Service Training

Linde IC Engined Truck

C 80
Series 313
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This training materiel is only provided for your use and remains the exclusive property of
LINDE AG Werksgruppe Flurförderzeuge und Hydraulik
 Service Training
IC Engined Truck C 80, Series 313

TABLE OF CONTENT

1 Drive engine
See H 100/120/136/150/160, Type 354

2 Hydrodynamic travel drive

See H 100/120/136/150/160, Type 354

3 Truck body
See H 100/120/136/150/160, Type 354

4 Steering system
See H 100/120/136/150/160, Type 354
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5 Air braking system

See H 100/120/136/150/160, Type 354

6 Electrical system
See H 100/120/136/150/160, Type 354

7 Hydraulic system 1
7.1 Hydraulic circuit diagram 2
7.1.1 Functional description of working hydraulics 7
7.2 Control schematic 10
7.2.1 Functional description of control 11
7.3 Routing of working hydraulics hoses 13
7.4 Routing of oil suction and return hoses 14

8 Lift mast 1
8.1 Installation of mast and spreader 4
8.2 Adjusting the angle of tilt 6
8.3 Lift cylinder 8
8.3.1 Sealing the lift cylinder 9
8.4 Tilt cylinder 10
8.4.1 Sealing the tilt cylinder 11
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8.5 Spreader 13
8.5.1 Valve block and hydraulic circuit diagram of spreader 14
8.5.2 Circuit diagram Spreader 16

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7 HYDRAULIC SYSTEM
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7.1 HYDRAULIC CIRCUIT DIAGRAM

NOTE: The legend applies for explanations, schematic and circuit diagram.

A WORKING HYDRAULICS - LIFTING

1 Pressure relief valve 200 bar

2 Check valve
3 Way valve - lifting
4 Combined slow lowering and pipe safety valve
5 Lift cylinder

B WORKING AND AUXILIARY HYDRAULICS

6 Tilt cylinder
7 Pressure relief valve 200 bar
8 Way valve - lifting
9 Way valve (spreader oil supply)
10 Way valve (auxiliary hydraulics)
11 Way valve - tilting

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C SHOCK VALVE (STEERING)

12 PRESSURE RELIEF VALVE 240 BAR

D STEERING CONTROL VALVE OSCPC/LS

13 Pressure relief valve 170 bar

14 Check valve

E FLOW PRIORITY VALVE OLS 80

F VALVE BLOCK

15 Combined check and shock valves

G SPREADER VALVE BLOCK

16 Pressure relief valve 140 bar

17 4/3-way solenoid valve (extension)
18 Shock valve 80 bar
18a Shock valve 140 bar
19 Beam extension cylinder (20 ft - 40 ft)
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20 4/3-way solenoid valve (twistlocks)

21 Hydraulic cylinder (twistlocks)
21a Locking valves
22 4/3-way solenoid valve
23 Sideshift hydraulic cylinder

H TANDEM PUMP

24 Steering and working hydraulics pump 44 cc

25 Working hydraulics pump 44 cc
26 Perkins 1006.6TE engine

J HYDRAULIC OIL TANK 305 LITRES

27 Suction filter 20 µ

K ENGINE SPEED-UP CONTROL CYLINDER

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L STEER CYLINDER

I Measuring point (pump 24 and pressure relief valve 1)

II Measuring point (pump 25 and pressure relief valve 7)
III Spreader boost pressure measuring point 140 bar
IV Spreader return pressure measuring point
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HYDRAULIC CIRCUIT DIAGRAM C 80, SERIES 313

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HYDRAULIC CIRCUIT DIAGRAM C 80, SERIES 313

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7.1.1 FUNCTIONAL DESCRIPTION OF WORKING HYDRAULICS

Tandem pump H is fitted to the powershift transmission. It is driven by the combustion engine (26). The
hydraulic oil is drawn from the oil tank through two suction filters (27) by two 44 cc gear pump units delivering
202 l/min at maximum engine speed.

OPERATING STATE: ZERO DELIVERY (ENGINE RUNNING)

When way valves A and B are in the neutral position and the steering is not being operated, the oil flow from
hydraulic pump (24) goes to flow priority valve E, which opens at a pressure difference of 7 bar, thus allowing
the oil to flow back to the tank through way valve A. At the same time the oil from hydraulic pump (25) is
returned back to the tank through way valve block B.

OPERATING STATE: STEERING OPERATED

When the steering is operated, a signal from steering valve D reaches priority valve E via a load sensing
line. The priority valve opens and the oil flows from pump (24) through steer control valve D and via shock
valve C to steering cylinder L.
Any oil not needed is returned to the tank via way valve A.
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OPERATING STATE: LIFTING

When lifting is selected, the delivery from working hydraulics pump (25) and pump (24) goes jointly to the
lift cylinders through way valve (8) and way valve (3) respectively.

OPERATING STATE: LOWERING

When the way valves (3) and (8) are operated, the oil flows from the lift cylinders (5) back to the tank via
valves (4), (3) and (8).

OPERATING STATE: TILTING

When tilting forward and back are selected, way valve (11) is operated and the delivery of pump (25) flows
through valve F to the tilt cylinders.
The oil from the double-acting tilt cylinders returns via the pilot controlled valve (15) and way valve (11) back
to the tank.
The angle of tilt is limited by two stop valves installed in the control circuit.

OPERATING STATE: SPREADER OPERATED

When a hydraulic spreader function (twistlocks open/close) is selected or the sideshift (extension/
retraction) is operated, way valve (9) is operated simultaneously so that the delivery from pump (25) goes
to valve block G on the spreader.
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SPEED GOVERNING

The engine speed-up control cylinder K is connected to way valves B.

When a working hydraulics function is selected, the cylinder is extended, thus accelerating the engine.

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7.2 CONTROL SCHEMATIC

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1 Air filter
2 Suction hose
3 Compressor 159 cc
4 Air dryer
5 Air tank (service brake)
6 Air tank (working hydraulics and parking brake control)
7 Manifold
8 Pilot control valve (joystick)
9 Reservoir
10 Lifting/lowering way valves
11 Spreader way valve
12 Tilt way valve
13 3/2-way stop valve, forward tilt angle limiting
14 3/2-way stop valve, rearward tilt angle limiting

A 3/2-way solenoid valve, lift stop

B 3/2-way solenoid valve, spreader

a Service brake air supply (see type 354, section 4.5)

b Service brake air supply (see type 354, section 4.5)
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7.2.1 FUNCTIONAL DESCRIPTION OF CONTROL

The compressed air of the braking system is also available for the control of the working hydraulics (see
section 4.5.2).

The compressed air flows from air tank (6) through the manifold (7) to the pilot control valve (8), where it
is constantly applied.

LIFTING

When the lifting function is selected with the joystick, compressed air pressure proportional to the position
of the joystick is applied through the open solenoid valve (A) to the way valves (10), which are opened by
double-acting servo cylinders.

If the twistlocks on the spreader are not in the end position (error), solenoid valve A is operated and control
pressure is reduced so that the way valves (10) return to the neutral position (lift stop).

LOWERING

For lowering, compressed air pressure proportional to the position of the joystick is applied to the opposite
end of the double-acting servo cylinder so that the way valves (10) are shifted to the lowering position.
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TILTING

For tilting the mast forward or back, compressed air pressure proportional to the position of the joystick is
applied from the pilot control valve (8) through the stop valves (13) or (14) to the double-acting servo cylinder
on way valve (12). The latter valve shifts to the position for tilting forward or back. When the preset 3° angle
of tilt is reached, the control pressure via the stop valves (13) or (14) is released and way valve (12) returns
to the neutral position (tilt stop).

SPREADER FUNCTION

When a spreader function is selected by pressing a button on the joystick, solenoid valve (B) opens and
the air pressure is applied to the control piston, opening way valve (11). This allows oil to flow to the valve
block on the spreader.

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7.3 ROUTING OF WORKING HYDRAULICS HOSES

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7.4 ROUTING OF OIL SUCTION AND RETURN HOSES

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8 LIFT MAST

For identification purposes, a lift mast number (manufacturer’s identification number) is stamped on the
channel of the mast.

A mast type with various heights is available for type 313 C80.

Mast type 174 4 containers high

5 containers high
6 containers high

Example: 174 H01 2 001 LL

Linde Lansing
Serial number
Mast height
Year /month built
Mast type

CODE FOR MAST HEIGHTS

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1 = 4 containers high
2 = 5 containers high
3 = 6 containers high
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1 Spreader 10 4 side rollers with adjustment plates

2 Chain 11 Lift cylinder
3 Chain anchor, top 12 Inner upright (on truck chassis)
4 Pin 13 Lifting eyes
5 Chain anchor, bottom 14 Tilt cylinder pins (mast)
6 12 mast rollers 15 Tilt cylinder
7 4 wear strips with adjustment plates (on outer 15 a Pointer (tilt angle 0 °)
upright) 15 b Marking
4 wear strips with adjustment plates (on 16 Tilt cylinder pins (chassis)
spreader) 17 Retaining plate
8 Hose roller 18 Bearing pin
9 Outer upright (moveable)
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LIFT MAST CROSS SECTION

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8.1 INSTALLATION OF MAST AND SPREADER

NOTE: For transport reasons, the truck is delivered with the mast and spreader removed.

PREPARING FOR INSTALLATION

- Crane or mobile crane > 15 t

- Working platform, truck with a cage, lifting height 8 - 10 m

- Lift the mast (own weight 7 tonnes) at the lifting eyes (13) with a crane and deposit on the ground on
squared timbers (lift cylinders facing up).
- Connect the short hoses (26) with fittings on the inner upright bracket (27).
- Fasten both hoses (26) with clamps and angle brackets (22).
- Fit the socket housing (28) to the inner upright and fasten the cable (24) with clamps (23) together with
the hose clamps (22) above the two hose lines (26).
- Insert the plug (25) into the socket (28) and lock it.
- Raise and secure mast sufficiently in order to fasten the cable (30) with cable clamp (29) to the mast
bracket (27) (strain relief).
- Slide the hose roller (8) and the cable (30) and the hoses (31) onto the pin on the outer upright, secure
with a circlip and install the guide plate on the hose roller.

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- Slip the chains (2) over the left and right chain rollers and fasten to the chain anchors (3) with pins (4).

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- Install the tilt cylinders (15) with the pins (16) on the truck intermediate frame and connect the hydraulic
hoses to the tilt cylinders.
NOTE: Install with the white marking on the tilt cylinder showing inward.
- Lift up both tilt cylinders about 45° and fasten with ropes.
- Lift the mast at the lifting eyes (13) with the crane and put it in a vertical position.
- Drive the truck slowly to the mast mounting points.
- Install the mast with the pivot pins (18) on the truck chassis and secure with the plates (17).
NOTE: Install the angle bracket for the tilt angle limit switches on the right-hand side seen in the
direction of travel (see "Adjusting the angle oft tilt", item 1).
- Position the tilt cylinders (15) at the mounting points on the mast and fasten them with the pins (14).
- Fasten the angle bracket on the tilt cylinder with the white marking.
- Insert the plug (19) into the socket on the truck and lock it.
- Remove the sealing plugs (20) and (21) on the hydraulic hoses (26) and install on the fittings on the truck.
- Pick up the spreader (1) (own weight 4.8 tonnes) at the lifting eyes with the crane and position it on a 20'
container available for this purpose.
- Fasten a rope on the cable (30) and the hoses (31) and keep them taut when lifting the mast.
- Lift the mast and drive the truck to the spreader until the outer upright (9) is in position in relation to the
rollers on the spreader.
- Slowly lower the mast until the rollers on the spreader are completely engaged in the outer upright (9).
- Fasten both chains (2) on the chain anchors (5) with pins (4) and secure them.
- Remove the caps from the hoses (31) and install the hoses on the spreader (1).
- Insert the cable plug (33) into the socket on the spreader (1) and lock it.
- Tensions the cable (30) and secure it with a clamp (32).
- Check all spreader functions, operate the mast through the full cycle several times and then bleed the
lift cylinders (11).
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8.2 ADJUSTING THE ANGLE OF TILT

There are two limit switches (3) and (4) mounted on the right-hand side in the direction of travel. These cut
off the control pressure to the way valves when the maximum angle of tilt is reached, thus limiting the angle
of tilt. In order to prevent the truck from tipping over during tilting, limit switches (3) and (4) must be checked
and adjusted.

- Position the mast in mid position (see the marking (9) on the tilt cylinder).
- Place the angle measuring device (6) on the mast channel, adjust to 3 ° and fasten with a screw (8). Tilt
the mast forward until the bubble (7) in the water level is level.
- Loosen the nuts (2) and slide the limit switch (3) towards the lever (1) until it operates.
- Tighten the nuts (2).
. Follow the same procedure for tilting back, but loosen nuts (5) and move the limit switch (4) towards the
lever (1).
- After the adjustment, recheck the angle of tilt.
Desired value: Tilting forward 3 °
Tilting back 3 °

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8.3 LIFT CYLINDER

1 Wiper ring
2 Groove ring
3 Bleed screw (torque 20 Nm)
4 Ball (Ø 6 mm)
5 Guide band
6 Cylinder head (torque 500 Nm)
7 Cylinder tube
8 Retaining ring (Ø 95 mm)
9 Piston rod
10 Guide ring
11 Sealing ring
12 Retaining screw (Loctite 243/torque 20 Nm)
13 Support ring
14 O-ring
15 Piston head (torque 500 Nm)
16 Fitting (slow lowering valve)

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8.3.1 SEALING THE LIFT CYLINDER

SEALING THE CYLINDER HEAD

- Heat the retaining screw (12) (secured with Loctite) and remove it.
- Remove the cylinder head by screwing it off the cylinder tube (7) with a hook wrench. Renew the wiper
(1), groove ring (2), guide band (5), O-ring (14), support ring (13) and sealing ring (11).

NOTE: If the lift cylinder is only leaking at the cylinder head, the repair can be carried out without
removal of the lift cylinder.

RENEWING THE GUIDE RINGS

- Pull out the piston rod (9) and check the guide rings (10) for wear, renewing them if required.
- Insert the piston rod (9) into the cylinder tube (7).

SEALING THE PISTON HEAD

- Heat the retaining screw (12) on the piston head (15) (secured with Loctite) and remove it.
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- Clamp the cylinder tube (7) in a vise and remove the piston head (15) by screwing it off the cylinder tube
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(7) with a hook wrench.

- Renew the sealing ring (11), O-ring (14) and support ring (13), oiling them lightly.
- Screw the piston head (15) into the cylinder tube (7) and tighten to 500 Nm.
- Install the retaining screw with Loctite and tighten to 20 Nm.

MOUNTING THE CYLINDER HEAD

- Slide the cylinder head (6) over the piston rod (9), screw it into the cylinder tube (7) and tighten to 500
Nm.
- Install the retaining screw (13) on the cylinder head with Loctite and tighten to 20 Nm.

NOTE: After the installation of the lift cylinder, loosen the bleed screw (3) and allow hydraulic oil to flow
until all the air is eliminated.
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8.4 TILT CYLINDER

1 Wiper
2 Guide bushing (torque 500 Nm)
3 O-ring
4 Groove ring
5 Support ring
6 O-ring
7 Cylinder tube
8 Piston rod
9 Piston (torque 750 Nm)
10 Piston rod seal
11 Packing
12 Guide band
13 Retaining screw (torque 20 Nm)
14 Fitting

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8.4.1 SEALING THE TILT CYLINDER

The tilt cylinder does not need to be removed for sealing.

- Start the engine and tilt the mast fully forward.

- Remove the tilt cylinder pin at the mast.
- Tilt the mast back slowly until the piston rod of the tilt cylinder to be sealed is retracted from the mast.
- Support the tilt cylinder and stop the engine.
- Remove the lock ring out of the guide bushing groove.
- Loosen the guide bushing (2) with a hook wrench (125.180 FACOM) and screw it out of the cylinder tube
(7).
- Pull the piston rod (8) and piston (9) out of the cylinder tube (7).
- Clean the inside of the cylinder tube (7) and inspect for damage such as scoring, traces of pitting and
corrosion.
- Place the piston rod and piston in a soft jawed vice.
- Heat the M8x125 screw (13) and remove it.
- Remove the piston (9) from the piston rod with a hook wrench.
- Remove the piston rod seal (10) and the packing (11) from the cylinder.
- Install a new packing (11) and piston rod seal (10) on the piston and lubricate it with hydraulic oil.
- Fit the piston (9) on the rod (8) and tighten it to 750 Nm.
- Install screw (13) with Loctite 243 and tighten it.
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- Slide the piston rod (8) and piston (9) into the cylinder tube (7).
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- Renew the support ring (5), O-ring (6), groove ring (4), wiper (1) and O-ring (3) on the guide bushing (2).
- Install the groove ring (4) with the sealing lip facing the pressure side.
- Coat the seals with hydraulic oil.
- Screw the guide bushing (2) into the cylinder tube and tighten it to 500 Nm with a hook wrench (125.180
FACOM).
- Install the lock ring in an appropriate groove on the guide bushing.
- Start the engine and extend the tilt cylinder slowly. Install the tilt cylinder pin at the mast.
- Check the tilt cylinder for leaks.
NOTE: Ensure that the tilt cylinders are synchronised, adjusting them if required.
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8.5 SPREADER

TYPE 568

Integrated telescopic side spreader for empty containers

Maximum load capacity 8000 kg
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Type plate

For use in: Elme model 568

- Integrated in the mast.
- Built-in sideshift.
Container pick-up at the side with two hydraulically operated twistlocks.

CAN PICK UP

20 ', 30 ', 40 ' dry freight, open top containers, refrigerated containers and flats containers
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8.5.1 VALVE BLOCK AND HYDRAULIC CIRCUIT DIAGRAM OF SPREADER

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1 Pressure relief valve 140 bar 16 Seal
2 4/3-way solenoid valve 17 Fastening screw (torque 20 Nm)
3 Hydraulic cylinder (sideshift) 18 Pressure relief valve setscrew 80 bar (twistlock
4 4/3-way solenoid valve (twistlock) closed)
5 Pressure relief valve 80 bar (twistlock open) 19 Pressure relief valve setscrew 80 bar (twistlock
6 Pressure relief valve 80 bar (twistlock closed) open)
7 Locking valve 20 Pressure relief valve setscrew 80 bar (spreader
8 Hydraulic cylinder (twistlock) extension)
9 4/3-way solenoid valve (container width 21 Pressure relief valve setscrew 140 bar
selection) (spreader retraction)
10 Pressure relief valve 80 bar (spreader
extension) A Pressure port
11 Pressure relief valve 140 bar (spreader B Return port
retraction)
12 Hydraulic cylinder (container width selection) III Spreader boost pressure measuring point
13 Nut (torque 20 Nm) 140 bar
14 Pressure relief valve setscrew, max. 140 bar IV Spreader return pressure measuring point
15 O-rings
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8.5.2 CIRCUIT DIAGRAM SPREADER

A1 Spreaderbox V1 Diode
A2 Electricbox on Chassis V2 Diode
A3 Central control lever (Joystick) V3 Diode
A4 Electricbox inside the cab V4 Diode

F6 Fuse Spreader Y1 Solenoid valve Twistlocks lock

F13 Fuse Working light Y2 Solenoid valve Twistlocks unlock
Y3 Solenoid valve Spreader open to 40 '
H1 Indicator light red (on Mast) Y4 Solenoid valve Spreader close to 20 '
H2 Indicator light yellow (on Mast) Y5 Solenoid valve Sideshift left
H3 Indicator light green (on Mast) Y6 Solenoid valve Sideshift right
H4 Indicator light Twistlocks green Y7 Solenoid valve Mainvalve pressure on vehicle
H5 Indicator light Twistlocks yellow Y8 Solenoid valve Lift interrupt
H6 Indicator light Twistlocks red
H7 Working light on Spreader left
H8 Working light on Spreader right
H9 Indicator light for Working light

K1 Relay Twistlock Lock

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K3 Relay Boom Extention
K4 Relay Boom Retraction
K5 Relay Sideshift left
K6 Relay Sideshift right
K7 Relay Control pressure
K8 Relay Lift interrupt

S1 Sensor for Twistlock locked, left side

S2 Sensor for Twistlock locked, right side
S3 Sensor for Twistlock not locked, left side
S4 Sensor für Twistlock not locked, right side
S5 Sensor for Spreader seated, left side
S6 Sensor for Spreader seated, right side
S8 Rockerswitch Twistlock lock/unlock
S9 Rockerswitch Working light
S10 Red button Sideshift left
S11 Red button Sideshift right
S12 Yellow button Beam close to 20 '
S13 Yellow button Beam open to 40 '

X1 Endbeam box right side

X2 Endbeam box left side
X3 Plug 16 connector (Mast/Spreader)
X4 Plug 16 connector (Vehicle/Mast)
X5 Connector terminals Working light
X6 Connector terminals
X7 Connector terminals
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CIRCUIT DIAGRAM SPREADER

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31308-10
LINDE AG
Werksgruppe Flurförderzeuge und Hydraulik
63701 Aschaffenburg
Postfach 10 01 36
Telefon (0 60 21) 99-0
Telefax (0 60 21) 99-15 70
http://www.linde.de/linde-stapler
eMail: service.training@linde-fh.de 313 804 2401.0699