Linde Container Handler Type 356: C400 Operating Instructions (User Manual)

Linde Forklift Truck Original instructions C400 356 801 1601 EN – 2011/07

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 lead- ing manufacturer of industrial trucks and hydraulics. It includes eight manufacturing plants in the Federal Republic of Germany, France and Great Britain, as well as sub- sidiaries and branches in all economically important countries. Linde industrial trucks enjoy a worldwide reputation - thanks to their high quality in engineering, performance and service. 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 Operating Instructions – 356 801 1601 EN – 2011/07 I

Table of contents g 1 Introduction Your 356 Forklift Truck ................................................. 2 Technical Description .................................................. 4 Intended use ........................................................ 7 Improper use ........................................................ 7 Symbols Used ....................................................... 8 Commissioning ...................................................... 9 Truck Takeover ...................................................... 9 EC declaration of conformity ............................................ 11 2 Safety Safety Rules ....................................................... 14 Safety Rules ....................................................... 14 Handling Fuel, Lubricants and Coolant .................................... 17 Residual risks ...................................................... 17 Stability ........................................................... 18 3 Overview General view of Truck ................................................. 20 Type Plates ........................................................ 21 Controls .......................................................... 22 Controls, Switches, Gauges and Warning Lights ............................. 23 4 Operation Wheel removal — drive axle ............................................ 30 Wheel removal — steer axle ............................................ 34 Wheel assembly inspection ............................................ 36 Wheel reﬁtting — drive axle ............................................ 37 Wheel reﬁtting — steer axle ............................................ 41 Examples of restraining devices ......................................... 44 Mirrors ............................................................ 45 Cab door opening and closing .......................................... 46 Emergency exit ..................................................... 47 Opening the bonnet .................................................. 47 Operating Instructions – 356 801 1601 EN – 2011/07 III

Table of contents g Opening the transmission cover ......................................... 48 Opening the cabin rear compartment door ................................. 49 Opening the working hydraulic system oil tank cover .......................... 49 Opening the brake hydraulic system oil tank cover ........................... 50 Opening the battery and air ﬁlter compartment door ........................... 50 Opening the radiator grille ............................................. 51 Opening the fuse box cover ............................................ 51 Isolating the battery .................................................. 52 Check tyre condition and pressure ....................................... 52 Tighten wheel nuts ................................................... 53 Check working hydraulic system oil level ................................... 53 Check brake hydraulic system oil level .................................... 54 Check battery condition ............................................... 54 Check the brake relay system oil level ..................................... 55 Check coolant level in radiator header tank ................................. 55 Check engine oil level ................................................ 56 Check windscreen washer reservoir ﬂuid level .............................. 57 Checking the fuel level ................................................ 57 Filling fuel ......................................................... 58 Check the transmission oil level ......................................... 58 Checking the handler for visible damage ................................... 59 Checking the twistlocks and warning lights for proper operation .................. 60 Adjusting the drivers seat .............................................. 61 Normal start ........................................................ 63 Malfunctions during operation .......................................... 66 Overload safety switch ................................................ 66 Start-up indications .................................................. 66 Truck status display .................................................. 67 Gear shift control .................................................... 78 Stopping the truck ................................................... 80 Operating transmission dump ........................................... 81 Steering .......................................................... 81 Service brake ...................................................... 82 IV Operating Instructions – 356 801 1601 EN – 2011/07

Table of contents g Parking brake ...................................................... 82 Automatic Parking brake operation ....................................... 83 Turning on the lights .................................................. 83 Operating the hazard warning lights ...................................... 85 Operating the horn ................................................... 85 Turning on the front windscreen wiper ..................................... 86 To operate the cab pre-heater system * ................................... 88 Fuses ............................................................ 89 Mast and handler controls ............................................. 91 Spreader .......................................................... 95 Operating the twistlocks ............................................... 96 Before lifting a load ................................................... 101 Picking up a container ................................................ 101 Travelling with loads .................................................. 103 Depositing the load .................................................. 104 Parking the truck .................................................... 105 Trailer coupling ..................................................... 105 Towing ........................................................... 106 5 Maintenance General remarks .................................................... 110 Wheel removal — drive axle ............................................ 110 Wheel removal — steer axle ............................................ 114 Wheel assembly inspection ............................................ 116 Wheel reﬁtting — drive axle ............................................ 117 Wheel reﬁtting — steer axle ............................................ 121 Examples of restraining devices ......................................... 124 Taking the truck out of operation ......................................... 125 General information .................................................. 126 Work on the mast, handler and the front part of the truck ....................... 128 Hoisting the truck .................................................... 129 Inspection and maintenance data ........................................ 130 Fuel and oil recommendations .......................................... 131 Check the condition of structured components .............................. 132 Truck welds inspection ................................................ 133 Operating Instructions – 356 801 1601 EN – 2011/07 V

Table of contents g Inspection and maintenance schedule .................................... 133 General overall check ................................................ 133 Daily checks ....................................................... 134 As required Service plan ............................................... 135 50 h service plan .................................................... 137 500 h service plan ................................................... 139 1000 h service plan .................................................. 142 2000 h service plan .................................................. 145 3000 h service plan .................................................. 148 5000 h service plan .................................................. 151 6000 h service plan .................................................. 154 Engine ............................................................ 157 Check engine oil level ................................................. 157 Change the engine oil ................................................. 158 Change the engine oil filters ............................................ 159 Drain the fuel filter ................................................... 161 Change the fuel filter ................................................. 161 Prime the fuel system ................................................. 162 Check the air filter ................................................... 162 Change the air filter safety element ....................................... 164 Change the air filter element - check the vacuum switch ........................ 165 Check the cooling system for leaks and tightness ............................ 166 Flush the cooling system .............................................. 167 Change engine coolant ............................................... 168 Check drive belt tension ............................................... 169 Check the fan drive idler pulley assembly .................................. 169 Fan hub, belt driven .................................................. 171 Clean the radiator and check for leaks ..................................... 172 Check the engine mountings ........................................... 173 Check the intake and exhaust systems for leaks and tightness ................... 173 Check the vibration damper ............................................ 175 Check the turbocharger ............................................... 175 Check valve clearances ............................................... 178 Gearbox .......................................................... 179 Change the transmission oil and clean the filter screen ........................ 179 Change transmission oil filters .......................................... 180 Check transmission mountings .......................................... 181 Chassis, bodywork and fittings .......................................... 182 Clean the truck ...................................................... 182 Check seat belt for condition and correct operation* ........................... 183 Tighten wheel nuts ................................................... 185 VI Operating Instructions – 356 801 1601 EN – 2011/07

Table of contents g Check the tyres for damage and foreign objects .............................. 186 Check the cab mountings .............................................. 186 Truck welds inspection ................................................ 187 Chassis frame ...................................................... 189 Check steer axle hub oil level ........................................... 189 Change the steer axle hub differential oil ................................... 189 Clean and lubricate steer axle, check the mounting ........................... 191 Check the drive axle centre differential oil level .............................. 192 Change the drive axle centre differential oil ................................. 192 Check the drive axle hub differential oil level ................................ 194 Change the drive axle hub differential oil ................................... 194 Check the drive axle mounting .......................................... 195 Check and lubricate the drive shaft ....................................... 195 Check and adjust hub bearings .......................................... 196 Controls .......................................................... 196 Check the steering lock ............................................... 196 Check the parking brake condition and mounting ............................. 197 Check the brake disc wear ............................................. 197 Electrics .......................................................... 197 Check battery condition ............................................... 197 Check electric cables, connectors and connections for condition and tightness ....... 198 Hydraulics ......................................................... 199 Check the hydraulic system, pumps, valves and lines ......................... 199 Change the working hydraulic system oil suction filters ........................ 200 Change the hydraulic oil - working system .................................. 202 Change the brake hydraulic system oil suction filter ........................... 203 Change the brake hydraulic system oil pressure filter .......................... 204 Change the brake hydraulic system oil .................................... 205 Load lift system ..................................................... 207 Check condition of mast, handler, gantry and mountings ....................... 207 Check and lubricate the mast and tilt cylinder pivot pins ........................ 207 Check and lubricate the mast main and side thrust bearings ..................... 208 Check the condition and security of the lift chains ............................. 209 Check and adjust the lift chain length and lubricate with chain spray ............... 210 Change the lift chains ................................................. 211 Check and lubricate gantry main and side thrust bearings ...................... 212 Check and lubricate the twistlocks ....................................... 212 Change the twistlocks ................................................ 214 Check and lubricate the handler sliding bearings ............................. 215 Lubricate the locking cylinder pin on the handler ............................. 216 Check and lubricate the handler suspension and hydraulic cylinder bearings ........ 217 Operating Instructions – 356 801 1601 EN – 2011/07 VII

Table of contents g Special equipment, accessories ......................................... 217 Check the central lubrication* lubricating points .............................. 217 Fill central lubrication* canister with grease ................................. 218 Trouble shooting .................................................... 219 Troubleshooting guide Diesel engine ..................................... 219 Troubleshooting guide hydraulic system ................................... 221 User manual feedback ................................................ 222 User manual improvement record. ....................................... 222 Annex 6 Technical Data Datasheet ......................................................... 232 Technical Datasheet ................................................. 232 Technical Datasheet ................................................. 233 7 Circuit Diagrams Electrical Circuit Diagram .............................................. 236 Electric Circuit Diagram ............................................... 236 Electric Circuit Diagram Legend ......................................... 249 Hydraulic Circuit Diagram .............................................. 250 Hydraulic Circuit Diagram .............................................. 250 Air Conditioning Circuit Drawing ......................................... 252 Air conditioning circuit diagram .......................................... 252 Elme Circuit Drawing ................................................. 253 [MODULE] ......................................................... 253 VIII Operating Instructions – 356 801 1601 EN – 2011/07

1 Introduction

1 Introduction Your 356 Forklift Truck Your 356 Forklift Truck d3561000 Linde lift trucks offer the best in economy, safety and driving convenience. Therefore it is mainly in the hands of the operator to pre- serve 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 start- ing, 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 for- ward in the travel direction. Approved applications Linde lift trucks are designed for transporting and lifting the loads stated in the load capacity diagram. In partic- ular, we refer to the attached VDMA booklet "Safety rules for industrial trucks" and acci- dent 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 person- 2 Operating Instructions – 356 801 1601 EN – 2011/07

Linde Container Handler Type 356: C400 Operating Instructions (User Manual)

You're Reading a Preview

Recently Viewed