenance 5
Inspection and maintenance as required

Hydraulic system: oil level check


CAUTION
Follow the instructions for handling fluids and lubricants.
1

Lower the spreader and put the mast upright.


Check oil level in sight glass (1), located in
the right side of the chassis.
NOTE

Maximum hydraulic capacity: 283 lts


d3181009

To add oil, slowly unscrew breather filter


located on the top of the hydraulic oil tank,
allowing the air to escape before removing
fully.
Top up hydraulic oil through filter fill plug (2).
Re-fit filler plug and breather filter.
2

d3591168

Operating Instructions 318 807 1001 EN 2008/10

99

5 Maintenance
Inspection and maintenance as required

100

Operating Instructions 318 807 1001 EN 2008/10

Maintenance 5
Inspection and maintenance after the first 50 hours

Inspection and maintenance after the first 50 hours


Clean the truck
NOTE

How often the truck needs cleaning depends


on its use. If used with very aggressive media
like salt water, fertilizer, chemicals, cement,
etc., the truck should be cleaned carefully and
more often.
WARNING
Hot steam or intensive degreasing solutions should
be used with utmost care. The grease in sealed
for life bearings may dissolve and leak out. Since
re-greasing is not possible, this will result in damage to the bearing.

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.

Operating Instructions 318 807 1001 EN 2008/10

101

5 Maintenance
Inspection and maintenance after the first 50 hours
Clean and spray the lifting chains
NOTE

The lifting chains must be cleaned if the dust


covering the chain prevents penetration of the
lubricant.
Place a container under the mast.
Clean the chain using paraffin derivatives
such as washing petrol, wear protective
clothing and observe the manufacturers
safety notes.
When using a steam jet, use without using
additives.
After cleaning, blow dry the chain at once
to remove any water in the chain links and
on the surface. During this procedure the
chain should be moved several times.

d3181025

Spray Linde chain spray immediately, move


the chain while spraying by raising and lowering the fork carriage.
CAUTION
Lifting chains are safety components. The use
of cold cleaners, chemical cleaning agents and
caustic or acidic and chlorinated fluids can be a direct cause of damage to the chain.

NOTE

Trucks in service in the food industry must be


lubricated with an oil approved for the food
industry instead of chain spray.

102

Operating Instructions 318 807 1001 EN 2008/10

Maintenance 5
Inspection and maintenance after the first 50 hours

Check seat belt for condition and


correct operation*

NOTE

For safety reasons the condition and proper


operation of the retention system should be
inspected regularly (monthly).
Under extreme operating conditions this
check is required daily before taking the truck
into operation.

Pull belt (1) out fully and inspect for fraying.


Check lock (2) for correct operation and the
retractor for proper return of the belt.
Check covers for damage.

d3591093

Check the automatic lock.


Park the truck on level ground.
Pull out the belt with a jerk. The automatic
lock should prevent the belt from unrolling
from retractor (3).
Slide the seat fully forward.
Tilt the backrest fully forward.
* option
CAUTION
Have a defective seat belt replaced immediately by
your authorised dealer.
Do not operate the truck with a faulty seat belt.

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

Operating Instructions 318 807 1001 EN 2008/10

Maintenance 5
Inspection and maintenance after the first 50 hours

Change the engine oil (every 12


months minimum)

CAUTION
Please observe lubricant recommendations. (Different types of oil/different maintenance intervals.)

3181044

Drain the engine oil


CAUTION
Follow precautions for handling fuels and lubricants. Wear eye protectors!

DANGER
Risk of scalding when draining hot engine oil.
Wear protective clothing.

NOTE

Change oil only when the engine is at operating temperature.


Place a suitable container under the sump.

2
3

d3591170

Remove filler cap (1) at the filler opening.


Remove engine oil drain plug (2) on the
sump.
Allow oil to drain completely into the container.
Refit drain plug (2) with a new sealing ring.

Operating Instructions 318 807 1001 EN 2008/10

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.

Wear protective clothing.

Place a catch tray with a capacity of at least


10 litres under filter (2).
Loosen filter (2) with a filter wrench and
remove it by hand.

Catch any oil flowing out and dispose of in


an environment friendly way.
Renew the O-ring on the cap.
Clean filter housing (1).

d3591096

Check filter seal rings (3) in new engine oil


filter (2), for proper seating.

Fill new filter (2), slowly with oil.


Lubricate seal rings (3) of new filter (2) with
engine oil.
Install filter (2), hand tightening only.

Start the engine and check the seal faces


for leakage.
Stop the engine and wait for at least 5 minutes for the engine oil level to stabilise.
Check the engine oil level and replenish
engine oil if necessary.

d3591097

106

Operating Instructions 318 807 1001 EN 2008/10

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

Operating Instructions 318 807 1001 EN 2008/10

107

5 Maintenance
Inspection and maintenance after the first 50 hours
Change the fuel pre-filter with water
monitor
1

Clean the area around fuel filter (1).


Disconnect water monitor (2), check for
damage. Replace if necessary.
Drain fuel filter (1) see Fuel system, draining.

2
1

Remove fuel filter (1) using an appropriate


filter wrench.
NOTE

If the entire filter unit with water separator is


not going to be changed the water monitor
should be moved to the new fuel filter.

d3591100

Clean the filters sealing surface on the filter


housing.
Spread a thin layer of oil on the sealing ring
and mount the new fuel filter according to
the instructions on the filter.
Connect water monitor (2).
Start the engine and check for leaks.

Renew the safety element


The safety element (3) must be changed:
3

After 2000 hours of service.


If the element is defective:
Depress catch (1) remove cover (5) and
withdraw filter element (2) and safety element (3). Before installing a new safety
element, ensure it is not damaged.
Insert new safety element (3).

2
1
4

CAUTION
Do not clean or reuse the safety element.

Install filter element (2) in filter housing (4).


Take care not to damage safety element (3)
when installing it and be sure that the seal
sits correctly in the filter casing.

5
6
d3181043

Refit cover (5) and secure with catch (1).

108

Operating Instructions 318 807 1001 EN 2008/10

Maintenance 5
Inspection and maintenance after the first 50 hours
The dust ejection valve (6) must point downward.
Close the access door.
NOTE

Use only genuine parts as incorrect parts may


reduce the service life of the engine and affect
its performance.

Check the engine mounting for condition and security


The engine rubber mounts are subject to great
stresses. Depending on the operating conditions, their service life is limited.
Check the rubber mounts for cracks and
deformation, and replace if necessary.
NOTE

Please contact your authorised dealer for this


service.
Check all bolts on engine mounts and bearings for security and damage.
d3591121

Operating Instructions 318 807 1001 EN 2008/10

109

5 Maintenance
Inspection and maintenance after the first 50 hours
Clean the radiator and oil cooler,
check for leaks
CAUTION

Clean the radiator only when the engine is stopped


and cool.
Do not touch the hot radiator.

NOTE

Do not open the engine cover.

Remove cover plates (1 & 2).


Remove any debris from the radiator and oil
cooler.

1
d3181014

Clean the radiator and oil cooler fins with


compressed air.
A cold cleaner or steam jet can be used if
the accumulation of dirt is excessive.
If a cold cleaner is used, allow sufficient time
for the cleaner to soak in before spraying
clean with a water jet.
NOTE

On trucks with a particle filter system* clean


the exhaust duct thoroughly.
Run the engine warm to evaporate any
residual water and to prevent the formation
of corrosion.
Check all fittings, hoses and pipes at the
radiator and oil cooler for leaks.
Change porous hoses, tighten the hose
clamps if required.
Inspect for leaks in the cooling system with
the engine running and at operating temperature.
CAUTION
When using compressed air, observe the safety
precautions.

Refit cover plates (1 & 2).


* option

110

Operating Instructions 318 807 1001 EN 2008/10

Maintenance 5
Inspection and maintenance after the first 50 hours

Check intake and exhaust systems


for leaks and security
Inspect air intake hoses for leaks. If leaking,
renew the hoses.
Check that hose clamps are secure, renew
if necessary.

d3181033

CAUTION
Ensure the exhaust system is cool before servicing.

Check the overall condition of the exhaust


system, replace any pipes or the silencer if
badly corroded.
Check exhaust mounting flange nuts.
Check that exhaust clamps are secure.
Check that silencer mountings are secure.
Torque .......................... 56 Nm
Check tail pipe mounting bolts are secure.

d3181032

Operating Instructions 318 807 1001 EN 2008/10

111

5 Maintenance
Inspection and maintenance after the first 50 hours
Check the cab mountings
1

Check cab mounting bolts (1) are secure;


tighten to 46 Nm if necessary.

d3181030

Tighten the wheel nuts


CAUTION
During initial operation and after each wheel
change, the wheel fasteners must be tightened
before starting work and thereafter every 10 service
hours until they have settled, i.e. until no further
tightening is possible.

Thereafter check wheel nuts (1) every 100


hours.

Torque all wheel nuts to 680 Nm.


A socket with an extension bar is needed to
tighten the front wheel nuts.

2
d3181013

112

Operating Instructions 318 807 1001 EN 2008/10

Maintenance 5
Inspection and maintenance after the first 50 hours

Tyres - check condition and pressure


CAUTION
Low tyre inflation pressure reduces tyre service life
and the stability of the truck.

Check tyres for damage and excessive


wear.
Remove any foreign objects from the
treads.

Check the tyres for specified pressure.


Inflate tyres according to stickers on the
chassis.

2
d3181013

If necessary, add air at filler valves for drive


axle (1) and steer axle (2).
Tyre specification:
Drive axle:
Front ......................................... 10.0 bar
Steer axle:
Rear ......................................... 10.0 bar

Clean and lubricate the steer axle

NOTE

Lubricate with grease according to the lubricant recommendations.


Stop the engine.
Thoroughly clean the steering axle with
water or cold cleaner.
Jack up the rear of the truck.
Turn the steering wheel half a turn. This will
relieve the pressure on the bearings and
allow grease to flow more easily.
Grease the track rod at grease nipples (1)
(2 points on each side of axle).

2
1

d3591107

Grease the swivel pins at grease nipples (2)


(2 points on each side of axle).
Apply grease until clean grease emerges at
the roller bearings.
Lower the rear of the truck to the ground.

Operating Instructions 318 807 1001 EN 2008/10

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

If the parking brake is not operating correctly,


contact your authorised dealer.

d3591118

Check the batteries.


CAUTION
Battery electrolyte is very caustic. If electrolyte
comes into contact with clothing, skin or eyes, flush
the areas in question immediately with water. In
case of eye contact see a doctor at once! Neutralize
any spilled battery acid immediately!
Avoid any contact with battery electrolyte.

The batteries are fitted in the air filter/battery


compartment (1) on the left-hand side of the
truck.
Check the batteries for cracks in the casings, and leaked electrolyte.
Remove any corrosion on battery terminals
and check the connections for tight seating.

d3181027

Tighten the terminals and coat with nonacidic grease.

114

Operating Instructions 318 807 1001 EN 2008/10

Maintenance 5
Inspection and maintenance after the first 50 hours

Check the tension of double hoses


The tension of the double hoses should be
5-10 mm per meter, referred to initial length.
Adjust the tension of the hoses to the
specified dimension by sliding them in the
clamps.

d3181053

Lubricate the mast and tilt cylinder


pivots
Lubricate the mast pivot pins
CAUTION

Take the weight off each pivot pin in turn using a suitable jack to ensure the optimum ingress of grease.

NOTE

Lubricate with grease according to the lubricant recommendations.


Lubricate mast pivot pin (1) through the front
of the mast.
Lubricate with grease gun until new grease
is visible at the bearing.
CAUTION

d3181031

Refer to safety notes on securing the mast when


working on the front of the machine.

Operating Instructions 318 807 1001 EN 2008/10

115

5 Maintenance
Inspection and maintenance after the first 50 hours
Lubricate the tilt cylinder pivots
NOTE

Lubricate with grease according to the lubricant recommendations.


Lubricate tilt cylinder pivots (2), two points.
Access to the bottom two points is from the
side of the tilt cylinder recess under the cab.
Access to the top two points is on either side
of the mast.
Lubricate with grease gun until new grease
is visible at the bearing.

2
d3591109

Check and adjust mast chains, lubricate with chain spray


NOTE

After some time in service the lifting chains


stretch and therefore must be checked and
adjusted as necessary on the left and right
sides of the mast.

Clean the mast chains.

Put the mast vertical.


Remove split pin (1).
Release locknuts (2).
Using nuts (3), adjust the chains to allow a
clearance of 12 mm (1/2 inch) between the
fork heels and the floor.

d3591115

Tighten locknuts (2).


Fit new split pin (1).
NOTE

Ensure both chains are adjusted equally.


Spray channel surfaces, pulleys and chains
with Linde chain spray.

116

Operating Instructions 318 807 1001 EN 2008/10

Maintenance 5
Inspection and maintenance after the first 50 hours
NOTE

Trucks in service in the food industry must be


lubricated with an oil approved for the food
industry instead of chain spray.

Operating Instructions 318 807 1001 EN 2008/10

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

Drain the engine oil


CAUTION
Follow precautions for handling fuels and lubricants. Wear eye protectors!

DANGER
Risk of scalding when draining hot engine oil.
Wear protective clothing.

NOTE

Change oil only when the engine is at operating temperature.


Place a suitable container under the sump.

2
3

d3591170

Remove filler cap (1) at the filler opening.


Remove engine oil drain plug (2) on the
sump.
Allow oil to drain completely into the container.
Refit drain plug (2) with a new sealing ring.

118

Operating Instructions 318 807 1001 EN 2008/10

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.

Wear protective clothing.

Place a catch tray with a capacity of at least


10 litres under filter (2).
Loosen filter (2) with a filter wrench and
remove it by hand.

Catch any oil flowing out and dispose of in


an environment friendly way.
Renew the O-ring on the cap.
Clean filter housing (1).

d3591096

Check filter seal rings (3) in new engine oil


filter (2), for proper seating.

Fill new filter (2), slowly with oil.


Lubricate seal rings (3) of new filter (2) with
engine oil.
Install filter (2), hand tightening only.

Start the engine and check the seal faces


for leakage.
Stop the engine and wait for at least 5 minutes for the engine oil level to stabilise.
Check the engine oil level and replenish
engine oil if necessary.

d3591097

Operating Instructions 318 807 1001 EN 2008/10

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

Check coolant strength

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

Check the concentration of antifreeze. Use


a mixture of 50% water and 50% ethylene
glycol or propylene glycol base antifreeze to
protect the engine to -32C (-25F), all year
round.
Use a refractometer to accurately measure
freezing point protection and concentration
level.

120

Operating Instructions 318 807 1001 EN 2008/10

Maintenance 5
Inspection and maintenance every 500 hours or 6 months whichever comes first

Change the fuel pre-filter with water


monitor
Clean the area around fuel filter (1).

Disconnect water monitor (2), check for


damage. Replace if necessary.
Drain fuel filter (1) see Fuel system, draining.

2
1

Remove fuel filter (1) using an appropriate


filter wrench.
NOTE

If the entire filter unit with water separator is


not going to be changed the water monitor
should be moved to the new fuel filter.

d3591100

Clean the filters sealing surface on the filter


housing.
Spread a thin layer of oil on the sealing ring
and mount the new fuel filter according to
the instructions on the filter.
Connect water monitor (2).
Start the engine and check for leaks.

Check the condition of the V-belt


CAUTION
Stop the engine and remove the ignition key.

Tilt the cab (see - Tilting the cab).


Inspect V-belt (2) for excessive wear, frays,
breaks and traces of oil.

Replace a damaged V-belt.


CAUTION
A defective and loose V-belt reduces the voltage.
Do not operate the truck with a defective V-belt.

Lower the cab.

Operating Instructions 318 807 1001 EN 2008/10

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.

Tilt the cab.


Inspect drive belt (1) for excessive wear,
frays, breaks and traces of oil.

Replace a damaged drive belt.


CAUTION
A defective and loose drive belt reduces the voltage.

d3591157

Lower the cab.

Check the cab mountings


1

Check cab mounting bolts (1) are secure;


tighten to 46 Nm if necessary.

d3181030

Brake control mechanism


NOTE

These checks must take place every 500


hours, PLUS after any component replacement, PLUS after any adjustment.
Check the operation and adjustment of
brake pedal micro switches.
Adjust the brake cable to ensure that brake
operating lever is in contact with brake valve
spool without any activation of the spool.
122

Operating Instructions 318 807 1001 EN 2008/10

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

Specialist knowledge is required to carry out


these procedures, please contact your authorised Linde dealer.

Check the security of the axle clamp


and drive motors
Check the fastening bolts (1) (M30) of the
drive motors with a torque of 1350 Nm, after
first removing the traction wheels.

1
d3591102

Operating Instructions 318 807 1001 EN 2008/10

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.

Remove cover (1).


Slowly unscrew breather filter (2) located on
the top of the hydraulic oil tank, allowing the
air to escape before removing fully.
If air is not heard to escape, replace
breather filter (2).

d3181026

Lubricate the spreader


1

5
2

2
3

d3181045

NOTE

Use Linde heavy duty lubricating grease with


additives EP and MOS2.

124

Operating Instructions 318 807 1001 EN 2008/10

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

Check for wear and general condition of


twistlock. If in doubt replace the twistlock.
NOTE

Replace twistlock if dimension (C) is less than


25 mm.

d3181052

Operating Instructions 318 807 1001 EN 2008/10

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

Position 3 - Main frame and extension


beam wear pads
Apply grease on the inside of the end rings
of each main frame beam.

d3181048

Position 4 - Side shift cylinder bearings


Apply grease to grease nipples on the cylinder tube bearing.

d3181049

126

Operating Instructions 318 807 1001 EN 2008/10

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.

Operating Instructions 318 807 1001 EN 2008/10

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

Clean the radiator and hydraulic oil cooler only


when the engine is stationary and cool.
See page 94.

Check the soot particulate filter system*


Check electric contacts for tightness,
corrosion and damage.
Check the system for correct operation
(soot warning, buzzer, regeneration).
Inspect filter mounts for security.
Check the screws on the filter casing
and parts conducting exhaust gases for
tightness.
Please contact your authorised dealer for
these services.
*option

Check electric cables, cable connectors


and connections for condition and
tightness
Check cable connections for tightness and
oxidation.

NOTE

Oxidised terminals and cracked cables result


in loss of voltage, thus leading to starting
difficulties.
Remove oxidation residue and replace any
cracked cables.

Check the hydraulic system, pumps,


valves and lines
Check all connections between the oil
tank, pumps and control valves for leaks.
If necessary, tighten any loose joints.
Check the mast and carriage, levelling and
steer cylinders for leaks.
Renew cracked hoses.
Check the hoses for damage and chafing,
renew if necessary.

Check and lubricate other pivots and


joints
Inspect and lubricate the pivots and mountings of: Seat guides, cab pivot pins, windscreen wipers, cab door hinges, window
hinges and locks etc.

Check earth lead for tightness.


Check electric wiring for chafe marks and
tightness.

128

Operating Instructions 318 807 1001 EN 2008/10

Maintenance 5
Inspection and maintenance every 1000 hours or 12 months, whichever comes first

Check the engine mounting for condition and security


The engine rubber mounts are subject to great
stresses. Depending on the operating conditions, their service life is limited.
Check the rubber mounts for cracks and
deformation, and replace if necessary.
NOTE

Please contact your authorised dealer for this


service.
Check all bolts on engine mounts and bearings for security and damage.
d3591121

Check intake and exhaust systems


for leaks and security
Inspect air intake hoses for leaks. If leaking,
renew the hoses.
Check that hose clamps are secure, renew
if necessary.

d3181033

Operating Instructions 318 807 1001 EN 2008/10

129

5 Maintenance
Inspection and maintenance every 1000 hours or 12 months, whichever comes first
CAUTION
Ensure the exhaust system is cool before servicing.

Check the overall condition of the exhaust


system, replace any pipes or the silencer if
badly corroded.
Check exhaust mounting flange nuts.
Check that exhaust clamps are secure.
Check that silencer mountings are secure.
Torque .......................... 56 Nm
Check tail pipe mounting bolts are secure.

d3181032

130

Operating Instructions 318 807 1001 EN 2008/10

Maintenance 5
Inspection and maintenance every 1000 hours or 12 months, whichever comes first

Check the cooling fan belt tensioner


With the engine turned off, check that both
the top and bottom tensioner arm stops are
not touching the cast boss on the tensioner
body. If either of the stops is touching a
boss, the alternator belt must be replaced.
Check to make certain the correct belt part
number is being used if either condition
exists.
WARNING
When using a steam cleaner, wear safety glasses
or a face shield, as well as protective clothing. Hot
steam can cause serious personal injury.

Check the tensioner pulley and body for


cracks. If any cracks are noticed, the tensioner must be replaced. Contact your
authorised dealer. Check the tensioner
for dirt build up. If this condition exists,
the tensioner must be removed and steam
cleaned.

d3591153

With the cooling fan belt removed, check


that the bottom tensioner arm stop is in
contact with the bottom tensioner arm stop
boss on the tensioner body. If these two
are not touching, the tensioner must be
replaced.

d3591154

Operating Instructions 318 807 1001 EN 2008/10

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

Maximum pulley misalignment is 3 degrees.


This measurement can be taken with a straight
edge and an inclinometer.
Install the belt.

d3591155

Renew the air filter element


The air filter (2) must be changed:
After 1000 hours of service.
If the element is defective:
Unclip (1), remove cover (5) and withdraw
filter element (2). Before installing a new
filter element, ensure it is not damaged.
Insert new filter element (2).
CAUTION
Do not clean or reuse the safety element.

Install cover (5) and secure with clip (1).


The dust ejection valve (6) must point downward.

Close the access door.


2

NOTE

Use only genuine parts as incorrect parts may


reduce the service life of the engine and affect
its performance.

5
6
d3181043

132

Operating Instructions 318 807 1001 EN 2008/10

Maintenance 5
Inspection and maintenance every 1000 hours or 12 months, whichever comes first

Clean and lubricate the steer axle

NOTE

Lubricate with grease according to the lubricant recommendations.


Stop the engine.
Thoroughly clean the steering axle with
water or cold cleaner.
Jack up the rear of the truck.
Turn the steering wheel half a turn. This will
relieve the pressure on the bearings and
allow grease to flow more easily.
Grease the track rod at grease nipples (1)
(2 points on each side of axle).

2
1

d3591107

Grease the swivel pins at grease nipples (2)


(2 points on each side of axle).
Apply grease until clean grease emerges at
the roller bearings.
Lower the rear of the truck to the ground.

Final drive oil level check


CAUTION
Perform the check with the engine running.

Follow the instructions for handling fluids and lubricants.

Ensure that filler plug (1), is at the 12 o clock


position, and drain plug (2) is at the 5 o clock
position.
Remove filler plug (1).

Check oil is visible at the base of drain plug


(2).
If required, replenish oil to the base of hub
drain plug (2).

d3591034

Replace filler plug (1) and drain plug (2).

Operating Instructions 318 807 1001 EN 2008/10

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

If the parking brake is not operating correctly,


contact your authorised dealer.

d3591118

Check the batteries.


CAUTION
Battery electrolyte is very caustic. If electrolyte
comes into contact with clothing, skin or eyes, flush
the areas in question immediately with water. In
case of eye contact see a doctor at once! Neutralize
any spilled battery acid immediately!
Avoid any contact with battery electrolyte.

The batteries are fitted in the air filter/battery


compartment (1) on the left-hand side of the
truck.
Check the batteries for cracks in the casings, and leaked electrolyte.
Remove any corrosion on battery terminals
and check the connections for tight seating.

d3181027

Tighten the terminals and coat with nonacidic grease.

134

Operating Instructions 318 807 1001 EN 2008/10

Maintenance 5
Inspection and maintenance every 1000 hours or 12 months, whichever comes first

Check the tension of double hoses


The tension of the double hoses should be
5-10 mm per meter, referred to initial length.
Adjust the tension of the hoses to the
specified dimension by sliding them in the
clamps.

d3181053

Lubricate the mast and tilt cylinder


pivots
Lubricate the mast pivot pins
CAUTION

Take the weight off each pivot pin in turn using a suitable jack to ensure the optimum ingress of grease.

NOTE

Lubricate with grease according to the lubricant recommendations.


Lubricate mast pivot pin (1) through the front
of the mast.
Lubricate with grease gun until new grease
is visible at the bearing.
CAUTION

d3181031

Refer to safety notes on securing the mast when


working on the front of the machine.

Operating Instructions 318 807 1001 EN 2008/10

135

5 Maintenance
Inspection and maintenance every 1000 hours or 12 months, whichever comes first
Lubricate the tilt cylinder pivots
NOTE

Lubricate with grease according to the lubricant recommendations.


Lubricate tilt cylinder pivots (2), two points.
Access to the bottom two points is from the
side of the tilt cylinder recess under the cab.
Access to the top two points is on either side
of the mast.
Lubricate with grease gun until new grease
is visible at the bearing.

2
d3591109

Check and adjust mast chains, lubricate with chain spray


NOTE

After some time in service the lifting chains


stretch and therefore must be checked and
adjusted as necessary on the left and right
sides of the mast.

Clean the mast chains.

Put the mast vertical.


Remove split pin (1).
Release locknuts (2).
Using nuts (3), adjust the chains to allow a
clearance of 12 mm (1/2 inch) between the
fork heels and the floor.

d3591115

Tighten locknuts (2).


Fit new split pin (1).
NOTE

Ensure both chains are adjusted equally.


Spray channel surfaces, pulleys and chains
with Linde chain spray.

136

Operating Instructions 318 807 1001 EN 2008/10

Maintenance 5
Inspection and maintenance every 1000 hours or 12 months, whichever comes first
NOTE

Trucks in service in the food industry must be


lubricated with an oil approved for the food
industry instead of chain spray.

Operating Instructions 318 807 1001 EN 2008/10

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.

The radiator drain plug is fitted at the base of


the radiator. It is reached from under the truck
through an access hole immediately in front of
the steer axle.

d3591124

Remove radiator cap (1).


Place a container of at least 25 L capacity
under the radiator drain plug (2).
Remove drain plugs (2), and allow the
coolant to drain.
Flush out the radiator through the filler cap
aperture.
Refit radiator drain plug (2).
Fill the cooling system with a 50:50 waterantifreeze mixture.
Refit radiator cap (1).
Run the engine for 5 minutes.
Check the coolant level, replenishing
coolant if required.

2
3

d3591170

Check the cooling system for leaks, top up if


necessary.
NOTE

Capacity of cooling system .......... 20 L

138

Operating Instructions 318 807 1001 EN 2008/10

Maintenance 5
Inspection and maintenance every 2000 hours or 24 months, whichever comes first

Check the vibration damper


NOTE

Silicone fluid inside the vibration damper will


become solid after extensive service, which
makes the vibration damper inoperative. This
could cause major engine or driveline problems.
Check the vibration damper for evidence of
loss of fluid, dents, and wobble.
Inspect the vibration damper thickness for
any deformation or raising of the damper
front cover plate.
If any deformations or variations are detected, please contact your authorised
dealer.

Operating Instructions 318 807 1001 EN 2008/10

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

Technical skill and knowledge are required for


this adjustment. Please contact your authorised dealer.

Isolate the batteries.


Remove the rocker lever covers. Locate top
dead center (TDC) for cylinder number 1.
d3591133

Use a -inch drive and engine barring tool


(1), part number 3824591, to rotate the
engine (clockwise when facing the damper)
until cylinder number 6 intake rocker arm
starts to open the intake valve.
NOTE

Move rocker arm (2) while barring the engine;


when rocker arm (2) gets tight, stop barring.
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

Ensure the engine is at top dead center


(TDC) for cylinder number 1. Set only the
valves indicated in the illustration (E = exhaust, I = intake).

140

Operating Instructions 318 807 1001 EN 2008/10

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

Adjust the valves as indicated. Set only


the valves indicated below (EX = exhaust,
IN = intake). Do not set valves that are not
indicated below.
Torque Value: = 24 Nm (18 ft-lb) .
Check the rocker lever covers for cracks,
replace if necessary.

d3591136

Refit the rocker lever covers.


Tighten the capscrews

Renew the safety element


The safety element (3) must be changed:
3

After 2000 hours of service.


If the element is defective:
Depress catch (1) remove cover (5) and
withdraw filter element (2) and safety element (3). Before installing a new safety
element, ensure it is not damaged.
Insert new safety element (3).

2
1
4

CAUTION
Do not clean or reuse the safety element.

Install filter element (2) in filter housing (4).


Take care not to damage safety element (3)
when installing it and be sure that the seal
sits correctly in the filter casing.

5
6
d3181043

Refit cover (5) and secure with catch (1).


The dust ejection valve (6) must point downward.
Close the access door.

Operating Instructions 318 807 1001 EN 2008/10

141

5 Maintenance
Inspection and maintenance every 2000 hours or 24 months, whichever comes first
NOTE

Use only genuine parts as incorrect parts may


reduce the service life of the engine and affect
its performance.

Checks - various
Check the starter motor, alternator and
injection pump
NOTE

Examination and service of these components


must be left to your authorised dealer.

Check condition and mounting of mast


and lifting chain
Clean the mast channels and chains
thoroughly.
Check the chains for wear or damage,
particularly in the area of the chain pulleys.

Replace damaged chains.


Check mast, guide surfaces and rollers for
condition and secure attachment.
Check that the mast pivot screws are
secure.

Check and adjust the hub bearings


Correctly adjusted hub bearings must not
allow any perceptible end float, but allow the
wheel to rotate freely without binding. In the
case of bearing play, contact your authorised
dealer.

Check the mounting of the chain at the chain


anchor.

Check the condition of structured components


CAUTION
Work on the truck on level ground. Lower the
carriage, stop the engine and put the parking brake
on when working.

CAUTION
This maintenance procedure requires to be carried
out at heights of more than 2 metres. Use suitable
access equipment. Danger of fall injuries.

should cover all areas of the main structures


and their connections. Attention should be
given to welds and material adjoining welds,
particularly at changes of section, bolted
interfaces and sliding pad pressure points.
Examine the mast, lift and tilt cylinders,
anchor and bearing points for damage,
wear, missing lock bolts, metal fatigue, etc.
Examine the bearings for damage, missing
retaining rings and abnormal wear.

Examine the structural components of the


truck to assure their integrity. Inspection

142

Operating Instructions 318 807 1001 EN 2008/10

Maintenance 5
Inspection and maintenance every 2000 hours or 24 months, whichever comes first

Change final drive hub oil


CAUTION

Follow the precautions for fluids and lubricants.

CAUTION
Work on the truck on level ground. Lower the carriage, stop the engine and put the parking brake on
when working.

Position the truck so that the final drive hub


level filler plug (1) is in a 1 o clock position
and the drain plug (2) is in the 6 o clock
position.

d3591138

Place a catch tray of at least 7 L capacity


under the hub.
Remove drain plug (2) and allow oil to drain
completely.
Remove and discard plug seal rings.
Rotate the wheel until the filler hole (1) is in
the 12 o clock position and the drain hole is
in the 5 o clock position.
Fill hub with gear oil to the base of drain plug
hole (2).

Fit filler plug (1) and drain plug (2) with new
seal rings.
Fit plugs (1) and (2).
2

d3591034

Operating Instructions 318 807 1001 EN 2008/10

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.

Depressurise the tank by rotating filler cap


(3) slowly until air is heard escaping from
the tank, keep rotating the filler cap until no
more air is heard.

d3591123

Remove nuts (1) from the top of housing (2),


remove housing (2) to expose filter element
retainer.
Press retainer down, rotate through 90 and
lift out to allow removal and replacement of
filters (4).
Lift out filters (4).
Replace filters (4).
Remove and retain cap (3), taking care to
retain spring.

Lift out filter.


Replace filter and seals, re-fit spring and
cap (3).

Check oil level and replenish, if required.


Remove plug (5) add oil, replace plug (5).
Dispose of used filters according to local
authority guidelines.
d3591125

144

Operating Instructions 318 807 1001 EN 2008/10

Maintenance 5
Inspection and maintenance every 2000 hours or 24 months, whichever comes first

Renew the hydraulic tank breather


filter
Remove cover (1).
Slowly unscrew breather filter (2) located on
the top of the hydraulic oil tank, allowing the
air to escape before removing fully.

NOTE

In a dusty atmosphere it may be necessary to


renew the filter earlier.
Fit new breather (2).
Refit cover (1).
Discard used filter according to local authority guidelines

Operating Instructions 318 807 1001 EN 2008/10

2
d3591137

145

5 Maintenance
Inspection and maintenance every 2000 hours or 24 months, whichever comes first

146

Operating Instructions 318 807 1001 EN 2008/10

Maintenance 5
Inspection and maintenance every 5000 hours

Inspection and maintenance every 3000 hours or 36 months,


whichever comes first
Replace the toothed belt and idler pulley
NOTE

Technical skill and knowledge are required


for this replacement. Please contact your
authorised dealer.

Inspection and maintenance every 5000 hours


Renewing the twistlocks
WARNING
Twistlocks are wearing parts and must be replaced
for safety reasons after maximum 5000 service
hours.

Operating Instructions 318 807 1001 EN 2008/10

Contact your authorised dealer for renewal of


the twistlocks.

147

5 Maintenance
Inspection and maintenance every 5000 hours

148

Operating Instructions 318 807 1001 EN 2008/10

Maintenance 5
Inspection and maintenance every 6000 hours

Inspection and maintenance every 6000 hours


Renew hydraulic oil of working hydraulic system
CAUTION
Follow the precautions for handling fluids and
lubricants.

CAUTION
Hydraulic oil and oil tank may be at operating
temperature. Danger of scalds and burns.

CAUTION

NOTE

The operator can have the hydraulic oil


analysed after about 2750 service hours to
determine if the hydraulic oil must be changed
at 3000 service hours.
NOTE

Technical skill and knowledge are required


for this procedure. Please contact your
authorised dealer.

Work on the truck on level ground. Lower the


carriage, stop the engine and put the parking brake
on when working.

Renewing the lift chains (at least every 3 years and when 3% stretch has been
attained)
NOTE

Please contact your authorised dealer for


renewal of the lift chains.

Operating Instructions 318 807 1001 EN 2008/10

149

5 Maintenance
Inspection and maintenance every 6000 hours

150

Operating Instructions 318 807 1001 EN 2008/10

Maintenance 5
Rated capacities

Rated capacities
Filling capacity/rated values

No.

Assembly

Aids/oils and lubrication

Filling capacity/Rated
values

Engine

Engine oil

approx. 15 lts.

Fuel tank

Diesel

approx. 190 lts.

Cooling system

Water and antifreeze mix

approx. 20 lts.

Working hydraulic system oil tank

Hydraulic oil

approx.330 lts.

Final Drive motor

Gear oil

approx. 4 lts.

Steer axle hub

Lubricating grease

as required

Batteries

Sealed for life

as required

Tyres

Air

10 bar

Wheel mounting nuts

10

Lubrication points on mast and


spreader

Lubricating grease

as required

11

Temperature switch

Oil

Engine oil temperature


130 C

12

Valve clearances

13

Fuel injection nozzle

Diesel

Operating pressure 246


bar Pressure setting 264
bar

14

Drive belt tension, Fan, Alternator

Belt deflection

approx. 10 mm

680 Nm

Inlet 0.254 mm
Exhaust 0.508 mm

Operating Instructions 318 807 1001 EN 2008/10

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

operation independent of the oil change


intervals.

API classification CH-4/SJ, ACEA E-5. Use


oils meeting the API classification CH by
choice.

Trucks equipped with a particle filter* system


should only be filled with oils having a low ash
content. Residues of oil additive combustion
(ash) can not be regenerated and they clog
the monolith in the long run.

Engine oils of API classification CD are


not recommended for the first 50 hours of
operation and for extra light duty. During
engine operation, part of the oil serving as
piston lubricant is burned (consumed). The
products of combustion combined with the
high temperatures lead to oil wear, especially
of the chemical additives.
Since this oil wear depends on operating
conditions and the quality of oil (productivity
of oil) and fuel used, oil change intervals of
different lengths result.
The longest possible oil change interval
for lubricating oil in engines is one year,
i.e. change oil at least once every year of

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.

Due to the disposal problem, the required


special tools and knowledge, the engine oil
and filter change should be performed by your
authorized dealer.
*option

Viscosity of oil
d3591144

Since the viscosity of lubricants varies with


temperature, the ambient temperature at the
locality of the trucks use is the determining
factor in selection of the viscosity range (SAE
class) of the engine oil (see diagram).

If the ambient temperature occasionally falls


below the temperature limit (e.g. using SAE 15
W/40 down to -15 C), the cold start capability
of the engine is reduced, but no damage to the
engine will result.

152

Operating Instructions 318 807 1001 EN 2008/10

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

used instead of hydraulic oil HLP 68, and a


SAE 30 engine oil can be used instead of HLP
100.
The above-mentioned recommendations are
only approximate values. If in doubt, contact
your authorized dealer. Recommendations of
representatives of the oil industry should also
be checked with your authorised dealer.

Oil additives of any kind must not be added to


any of the above mentioned engine oils! Their
use jeopardizes the warranty!

Only the above-mentioned mineral oils are


approved by the manufacturer. If other
hydraulic oils are used or mixed, costly
damage can result.

Mixing of different oil brands should be


avoided.

Final drive motor oil

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

To ensure faultless cold starts, it is important


to select the SAE classification of oil according
to the ambient temperature when starting the
engine.
For temperatures below -10 C it is recommended using SAE 5W/30 oil for sure cold
start performance.

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

Mixing ratio for lower temperature:

Recommendation for normal duty: Hydraulic


oil HLP ISO VG 68 to DIN 51524, T.2, average
continuous oil temperature 60 C - 80 C.
Hydraulic oil recommendation for heavy duty:

Temperature Antifreeze

Water

-30 C

45 %

55 %

-35 C

50 %

50 %

Hydraulic oil HLP ISO VG 100 to DIN 51524


T.2 for heavy duty and multi-shift operation,
operation in extreme climate zones or high
ambient temperatures, average continuous oil
temperature over 80 C.

Factory fill

50 %

50 %

For normal and heavy duty: Hydraulic oil


HVLP ISO VG 68 to DIN 51524 T.3 (multigrade
oil).
If it is difficult to obtain hydraulic oils that must
be imported, a SAE 20W/20 engine oil can be

Operating Instructions 318 807 1001 EN 2008/10

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 ...... 45 minimum


Viscosity ...... 2/4.5 centistrokes at 40 C
Density ...... 0.820/860 kg/litre at 15 C
Sulphur ...... 0.20% of mass, maximum
Distillation ...... 85% at 350 C

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
(%)

Oil change interval

<0.5

Normal

0.5 - 1.0

0.75 of normal

>1.0

0.5 of normal

Distillation: This is an indication of the mixture


of different hydrocarbons in the fuel. A high
ratio of lightweight hydrocarbons can affect
the combustion characteristics.

Low temperature fuels


Special winter fuels may be available for
engine operation at temperatures below
0C. These fuels have a lower viscosity and
also limit the wax formation in the fuel at low
temperatures. If wax formation occurs, this
could stop the fuel flow through the filter.

Sulphur: A high amount of sulphur (not


normally found in Europe, North America or
Australasia) can cause engine wear.

154

Operating Instructions 318 807 1001 EN 2008/10

Maintenance 5
Troubleshooting

Troubleshooting
Troubleshooting guide (Diesel engine)
Trouble

Possible cause

Correction

Engine will not start

Fuel tank empty.

Refill the tank.

Fuel filter clogged, in winter


by paraffin deposit.

Renew the filter, use winter fuel.

Water in fuel system prefilter. Drain the prefilter.


Fuel shut-off solenoid fails to Check for electric current with test
open.
lamp. If there is no current, check
fuses (5, 53 & 54) and switch.
Fuel line leaking.

Check all pipe connections for leaks


and tighten fittings.

Discharge indicator light not


illuminated although lamp is
okay.

Tighten connecting clamps at


battery, check cable connections.

Preheating system defective.

Check the power supply.

Fuel pump defective.

Check the cables and connections


at the preheat/starting switch. If the
fault can not be remedied, contact
your authorised dealer.

Injection nozzles defective.

These faults should always be


checked and corrected by skilled
staff. Please contact your authorised
dealer.

Injection pump defective.


Engine idling speed
incorrect.
Engine starting
performance is poor

Battery power is too low.


Check battery, clean battery termiBattery terminal is poor
nals, tighten clamps and cover with
loose or oxidized, causing
non-acidic grease.
the starter to turn only slowly.
Fuel supply insufficient.
Restriction or air in fuel
system due to paraffin
deposits in winter.

Renew the fuel filter. Check the fuel


line connections for leaks and tighten
fittings. Use winter fuel in the cold
season.

Particularly in winter: Engine Use engine oil appropriate for the


oil viscosity too high.
ambient temperature.

Operating Instructions 318 807 1001 EN 2008/10

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.

Renew the fuel filter. Check the fuel


line connections for leaks and tighten
fittings. Use winter fuel in the cold
season.

Injection pump overflow


valve not functioning
correctly.

Contact your authorised dealer.


Adjust valve clearance.

Valve clearance not as


specified. Injection nozzles
defective. Engine oil level
too high.

Contact your authorised dealer.


Drain oil to the top mark on the
dipstick.

Excessive exhaust
smoke

Poor compression due to


burned-in or broken piston
rings or incorrect valve
clearance.

Adjust valve clearance. Contact your


authorised dealer.

Idle running trouble

Fuel system not in order.

Clean and inspect fuel prefilter and


fuel filter. Repair or replace leaky,
fouled or bent fuel return lines and
injection lines.

Speed setting incorrect.

Should only be adjusted by skilled


staff. Contact your authorised dealer.

Coolant level low.

Check cooling system for leaks, seal


if necessary. Add coolant.

Fan V-belt either slack or


broken.

Tighten or renew the V-belt.

Radiator fins restricted due


to dirt or foreign objects.

Clean the radiator.

Injection system setting


incorrect.

Contact your authorised dealer.

Leaks in the lubricating


system.

Contact your authorised dealer.

Oil level too low.

Add lubricating oil.

Engine overheating,
red warning light in
composite instrument
illuminated. Stop the
engine immediately.

Engine oil pressure too


low. Stop the engine
immediately.

156

Operating Instructions 318 807 1001 EN 2008/10

Maintenance 5
Troubleshooting
Discharge indicator
light illuminated during
operation

Alternator RPM too low.

Check V-belt tension.

Alternator not charging the


Contact your authorised dealer.
battery because alternator or
relay defective.

Operating Instructions 318 807 1001 EN 2008/10

157

5 Maintenance
Troubleshooting

158

Operating Instructions 318 807 1001 EN 2008/10

Maintenance 5
Troubleshooting

Troubleshooting guide (Hydraulic system)


Abnormal noise

Suction filter restricted.

Renew the filter.

Suction hoses leaking, oil foaming. Tighten lines. Replace suction


hoses. Check oil level, top up if
necessary.

No or too low
pressure in system

Oil pressure
fluctuating

No oil flow or low oil


flow

Hydraulic pump or motor failure,


seals defective, causing air intake.

Have hydraulic unit inspected by


your authorised dealer.

Incorrect oil viscosity, low oil level


in tank or in hydraulic pump.

Change oil, be sure to use the


correct viscosity, top up oil.

Pump suction defective, noise.

Change oil, top up oil. Contact your


authorised dealer.

Pump failure, leakages, pressure


valves do not close, valve seat
damage.

Contact your authorised dealer.

Pipe broken or leaky.

Replace or tighten line.

Oil of low viscosity, causing high


leakage losses.

Change oil, be sure to use oil of


correct viscosity.

Oil temperature warning lamp


illuminated.

Check oil level, clean oil cooler.

Cause as under abnormal noise.

See abnormal noise.

Pressure limiting valves or boost


pressure valves sticking.

Contact your authorised dealer.

Lift and tilt cylinders have tight


spots.

Contact your authorised dealer.

Mast does not extend completely


or retracts slightly after being
extended.

Top up hydraulic oil.

Filter restricted (if accompanied by


noise).

Clean or replace filter.

Pump failure, leakages, pressure


limiting valves do not close, valve
seat damaged.

Contact your authorised dealer.

Pipe broken or leaking.

Tighten or replace line.

Valves restricted.

Contact your authorised dealer.

Hydraulic system overheating.

Check oil level, use specified oil,


clean oil cooler, if needed.

Operating Instructions 318 807 1001 EN 2008/10

159

Maintenance

Hydraulic oil
temperature too high

160

Pump failure, valves leaking.

Contact your authorised dealer.

Oil level too low or oil cooler


defective.

Check oil level, if necessary top


up oil. Clean cooler and check for
leaks. If defective, contact your
authorised dealer.

Operating Instructions 318 807 1001 EN 2008/10

Index
g

NUMBERS AND SYMBOLS


1000 h Service plan
2000 h Service plan
3000 h Service plan
500 h Service plan .
5000 h Service plan
6000 h Service plan

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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

Operating Instructions 318 807 1001 EN 2008/10

Check intake and exhaust systems for


leaks and security . . . . . . . 111, 129
Check seat belt for condition and
correct operation* . . . . . . . . . 93, 103
Check the air lilter . . . . . . . . . . . . . . . . . . 91
Check the batteries. . . . . . . . . . . . 114, 134
Check the cab mountings . . . . . . . 112, 122
Check the condition of structured
components . . . . . . . . . . . . . . . . 142
Check the condition of the drive belt . . . 122
Check the condition of the V-belt . . . . . . 121
Check the cooling fan belt tensioner . . . 131
Check the engine mounting for
condition and security . . . . . 109, 129
Check the hydraulic system, pumps,
valves and lines . . . . . . . . . . . . . 128
Check the hydraulic tank breather filter . 124
Check the parking brake for proper
operation . . . . . . . . . . . . . . 114, 134
Check the security of the axle clamp
and drive motors . . . . . . . . . . . . 123
Check the soot particulate filter
system* . . . . . . . . . . . . . . . . . . . 128
Check the starter motor, alternator and
injection pump . . . . . . . . . . . . . . 142
Check the tension of double
hoses . . . . . . . . . . . . . . . . 115, 135
Check the tyres for damage and foreign
objects . . . . . . . . . . . . . . . . . . . . . 97
Check the vibration damper . . . . . . . . . 139
Check valve clearances . . . . . . . . . . . . 140
Checking the coolant level in the
reservoir . . . . . . . . . . . . . . . . . . . 41
Checking the fuel . . . . . . . . . . . . . . . . . . 40
Checks - various . . . . . . . . . . . . . . . . . 142
Checks prior to first operation* . . . . . . . . . 9
Clean and lubricate the steer
axle . . . . . . . . . . . . . . . . . . 113, 133
Clean the fuel filter . . . . . . . . . . . . . . . . . 92
Clean the radiator and hydraulic oil
cooler . . . . . . . . . . . . . . . . . . . . 128
Clean the radiator and oil cooler, check
for leaks . . . . . . . . . . . . . . . . 98, 110
Clean the truck . . . . . . . . . . . . . . . . 95, 101

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

Operating Instructions 318 807 1001 EN 2008/10

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

Operating Instructions 318 807 1001 EN 2008/10

163

Linde Material Handling GmbH


318 807 1001 EN 2008/10

Operating Instructions
Container Handler

8, C90-5, C90-6, C90-7

Annex

318 807 1001 EN 2008/10

6
Technical data

170

Technical data

Operating Instructions 318 807 1001 EN 2008/10

Technical data

Technical Data

a
2

a
2

Operating Instructions 318 807 1001 EN 2008/10

171

Technical data

BR318 - C90/5, C90/6, C90/7

Track width, rear

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

Axle load with


load, front/rear

kg 34,217/9,161
35,315/9,341
35,466/9,462
33081/10007
33666/10210
33858/10351
35198/1211

Axle load without


load, front/rear

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

Length to fork face

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

Tyre size, front

12.00
x 24 20
pr

12.00
x 24 20
pr

12.00 x 12.00 x 12.00 x 12.00 x 12.00 x


24 20 pr 24 20 pr 24 20 pr 24 20 pr 24 20 pr

342

342

342

342

342

342

342

Tyre size, rear

12.00
x 24 20
pr

12.00
x 24 20
pr

Ground
clearance, centre
of wheelbase

12.00 x 12.00 x 12.00 x 12.00 x 12.00 x


24 20 pr 24 20 pr 24 20 pr 24 20 pr 24 20 pr

Stacking aisle, 20 Ast


9702
(mm)
containers

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

Stacking aisle, 40 Ast


14232
(mm)
containers

5,292

5,292

5,792

5,792

5,792

5,792

Track width, front

b10
2,900
(mm)

Wa
5,292
(mm)

2,900

2,900

2,900

2,900

2,900

2,900

172

Turning radius

Operating Instructions 318 807 1001 EN 2008/10

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

m/s 0.58/0.580.58/0.580.58/0.58 0.58/0.58 0.58/0.58 0.58/0.58 0.58/0.58

Lowering speed
with/without load

m/s 0.54/0.540.54/0.540.54/0.54 0.54/0.54 0.54/0.54 0.54/0.54 0.54/0.54

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

V/aH 2x12/2002x12/2002x12/200 2x12/200 2x12/200 2x12/200 2x12/200

Engine manufacturer/type
Engine
performance
according to ISO
1585

Noise level,
at operators
ear, overhead
guard/cab

bar

Operating Instructions 318 807 1001 EN 2008/10

173

174

Technical data

Operating Instructions 318 807 1001 EN 2008/10

7
Circuit diagrams

7 Circuit diagrams
Cummins engine electrical circuit drawing
Cummins engine electrical circuit drawing

176

Operating Instructions 318 807 1001 EN 2008/10

Circuit diagrams 7
Cummins engine electrical circuit drawing
WARNING

5V Power supply (sensor and switch)

Pressure
(kPa)

Pressure
(psi)

Voltage (V)

0.42 to 0.58

This diagram is provided as a diagnostic tool for


trained, experienced technicians only. Improper
troubleshooting or repair can result in severe
personal injury or death or property damage. See
important instructions in service manual.

@ ECM - 4.75 to 5.25 VDC

172.37

25

1.42 to 1.58

Solenoids

344.74

50

2.42 to 2.58

Electrical specifications

Intake air heater

517.11

75

3.42 to 3.58

Data link

Coil resistance (12 VDC system) - 0.09 to 0.11


Ohms

689.48

100

4.42 to 4.58

Positive wire to chassis ground (J1587) - 4.0


to 5.0 VDC

Coil resistance (24 VDC system) - 0.18 to 0.22


Ohms

Negative wire to chassis ground (J1587) - 0.0


to 2.5 VDC

Priming pump

J1939 Backbone resistance


Positive wire to return wire - 50 to 70 Ohms
J1939

@ harness - 4.50 to 5.25 VDC

Temp F

Temp C

Resistance
(Ohms)

ECM connector

32

30k to 36k

Retaining cap screw torque = 2.8 Nm (25 in-lb)

25

77

9k to 11k

50

122

3k to 4k

75

167

1350 to 1500

100

212

600 to 675

Sensor specifications

All continuity tests

Vehicle speed sensor


Torque = 47 Nm (35 lb/ft)
Coil resistance:

All shorts to ground

First coil resistance = 750 to 1100 Ohms

VSS circuits - OK (no short circuit) if 10 Ohms

Second coil resistance = 1100 to 1500 Ohms

All other circuits - OK (no short circuit) if 10


Ohms

Oil pressure sensor

Short circuit to external voltage

Torque (Threaded style) = 40 Nm (30 ft/lb)

75.35

2.44 to 2.56

2585.76

101.80

3.44 to 3.56

Accelerator pedal (IVS, ISS & APS)


Idle validation circuit resistance:
For ON and OFF IDLE states
ISS - MAX closed circuit resistance < 125
Ohms
ISS - MIN open circuit resistance 100 Ohms

Torque = 14 Nm (30lb/ft)

Resistance - 1.0 to 1.2 Ohms

Termination resistance - 110 to 130 Ohms

OK (no open circuit) if <10 Ohms

All temperature sensors

1939.36

Accelerator pedal and remote accelerator


Accelerator position sensor coil resistance:
Between supply and return wires - 2000 to
3000 Ohms
Between supply and signal wires (released
pedal) - 1500 to 3000 Ohms
Between supply and signal wires (depressed
pedal) - 200 to 1500 Ohms
NOTE

Boost pressure sensor


Torque (threaded style) = 40 Nm (30lb/ft)
Pressure
(mm Hg)

Pressure (in
Hg)

Voltage (V)

646.48

25.45

0.44 to 0.56

1292.88

50.90

1.44 to 1.56

Released resistance minus depressed resistance MUST be 1000 Ohms.

OK if < 1.5 VDC

Operating Instructions 318 807 1001 EN 2008/10

177

7 Circuit diagrams
Cummins fault code list
Cummins fault code list
Fault code list page 1

178

Operating Instructions 318 807 1001 EN 2008/10

Circuit diagrams 7
Cummins fault code list
Fault code list page 2

Operating Instructions 318 807 1001 EN 2008/10

179

7 Circuit diagrams
Cummins fault code list
Fault code list page 3

180

Operating Instructions 318 807 1001 EN 2008/10

Circuit diagrams 7
Electrical Circuit

Electrical Circuit
Page 1

Operating Instructions 318 807 1001 EN 2008/10

181

7 Circuit diagrams
Electrical Circuit
Page 2

182

Operating Instructions 318 807 1001 EN 2008/10

Circuit diagrams 7
Electrical Circuit
Page 3

Operating Instructions 318 807 1001 EN 2008/10

183

7 Circuit diagrams
Electrical Circuit
Page 4

184

Operating Instructions 318 807 1001 EN 2008/10

Circuit diagrams 7
Electrical Circuit
Page 5

Operating Instructions 318 807 1001 EN 2008/10

185

7 Circuit diagrams
Electrical Circuit
Page 6

186

Operating Instructions 318 807 1001 EN 2008/10

Circuit diagrams 7
Electrical Circuit
Page 7

Operating Instructions 318 807 1001 EN 2008/10

187

7 Circuit diagrams
Electrical Circuit
Page 8

188

Operating Instructions 318 807 1001 EN 2008/10

Circuit diagrams 7
Electrical Circuit
Page 9

Operating Instructions 318 807 1001 EN 2008/10

189

7 Circuit diagrams
Electrical Circuit
Page 10

190

Operating Instructions 318 807 1001 EN 2008/10

Circuit diagrams 7
Elme electrical circuit

Elme electrical circuit


Page 1

Operating Instructions 318 807 1001 EN 2008/10

191

7 Circuit diagrams
Elme electrical circuit
Page 2

192

Operating Instructions 318 807 1001 EN 2008/10

Circuit diagrams 7
Elme hydraulic circuit

Elme hydraulic circuit


Page 1

AA

AH

AB
AG

AD

AC

AA
AB

AC

AE
AF

AD

AG
AH

Operating Instructions 318 807 1001 EN 2008/10

AE

AF

193

Linde Material Handling GmbH


318 807 1001 EN 2008/10