Folleto PDF

Reachstacker
Original instructions
C4230 - C4540 TL /5,

C4026 - C4535 CH /5
3578011501 EN – 2010/01/27
Preface
g
Linde - Your Partner

Linde, an enterprise operating worldwide in Linde industrial trucks enjoy a worldwide
the investment and service sector, is one of reputation - thanks to their high quality in
the large industrial enterprises in the EC with engineering, performance and service.
its three business segments and six divisions.
Wishing you satisfactory operation,
The Linde Material Handling division is a lead-
Linde Heavy Truck Division Limited
ing manufacturer of industrial trucks and
Linde Industrial Park
hydraulics. It includes eight manufacturing
Merthyr Tydfil
plants in the Federal Republic of Germany,
South Wales, UK
France and Great Britain, as well as sub-
CF48 4LA
sidiaries and branches in all economically
Tel: +44 (0)1443 624300
important countries.
Fax: +44 (0) 1443 624302
Operating Instructions – 3578011501 EN – 2010/01/27 I

Table of contents
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1 Introduction
Your Linde truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Technical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Improper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Truck takeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
EC declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2 Safety
Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Do not operate with guards removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Handling Fuel, Lubricants and Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Frequency characteristic for human body vibrations . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Frequency characteristic for human body vibrations . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Noise emission data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Noise emission data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3 Overview
General view of the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
General view of the handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Gauges, switches and warning lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4 Operation
Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Cab door opening and closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Opening the engine cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Opening the transmission cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Operating Instructions – 3578011501 EN – 2010/01/27 III

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Opening the cabin rear compartment door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Opening the working hydraulic system oil tank cover . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Opening the brake hydraulic system oil tank cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Opening the battery and air filter compartment door . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Opening the fuse box cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Adjusting the drivers seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Isolating the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Check battery condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Check tyre condition and pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Tighten wheel nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Check working hydraulic system oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Check brake hydraulic system oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Check engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Checking the fuel level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Filling fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Check the transmission oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Check coolant level in header tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Check windscreen washer reservoir fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Checking the twistlocks and warning lights for proper operation . . . . . . . . . . . . . . . . . . 44
Normal start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Truck status display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Malfunctions during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Overload safety switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Start-up indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Gear shift control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Stopping the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Operating transmission dump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Truck lighting and turn indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Operating the hazard warning lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
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Operating the horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Turning on the front windscreen wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
To operate the cab pre-heater system * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Opening the fuse box cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Boom and handler controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Operating the spreader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Before lifting a load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Picking up a container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Travelling with loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Depositing the load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Parking the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Trailer coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Wheel change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
5 Maintenance
General remarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Taking the truck out of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Work on the boom and the front part of the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Hoisting the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Inspection and maintenance data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Fuel and oil recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Check the condition of structured components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Truck welds inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Inspection and maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Daily checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
As required Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
50 h Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
500 h Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1000 h Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
2000 h Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
3000 h Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
5000 h Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
6000 h Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
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Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Check engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Change the engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Change the engine oil filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Drain the fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Change the fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Prime the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Check the air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Change the air filter element - check the vacuum switch . . . . . . . . . . . . . . . . . . . . . . . . 135
Change the air filter safety element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Check the engine mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Clean the radiator and check for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Check the injection nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Check valve clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Check the intake and exhaust systems for leaks and tightness . . . . . . . . . . . . . . . . . . . 141
Check the cooling system for leaks and tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Flush the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Change engine coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Check the vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Check drive belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Check the fan drive idler pulley assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Fan hub, belt driven . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Check the turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Change the transmission oil and clean the filter screen . . . . . . . . . . . . . . . . . . . . . . . . 151
Change transmission oil filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Check transmission mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Chassis, bodywork and fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Clean the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Check seat belt for condition and correct operation* . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Tighten wheel nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Check the tyres for damage and foreign objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Check the cab mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Truck welds inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Chassis frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Check steer axle hub oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Clean and lubricate steer axle, check the mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Check and lubricate the drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Check the drive axle mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Check the drive axle centre differential oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Check the drive axle hub differential oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
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Change the drive axle hub differential oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

Check and adjust hub bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Check the steering lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Check the parking brake condition and mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Check the brake disc wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Electrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Check battery condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Check electric cables, connectors and connections for condition and tightness . . . . . . . 167
Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Check the hydraulic system, pumps, valves and lines . . . . . . . . . . . . . . . . . . . . . . . . . 168
Change the working hydraulic system oil suction filters . . . . . . . . . . . . . . . . . . . . . . . . 169
Change the brake hydraulic system oil suction filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Change the brake hydraulic system oil pressure filter . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Change the brake hydraulic system oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Change the hydraulic oil - working system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Load lift system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Check and lubricate boom cylinder, boom pivot and sliding bearings . . . . . . . . . . . . . . 176
Lubricate slewing ring bearing and gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Slew gearbox and brake oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Check and lubricate the twistlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Check and lubricate feet at the bottom of each leg . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Change the twistlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Special equipment, accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Check the central lubrication* lubricating points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Fill central lubrication* canister with grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Troubleshooting guide Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Troubleshooting guide hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
User manual feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
User manual improvement record. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Annex
6 Technical Data
Datasheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Operating Instructions – 3578011501 EN – 2010/01/27 VII

Table of contents
g
7 Circuit Diagrams
Electrical Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Electrical Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Hydraulic Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
VIII Operating Instructions – 3578011501 EN – 2010/01/27

1
Introduction
1 Introduction
Your Linde truck
Your Linde truck

Linde lift trucks offer the best in economy, written approval by the manufacturer. Linde
safety and driving convenience. Therefore it pursues a policy of continuous progress in the
is mainly in the hands of the operator to pre- design and construction of its products. As a
serve the qualities of the trucks for a long and result, the illustrations and technical details
profitable service life and to make full use of referring to design, fittings and engineering
their benefits on the job. For attachments, the of lift trucks are subject to change if progress
proprietary operating instructions supplied warrants it. Therefore, the manufacturer will
with them are applicable. Follow all hints for not accept any claims based on the specifica-
operating the lift truck and carry out the main- tions, illustrations and descriptions contained
tenance and care prescribed in the inspection in this operating manual. Please submit all
and maintenance schedule regularly, on time enquiries concerning your truck and all orders
and with the specified lubricants. This manual for spare parts to your authorized distributor,
tells you all you need to know about start- making sure to state your correct shipping
ing, running, servicing and maintaining your address. For repairs, use only genuine Linde
lift truck. The terms “front”, “rear”, “left” and spare parts to ensure that your Linde truck will
“right” refer to the position in which the item maintain its original technical standard.
concerned is installed in the truck, looking for-
• Lift truck model:......................................
ward in the travel direction.
• Serial no./year built:...............................
Approved applications Linde lift trucks are
• Handing-over date:................................
designed for transporting and lifting the loads
stated in the load capacity diagram. In partic- When ordering parts for the engine, mast,
ular, we refer to the attached VDMA booklet drive motors, drive pumps, steer axle, hy-
"Safety rules for industrial trucks" and acci- draulic pump and transmission, also state the
dent prevention rules of your trade association serial number of the assembly. When taking
and the special measures required for driving over the lift truck, transfer the details from the
on public roads in accordance with the traffic assembly type plates into this operating man-
regulations. The safety rules for the use of ual.
industrial trucks must be followed under all
Truck takeover Every truck undergoes careful
circumstances by the responsible persons,
inspection before leaving the factory in order
especially by the operator and service person-
to make sure that it will be in satisfactory
nel. The user, and not Linde, is responsible
condition and fully equipped as ordered
for any danger arising from applications not
when delivered to the customer. Authorised
authorised by the manufacturer. If you desire
distributors are under obligation to re-inspect
to use the truck for applications not mentioned
the truck before delivery and to hand it over in
in the manual and convert or supplement it for
good order. In order to avoid later complaints
this purpose, please first contact your autho-
and inconvenience to customers, you are
rised dealer. No changes, especially conver-
requested to ascertain that the truck is in
sions or modifications, may be made on your
satisfactory condition and fully equipped
truck without the prior permission of the man-
at the time of delivery and to acknowledge
ufacturer. Only qualified persons authorised
orderly handing/taking over of the truck in the
by Linde are allowed to service the trucks. To
manufacturer’s certificate of conformity.
keep your warranty valid, keep a record of all
maintenance services. The following technical documents are sup-
plied with each truck:
Technical note These operating instructions
or excerpts thereof may only be copied, trans-
lated or transmitted to third parties after prior
2 Operating Instructions – 3578011501 EN – 2010/01/27

Introduction 1
Your Linde truck
• 1 Operating instructions
• 1 EC certificate of conformity (The man-
ufacturer 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
Operating Instructions – 3578011501 EN – 2010/01/27 3

1 Introduction
Technical Description
General to the left hand side of the chassis in the engine
compartment.
Type 357 reachstackers are designed to lift
and transport containers between 20 ft and
40 ft in lenght and at weights up to 45 tonnes. Driving cabin, controls, switches and
Maximum travel speed is 25 k.p.h. loaded, instruments
28 k.p.h. unloaded, and maximum climbing
The driving cab frame forms the load guard; it
gradient is 30.9%. The handler has automatic
conforms to International safety standards.
self-levelling and sway damping, 95°/185°
rotation and +/- 800 mm sideshift. The cab is fitted to a rolling platform and locked
at the rear of the chassis. (CH versions are
Engine provided with an automated hydraulically
powered moving cabin as standard). To gain
The trucks are fitted with a Cummins 11 litre access for maintenance services, it can be
liquid cooled, 6 cylinder turbocharged direct unlocked and moved.
injection diesel engine which develops a rated
output of 250 kW maximum engine torque Steps and a walkway on the left hand side of
is attained at 1100 rpm. The engine draws the truck are provided for normal access. The
fuel from two tanks fitted in the chassis left right hand door can be used in an emergency.
hand compartment and fuel consumption is On CH models an emergency exit is situated
between 15-28 l/h (according to VDI cycle). at the rear of the cabin.
Engine lubricating oil is filtered by a twin The cab and doors have large glazed areas
element oil filter and a rotary bypass filter. to allow the driver maximum visibility during
The oil cooler is of the plate type and is located operations. Screen wipers and washers are
under a cast-iron cover on the right-hand side fitted to the front, top and rear screens with
of the engine block. A combined cooler for demist functions as part of the heater system
engine air, water and transmission oil is fitted to maintain visibility.
in the engine compartment. The boom positioning and container handler
Cooling air is drawn through the radiator by the functions are controlled by a central control
engine cooling fan and is discharged through lever mounted on the driver’s control centre.
the engine compartment and under the drive Operational travel speed of the truck is re-
axle. stricted to 5 km/hr when: -
- the load lifted exceeds 70% of the truck
Transmission capacity at the given mast position.
An automatic, electronically controlled four- - the boom is extended to 930 cms above
speed powershift transmission is driven by normal travel position height.
the engine. Manual pre-selection of gears can
also be made. The driving direction is selected System faults are indicated on the truck status
with a control lever mounted on the steering display screen fitted in the cab to the right
column. of the operator. Working light switches are
mounted in a panel fitted on the left of the
steering column at the front windscreen lower
Transmission Disconnect (De-clutch) corner.
De-clutch is the standard transmission setting,
Also indicated on the truck status display
controlled by the APC unit and is activated by
screen when driving is the actual gear se-
depressing the brake pedal. The transmission
lected, engine revs (selectable) and the fuel
oil is filtered through a twin element filter fitted
level in litres. When the twistlocks are locked

Introduction 1
into a container actual load weight, maximum Steering

load weight, boom angle and boom length
The steering is a hydrostatic power system,
are displayed. The truck status display unit
which operates the rear wheels with the
also logs all lifting and driving activities, and
steering wheel via the steering cylinder. The
all error codes and fault codes along with the
steering system can also be operated when
operators actions when error and fault codes
the engine is stopped, but a greater effort is
are displayed.
required to turn the steering wheel.
The gearchange control unit and combined
electrical control switch are fitted on either side Braking System
of the steering column. The switches for the
top and rear windscreen wipers and washers The truck braking system is hydraulically op-
are fitted on the driver’s control centre. erated. It is designed as a Fail Safe system
which will not release unless hydraulic pres-
The windscreen washer reservoir is fitted to sure in the system is correct. Audible warning
the right rear of the cab, with access to the filler of low pressure in the brake hydraulic system
cap from the outside of the cab. is given by a buzzer fitted in the drivers cab
The ventilation switch and temperature and a visual warning on the truck status dis-
regulator is fitted to the rear right of the cab. play unit.
The right rear skin panels of the cab can be The service brake is controlled by connected
removed to allow access to the windscreen foot pedals, one fitted on either side of the
washer reservoir. steering column.
The heater / fresh air unit is fitted behind The parking brake by an electrical push button
the rear access door. This can be pivoted fitted on the drivers control centre and is
outwards to allow access for maintenance. automatically applied after the truck has been
The fuel filler cap is located within a compart- stationary for 4 seconds.
ment in the left side of the chassis behind a An engine mounted oil pump draws oil from a
lockable door. tank in the right hand chassis compartment.
The oil passes through a pressure filter and
Drive Axle is circulated through the brake chambers in
the drive axle to provide brake cooling and
The drive (load) axle is driven by the trans-
lubrication, with a high pressure bleed to the
mission through a propeller shaft. The axle
brake system pressure accumulator.
is a double reduction type with spiral bevel
primary and hub planetary reduction gears. The service brakes are of the oil immersed
The half shafts are fully floating, with the hubs disc type. The disc type parking brake is fitted
running on adjustable taper roller bearings. to the drive axle differential.
The service brake is controlled by valves fitted
Steer Axle directly under the service brake pedals which
The steer (rear) axle is mounted on bushes, are mechanically connected to each other
which allow sufficient wheel movement using a rigid bar. The pedal control valve is
for stability over uneven ground. Steering connected directly to the main brake system
movement is provided by a double acting control valve fitted on the top of the brake
hydraulic cylinder, acting on fixed length system oil filter block on the chassis.
steering links. The steering stub axles pivot Transmission disconnect is activated when
on adjustable roller bearings and the steering either of the brake pedals are depressed and
links are fitted with spherical bearings. throttle selected.

1 Introduction
Working and Steering Hydraulics bearings for the handler turntable and levelling
cylinders.
The working hydraulic and steering hydraulic
systems are supplied by a single pump and The hydraulic service lines to the lift and
two pumps mounted in tandem which are extension cylinders have lock valves fitted
fitted to the transmission. to prevent sudden lowering of the boom upon
loss of hydraulic pressure .
The pumps draw oil through positive suction
filters from a tank built into the right hand chas- The extension cylinder is attached to the inner
sis compartment and deliver at regulated pres- and outer boom sections.
sure to the flow selection valves and steering
priority valve. With the truck stationary and no Container Handler
working or steering function selected, pres-
sure in the pump control system is maintained The container handler has a hydraulic ro-
between 435 and 725 p.s.i., with all other flows tator and a spreader beam assembly. The
returned to the hydraulic oil tank. hydraulic rotator is attached to the boom by
bearings fitted at the turntable top plate. Two
The flow selection, steering priority and hydraulic brake drive units are fitted on the
hydraulic control valves for the mast and turntable top plate and both units are meshed
handler are mounted under the centre engine to a slewing gear fitted on the turntable bottom
compartment cover on the right hand side of plate.
the chassis. They are operated by the central
control lever, and switches mounted on the The spreader beam has a centre section
drivers control centre and the steering hand manufactured from two square tubes in which
pump. the beam extensions slide. Two hydraulic
cylinders for extending the beam extensions
A bleed from each control valve operates to the container length are attached to each
the engine speed-up control cylinder on beam extension and to the centre beam.
the fuel injection pump. In operation the
steering system demand is given priority with The electrical control boxes for the beam
the working hydraulic functions selected as functions are fitted on the top of the beam,
demand requires. together with the hydraulic hoses. A beam
locking hydraulic cylinder (optional on TL
When there is no steering demand all steering models standard on CH models), is fitted on
pump delivery is diverted if required, to the each end of the centre section, each cylinder
working system. Pressure relief valves has a sliding bolt which engages in a slot at the
are fitted in all hydraulic circuits to prevent 24’ and 30’ extension positions.
overloading.
The twistlock mechanisms are fitted in each
end of the cross beams. They engage in the
Telescopic Boom
corner castings of the container and are locked
The telescopic boom comprises two square or unlocked with a cross shaft. When the
section tubes. It is raised and lowered by container is raised, it is suspended on these
two single-acting hydraulic lift cylinders fitted four twistlocks.
between the chassis and the boom, and it is
The positions of the twistlocks are indicated
extended and retracted by a double acting
by a three colour light display fitted under the
hydraulic cylinder fitted inside the boom.
boom head and duplicated in a repeater unit
Movement of the inner boom within the outer mounted on the top left-hand side of the front
is guided by heavy-duty main and side thrust cab windscreen rail.
bearing pads. The boom assembly pivots on
Additionally mechanical flags are fitted to the
two large bearings fitted to the outer section,
rear twistlocks to show the positions. Interlock
with the head of the inner section having

Introduction 1
Intended use
switches cut out the boom lift function if all four If hazardous operating conditions are de-
twistlocks are not locked properly. tected, the yellow indicators illuminate pro-
gressively as the condition becomes less safe.
Electrical System If unsafe operating conditions occur, the red
The truck has a 24 V DC electrical system indicators illuminate and the safety system
supplied by the alternator. Two 12 V 143 prevents further unsafe operation. Any further
Ah heavy-duty batteries connected in series movement of the boom or handler is allowed
are fitted in the leftside chassis compartment only if it gives a safe load state.
beside the air filter. A battery isolator facility is When the red indicators illuminate an audi-
included with safety in mind, as well as acting ble buzzer sounds within the cabin. A second
as an anti-theft device. buzzer is fitted and will emit an audible warning
The battery isolator is located between the two when the load exceeds 75% of the truck ca-
lockable compartments on the left side of the pacity. The frequency of this buzzer increases
chassis. until 100% of the load is reached.
The electrical fuse box for main truck systems, These indications are also displayed on the
is located at the rear right of the cab. truck status display screen in the cab. A load
safety status bar is displayed whenever a
The truck is fitted with basic road lighting, in- load is locked onto the spreader which gives a
cluding sidemarker and tail lights, headlights, visual indication of the safety of the load.
stop lights and turn indicator lights, and re-
verse warning buzzer. The working lights, 8
Automatic lubrication system*
chassis, 4 boom, are fitted to illuminate the
area around the truck. The truck is fitted with an electrically operated
automatic lubrication system which supplies
Safety Systems and Shut Down Devices grease to key points around the truck indicated
below.
The truck safety system uses sensors fitted on
the boom, chassis and lift cylinders to detect Measured quantities of new grease are
overload. The system gives a visual indication supplied at regular pre-programmed timed
of the safety state to the driver using a series intervals to ensure efficient operation of wear
of green, yellow and red colour lights. pads, bearings etc..
When operating conditions are safe, the green Indicator lights are fitted inside the drivers cab
indicators illuminate. which inform the operator of the status of the
lubrication system.
* option
Intended use
Linde trucks are designed for transporting and • the special measures required for driving on
stacking the loads stated in the load capacity public roads in accordance with the C.U.R.,
diagram. In particular; • other local regulations.
• we refer to the VDMA Guidelines for the The rules for the intended and approved
normal and proper use of industrial trucks use of industrial trucks must be followed
(or BITA for UK market), under all circumstances by the responsible
• the safety rules of your trade association, persons, especially by the operator and
service personnel.

1 Introduction
Improper use
The user, and not Linde, is responsible for No changes, particularly no modifications and
any danger arising from applications not additions, may be made to the truck without
authorised by the manufacturer. the approval of the manufacturer.
If you desire to use the truck for applications
not mentioned in this manual, please first
contact your authorised dealer.
Improper use
The operating company or driver, and not the Prior to, and whilst travelling, ALWAYS look in
manufacturer, is liable if the truck is used in a the direction of travel.
manner that is not permitted.
Be aware of pedestrians, and avoid situations
WARNING where they could become trapped between
the truck and a fixed object.
One of the major causes of accidents involving lift
trucks is the operator ignoring, or being unaware of When approaching blind corners, always
basic safe operating practices. sound the horn.
In order to ensure the safety of the operator and
others, a few basic safe operating practices outlined Only use the truck and any attachments for
below must be followed. authorised applications.
When transporting a load, follow the directions
Never operate the truck in a potentially explo-
in the user manual.
sive atmosphere.
On a ramp or incline: • Ensure the truck
Never carry passengers (unless a ’buddy seat’
has adequate ground clearance to clear the
is fitted).
camber • Raise the load sufficiently to clear
Do not overload the truck beyond it’s rated the camber
capacity as stated on the capacity plate.
Travel uphill with the load leading
Do not carry off centre loads.
Travel downhill with the load trailing
Do not turn or stack loads on a slope.
When raising the load lift device, ensure there
Do not operate the truck on loose or greasy is adequate clearance.
surfaces.
When working near overhead electric cables,
Do not travel on uneven or obstructed ground. observe the safe distance established by the
responsible authorities.
Do not park the truck in front of fire extinguish-
ers, emergency exits or gangways where it Make sure the surface on which you are trav-
can cause an obstruction. elling is capable of supporting the combined
weight of the truck and load.
Never alight from a moving truck.
Before leaving the operator’s driving position,
Never leave the truck unattended with a raised always turn the ignition off and ensure the park
load. brake is applied.
Operating Procedures Summary

Always adapt your driving style to the condi-
A safe, competent operator is one who takes
tions of the roadway, particularly hazardous
pride in the way they operate their truck,
work areas and the load being transported. respects the goods they handle, and follows

Introduction 1
Truck takeover
the correct operating procedures. NEVER

TAKE CHANCES.
Symbols used
The precautions Danger, Warning, Caution, CAUTION
Note und Environment Note in this manual
indicates hazards that may result in damage to or
are provided to indicate special hazards destruction of the product.
or unusual information requiring special
identification:
NOTE
DANGER
Identifies technical information requiring
indicates hazards that may result in personal injury
or death and/or substantial damage to the product. special attention because the connection may
not even be obvious to skilled personnel.
WARNING ENVIRONMENT NOTE

indicates hazards that may result in personal injury The information contained herein must be
and/or substantial damage to the product. observed, otherwise environmental damage
may occur.
For your safety other symbols are also used.
Please note the different symbols.
Commissioning
¾ Check the engine oil level ¾ Check the lifting device and attachments
¾ Check coolant level in expansion reservoir ¾ Regenerate the soot filter (option)
¾ Refuel the truck The truck can be operated at full speed im-
mediately. Avoid sustained high loads on
¾ Check the condition of the battery
the working hydraulic system and transmis-
¾ Check the tyre inflation pressure sion system in the first 50 hours of operation.
Re-tighten wheel nuts daily prior to starting
¾ Tighten the wheel nuts
operation until they are seated firmly, i.e. until
¾ Working hydraulic system: Check the oil no further tightening is possible.
level
¾ Tighten opposite wheel nuts to a torque of
¾ Check the braking system 680 Nm.
¾ Check the steering system
Truck takeover
Every container handler undergoes careful when delivered to the customer. Authorised
inspection before leaving the factory in order distributors are under obligation to reinspect
to make sure that it will be in satisfactory the truck before delivery and to hand it over in
condition and fully equipped as ordered good order.

1 Introduction
Truck takeover
In order to avoid later complaints and incon- • Truck model:

venience to customers, you are requested to • Serial number/year of manufacture:
ascertain that the truck is in satisfactory condi-
• Hand over date:
tion and fully equipped at the time of delivery
and to acknowledge orderly handing/taking Additionally, specify the serial number of the
over of the truck in the manufacturer’s certifi- engine, mast, hydrostatic hydraulic pump,
cate of conformity. drive pump and drive motors when ordering
parts for these assemblies.
Linde pursues a policy of continuous improve-
ment in the design and manufacture of its • Engine number:
products. The illustrations and technical de- • Mast / Boom number:
tails referring to design, fittings and engineer- • Mast lift:
ing of lift trucks are subject to change or mod-
• Hydraulic pump number:
ification as a result of technological progress
by Linde. • Drive pump number:
• Drive motor number:
Linde is therefore unable to consider any
claims based on the specifications, illustra- • Spreader serial number:
tions and descriptions contained in this Oper- This information can be found on the type
ating Instructions manual. plates on the truck. We recommend that you
Please submit all enquiries concerning Linde transfer this information to this manual for
container handling truck orders for spare parts ease of future reference.
to your local Linde representative, making The following technical documents are sup-
sure to give the correct delivery address. plied with each fork truck:
For repairs use only original Linde spare parts. • 1 Operating Instructions
Only in this way can it be guaranteed that your • 1 EC certificate of conformity (The man-
Linde truck maintains its original technical ufacturer certifies that the industrial truck
standard. conforms to EC guidelines for machines)
These operating instructions or excerpts • Safety rules for the use of industrial trucks
thereof may only be copied, translated or (VDMA)
transmitted to third parties after prior written
approval by the manufacturer. We wish you satisfactory operation.
When ordering spare parts, please specify the Linde Material Handling
part number and state the following truck data:

Introduction 1
EC declaration of conformity
The manufacturer declares that the truck
complies with the requirements of the EC
directives valid at the time of marketing. This is
confirmed by the EC declaration of conformity
and by the CE labelling on the nameplate. See
also the following explanation.
An independent structural change or addition
to the truck can compromise safety, thus
invalidating the EC declaration of conformity.
The EC declaration of conformity must be
carefully stored and made available to the
responsible authorities.
Declaration

Linde Industrial Park
Merthyr Tydfil, CF40 4LA, Wales, UK
We declare that the machine
Industrial truck according to these operating instructions

Model according to these operating instructions
complies with the most recent version of machinery directive 2006/42/EC.
Personnel authorised to compile the technical documents:
see EC declaration of conformity

1 Introduction

2
Safety
2 Safety
Safety rules
Safety rules
Safety rules
WARNING • information related to starting, driving and

braking
Exercise care when operating your machine in
wind velocities of 24 knots / 28 mph / 45 km h or • service and repair information
greater, handling characteristics may be affected, • recurrent inspections, accident prevention
specifically, high lifting and lowering operations.
check
Further information should be sought from the
manufacturer, or local statutory authorities. • disposal of grease, oil and batteries
• remaining risks
The responsible persons, particularly the truck
The operator (employer) or the responsible
operator and servicing personnel, must be
person must ensure that all the guidelines
instructed in the safety rules for the normal
and safety rules applicable for your truck
and proper use of the trucks included with
are observed. When instructing a trained
these operating instructions.
operator, acquaint him with the:
The employer must ensure that the operator
• special features of the truck
has understood all safety information.
• optional attachments
Please observe the guidelines and safety • special operating and working area char-
rules therein for example: acteristics, by training and practice driving,
• information on the operation of container shifting and steering operations until they
handling trucks are completely mastered.
• rules for roadways and work areas Only then start to train for stacking operations.
• rights, duties and safety rules for the The stability of the truck in the work is ensured
operator if employed properly. Should the truck tip
• operation in special areas over during unauthorised application or due
to incorrect operation, always follow the
instructions depicted below.
In case of tip-over
! Follow these Stay

WARNING Instructions buckled up Don't jump Hold on tight Brace feet lean away
Safety precautions WARNING

The precautions WARNING, CAUTION, AT- Indicates hazards that may result in personal injury
TENTION and NOTE in this manual are pro- and/or substantial damage to the product
vided to indicate special dangers or unusual
information requiring special identification:
CAUTION
DANGER Indicates hazards that may result in damage to or
Indicates hazards that may result in personal injury destruction of the product
or death and/or substantial damage to the product

Safety 2
Safety rules
CAUTION CAUTION
This note is found on various Improper handling of coolant and coolant additives
positions of the truck where special puts your health and the environment at risk.
attention is required. Read the Always handle fuel, lubricants and coolant as
appropriate section of your operating required and as specified by the manufacturer.
instructions.
Accident prevention check
NOTE The accident prevention rules in some coun-

tries prescribe that the forklift truck must be
Identifies technical information requiring checked at least once a year for proper work-
special attention because the connection may ing condition by trained personnel. Please
not even be obvious to skilled personnel. contact your authorised dealer in this regard.
Handling fuel, lubricants and coolant Operation of container handlers in the

Always handle fuel, lubricants and coolant as plant area
required and as specified by the manufacturer. WARNING
Only store fluids and lubricants in approved
containers at specified storage places, as they Many plant areas are so-called limited public traffic
could be inflammable. Do not allow them to areas. We advise you to check if your company
liability insurance covers any damages occurring
come into contact with hot objects or naked with your truck against third parties on “limited”
flame. public traffic areas.
Only use clean containers when replenishing
fluids and lubricants. Running-in Instructions
Follow the manufacturer’s safety and disposal The truck can be operated at full speed im-
instructions when using fluids, lubricants and mediately. Avoid sustained high loads on
cleaning compounds. Avoid spilling fluids and the working hydraulic system and transmis-
lubricants. sion system in the first 50 hours of operation.
Re-tighten wheel nuts daily prior to starting
Remove any spillage immediately with a suit- operation until they are seated firmly, i.e. until
able binding agent and dispose of as specified. no further tightening is possible.
Also dispose of used or contaminated fluids
and lubricants as specified. Tighten opposite wheel nuts to a torque of 350
Nm.
Follow laws and regulations.
Clean the area surrounding the part in ques- NOTE
tion before lubrication, filter renewal or repairs
Observe the tightening instructions on the tag
in the hydraulic system. Discard parts in an
attached to the steering column.
environmentally friendly way.
CAUTION Checks prior to first operation*

Medical aid is required if such an injury occurs. • Coolant level in reservoir
Do not allow hydraulic oil under pressure, for • Engine oil level
example at a leak, to penetrate the skin.
• Fuel level
• Working hydraulic system oil level
• Tightness of wheel nuts
• Tyre pressure

2 Safety
Safety rules
• Drive motors oil volume Daily checks*

• Battery terminals • Coolant level in reservoir
• Boom and spreader • Engine oil level
• Function of braking system • Hydraulic system oil level
• Function of steering system • Tyre pressure
• Regenerate the soot filter (option) • Windscreen washer fluid level
• Clean, check and adjust mirrors
*A description of the services can also be
located in the alphabetical index.
Do not operate with guards removed
CAUTION NOTE
Do not operate the truck with guards removed
Guards and covers are fitted to prevent injury,
Danger of injury.
and should only be removed for maintenance
purposes. They should be refitted before
returning the truck to service.
Park Brake
CAUTION
Always check that the park brake (manual and
automatic), is applied before leaving the truck.
Automatic park brake - option.
Malfunctions
In the event of a malfunction park the truck in a CAUTION
safe condition, lower the load and shut off the
Some safety features are disabled when the over-
engine. ride function is activated. Exercise extreme cau-
tion.
If fitted the truck override system may be used
to make the truck safe and in some cases a Do not continue to operate the truck.
’limp home’ mode is available to allow the truck
to be moved to a safe location for investigation
into the malfunction.
Handling Fuel, Lubricants and Coolant

Always handle fuel, lubricants and coolant as Only store fluids and lubricants in approved
required and as specified by the manufacturer. containers at specified storage places, as they
could be inflammable. Do not allow them to

Safety 2
Safety rules
come into contact with hot objects or naked CAUTION

flame.
Improper handling of coolant and coolant additives
Only use clean containers when replenishing puts your health and the environment at risk.
fluids and lubricants. Follow the manufac- Always handle fuel, lubricants and coolant as
turer’s safety and disposal instructions when required and as specified by the manufacturer.
using fluids, lubricants and cleaning com-
pounds. Accident prevention check
Avoid spilling fluids and lubricants. Remove The accident prevention rules in some coun-
any spillage immediately with a suitable tries prescribe that the forklift truck must be
binding agent and dispose of as specified. checked at least once a year for proper work-
Also dispose of used or contaminated fluids ing condition by trained personnel. Please
and lubricants as specified. contact your authorised dealer in this regard.
Follow laws and regulations. Operation of forklift trucks in the plant area
Clean the area surrounding the part in ques- CAUTION

tion before lubrication, filter renewal or repairs Many plant areas are so-called limited public traffic
in the hydraulic system. areas.
Discard parts in an environmentally friendly We advise you to check if your company liability
way. insurance covers any damages occurring with your
fork truck against third parties on “limited” public
traffic areas.
CAUTION
Do not allow hydraulic oil under pressure, for
example at a leak, to penetrate the skin.
Medical aid is required if such an injury occurs.
Residual risks
Despite careful working and compliance with DANGER
all applicable standards and regulations, the
Persons in the vicinity of the truck must be instruc-
possibility of other dangers when using the ted regarding these dangers that arise through use
truck cannot be entirely excluded. of the truck.
The truck and its possible attachments comply These operating instructions also contain additional
safety regulations.
with current safety regulations. Nevertheless,
even when the truck is used for its proper
Residual dangers can include:
purpose and all instructions are followed,
some residual risk cannot be excluded. • Escape of consumables due to leakages or
the rupture of lines, hoses or containers,
Even beyond the narrow danger areas of the
truck itself, a residual risk cannot be excluded. • Risk of accident when driving over difficult
Persons in this area around the truck must ground such as gradients, smooth or
exercise a heightened degree of awareness, irregular surfaces, or poor visibility,
so that they can react immediately in the event • Risk of falling, tripping, slipping etc. when
of any malfunction, incident or breakdown. moving on the truck, especially in the
wet, with leaking consumables or on icy
surfaces,
• Risk of fire and explosion due to the battery
and electrical voltages,

2 Safety
Noise emission data
• Human error, • Risk caused by insufficient maintenance or

• Disregarding the safety regulations, testing,
• Risk caused by unrepaired damage, • Risk caused by using the wrong consum-
ables.
Stability
Stability is guaranteed if your truck is used • turning and driving diagonally across
properly and according to its intended pur- slopes,
pose. Common reasons for a loss of truck • driving on slopes with the load on the
stability include: downhill side,
• cornering at excessive speeds, • loads that are too wide,
• moving with the load raised, • swinging loads,
• moving with a load that is protruding to the • ramp edges or steps.
side (e.g. sideshift),
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 informa-
tion should be sought from the manufacturer, your authorised distributor, or local statutory authorities.
Avoid operating the truck in high winds.
Frequency characteristic for human body vibrations

Frequency characteristic for human body vibrations
The values are determined in conformance
NOTE
with EN 13059 on trucks with standard equip-
ment according to the technical data sheet The frequency characteristic for the human
(driving over test course with bumps). body cannot be used to determine the actual
frequency load during operation. This load de-
Frequency characteristics acc. to EN 12096
pends on the working conditions (conditions of
Measured frequency characteristic aw, ZS = roadway, type of operation, etc) and must the-
0.4 m/s² Uncertainty K = 0.1 m/s² refore be determined at the site, if necessary.
The specification of hand and arm vibration is
Frequency characteristic for hand arm vibra-
required by law, even if the values, as in this
tions
case, do not indicate any danger.
Noise emission data

Noise emission data
Determined in the test cycle according to EN Noise level at the driver’s station
12053 from the weighted data in the operating • 357 LPAZ = 72 dB(A)
modes DRIVING, LIFTING, IDLE.
• While lifting Lpa = 75 dB(A)
• While Idling LPb = 61 dB(A)

Safety 2
Noise emission data
• While driving LPc = 75dB(A)

• Uncertainty KPA = 4 dB(A)

2 Safety
Noise emission data

3
Overview
3 Overview
General view of the truck
General view of the truck
1 Lift cylinder 13 Exhaust system

2 Boom 14 Steer axle
3 Boom extension cylinder 15 Cooling system radiator
4 Levelling cylinder 16 Bonnet
5 Rotator head 17 Heater / Climate control* system
6 Indicator lights 18 Air intake system
7 Container handler 19 Driver’s cab
8 Transmission cover 20 Fuse and relay box
9 Drive axle 21 Battery and air filter access door
10 Transmission 22 Battery isolator
11 Variable displacement pumps 23 Fuel filler access door
12 Engine

Overview 3
General view of the handler
* option
General view of the handler

1
15 3
14 4
13
12
11 5
10 9 7 6
1 Inner boom 9 Extension sliding bearings

2 Levelling cylinder 10 Twistlocks guides
3 Rotator drive motor 11 Handler extension
4 Handler electrical box 12 Hydraulic system control valves
5 Handler centre beam 13 Rotator gearbox
6 Sideshift sliding bearings 14 Rotator brake
7 Sideshift cylinder 15 Handler mountin pin
8 Twistlocks

3 Overview
Controls and Indicators
Controls and Indicators
2 3 4 5
1
7
F
N
R
10
11
16 15
12
13
14
d3571000
1 Left hand display unit (LHD) 9 Driver’s control centre (DCC)

2 Electronic gear shift control lever (EGS) 10 Parking brake switch
3 Turn indicator lamp 11 Hazard warning light switch
4 Steering wheel 12 Emergency shutdown switch
5 Multiple function electrical control lever 13 Emergency override key
6 Ignition key switch 14 Heater control
7 Display screen 15 Accelerator pedal
8 Central control lever (joystick) 16 Service brake pedals

Overview 3
Gauges, switches and warning lights

LHP RHP
1 1
2 SC
F
N
R
1
3
d3571001
Left hand control panel (LHP) 2 Truck status display

1 Left hand panel
2 Headlamp main beam indicator light Steering column (SC)
1 Electronic gear shift control lever (EGS)
Right hand control panel (RHP) 2 Turn indicator lamp
1 Right hand panel 3 Multiple function electrical control lever

3 Overview
DCC LSSP
2
1 1
5 4 3
6
7
TI
CHI 2
1 1
1 1 3
2
1
CRB 1
1 2 3
d3571002
Driver’s control centre (DCC) Twistlock indicators (TI)

1 Central control lever (joystick) 1 Truck status display indicator lights
2 Twistlock switch 2 Boom indicator lights
3 Top screen wiper and washer switch 3 Flag indicators on handler
4 Rear screen wiper and washer switch
5 Parking brake button Combi-Handler indicators (CHI)
6 Hazard warning indicator light switch 1 Handler indicator lights
7 Emergency stop button 2 Boom indicator lights
8 Override switch Cab rear bulkhead (CRB 1)
Load safety system panel (LSSP) 1 Climate control unit
1 Load state indicator 2 Fan speed switch
3&4 Temperature regulation switches
5 Climate control switch

Overview 3
NOTE
A warning buzzer will sound if brake system
hydraulic pressure is low. A warning buzzer
will also sound if maximum load/position is
approached (red illuminated LED’s).

3 Overview

4
Operation
4 Operation
Cab door opening and closing
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.
Cab door opening and closing

¾ Press button (1) on handle (2) and pull the 1
door.
Opening the cabin door from the inside

¾ Hold handle (3) and press lever (4) and
push the door.
2
3
d3561006
Securing the open cabin door

¾ Open the cab door.
¾ Open door fully rearward until spring loaded
plunger (2) locks into retainer (3).
Cabin door - closing

¾ Lift lever (1)inside the cabin, or pull down
the lever on the door retainer (3) to release
(2). Pull the door outwards. 1
¾ Close the door.
NOTE 2 3
Lock the cabin door with the key when leaving d3561007
the truck unattended.

Operation 4
Opening the transmission cover
Opening the engine cover

WARNING
The engine cover is raised by gas struts which
operate as it is released. When opening, the engine
cover passes close to the cab support frame with
possibility of trap injury.
Do not hold the front edge of the engine cover as it 1 2
rises.
¾ Check that engine cover (1) is free from

obstruction. .
¾ Insert key (2) and turn it fully anticlockwise
¾ Engine cover (1) opens when released.
d3571013
Closing the engine cover

¾ Pull engine cover (1) down against gas strut
pressure.
¾ Insert key (2) into the lock and turn it fully
clockwise.
Opening the transmission

cover
WARNING
The front deck cover opens forward leaving open
2
access to the transmission compartment from both
sides of the truck.
1
Danger of injury due to slips and falls.
¾ Check that cover (1) is free from obstruction.

anticlockwise.
¾ The transmission cover opens as it is
released. d3571014
Closing the transmission cover

¾ Pull transmission cover (1) down against
gas strut pressure.
clockwise.

4 Operation
Opening the working hydraulic system oil tank cover
Opening the cabin rear

compartment door 1
2
¾ Release catches (1&2) on door (3).
3
¾ Open the door under control until the strut
(4) engages.
4
Closing the cabin rear compartment door

¾ Raise door (3) to unlock strut (4) and then
lower the door to the closed position.
¾ Push door inward until the catches (1&2)
engage.
WARNING
d3561012
Danger of injury due to trapped fingers
Take care when closing door (2).
Opening the working hydraulic

system oil tank cover
¾ Fit deck key (2) into each lock (3) and turn
anticlockwise to open the lock.
¾ Raise cover (1). 1
Closing the working hydraulic system oil

tank cover 2
¾ Check that all tank covers and fillers are

closed.
3
¾ Lower cover (1).
d3561013
¾ Fit deck key (2) into lock (3) and turn
clockwise to close the lock.

Operation 4
Opening the battery and air filter compartment door
Opening the brake hydraulic

system oil tank cover 1
anticlockwise to open the lock.
¾ Raise cover (1).
2
Closing the brake hydraulic system oil

tank cover
¾ Check that all tank covers and fillers are 3
closed.
¾ Lower cover (1).
d3561014
clockwise to close the lock.
Opening the battery and air

filter compartment door
¾ Check that door (1) swing area is free from
obstruction. 1
¾ Insert key (2) and turn it anticlockwise to
open the lock.
¾ Pull door (1) open fully.
Closing the battery and air filter compart-

ment door
¾ Check that door (1) swing area is free from 2
obstruction.
¾ Close the door and turn key (2) clockwise to d3561015
close the lock.

4 Operation
Adjusting the drivers seat
Opening the fuse box cover

¾ The fuse box (1) is situated inside the cabin,
to the rear of the driver’s seat. 1
¾ Check that fuse box door (2) lowering area

is free from obstruction.
¾ Insert key (or coin), into lock and turn
anticlockwise to open the lock. 2
¾ Lower the door to open.
Closing the fuse box cover

¾ Check that door raising area is free from
obstruction.
¾ Close door (2), insert key (or coin) into lock d3571015
and turn fully clockwise.

NOTE
Maximum driving comfort is obtained and
vibrations are reduced by setting the seat to
the correct weight of the driver.
Setting the drivers weight

¾ Sit on the driver’s seat.
¾ Rotate the weight setting adjuster (1) until
the drivers weight shows in the window.
d3561033

Operation 4
Adjusting the seat position

¾ For a horizontal adjustment of the seat lift
lever (5).
¾ Slide the seat forward until the desired
position to the steering wheel and pedals
is achieved.
¾ Re-engage the lever (5).
5
d3561034
Setting the seat height
To raise the seat cushion: 2
¾ Raise both levers (3&4) and lift the cushion

to the required height.
¾ Re-engage the levers.
To lower the seat cushion:

¾ Raise both levers (3&4) and push the
cushion down to the desired height. 3

4
Adjusting the seat cushion angle d3561035
¾ Lift both levers (3&4) individually and raise
or lower the cushion to the desired angle.
Adjusting the seat backrest angle

¾ Push handle (2) forwards and set the
backrest to the desired angle.
¾ Re-engage the handle.
NOTE
Long sitting puts excessive strain on the spinal
column. Prevent strain with regular, light
exercising.

4 Operation
Check battery condition
Isolating the battery

NOTE
In case of an electrical fire isolate the battery to
ensure any recovery work can be carried out 1
safely.The battery Isolator does not shut down
the engine, but isolates the truck electrically
and should be used only for maintenance
purposes or in the case of emergency.
_ +
ISOLATOR
¾ To isolate the battery rotate isolator handle 1
(1) fully anti clockwise.

¾ To reconnect the battery rotate isolator
handle (1) fully clockwise.
d3571081

The battery is fitted in the left hand chassis
compartment (1) with the air filter and fuel
system water separator.
1
¾ Check the battery, for cracks in the casing
and leakage of electrolyte.
¾ Remove corrosion on battery terminals and
check the connections are tight.
¾ Smear the terminals with non acid grease.
d3561023

Operation 4
Tighten wheel nuts
Check tyre condition and 1

pressure
NOTE
Low tyre pressure reduces the tyre service life
and the stability of the truck.
¾ Check tyres for damage or excessive wear.
¾ Remove any foreign objects from the
treads. 2
¾ Check tyres for specified pressure.

¾ Inflate tyres according to stickers (1) on the 2
chassis.
¾ If necessary add air at filler valves (2), Drive d3561019
axle, two valves each side, Steer axle, one
valve each side.
Tyre Specifications - Drive and Steer

Axle
Front 18.00 x 25 / 40 pr 145 p.s.i.
Rear 18.00 x 25 / 40 pr 145 p.s.i.
Tighten wheel nuts

CAUTION
On new trucks, or if a wheel has been removed and
replaced, the wheel nuts must be checked before
use and daily for two weeks.
Check wheel nuts every 100 hours.
¾ Torque all wheel nuts to: approx. 350 Nm.
d3561020

4 Operation
Check brake hydraulic system oil level
Check working hydraulic 1
system oil level

CAUTION
The hydraulic oil and tank may be at working
temperature. 2
Danger of scalding
¾ Fully lower the boom.

¾ Close the spreader to the 20’ position.
¾ Stop the engine and put the parking brake
3
on.
¾ Check sight glass (3) located on the RHS of
the truck.
d3571004
¾ If required, replenish with hydraulic oil to the

high mark on the dipstick.
¾ Open tank cover.
¾ Rotate breather cap (1) until escaping air is
no longer heard.
¾ Remove filler cap (2).
¾ Fill to upper level in sight glass (3).
¾ Refit filler cap (2), tighten breather cap (1)
and close tank cover.
Check brake hydraulic system

oil level
2
CAUTION 3
The hydraulic oil and tank may be at working

temperature.
Danger of scalding
¾ Fully lower and retract the boom.

¾ Close the spreader to the 20’ position.
¾ Stop the engine and put the parking brake
on.
4
¾ Check sight glass (4) located on the LHS of
the truck. d3571005
¾ If required, replenish with hydraulic oil to the

high mark on the dipstick.

Operation 4
Check engine oil level
¾ Open tank cover (2).

¾ Fill to upper level in sight glass (4).
¾ Refit filler cap (2) and close tank cover (2).
WARNING
The oil level must not drop below the low marking or
the brake may malfunction.
Maintain correct oil level.

CAUTION
The bonnet opens forward leaving open access
to the engine compartment from both sides of the
truck.
CAUTION
The engine may be at operating temperature.
Danger of scalding.
CAUTION
Follow the precautions for handling fluids and
lubricants.
¾ Park the truck on firm level ground, put the

parking brake ON and stop the engine.

4 Operation
Filling fuel
¾ Behind the cab, remove dipstick (2) and

wipe with a clean cloth.
¾ Fully re-insert dipstick (2) and remove it
again.
1
¾ The oil level should be between the High
and LOW marks on dipstick (2).
¾ If necessary, unscrew filler cap (3) and fill 3
engine oil as far as the high mark.
¾ Insert dipstick (2), refit the filler cap.
NOTE
2
Filling capacity between HIGH and LOW level
marks is approximately 5 lts.
d3571018
Total filling capacity ............ approx. 35 lts.
Checking the fuel level

¾ Turn ignition key (1) to position II.
1
¾ Check the fuel level displayed on truck sta-
2
tus monitor (2) on the right-hand instrument
panel (RHP).
3
d3571021
Filling fuel
CAUTION
Stop the engine before filling fuel. No smoking or
naked lights when filling fuel.
Do not spill or allow fuel to contact hot parts. Follow
local regulations for handling diesel fuel.
Do not allow the fuel tank to run dry to prevent
damage to the fuel system.
¾ Turn the ignition off.

Operation 4
Check the transmission oil level
¾ The fuel tank filler cap (1) located in the front

access panel on the left side of the truck.
d3571073
¾ Remove fuel cap (1), (if the fuel cap is

lockable, rotate flap (2) and use the key
provided in lock (3) to unlock).
¾ Fill the tank with clean diesel fuel.
¾ Fit the tank filler cap (1) (lock the fuel cap if
fitted). 2
NOTE
Maximum fuel capacity - 800 L
d3571074
Check the transmission oil

level
CAUTION
The engine must be running when making the oil
level check. Ensure that the truck is parked on
firm level ground with the parking brake on and the
transmission in neutral.

4 Operation
CAUTION
The engine and transmission will be at working
temperature. Danger of burns and scalds.
lubricants.
¾ Start the engine and run it until the transmis-

sion oil is at operating temperature.
¾ Open the transmission cover.
¾ Remove filler cap (1) on the left hand 1
chassis wall.
¾ Remove dipstick (2) and wipe it with a clean
cloth.
¾ Replace dipstick (2) and remove it again.
d3571075
¾ Check that the oil level is between the HIGH 1

and LOW mark on the dipstick.
¾ If necessary, replenish oil through filler cap
(3), up to the high mark on dipstick (2).
¾ Refit the dipstick
L
¾ Fit the transmission filler cap.

FUL
¾ Close the transmission cover.

2
NOTE
marks is approximately approx. 10 lts.
D
AD
3
Total filling capacity ......... 60 lts.
d3571076

Operation 4
Check windscreen washer reservoir fluid level
Check coolant level in header

tank
CAUTION 1
Danger of scalding.
Do not remove the header tank cap when the
radiator is hot or with the engine running. 3
¾ Check that coolant level is between low and

high marks.
2
¾ If required, replenish with coolant mixture.
¾ Refit filler cap (1).
d3571018
NOTE
In hot climates check the coolant level twice
daily.
Check windscreen washer

reservoir fluid level
NOTE
The windscreen washer reservoir is fitted
under a flexible cover in the cab right rear bulk-
head. The reservoir should be replenished
using a good quality washer fluid/water mixed
to the fluid manufacturer’s specifications.
¾ Lift flexible cover (1). 1
¾ Open reservoir cap (2).

2
¾ Fill the reservoir to the base of the filler neck
with washer fluid/water mixture.
d3561176
¾ Close reservoir cap (2).
¾ Fit flexible cover (1).

4 Operation
Checking the twistlocks and warning lights for proper operation
Checking the twistlocks and

warning lights for proper 2, 3
operation
1 1
NOTE 4
A container is required for this inspection. The

operation of the controls is described in the 1
1
section on the lifting device and handler. 2, 3
¾ Position the handler over a container and

lower the twistlocks into the corner castings.
3
When the twistlocks are seated, yellow lights 2 1
(2), and red lights (3) will illuminate on the

boom twistlock indicators and on the truck
status display screen. Indicator flags (4) on
d3571016
the handler are in the “not locked” position

If the twistlocks are not correctly seated, lights
(2) will flash.
¾ Lock the twistlocks.
Yellow lights (2) will remain illuminated. Red
lights (3) will extinguish, and green lights
(1) will illuminate on the boom twistlock
indicators and on the truck status display
screen. Indicator flags (4) must be in the
“locked” (orange) position.
If the twistlocks are not correctly locked lights
(1) or (3) will flash, the truck status display
screen will indicate which twistlock is not
correctly locked.
¾ Lift the handler slightly.
¾ Yellow indicator lights (2) extinguish.
Handler and indicator lights are working
properly.
CAUTION
Contact your authorised dealer if one of the functi-
ons and indicator lights does not operate as descri-
bed above.

Operation 4
Normal start
Normal start
NOTE
The engine is equipped with a start-stop
system controlled by the engine oil pressure.
When the engine does not reach or hold
operating pressure when starting or during
operation, the engine is shut off. Please
CAUTION
If this start-stop system is activated, discontinue
the starting procedure to prevent damage to the
engine.
WARNING
Danger of carbon monoxide poisoning!
Do not let the engine run in unventilated enclosed
spaces.
CAUTION
Do not operate the starter with the engine running!
This will damage the engine and starter.
Starting the engine 0 I
II
NOTE
III
The directional lever to the left of the steering
column must be in the neutral position.
¾ Sit on the drivers seat.
¾ Insert ignition key (1).
¾ Turn the key clockwise to position (I). The
electrical system is now energised, and an
audible buzzer sounds while hydraulic and
engine oil pressures are checked by the 1
ECM and found to be within specifications.

¾ The red indicator lights on the mast and in
the cabin are illuminated. d3571020
¾ On the truck display monitor, enter the driver

pin code by pressing buttons A, B, C & D
until the correct code is shown.
¾ Press F2 to enter.

4 Operation
Normal start
NOTE
Driver pin code is optional.
The truck can then be started normally.
¾ Ensure the truck is in neutral, and that the
parking brake is applied.
¾ After the buzzer has stopped, turn the
key clockwise to position (III), the engine
warning lights illuminate.
¾ As soon as the engine starts, release the
ignition key.
¾ The engine warning lights extinguish.
NOTE
If the engine does not start after 20 seconds,
wait at least 2 minutes before repeating the
starting procedure. If the engine fails to start
after the third attempt, check the fluidity of
the diesel fuel and the battery charge levels
against the recommended values.
Electronic control module system

The Cummins engine is fitted with an ad-
vanced electronic monitoring and fuel injec-
tion system controlled by the ECM (electronic
control module). This unit will indicate faults or
potential problems on display screen.
NOTE
Do not start the engine if an engine fault is
displayed on the truck status display.
On start up all of the lights will illuminate, and
extinguish after a few seconds in the order
yellow, red, blue. When a fault is detected by
the ECM the engine will be shut down or power
will be reduced.
There is a fault analysis procedure available -
please contact your authorised Linde dealer
for further information.
CAUTION
Failure to observe the warning lights could lead to
serious engine damage.

Operation 4
Normal start
CAUTION
On start up, the truck must always be in neutral.
If forward or reverse gears are selected before
switching on the ignition, start up is isolated, and
the truck cannot be started.
Cold Start
¾ Turn ignition key to position II and hold for
15 - 20 seconds. 1
¾ On the truck display monitor, enter the driver 2

pin code by pressing buttons A, B, C & D
until the correct code is shown. 3
¾ Press F2 to enter.
NOTE
Driver pin code is optional.
¾ Turn key clockwise to position (III). 4
¾ As soon as the engine starts, release the
accelerator pedal and return the key to d3571021
position (II).
¾ Release ignition key.
NOTE
Do not warm up the engine at idle speed.
Always allow time for the engine to warm up
before using maximum speed, especially
in cold climates. The engine will attain its
operating temperature after running briefly
with a moderate load and at various revs.
Stopping the engine
NOTE
Do not stop the engine at full speed, allow to
idle for at least 3 minutes before shutting off.
¾ Release accelerator pedal (4).
¾ Bring the truck to a controlled stop.
¾ Press parking brake button (3).
¾ Shift the electronic gear shift control lever to
neutral and let the engine idle for 3 minutes
to achieve a temperature balance.

4 Operation
Truck status display
CAUTION
With engines fitted with a turbocharger there is also
the danger of the shaft bearing running dry and
becoming damaged due to the high speed of the
turbocharger shaft (approx. 100,000 rpm at full
speed).
¾ Turn ignition key anticlockwise to the zero

position.
¾ Remove the ignition key when leaving the
truck.
CAUTION
Do not disconnect or isolate the batteries for at least
3 minutes after the engine has been switched off.
Danger of possible damage to the engine manage-
ment system.

The drive monitors purpose is to efficiently
control the trucks hydraulic system and
drive line by utilising both analog and digital
information from various sensors. This will
give the driver a complete overview of the
trucks status and activities during operation,
and give a complete history of the trucks
activities. It also provides truck information
such as:
• Load table
• Engine serial number
• Machine serial number
• Transmission serial number
• Hydraulic pump serial number
• Valve serial number
• Spreader serial number
• Boom serial number
• Machine model
• Commission date

Operation 4
Start-up menu
2 3
1 4
5
6
7
8
16
9
15 14 13 12 11 10
d3571023
1 Selected gear 11 F5 key. In main screen (shown) this button

2 Speedometer alternates automatic / manual wiper opera-
3 Clock tion
4 Engine menu 12 F4 key. In main menu screen resets the trip
5 Transmission menu counter
6 Hydraulics menu 13 F3 key. In main menu screen resets the trip
7 Spreader menu fuel counter
8 Measure and adjustment menus 14 F2 key. In main menu screen turns engine
9 Scroller knob rpm monitor on / off
10 Return key 15 F1 key. In main menu screen toggles
between first / second gear start
16 Fuel level indicator
The scroller knob

4 Operation
To step up/down in the menu, turn scroller

knob(8). The selected function is highlighted.
Press scroller knob (8) to activate the selected
function.
NOTE
Menu content may vary depending on which
screen is open.
Driver pin code (optional)

When the ignition is switched on this screen is
displayed.
¾ Enter the driver pin code by pressing
buttons A, B, C & D until the correct code
is shown.
¾ Press F2 to enter
The truck can then be started normally.
Main screen
When the truck has been started the main
screen is displayed.
The main screen displays:
• Selected startup gear
• Current engine RPM
• Total distance travelled
• Trip distance
• Total fuel used
• Trip fuel used
• Idle hours
• Active hours
¾ Press (F1) to toggle between first and
second gear startup.
¾ Press (F2) to toggle between engine rpm on
/ off.
¾ Press (F3) to reset the trip fuel.
¾ Press (F4) to reset the trip distance.
¾ Press (F5) to toggle between automatic /
manual wiper operation.
¾ Press (A) to open the engine menu

Operation 4
¾ Press (B) to open the transmission menu

¾ Press (C) to open the hydraulics menu
Engine menu
¾ With the main screen displayed, press (A)
to go to the engine screen.
This screen displays:
• gear selected
• truck speed
• fuel level
• battery voltage
• engine oil temperature
• total fuel used
• trip fuel used
• engine oil pressure
• engine boost pressure
• manifold intake pressure
• engine torque
This menu screen will be displayed for a preset
time and will then return to the main screen.
¾ Press (A) again to view truck history statis-
tics.
¾ Press (←) to return to the main screen.
¾ Press (←) once to exit and return to the main
menu.

4 Operation
Transmission menu
¾ With the main screen displayed, press (B)
• gear selected
• truck speed
• fuel level
• driving speed
• transmission oil temperature
• accelerator and brake pedal positions
• total distance travelled
• trip distance
• total economy
• trip economy
¾ Press (←) to return to the main screen.
Hydraulics menu
¾ With the main screen displayed, press (C)
• gear selected
• truck speed
• fuel level
• joystick position (X & Y axis)
• hydraulic oil temperature

Operation 4
Spreader menu
¾ With the main screen displayed, press (D)
• status of the load on the spreader
• status of each leg
¾ Press (D) again to display the spreader
information menu.
Adjust & measure menu

¾ Press (≡) in main screen.
¾ Press (F1) to go to sub-menu Adjust.
¾ Press (F2) to go to sub-menu Measure.
¾ Press (F3) to go to sub-menu Settings.
¾ Press (F4) to go to sub-menu Info.
¾ Press (≡) to return to the Start-up menu.
Sub-menu Adjust
¾ Press (F1) to enter the adjust list.
¾ Rotate scroller knob to select required
setting.

4 Operation
¾ Press scroller knob.

¾ Press (A) to adjust setting.
¾ Press (←) once to return to the previous
menu, and again to return to the Adjust &
measure main screen.
Sub-menu Measure
¾ Press (≡) in main screen.
¾ Press (F2) to go to sub-menu Measure.

¾ Rotate scroller knob to select required
setting.

¾ Press (A) to toggle between raw value and
scaled value.
¾ Press (←) once to return to the previous
menu, and again to return to the Adjust &
measure main screen.

Operation 4
Sub-menu Preferences
¾ Press (F3) in the Adjust & measure main
menu.
¾ Press (A) to set Date/time.
¾ Press (B) to select Display settings.
¾ Press (C) to select Language.
¾ Press (←) to return to the previous menu.
¾ Press (F1) to return to Adjust & measure
main menu.
Third menu Date/time

¾ Press (A) to set date.
¾ Press (B) to set time.
¾ Select the required value by turning the
scroller knob.
¾ Press the scroller knob to save the value.
main menu.
Third menu Display

¾ Select settings by pressing buttons (A - D).
¾ Change settings by pressing the scroller
knob.
¾ Save settings by pressing the scroller knob.
main menu.

4 Operation
Third menu Language

¾ Select the required language by turning the
scroller knob.
¾ Save settings by pressing the scroller knob.
main menu.
Sub menu Info

¾ Press (F4) in the Adjust & measure main
menu.
¾ Press (A) to view modules status.

Operation 4
Malfunctions during operation
¾ Press (B) to view modem information and

status.
¾ Press (C) to view truck logs

¾ Rotate scroller knob to required log.
¾ Press scroller knob to view log data.
¾ Press (≡) to return to the main screen.

CAUTION
If a fault is detected and displayed on the truck
status display screen, take necessary action to
eliminate the malfunction.
Do not continue to operate the truck if critical faults
are indicated.
There are four types of message, Message

Alarm, Warning and Critical.
Message
These are messages indicating faults which
may not require immediate action, and may be
rectified at the next scheduled service interval.
Warning
These are messages which should be acted
upon as soon as it is safe to do so.
Alarm

4 Operation
These are messages which must be acted

upon immediately.
Critical
These are messages which indicate a fault
which may cause serious mechanical damage
to the truck.
Examples of faults detected;
• Water in fuel
• Low Battery voltage
• Low Battery charge
• Engine coolant temperature
• Air cleaner restriction
• Hydraulic oil temperature
• Brake oil temperature
• Engine oil pressure
• Coolant temperature
• Low oil pressure in brake system
These faults are also identified with a fault
code. A full list of fault codes can be found in
the annex.
An example of a message which may not
require immediate attention is water in fuel
message.
¾ When this message is shown, the operator
may decide to temporarily ignore the
message until the next scheduled service
interval.
An example of a warning which requires
immediate attention is engine oil temperature
warning.

Operation 4
¾ When this message is shown, immediate

action is required to rectify the fault.
An example of an alarm message which
requires attention as soon as possible is
spreader lock/unlock which indicates a hard-
wire fault on the truck.
¾ When this message is shown, action is

required as soon as it is safe to do so to
rectify the fault.
An example of a critical message which
requires immediate attention is hydraulic oil
pressure difference at the lift cylinders.
¾ When this message is shown, immediate

action is required to rectify the fault to
prevent serious mechanical damage to
the truck.
CAUTION
Failure to act accordingly when warnings are
displayed may result in serious damage.
Do not continue to operate the truck if critical faults
are indicated.

4 Operation
Start-up indications
Overload safety switch

Operating overload safety switch (1) will
enable the handler lowering function as long
as the switch is operated so that the handler
can be lowered along with the load.
NOTE
Overload safety switch (1) may only be used F
N
by authorised persons who can estimate and

R
bear responsibility for the safety risk when

lowering the load. Some safety features are
disabled when the overload safety switch is
activated - exercise extreme caution.
1
When the Overload safety switch (1) is oper-
ated, the truck display unit will also warn the
d3571022
driver that this activity will be logged.

¾ Override options are displayed.
Start-up indications
The load safety system has an automatic
self-test function, which operates whenever
the truck electrical system is energised. After
a successful self-test (duration approx. 10
sec), the green LEDs will illuminate.
WARNING
Contact your authorised dealer in case of defect.
Do not operate the truck if the load safety system
self-test is not correct, i.e. no illumination of green
LEDs and sounding of the buzzer.

Operation 4
Driving
Driving
WARNING
wind velocities of 24 knots / 28 mph or 45 km/h or
greater, handling characteristics may be affected,
manufacturer, your authorised distributor, or local
statutory authorities
CAUTION
Travel on slopes over 15% is not allowed as a rule
due to the prescribed minimum brake applications
and truck stability characteristics. Before driving
on steeper slopes you should contact your dealer.
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 small
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.
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.

4 Operation
Gear shift control
Gear shift control

The gear control (APC 200) is an electronically
controlled system which detects truck speed
through the transmission and selects the
appropriate gear for a driving condition.
The system will default to second gear start F
(as factory setting, first gear start is available). N

R
The anti-reverse facility prevents the trans-
mission from engaging reverse direction drive 1
until the truck is stopped. The operating lever
is fitted to the left of the steering column and
has a dual function control lever (1), (direction
and gear selector).
The control lever has three movements, two of
d3561053
which select the drive direction (fore / aft), with
the third selecting gears (rotate).
Selecting the travel direction

Forward travel
¾ Push electronic gear shift control lever (1)
forward. The transmission will shift into 2nd
forward gear.
Reversing
¾ Pull electronic control lever (1) back.
Moving off
¾ Gently depress accelerator pedal (3) to
prevent jerky starting.
NOTE
The parking brake will release automatically. 2
The truck will move in the selected direction of

travel.
At the preset speed the transmission will au-
tomatically select 3rd gear. Also, at the preset
speed the transmission will automatically se-
lect 4th gear. 3
d3571037

Operation 4
Gear shift control
Slowing down and stopping

¾ Operate brake pedal (3).
¾ Controlled transmission drive dump will
take place during the depression of brake
pedal (4), when accelerator pedal (3) is
depressed.
¾ Transmission drive is re-engaged upon
F
N
R
depression of accelerator pedal (3).
Manual 1st gear selection when stopped

To select forward 1st gear
1
¾ Push electronic gear shift control lever (5) d3571038
forward.
¾ Rotate the gear selector knob clockwise.
Gear selection will be displayed on the
MDM display screen.
To select reverse 1st gear
¾ Pull electronic gear shift control lever (5) to
the rear.
¾ Rotate the gear selector knob clockwise.
Gear selection will be displayed on the
MDM display screen.
Preselection of 1st gear when travelling
NOTE
1st gear can be preselected for manoeuvring
and on the approach to steep gradients when
travelling.
CAUTION
Danger of incorrect transmission operation causing
severe damage.
Do not hold gear change lever (5) in the rotated
position after selecting the gear.
To preselect 1st gear

¾ From 4th gear - Rotate gear selector lever
(5) clockwise three times.
¾ From 3rd gear - Rotate gear selector lever
(5) clockwise twice.

4 Operation
Steering
¾ From 2nd gear - Rotate gear lever (5)

clockwise once.
NOTE
After pre-selection of 1st gear the transmission
will remain in 1st gear until speed increases
above the preset speed or until the truck
is stopped and NEUTRAL is selected. On
reversion to automatic gear change, 1st
gear is available only by manual selection
or pre-selection.
Steering
¾ Start the engine and drive the truck.
¾ Turn the steering wheel to the left and right
through the full cycle.
Turning radius Wa:
6.4mtr wheelbase: 8.6 m
7 mtr wheelbase: 9.3 m
NOTE
Very little effort is required to turn the steering
wheel. This is especially beneficial when ope-
rating in narrow aisles. To avoid unnecessary
tyre wear, turn the steering only when the truck
is moving.
WARNING
Contact your authorised dealer if steering requires
too much effort or if there is too much play in the
steering.

Operation 4
Operating transmission dump
Stopping the truck

¾ Depress brake pedal (3) to slowly brake the
truck to a standstill.
¾ Press parking brake button before releasing
brake pedal (3). 4 1
¾ Move electronic gear shift control lever (4) F
to neutral.
N
R
NOTE
The transmission will automatically disengage 3 2
gear when brake pedal (3) is depressed.
¾ Lower the handler and ground any load. d3571082
¾ Allow the engine to idle for at least 3 minutes

to stabilise the turbocharger, lubricating oil
and coolant temperatures.
¾ Stop the engine.
¾ Remove ignition key (1).
Operating transmission dump

Operating either brake pedal (3) disconnects
the transmission from the drive and applies
the brakes in a controlled sequence.
CAUTION
Danger of damage to the transmission if engaged
at high engine speed.
Allow the engine to idle before releasing brake
pedal (3).
NOTE
Active steering system is installed which
varies steering resistance dependant upon
the operation of the machine.

4 Operation
Parking brake
Service brake
To operate the service brake:
¾ Release accelerator pedal (2) and allow it to
return to its rest position.
¾ Depress either brake pedal (3).
F
N
R
1
3 2
d3571039
Parking brake
The parking brake button (2) for applying the
parking brake is mounted in the driver’s control
centre located to the right of the seat.
This is illuminated for low light recognition.
2
d3571037
¾ To release the parking brake, depress

parking brake button (2). The parking brake
warning symbol in the truck display monitor
will extinguish.
¾ To apply the parking brake manually,
depress parking brake button (2) again.
The parking brake warning symbol in the
truck display monitor will illuminate.
¾ During operation, should the truck become
stationary for 4 seconds or more in neutral
(no gear is selected), the parking brake will
automatically switch on.

Operation 4
Truck lighting and turn indicators
¾ To release the parking brake depress

parking brake button (2). The parking brake
will extinguish.
¾ During operation, should the truck become
stationary for 5 seconds or more while in
gear (forward or reverse gear selected), the
parking brake will automatically switch on.
¾ To release the parking brake gently depress
accelerator pedal (3). The parking brake
will extinguish.
WARNING
If the braking system is becoming faulty or worn,
Do not drive your truck with faulty brakes.
Truck lighting and turn LHP

1
indicators 2
Light switches (3, 4&5) are located on the

3
left-hand panel (1). 4
5
To illuminate the side marker lights:
¾ Push light switch (3) to the first position. SC 7
To illuminate the side marker lights and dip

beam headlights:
¾ Push light switch (3) to the second position.
The side marker lights and dip beam head- F
lights are on.

N
R
The indicator lamp in the light switch will d3571019

illuminate when the side marker and dip beam
headlights are illuminated.
To illuminate the working lights* on the handler
and boom:
¾ Depress light switch (4) fully.
To illuminate additional working lights* :
¾ Depress light switch (5) fully.
* option

4 Operation
Truck lighting and turn indicators
Turning on the main beam headlights

¾ Push multiple function electrical lever (6)
away from the steering wheel to illuminate
6
the main beam headlights permanently.
Headlight main beam indicator light (2) will
be illuminated.
¾ Pull multiple function electrical lever (6)
O I II
towards the steering wheel to flash the
headlights.
NOTE
The main beam headlight can only be turned
on permanently when switch (3) is turned on.
d3561060
Turning on the turn indicator lights

¾ For left turn indication push the multiple
function electrical control lever (6) on the
6
right-hand side of the steering column up.
Turn indicator warning light (7) will flash.
¾ For right turn indication pull the multiple
function electrical control lever (6) on the
O I II
right-hand side of the steering column

down. Turn indicator warning light (7) will
flash.
NOTE
To stop turn indicator lights flashing multiple
function electrical lever must be returned to its
central position manually. d3561061

Operation 4
Operating the horn
Operating the hazard warning

lights 1
The hazard warning light switch (2) is located
in the driver’s central control panel (1).
¾ Push button (2) to operate the hazard
2
warning lights.
¾ Push button (2) again to turn the hazard
warning lights off.
NOTE
The indicator light in RHP illuminates.
d3561069
Operating the horn

The horn is used as a warning signal at e.g.
blind corners and junctions. 1
2
¾ To sound the horn, press horn button (2) at

the end of multiple function electrical control
lever (1).
O I II
d3561062

4 Operation
Turning on the front windscreen wiper
Turning on the front wind-

screen wiper
2 3
The front windscreen wiper switch (3) is part of 1
multiple function electrical control lever (1).
¾ For slow wiping: Turn switch (3) from the
zero position one step back to position (5).
O I II
¾ For fast wiping: Turn switch (3) from the
zero position back two steps to position (4).
¾ For intermittent wiping turn switch (3)
5 4
from the zero position one step forward
to position (2).
NOTE
d3561063
The wiper motor is fitted with a thermal cut-out
which, during operation, will switch off the
wipers to prevent overheating of the motor,
when the windscreen is dry.
Turning on the front windscreen washer

The windscreen washer switch (2) is located
on the end of multiple function electrical
1
control lever (1) . It is the collar surrounding 2
the horn button.
¾ Push switch (2).
O I II
NOTE
The washer stops automatically when the
switch is released.
d3561064

Operation 4
Turning on the front windscreen wiper
To operate rear screen wiper and washer

The rear screen wiper/washer switch (2) is
fitted in the drivers central control panel (1).
1
To operate the wiper.
¾ Push switch (2) to the first position. 2 3
To operate the wiper and washer.

¾ Push switch (2) all the way down and hold.
NOTE
The washer stops automatically when switch
is released. The wiper continues to operate
until the switch is returned to the starting
position. d3561065
NOTE
The wiper motor is fitted with a thermal cut-out
which, during operation, will switch off the
wipers to prevent overheating of the motor,
To operate top screen wiper and washer

The top screen wiper/washer switch (3) is
fitted in the drivers central control panel (1).
To operate the wiper.
¾ Push switch (3) to the first position.
To operate the wiper and washer.
¾ Push switch (3) all the way down and hold.
NOTE
The washer stops automatically when switch
is released. The wiper continues to operate
until the switch is returned to the starting
position.

4 Operation
To operate the cab pre-heater system *
Automatic wiper function

2
¾ Press button (F5) to operate automatic 3
wipers.
When the automatic wiper function is acti- 1 4
vated, the front wipers will operate at all times 5
unless turned off manually. 6

7
In addition, when reverse gear is selected the
8
rear wipers will operate and will stop when 16
reverse is de-selected. 9
Also, whenever the boom angle is greater than

a pre-set height the top wipers will operate,
and will stop when the boom is lowered below 15 14 13 12 11 10
the pre-set height.
d3571023
NOTE
Switch positions may differ.
NOTE
The wiper motors are fitted with a thermal
cut-out which, during operation, will switch off
the wipers to prevent overheating of the motor
To operate the cab pre-heater

system *
The cab pre-heater (1) is fitted in the cab rear
right corner. The heater operates for 120 1
minutes (default setting). 2

P
• (1) Cab pre-heater 7 6 5 4 3

P
• (2) Temperature controller (rotate to in-

crease / decrease cab temperature)
• (3) Forward
• (4) Backward
• (5) Heating (depress to activate / deactivate
heating) d3571084
• (6) Preselection
• (7) Clock time
NOTE
The cab pre-heater must not be used indoors.

Operation 4
To operate the cab pre-heater system *
NOTE
Always shut off the heater when refuelling the
truck.
* Option
To operate climate control *
NOTE
1 2
Do not operate the system with all vents
3
closed. Heating and cooling systems will 4

operate only while the engine is running and
the batteries are charging. 5
¾ Switch the fan on and select required fan

speed by rotating switch (2).
NOTE
The indicator display (3) shows the current
cab temperature in normal operating mode.
¾ Select temperature by depressing up/down d3561067
buttons (4), a single press increases/de-
creases the temperature by one degree.
NOTE
Temperature is selectable between 5 and
30°C.
¾ When frost button (5) is selected (switch
illumination changes from yellow to green),
additional cooling is obtained.
NOTE
Where maximum heating effect is required,
the air conditioning should be disengaged.
¾ Adjust vents to suit.
NOTE
Maximum heating/cooling effect will be achie-
ved with lower vents open.

4 Operation
Fuses
Opening the fuse box cover

¾ The fuse box (1) is situated inside the cabin,
to the rear of the driver’s seat. 1
¾ Check that fuse box door (2) lowering area

is free from obstruction.
¾ Insert key (or coin), into lock and turn
anticlockwise to open the lock. 2
¾ Lower the door to open.
Closing the fuse box cover

¾ Check that door raising area is free from
obstruction.
¾ Close door (2), insert key (or coin) into lock d3571015
and turn fully clockwise.
Fuses
The truck and handler electrical circuits are
protected by fuses in fuse box (1) fitted behind 1
the cab rear compartment door.
2
WARNING
If fuses fail continuously, stop the truck, ground the
load and stop the engine. Contact local authorised
dealer. Danger of fire and severe damage to
equipment.
Do not continue to operate with faulty electrical
circuits.
To check the fuses, open the cab rear com-

partment door and take off fuse box covers
(2). d3561068
01 Ignition switch 30 A
02 Iqan cab MDL unit 10A
03 Iqan cab front XS2-A0 unit 15A
04 Iqan cab fusebox XS2-A1 unit 15A
05 Spare \
06 Iqan chassis left XT2 - 0 unit 20A
07 Iqan chassis right XT2 - 1unit 20A
08 External modem 3A

Operation 4
Fuses
09 Elme Iqan ES supply 30A

10 Elme spreader supply 1 10A
13 Elme ignition supply 10A
15 J 1939 printer (option) 5A
16 Spare \
17 Ignition switch 5A
18 Engine ECM 1 10A
19 Engine ECM 2 10A
20 Transmission 20A
21 Brake cooler motor 20A
22 Hazard warning lights 5A
23 Headlights flasher 15A
24 Interior light 5A
25 LFM bat + supply 5A

26 Rear wiper 10A
27 Top wiper 10A
28 Horn supply 5A
29 Diesel cab heater 1 10A
30 Diesel cab heater 2 10A
31 Compressor seat 5A
32 Step lighting 5A
33 Transmission 5A
34 Alternator excitation 3A
35 Heater blower 30A
36 24/12 converter 20A
37 Front wiper/horn 15A
38 Central greasing 10A
39 Radio 5A
40 Rotating beacon 5A

4 Operation
Fuses
41 Side lights / dipped lights 15A

42 Switch illumination 1A
43 Side lights left 3A
44 Side lights right 3A
45 Dip light left 5A
46 Dip light right 5A
47 Head lights left 10A
48 Head lights right 10A
49 Indicators 5A
50 Reverse lights / buzzer 10A
51 Spreader lights 20A
52 Boom lights 20A
53 Side spot lights 10A
54 Cab roof lights 20A
55 LFM ignition 3A
56 Red dot air con unit 1 15A
57 Red dot air con unit 2 15A
58 Heated seat 5A
59 Heated seat 1A
60 Heated mirrors 5A
61 Spare \
62 Spare \
63 Spare \
64 Spare \
* optional

Operation 4
Boom and handler controls
Boom and handler controls DCC

The standard control for mast and handler is
the central control lever (1) (joystick). 1
NOTE
The symbol of the control lever movements
are shown on a label attached to the wind-
screen pane to the right of the driver. Observe
the symbols with direction arrows.
Central control lever (joystick)

CAUTION
Use the reach stacker only for authorised applica-
tions. The operator must be trained in the handling d3571065
of containers, the boom and handler

Do not operate this machine if you are not trained.
NOTE
The central control lever has been calibrated
to allow 5% movement in all directions before
function is activated.
The central control lever (1) is mounted on
the driver’s control centre to the right of the
seat. Always shift the control lever gently and
slowly. The control lever returns to its initial
position automatically when released.
NOTE
When operating central control lever (1), the
engine speed will increase automatically to
the power required for operating the rotation,
sideshifting and telescoping the handler.
Operating accelerator pedal for higher speeds
does not have any effect on the speed of
these work cycles. Central control lever (1)
is provided for lifting and lowering, rotating
and slewing the handler.

4 Operation
To lift the boom

DCC
¾ Pull central control lever (1) back. 1
To lower the boom

¾ Push central control lever (1) forward.
d3571066
To extend the boom

DCC
¾ Push central control lever (1) to the right. 1
To retract the boom

¾ Push central control lever (1) to the left.
d3571067

Operation 4
Operating the sideshift

CAUTION
1
Do not operate the sideshift with a container in the
handler and the container grounded.
Danger of severe damage to the equipment.
¾ If necessary, raise the load slightly. 3

2
NOTE
The handler beam centre line is indicated by a
white fluorescent marking on the REAR face.
When the beam is central, the line coincides
with a white fluorescent centring mark on the
rear face of the rotator.
d3571068
To sideshift left
Press and hold (2) on central control lever (1).
To sideshift right
Press and hold (3) on central control lever (1).
Rotating the handler

CAUTION
1
A foul condition can occur between the truck,
load and handler, while rotating the handler. This
condition can occur with or without load. ALWAYS
observe the load and handler while rotating the
4
handler.
Do not slew the handler if fouling of the load can
occur. Danger of severe damage to the handler.
Rotating the handler clockwise

¾ Press and hold the left side of button (4) on
central control lever (1).
Rotating the handler anticlockwise
¾ Press and hold the right side of button (4) on d3571069
central control lever (1).
NOTE
The front face of the handler is identified by
yellow and black high visibility markings on the
sideshift bearing mountings. The rear face of
the handler is identified by white fluorescent
markings and the beam sideshift centring
marks.

4 Operation
Before lifting a load
Operating the spreader

Operating the spreader
The beam spreader opens and closes to 20 ft
and 40 ft for standard containers.
Setting the spreader to container width 40 ft
¾ Press and hold button (5) on central control
lever (1).
1
Setting the spreader to container width 20 ft
¾ Press and hold button (7) on central control
lever (1). 5
Twistlock autolock* 9 6
* option 8
7
¾ To operate twistlock autolock, depress
button (6).
Vertical lift*
* option
¾ To operate vertical lift, depress button (8)
and pull back central control lever (1). d3571070
Power pump lock*

* option
¾ To operate power pump lock, depress
button (9).

WARNING
000.000.00.00
wind velocities of 24 knots / 28 mph or 45 km / h or
greater, handling characteristics may be affected,
manufacturer, your authorised distributor, or local
statutory authorities.
Before lifting a load, check the load capacity

diagram.
Machine Serial Number
CC
The load table can also be viewed on the truck
status display unit.

Operation 4
¾ In the main screen, press (≡).
¾ Press F4 (info).
¾ Rotate scroller knob until load table is
highlighted.

4 Operation
Picking up a container
¾ Press scroller knob to view load table

information.
¾ To return to the main screen, press (←) three
times.
WARNING
The values stated on the load capacity diagram and
the handler apply for the standard containers and
towed loads.
These values must not be exceeded as this will
reduce the stability of the truck and the strength of
the handler.
NOTE
Maximum capacity is governed by the height
of lift and the load centre distance.
Picking up a container TL model
WARNING
Do not attempt to lift a load or continue to lift if the
twistlocks do not seat and lock correctly.
WARNING
No person is allowed to stand underneath the
elevated load.
¾ The twistlocks must be unlocked and red

indicator lamps (3)must be illuminated.
¾ Approach the container to be lifted as
2, 3
1 1
carefully and accurately as possible.
¾ Raise and extend the mast sufficiently to
allow the handler to clear the load and 4
intervening stacks.
1 1
2, 3
3 2 1
d3571016

Operation 4
¾ Stop the truck centred and as close as

possible to the container.
NOTE
After a period of approx 5 seconds * the
parking brake is applied, and the direction
control lever shifts to the neutral position
automatically. In this condition, lift speed is A
regulated by throttle.
20'
40'
d3571053
¾ Lower the handler over the container using

the sideshift, slew, outreach and inreach
and mast for final positioning.
NOTE
The levelling system will automatically set
the handler with a 5° tilt up. As the handler
is lowered on the container, the levelling
cylinders reset allowing the twistlocks to enter
into the front container pockets first.
d3571054
¾ Lock the twistlocks.

¾ Elevate the boom until the container is clear
of the ground or transport vehicle.
CAUTION
The load being lifted my be unevenly balanced,
in this case use the sideshift to stabilise the load.
Reposition the truck where the unbalanced load is
within a stack.
¾ Release the parking brake.

¾ Move the truck and rotate the load as
necessary until it is free of obstructions.

4 Operation
¾ Raise or lower the load to travelling height.
Picking up a container CH model

WARNING
Do not attempt to lift a load or continue to lift if the
legs do not seat and lock correctly.
WARNING
No person is allowed to stand underneath the
elevated load.
WARNING
When operated, legs must not foul the truck or d3571055
ground.
¾ The twistlocks must be unlocked and red

indicator lamps (3)must be illuminated.
¾ Approach the container to be lifted as
2, 3
1 1
carefully and accurately as possible.
¾ Raise and extend the mast sufficiently to
allow the handler to clear the load and 4
intervening stacks.
1 1
2, 3
3 2 1
d3571016

Operation 4
¾ Stop the truck centred and as close as

possible to the container.
NOTE
automatically. In this condition, lift speed is A
¾ If necessary move the cab so that the back
legs can be observed. 20'
¾ Position the legs in front of the load using

boom raise/lower and extend/retract con- 40'
trols.
d3571053
¾ For sloping trailers, use slope pyle* to

compensate, (* option).
NOTE
The levelling system will automatically set 2 4
5
6
the handler with a 5° tilt up. As the handler 1 3
is lowered on the container, the levelling
cylinders reset allowing the twistlocks to enter
into the front container pockets first.
NOTE
When the container handler legs are activated
the handler is set horizontal automatically.
d3571056

4 Operation
¾ Lower the front legs. Indicators (2 & 4)

illuminate, and indicator (6) extinguishes. CHI
NOTE
Indicator (5)will flash while legs are in motion.
2 4 6
¾ Lower the back legs. Indicators (1 & 3) 1 3 5
illuminate.
NOTE
When all legs are lowered, indicator (5)
illuminates.
d3571078
¾ Clamp the legs. The load status is indicated

on the truck status display screen.
¾ Raise the load slightly, indicators (1,2,3,
& 4) illuminate to indicate that all legs are
seated correctly.
CAUTION
The load being lifted my be unevenly balanced, in
this case use the sideshift to stabilise the load.
Reposition the truck where the unbalanced load is
within a stack.
¾ Elevate the boom until the container is clear

of the ground or transport vehicle.
¾ Release the parking brake.
¾ Move the truck and rotate the load as
necessary until it is free of obstructions.

Operation 4
Travelling with loads
¾ Raise or lower the load to travelling height.
Automatic parking brake operation

When stationary, with the footbrake applied
and in gear, following a period of 5 seconds*,
the handbrake will engage and neutral will be
selected automatically.
NOTE
During this time the working hydraulics speed
is regulated by the throttle pedal.
Upon gear selection (forward/reverse), engine
revs falling below 950 r.p.m, and activation of
the throttle pedal the handbrake will disengage
and selected travel direction will commence.
d3571055
(* variable 0.5 - 5 seconds)

WARNING
Do not stand underneath an elevated load.
d3571062

4 Operation
¾ Travel with the container centred (no

sideshift).
d3571060
¾ Transport the load as low as possible whilst

maintaining forward visibility.
NOTE
If the travel lift height is exceeded, truck speed
will be automatically reduced to 3 m.p.h. (5
kph). Lower the load to the travel height to
return to normal truck speed.
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 d3571055
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.

Operation 4
Depositing the load
Depositing the load

WARNING
Do not stand underneath an elevated load.
d3571062
¾ Approach the stack or device receiving

the load as carefully and as accurately as
possible.
¾ Lift the handler to the correct height.
¾ Carefully move into the stack.
NOTE
automatically. In this condition, lift speed is
d3571063

4 Operation
Depositing the load
¾ Lower the load onto the stack using the

sideshift and rotate for final positioning.
TL model
¾ Slowly lower the handler until the twistlocks
are loose in the load and the yellow indicator
lamps are illuminated in addition to the
green indicator lamps.
¾ Unlock the twistlocks. The yellow and red
lamps will illuminate and no flags are visible.
NOTE
For sloping trailers use Slope pyle * to com-
pensate (* option).
¾ Lift the handler up out of the corner castings. d3571064
¾ The yellow lamps extinguish, the red lamps

continue to illuminate and no flags are
visible.
CH model
¾ Slowly lower the handler until the legs are
no longer seated. Indicators (1,2,3, & 4) will
extinguish.
¾ Unclamp the legs.
¾ Raise the front legs. Indicators (2 & 4)
extinguish.
¾ Raise the back legs indicators (1 & 3)
extinguish.
¾ Select reverse gear.
NOTE
Selection of reverse gear will automatically
release the parking brake as soon as the
accelerator pedal is pressed.
¾ Reverse the truck away from the stack.
¾ Lower the handler to driving height.
WARNING
Do not leave the truck unattended with the load
elevated.

Operation 4
Trailer coupling
Parking the truck

¾ Lower the boom and ground the load.
¾ Apply the parking brake.
NOTE
The parking brake will be applied automati-
cally if neutral is selected and after the truck
has been stationary for approx 5 seconds.
¾ Stop the engine and remove the ignition key
from the key switch.
¾ Lock the cabin door and remove the door
key.
NOTE
When parking the CH model, take care not
to damage the front and rear legs on the
container handler.
Trailer coupling
NOTE
The trailer coupling should be used only for
towing light trailers inside the plant working
area (refer to the technical data for nominal
towing capacity).
¾ Lift tow pin (1).
¾ Place the tow bar in coupling recess in the
lower retaining hole. 1
¾ Push tow pin (1) down to engage the

drawbar.
d3561088

4 Operation
Wheel change
Wheel change
WARNING
Before removing a wheel on the steer or drive axle,
deflate the tyre to under 2 bar pressure.
Danger of damage or injury through wheel rims.
To remove a wheel
Drive axle outer wheels:
¾ Remove wheel nuts (6) and lugs (5).
¾ Release the outer wedge band (4) from
wheel (3) by striking the rim using a hammer 1 2 3 4 56
and drift.
d3181051
¾ Remove wheel.
Drive axle inner wheels:
¾ Release the inner wedge band (2) from the
hub.
¾ Remove wheel (1) from hub.
Steer axle wheels
¾ Remove the wheel nuts and lugs.
¾ 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:

¾ Fit wheel (1) to the hub. Ensure that the
tyre inflation valve extension is positioned
correctly in the hub cutaway.
¾ Fit centre wedge band (2).
Drive axle outer wheels:
¾ Fit wheel (3). Ensure the tyre inflation valve
is correctly located in the hub cutaway.
¾ Fit outer wedge band (4).

Operation 4
Towing
NOTE
Tighten opposite wheel nuts sequentially
spanner tight then torque to the correct torque
setting.
¾ Fit wheel lugs (5) and nuts (6).
¾ Tighten the nuts.
Steer axle wheels:
¾ Fit the wheel.
¾ Fit the wheel lugs and nuts Tighten the nuts.
NOTE
The steer axle wheels fit directly to the hub.
Wheel nut torque = 680 Nm.
¾ Inflate tyres to 10 bar (145 psi)
Towing
If the truck must be towed, first release the
hydraulic parking brake and remove the
propeller shaft.
NOTE
Disconnect the propshaft at the drive axle end
only.
WARNING
Care must be taken to ensure the propshaft is
suspended clear of the roadway.
CAUTION
The truck must only be towed with a rigid towbar and
by a vehicle with sufficient tractive braking power to
stop both vehicles.
NOTE
With the engine stopped, the truck can still be
steered, although with much increased effort
at the steering wheel.
Towing procedure
¾ Lower and release the load.

4 Operation
Towing
¾ Attach the towing vehicle to the towing pin

with a rigid tow bar (tractive and braking
power are sufficient).
¾ Chock the drive axle wheels.
Releasing the parking brake

4
¾ Remove cover (2) from brake calliper (4).
3
¾ Turn bolt (3) anti-clockwise to release the
brake until the brake disc is clear.
Removing the propeller shaft 5
¾ Remove bolts, nuts and spacers (5) on the 2

coupling joints.
¾ Take off propeller shaft (1) and suspend it
with a chain, for example, to prevent it from
touching the ground during towing.
CAUTION 1
Because of a lack of hydraulic power during towing, d3561091

increased effort is required when steering.
Tow the truck only with great caution and at a speed
of not over 3-5 kph.
After towing and repair

¾ Chock the wheels.
¾ Reset the parking brake.
Resetting the parking brake

¾ Turn bolt (3) clockwise to reset the brake
until the brake disc is tight again.
¾ Fit cover (2) to brake calliper (4).
Refitting the propeller shaft

¾ Detach the propeller shaft, position it and fit
the axle.
¾ Fit bolts, nuts and spacers (5) on the
coupling joints.
¾ Tighten the bolts.
Torque approx ..... 135 Nm

Operation 4
Towing
CAUTION
Bolts may be used 2 times maximum.
¾ Remove the chocks.

Check the function of the brakes after carrying
out repairs.

4 Operation
Towing

5
Maintenance
5 Maintenance
General remarks
General remarks
Taking the truck out of operation
If the truck is taken out of operation for over 2
NOTE
months, it must be parked in a well ventilated,
frost-free, clean and dry room and the follow- Block up the truck so that all wheels are clear of
ing measures must be carried out. the ground. This will prevent tyre deformation.
Measures before taking the truck out of NOTE

operation Do not use plastic foil to cover the trucks as
¾ Thoroughly clean the truck. this enhances the formation and collection of
condensation water.
¾ Rotate,Slew and sideshift the spreader.
Extend and retract the boom.
Putting the truck back into operation
¾ Raise, lower and tilt the boom several times
through the full cycle. ¾ Thoroughly clean the truck.
¾ Check the hydraulic oil level and add oil if ¾ Lubricate the truck.
needed. ¾ Coat the battery terminals with non-acid
¾ Add diesel fuel. grease.
¾ Apply a thin film of oil or grease on all ¾ Check the condition of the battery.
unpainted mechanical parts. ¾ Check the engine oil for condensation water
¾ Lubricate the vehicle. and change the oil if necessary.
¾ Check the condition of the battery. Coat ¾ Perform the same services as for commis-
the battery terminals with non-acid grease sioning.
(follow the instructions of the battery manu- ¾ Take the truck into service.
facturer).
If the vehicle is to be taken out of operation for
¾ Spray all open electrical contacts with a over 6 months, contact your authorised dealer
suitable contact spray. for further measures.
General information
Your truck will remain operational only if the If you wish to do the work yourself, we rec-
maintenance and checks are carried out ommend that the first three customer service
regularly and according to the information checks be carried out by your distributor’s
and instructions in the operating manual. mechanic in the presence of the responsible
The maintenance may only be performed by mechanic in your workshop, so that your staff
qualified authorised personnel. This work can can receive the appropriate instruction.
be carried out by your authorised distributor
For all servicing, the truck must be placed on
under a service contract.
a level surface and the wheels secured. Stop
We recommend reserving a special service the engine and remove the ignition key.
area for the truck with a container or support
When working on the truck with the mast ele-
onto which the handler can be lowered to gain
vated, secure it against inadvertent lowering.
easy and safe access to the service points.

Maintenance 5
General remarks
For work on the front end of the truck, secure

NOTE
the mast against tilting back. No changes,
particularly no modifications and additions, When operating the truck under extreme
may be made to the truck without the approval conditions (i.e. extreme heat or cold, intensive
of the manufacturer. dust concentration, etc.), the intervals given in
the maintenance schedule should be reduced
NOTE accordingly.
Missing or damaged type and/or adhesive CAUTION
labels must be replaced. See the Parts
Catalogue for location and order numbers. Follow the precautions for handling fluids and
lubricants.
Perform a functional check and trial run after
every servicing.
Work on the boom and the front part

of the truck
CAUTION
These safety precautions are only sufficient for
the general servicing of the truck (inspections and
lubrication). When carrying out repairs (e.g. boom
cylinder removal), additional safety precautions
are required. Please contact your authorised
distributor.
Do not carry out any work on the boom or the
front part of the truck with the boom raised without
securing it as described below.
¾ Park the truck on firm level ground and

chock the wheels.
¾ Support the handler (on a container).
¾ Turn the ignition key to the zero position and
remove it.
¾ Lock all cab doors and remove the key.

5 Maintenance
General remarks
Hoisting the truck

3
DANGER
When loading the truck by crane, make sure no
persons are within the working range of the crane! 4
Do not step under the elevated load!
CAUTION
The weight of the unladen truck is between 70 & 84
tonnes. 2
Only use a crane and slinging gear with sufficient 1
lifting capacity.
CAUTION d3571071
Safety lock (4) must close after attaching the slings

to lifting hook (3).
When the truck is hoisted, the lifting sling must not
rub against any attachment fitted.
Attach the lifting slings at the four points

shown.
¾ Attach two hooks to rear sling points (2) in
front of the boom bearings.
¾ Attach two lifting hooks to front sling points
(1) in front of the boom cylinders.
¾ Attach the slings to crane hook (3).
Handler removal
WARNING
This work may only be performed by the qualified
staff of your authorised dealer.
Table of weights
C 4230 TL / 5 70400 kg
C 4531 TL / 5 71400 kg
C 4234 TL / 5 73200 kg
C 4535 TL / 5 76300 kg
C 4540 TL / 5 77000 kg
C 4540 TL / 5 (2nd
77700 kg
rail)

Maintenance 5
General remarks
C 4226 CH / 5 73950 kg
C 4127 CH / 5 74900 kg
C 4527 CH / 5 74900 kg
C 4030 CH / 5 76700 kg
C 4531 CH / 5 81250 kg
C 4535 CH / 5 81970 kg
C 4535 CH / 5 (2nd
83470 kg
rail

5 Maintenance
General remarks
Inspection and maintenance data
Filling capacities/rated
No. Assembly Aids/oils and lubrication
values
1 Engine Engine oil approx. 35 lts
2 Fuel tank Diesel approx. 800 lts
Water and antifreeze
3 Cooling system approx. 45 lts
mixture
Working hydraulic system
4 Hydraulic oil approx. 800lts
oil tank
Hydraulic oil
approx. 100 lts
5 Braking system oil tank Oil additive (mixed at ratio
approx. 6lts
6%)
Brake relay hydraulic
6 Hydraulic oil as required
system
7 Drive axle differential Gear oil approx. 75 lts
8 Drive axle hub Gear oil each side approx. 7 lts
9 Steer axle hub Gear oil each side approx. 4 lts
10 Transmission Transmission oil approx. 60lts
11 Battery Maintenance free
12 Tyres Air 10 bar
13 Wheel mounting nuts 350 Nm
Grease points on boom,
14 Lubricating grease as required
handler and chassis
Engine oil temperature to
15 Temperature sensor Oil
130°C
Inlet 0.2 mm
16 Valve clearances
Exhaust 0.5 mm
Operating pressure 246 bar
17 Fuel injection nozzle Diesel
Pressure setting 264 bar

Maintenance 5
General remarks
Fuel and oil recommendations

Engine oils e.g. Mobil Glygoyle 22
API classification: CCMC D5, API-CE specifi- Hydraulic oil for working hydraulics
cation oils may be used but must be renewed
ISO VG 46 (factory filling)
at 250 hour service intervals. API classifica-
tion: CH-4 or ACEA E5 may be used for up to Hydraulic oil analysis
500 hour service intervals.
The working hydraulic system has a capacity
Oil grades of approx. 800 ltrs. To reduce the high level
of expenditure required if the oil is renewed at
Engine oils of API classification CD or less are
the 3000 hour service, the operator may use a
not recommended due to the extended drain
reputable oil analysis company to determine
cycle given for this engine application.
the state of the hydraulic oil. This analysis
During engine operation, part of the oil serving should be made between 2750 and 3000
as a lubricant for the piston is combusted hours run.
(“consumed”). The products of combustion
The results of the analysis should be recorded
and the high temperatures combined lead
to support any warrant claim which may arise
to “wear”, particularly of the chemical oil
from defects in the working hydraulic system
additives. For this reason the oil must be
subsequent to the analysis. Where oil analysis
changed at certain intervals.
is not available, the recommended 3000 hour
Since this oil wear depends on the operating oil renewal is mandatory.
conditions and the quality of the oil (oil perfor-
Hydraulic oil (brake system, brake cylinder)
mance) and fuel used, oil change intervals of
different lengths result. ISO VG 46 (factory filling)
Oil additives of any kind must not be used with Hydraulic oil additives (brake system)
any of the recommended engine oils. Use of
Use only pre-mixed Lubrizol solution.
additives will invalidate the warranty.
Electrical contact grease
The longest possible oil change interval for
lubricating oil in the engine is one year. This For use on all electrical connections.
means that the oil must be renewed at least
once every year, regardless of the oil change Lubricating grease
intervals. Linde heavy duty grease with additives EP and
Gear oil MOS2. Designation acc. to DIN 51825-KPF
2K-20 (see the Parts Catalogue for the order
MIL-L2105B, API GL5, SAE 90 or multi number). Any mixing with grease types other
grade oils for normal external temperatures, than lithium-based greases is not allowed.
recommended - 75w 90.
Battery grease
Sae 140 or mulitgrade oils for external temper-
atures over 30° C Non-acidic grease (terminal grease).
Transmission oil Chain spray
Only Dexron III oil is approved for use. Linde chain spray (see the Parts Catalogue for
the order number).
Handler slew gearbox and brake
Central lubrication
SAE 90 Gear oil to with additives to specifica-
tion J306a. The grease must be an EP grade NLGI-0
grease with a lithium/calcium base. It must
e.g. Esso compressor oil G150

5 Maintenance
General remarks
not contain any additives such as graphite or If the sulphur content is 0.5 to 1%, the oil
PTFE. change intervals must be halved.
A grease from Greenlube is recommended. If the values are higher, contact the manu-
If difficult to obtain, please contact your facturer of the lift truck or the supplier of the
authorised dealer. lubricant.
Coolant
NOTE
Only use coolants with a monoethylene glycol
base and containing a rust inhibitor.
As the ambient temperature decreases, so
does the fluidity of Diesel fuel due to the
Do not mix with antifreeze containing precipitation of paraffin. If “summer grade”
ethanolamine. diesel fuel is used, malfunctions can result.
For this reason, “winter grade” diesel fuel that
Mixing ratio for lower temperatures:
functions reliably at temperatures down to
Mixture ratio approximately -15°C is available in the cold
Temperature Antifreeze
water:an- season of the year.
down to %
tifreeze
The addition of any form of additive will invali-
-12°C 25 1:3 date the engine manufacturer’s warranty.
-18°C 33 1:2 In winter, fill only winter diesel fuel to prevent
any clogging caused by paraffin precipitation.
-22°C 40 1:1.5
At very low temperatures you must reckon with
-37°C 50 1:1 disturbing precipitations even if winter diesel
fuel is used.
-60°C 66 2:1
NOTE
Diesel fuel
These are only recommendations. In case
Use only Diesel fuel to DIN EN 590 with a
of doubt we recommend you contact your
cetane number not lower than 45.
authorised dealer.
The sulphur content should not exceed 0.5 %.
NOTE
The digital clock display must be reset whenever the battery isolator has been used for more than
four days.
Check the condition of structured components
CAUTION CAUTION
Work on the truck on level ground. Lower the This maintenance procedure requires to be carried
carriage, stop the engine and put the parking brake out at heights of more than 2 metres. Use suitable
on when working. access equipment. Danger of fall injuries.
¾ Examine the structural components of the

truck to assure their integrity. Inspection
should cover all areas of the main structures
and their connections. Attention should be
given to welds and material adjoining welds,

Maintenance 5
General remarks
particularly at changes of section, bolted

interfaces and sliding pad pressure points.
¾ Examine the mast, lift and tilt cylinders,
anchor and bearing points for damage,
wear, missing lock bolts, metal fatigue, etc.
¾ Examine the bearings for damage, missing
retaining rings and abnormal wear.
Truck welds inspection
NOTE
It is very important that these inspections are
carried out as specified in daylight or with
adequate artificial lighting, to allow close
examination of the welds. Please follow the
guidelines below:
CAUTION
These maintenance procedures may need to be
carried out at heights of more than 2 metres. Use
suitable access equipment.
Danger of fall injuries.
¾ Wash the truck thoroughly and allow to dry.

¾ Corrosion and/or deposits should be
removed to facilitate the inspection.
¾ Carry out a detailed inspection of all welded
joints on the chassis, load lifting device and
attachment.
¾ If there is any visible abnormality which
suggests that a crack is present, carry
out a more detailed inspection using non
destructive methods.
Please forward copies of any existing struc-
tural inspection reports (as advised in the
service operators manual) to LHTD.
Reports including any photographs should
be sent to Mr. Andrew Dickson, (email:
andrew.dickson@linde-htd.com) as soon as
they are available.

5 Maintenance
Inspection and maintenance schedule

Daily checks
¾ Check the tyres for damage and foreign ¾ Check the fluid level in the washer fluid
objects reservoir
¾ Check the working hydraulics oil level ¾ Check the fuel level
¾ Check the brake hydraulic system oil level ¾ Check the handler for visible damage
¾ Check the hydraulic oil level in the brake ¾ Check the operation of the twistlocks and
system reservoir indicator lights
¾ Check the transmission oil level ¾ Clean, check and adjust mirrors
¾ Check the coolant level in the heater tank ¾ Check the central warning system
¾ Check the engine oil level

Maintenance 5
As required Service plan

Carried
At operating hours
out
As
9 8
required
Comment
Depending on application, environmental conditions and driving style, the following
procedures should be carried out at the intervals shown above.
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 next maintenance interval
Engine
Drain the fuel filter
Prime the fuel system
Check the air filter - replace if necessary
Check the air filter safety element - replace if necessary
Check coolant level in the reservoir
Check and clean the climate control filter element (option)
Transmission
Check transmission oil level
Chassis, bodywork and fittings
Clean the radiator and oil cooler, check for leaks
Lubricate cab door hinges
Check central lubrication lubricating points (option)
Fill central lubrication canister with grease (option)
Steering and wheels
Check wheel nuts for correct torque (see safety rules)
Check tyre pressure
Check tyres for damage and foreign objects

5 Maintenance
Carried
At operating hours
out
As
9 8
required
Check the steering lock
Clean and lubricate the steer axle, check the mounting
Check steer axle hub oil level
Check and lubricate the drive shaft
Controls
Check the functionality of the control levers
Check the functionality of the braking system (park brake and service brake)
Check the functionality of the absent driver seat switch (if fitted)
Check the functionality of the emergency shutdown switch
Electrical equipment
Check the batteries
Hydraulics
Check hydraulic oil level
Load lift device
Inspect the load lifting device for proper operation
Lubricate slewing ring bearing and gear
Check the slewing gearbox and brake oil level
Check and lubricate the leg folding group
Check and lubricate feet at the bottom of each leg
Check and lubricate boom cylinder, boom pivot and sliding bearing
Check and lubricate the twistlocks
Subsequent tasks
Attach maintenance sticker

Maintenance 5
50 h Service plan
Carried
At operating hours
out
50h 9 8
General
Check the seat belt
Engine
Change engine oil
Change engine oil filter
Check the air filter
Check the air filter safety element
Drain the water separators in the fuel system
Change the fuel filter
Check the coolant level
Check the coolant concentration
Check condition of drive belts
Check engine mounting for security
Clean the radiator and oil cooler and check for leaks
Examine intake and exhaust pipes for tightness
Transmission
Change the transmission oil filter
Clean and lubricate all pivots and joints
Check cab mountings
Check steer axle, check mounting
Check drive axle mounting
Change transmission oil filter canisters

5 Maintenance
Carried
At operating hours
out
50h 9 8
Steering and wheels
Check the wheel nuts for tightness
Check tyre pressure
Clean and lubricate steering axle
Check mounting of steering axle
Check mounting of steering cylinder and steering axle swivel pins
Controls
Check the battery condition
Check the electrical system
Hydraulics
Check hydraulic oil level
Check the hydraulic system, drive motors, pumps, valves and lines for leaks
Clean the radiator and check for leaks
Load lift device
Check and lubricate the boom cylinder, boom pivot and sliding bearings
Check the handler hydraulic system gearbox and electrical lines
Change handler slewing gearbox and brake oil
Lubricate slewing ring bearing and gear
Lubricate the twistlocks
Subsequent tasks
Check the central lubrication* lubricating points

Maintenance 5
500 h Service plan

At operating hours
500 1500 2500 3500 4500
5500 6500 7500 8500 9500
Carried
10500 11500 12500 13500 14500 out
15500 16500 17500 18500 19500 9 8
General
Check the seat belt
Enter the next maintenance interval
Engine
Change engine oil
Check engine mounting
Check vacuum switch
Check intake and exhaust system for leaks
Check turbocharger
Check condition and tension of drive belt
Check the mounting of the turbocharger intake pipe
Transmission
Check and adjust the steer stops
Chassis
Check mounting of the steer axle, mast and drivers cabin
Check condition of the overhead guard frame

5 Maintenance
At operating hours
500 1500 2500 3500 4500
5500 6500 7500 8500 9500
Carried
10500 11500 12500 13500 14500 out
15500 16500 17500 18500 19500 9 8
Steering and wheels
Check wheel nuts for correct torque
Check tyre pressure
Check the steering
Check mounting of the steer cylinder
Check and lubricate steer axle link arms and swivel pins
Check wheel hub bearing end float
Check the security of the axle clamp and drive motors
Controls
Check the functionality of the absent driver seat switch
Check batteries
Check electric cables, cable connectors and connections for condition and tightness
Check the functionality of the electrical system
Hydraulics
Hydraulic system: Check the oil level.
Check the hydraulic tank breather filter
Check condition of auxiliary hoses and replace if necessary
Load lift device

Maintenance 5
At operating hours
500 1500 2500 3500 4500
5500 6500 7500 8500 9500
Carried
10500 11500 12500 13500 14500 out
15500 16500 17500 18500 19500 9 8
Check the condition of the tilt cylinders
Lubricate locking cylinder pin on the handler
Check and lubricate boom cylinders, boom pivot and sideshift sliding bearings
Lubricate the sideshift cylinder bearings
Lubricate the spreader
Subsequent tasks

5 Maintenance
1000 h Service plan

At operating hours
Carried
1000 7000 11000 13000 17000 out
19000 9 8
General
Check the seat belt
Engine
Change engine oil
Check the engine mountings
Change the air filter element
Check the vacuum switch
Check the intake and exhaust system for leaks and tightness
Transmission
Check the transmission mountings
Change the transmission oil
Chassis
Check cab mountings
Check the condition of the overhead guard frame

Maintenance 5
At operating hours
Carried
1000 7000 11000 13000 17000 out
19000 9 8
Steering and wheels
Check tyre pressure
Check the steering
Controls
Check the batteries
Hydraulics
Hydraulic system: Check the oil level.
Clean the radiator and hydraulic oil cooler
Load lift device

5 Maintenance
At operating hours
Carried
1000 7000 11000 13000 17000 out
19000 9 8
Subsequent tasks

Maintenance 5
2000 h Service plan

At operating hours
Carried
2000h 4000h 8000 10000 14000 out
16000 20000 9 8
General
Check the seat belt
Engine
Change engine oil
Change fuel filter
Check engine mounting
Renew air filter element
Renew safety element
Change the fuel tank breather filter
Renew engine coolant and filter
Check air con drive belt (if fitted)
Check cooling fan belt tensioner
Check viscous vibration damper
Check vacuum switch
Check intake and exhaust pipes for leaks
Transmission
Chassis
Check condition of the overhead guard frame

5 Maintenance
At operating hours
Carried
2000h 4000h 8000 10000 14000 out
16000 20000 9 8
Steering and wheels
Check tyre pressure
Check the steering
Check the condition of the steer axle
Clean and lubricate steer axle, check the drive axle mounting
Check the drive axle centre and hub differential oil level
Check and adjust hub bearings
Controls
Check the batteries
Hydraulics
Hydraulic system: check the oil level.
Renew the feed, pressure, suction and breather filter

Maintenance 5
At operating hours
Carried
2000h 4000h 8000 10000 14000 out
16000 20000 9 8
Load lift device
Inspect load lifting device for proper operation
Lubricate tilt cylinder bearings
Subsequent tasks

5 Maintenance
3000 h Service plan

Carried
At operating hours
out
3000 9000 15000 9 8
General
Check the seat belt
Engine
Change engine oil
Check safety element
Check vacuum switch
Check cooling fan belt tensioner
Check coolant concentration
Check vibration damper
Check starter motor, alternator and injection pump
Transmission
Chassis
Check cab mountings

Maintenance 5
Carried
At operating hours
out
3000 9000 15000 9 8
Change transmission oil filter canisters
Check condition of structural components
Steering and wheels
Check tyre pressure
Check the steering
Controls
Check the batteries
Hydraulics
Change the brake hydraulic system oil
Change the working hydraulic system oil
Clean the hydraulic tank pre-filter
Change hydraulic oil filter

5 Maintenance
Carried
At operating hours
out
3000 9000 15000 9 8
Renew the feed, pressure, suction and breather filter
Check hydraulic pump mounting bolts
Load lift device
Change the handler slewing gearbox and brake oil
Check the condition of the boom mountings
Subsequent tasks
General overall check

Maintenance 5
5000 h Service plan

Carried
At operating hours
out
5000 10000 15000 20000 9 8
General
Check the seat belt
Engine
Change engine oil
Change the air filter safety element
Check vacuum switch
Check coolant concentration
Check valve clearances
Transmission
Chassis

5 Maintenance
Carried
At operating hours
out
5000 10000 15000 20000 9 8
Steering and wheels
Check tyre pressure
Check the steering
Controls
Check the batteries
Hydraulics
Check the brake hydraulic system oil
Check the working hydraulic system oil
Load lift device

Maintenance 5
Carried
At operating hours
out
5000 10000 15000 20000 9 8
Change the twistlocks
Check the handler extension cylinder bearing pads
Subsequent tasks

5 Maintenance
6000 h Service plan

Carried
At operating hours
out
6000 12000 18000 9 8
General
Check the seat belt
Engine
Change engine oil
Check the fan drive idler pulley assembly and belt
Check the turbocharger
Check the vibration damper
Flush the cooling system
Change the coolant and coolant filter
Check starter motor, alternator and injection pump
Transmission
Chassis

Maintenance 5
Carried
At operating hours
out
6000 12000 18000 9 8
Check cab mountings
Change the fuel tank breather filter
Steering and wheels
Check tyre pressure
Check the steering
Controls
Check the batteries
Hydraulics
Change the working hydraulic system oil

5 Maintenance
Engine
Carried
At operating hours
out
6000 12000 18000 9 8
Load lift device
Change the handler slewing gearbox and brake oil
Check the handler extension cylinder bearing pads
Subsequent tasks
Engine
CAUTION
The bonnet opens forward leaving open access
to the engine compartment from both sides of the
truck.
CAUTION
Danger of scalding.

Maintenance 5
Engine
CAUTION
lubricants.
¾ Park the truck on firm level ground, put the

parking brake ON and stop the engine.
¾ Behind the cab, remove dipstick (2) and
wipe with a clean cloth.
¾ Fully re-insert dipstick (2) and remove it
again.
1
¾ The oil level should be between the High
and LOW marks on dipstick (2).
¾ If necessary, unscrew filler cap (3) and fill 3
engine oil as far as the high mark.
¾ Insert dipstick (2), refit the filler cap.
NOTE
2
marks is approximately 5 lts.
d3571018
Total filling capacity ............ approx. 35 lts.
Change the engine oil
CAUTION
lubricants.
CAUTION
anger of burns and scalding.
Engine and engine oil may be at operating tempe-
rature.
NOTE
Change the oil when the engine is at operating 1 d3561122
temperature.
¾ Open the engine cover.
¾ Put a catch tray with a capacity of at least 35
lts under drain plug (1).
¾ Remove oil drain plug (1) and drain the
engine oil.

5 Maintenance
Engine
¾ Clean drain plug (1) and install with a new

washer.
¾ Torque drain plug (1) to 60 Nm (45 lb. ft.).
¾ Remove oil filler cap (3) on the filler neck.
¾ Fill engine oil.
Capacity ............... approx. 35 lts.
¾ Fill engine oil.
¾ Check the engine oil level. The oil level
should be between the high and low marks.
The oil level must not exceed the high mark.
¾ Start the engine and check drain plug (1) for
leakage.
¾ Stop the engine and wait at least 5 minutes
for the oil level to stabilise.
¾ Check the oil level again and replenish
engine oil, if necessary.
Change the engine oil filters
CAUTION
lubricants.
CAUTION
rature. Danger of burns and scalding.
¾ Open the bonnet.

¾ Put a catch tray with a capacity of at least 10
lts under oil filters (2).
¾ Loosen filters (2) using a filter wrench and 2
remove by hand. d3561124
¾ Clean filter housing (1).

Maintenance 5
Engine
¾ Check filter seal rings (3) in new filters for

proper seating.
¾ Fill new fillers slowly with oil. 2 3
¾ Lubricate seal rings (3) of new filters with

engine oil.
¾ Install filters (2) by hand until seal rings
(3)mate with the filter head, then tighten
by quarter turns using a filter wrench with
tightening band.
¾ Start the engine and check the seal faces
for leakage.
2
¾ Stop the engine and wait for at least 5
minutes for the engine oil level to stabilise. 2
d3561125
¾ Check the engine oil level and replenish
engine oil if necessary.

5 Maintenance
Engine
Drain the fuel filter

CAUTION
lubricants.
The fuel filter is located in the air filter/battery

compartment on the left-hand side of the
chassis.
¾ Visual check for any water in the water
1
separator, draining it if required.
¾ Place a catch tray of approximately 11 pints
capacity under sediment bowl (1).
¾ Release drain screw (2) and drain the
sediment/water.
2
d3561097 ¾ Tighten drain screw (2) as soon as clean
fuel flows.

Maintenance 5
Engine
CAUTION
lubricants.
CAUTION 1
rature. Danger of burns and scalding.
¾ Place a catch tray of at least 6 ltrs capacity

under filter element (2) to catch the fuel.
2
¾ Using filter wrench, remove filter, and seal
ring (1).
¾ Clean all components with paraffin deriva- d3561126
tives (washing petrol) and dry with com-
pressed air.
¾ Fit a new seal ring (1) to the filter head.
¾ Fill the new filter with fuel before fitting.
¾ Rotate filter by hand until the gasket con-
tacts filter head surface, then ½ to ¾ of a
turn further, maximum.
Prime the fuel system

CAUTION
lubricants.
CAUTION
Danger of scalds and burns
¾ Remove filler cap from the top of the fuel

pump (1).
¾ Fill the pump with clean fuel.
¾ Refit filler cap (1).
d3561098

5 Maintenance
Engine
Check the air filter
NOTE
This service is only required once after the first
50 service hours. Further service intervals as
required.
WARNING
This work may only be performed by the qualified
staff of your authorised dealer.
CAUTION
Clean the air filter casing with a damp cloth.
Do not clean the filter element.
The use of wet cleaning agents will destroy the

filter element. Follow precautions for handling
fluids and lubricants. If a warning indicator
appears on the display unit located on the right
hand pod, stop the engine at once and renew
the air filter.
CAUTION
A dirty filter element decreases engine perfor-
mance.
Careful filter servicing is essential for the engine.
¾ Open the air filter/battery compartment

door. 2
1
¾ Unscrew nut (1) and remove the filter end
cover.
¾ Empty the dust collected in the cover and
wipe it with a clean damp cloth.
¾ Replace dust valve (3) to remove any
collected dust. If necessary, clean the dust
valve with a damp cloth.
¾ Replace dust valve if split or torn.
¾ Unscrew wing nut (4) and carefully remove 3
filter element (5).
¾ Wipe the inside of filter casing (6) using a
d3561100
damp cloth.
¾ Examine the filter.

Maintenance 5
Engine
¾ Replace the filter element if it is damaged,

after 1000 service hours or at least every 12
months.
Before installing a new filter element, examine
it for damage with an inspection lamp held
inside the element.
¾ Examine the seals for damage.
¾ Renew the filter or seals if damaged.
¾ Examine the safety element. Renew if
damaged.
4
¾ Install filter element (5) into filter casing (6)
and secure it with wing nut (4).
¾ Refit end cover (2), ensuring that dust valve
(3) is positioned through the deck plate, and
secure with the wing nut.
5
¾ Close the air filter/battery compartment
door.
6
d3561101
Change the air filter element - check

the vacuum switch 1
2
At least every 12 months or after 5 cleanings.
CAUTION
Work on the truck on level ground.
Lower the mast and handler, stop the engine and
put the parking brake on when working.
CAUTION
Stop engine before servicing the air Intake system. 3
Do not start the engine with the filter element
removed. Wear a protective mask for all services
on the air Intake system.
d3561100
CAUTION
Clean the filter case with a damp cloth.
Do not wet clean the filter element.
¾ Open the air filter/battery compartment

door.

5 Maintenance
Engine
¾ Unscrew nut (1) and remove filter end cover

(2).
wipe clean with a damp cloth.
¾ Remove dust valve (3) and clean with a
damp cloth.
¾ Renew dust valve (3) if damaged.
¾ Unscrew wing nut (4), remove element (5)
and discard it.
¾ Wipe filter casing (6) with a damp cloth.
¾ Examine the new filter element for damage
before installation. 7
¾ Install filter element (5) into filter casing (6)
and secure with wing nut (4).
¾ Refit end cover (2) and secure with nut (1).
Ensure that dust valve (3) is positioned 8
through the casing hole.
¾ Ensure that dust valve (3) is pointing
downwards.
¾ Remove the intake hose from the air filter
d3561102
intake.
¾ Close the air filter Intake when the engine
is running. The Air filter restriction warning
indicator will be visible on the truck display
unit.
NOTE
If air filter restriction indicator is not shown on
the truck display unit, contact your authorised
dealer.
¾ Refit the intake hose.
¾ Close the air filter/battery compartment
door

Maintenance 5
Engine

8
WARNING 7
6
Stop the engine before servicing the air intake
system. 2
WARNING
Under no circumstances must the safety element
be cleaned, or an attempt made to start the truck
with the safety element removed.
CAUTION 5
4
Clean the filter casing with a damp cloth. Do not 1
clean the filter element. 3
The use of cleaning agents will destroy the
d3561156
filter element. Follow the precautions for
handling fluids and lubricants.
¾ Unscrew nut (1) and remove filter end cover
(2).
wipe clean with a damp cloth.
¾ Remove dust valve (3) and clean with a
damp cloth.
¾ Renew the dust valve if damaged.
¾ Refit dust valve (3).

2
¾ Unscrew wing nut (4) and remove main 1
air filter element (5). Inspect and renew if
damaged.
¾ Unscrew nut (6) and remove safety element
(7).
¾ Examine the new safety element for signs
of damage, before installation.
¾ Fit safety element (5) into filter casing (8)
and secure with nut (6).
¾ Refit main air filter (5) into filter casing (8) 3
and secure with wing nut (4).
¾ Refit end cover (2) and secure with nut (1).
d3561100
Ensure that dust valve (3) is positioned
through casing hole (9).

5 Maintenance
Engine
CAUTION
Engine and transmission may be at operating
temperature. Danger of burns and scalding. 1
Check the engine mountings and spherelastic

mounts for condition. Renew the rubber
mounts, if damaged.
¾ Check mounting bolts (1).
¾ Torque ......... 68 Nm (50 lbf- ft.)
¾ Check mounting bolt (2).
2 3
¾ Torque ......... 195 Nm (145 lbf- ft.)
¾ Check mounting bolts (3). d3561139
¾ Torque ......... 100 Nm (75 lbf- ft.)
Clean the radiator and check for

leaks
CAUTION
Clean the radiator only when the engine is stopped
and cool.
CAUTION
lubricants.
¾ Remove radiator grille (1) and clear the

radiator and oil cooler of any debris.
¾ Clean the radiator and oil cooler fins with
compressed air or use a cold cleaner or
steam jet if necessary.
¾ Start the engine and let it idle to allow water
to evaporate quickly.
¾ Check the cooling system for leaks with the
engine at operating temperature.
¾ Install the radiator grille.

Maintenance 5
Engine
Check the injection nozzles

Servicing of the Injection nozzles before the Emitting smoky black exhaust
normal interval is indicated if the engine is:
Using more fuel
Misfiring
Knocking in one or more cylinders NOTE
Overheating Technical skill and knowledge are required

for this adjustment. Please contact your
Losing power authorised dealer
CAUTION
CAUTION
Engine and radiator may be at operating tempera-
ture.
Danger of scalds and burns.
¾ Isolate the battery.

¾ Remove the rocker arm cover nuts and seal
rings. d3561144
¾ Remove the rocker arm covers and gas-
kets.
¾ Rotate the accessory drive clockwise until
the ‘A’ valve set mark on the accessory drive
pulley is aligned with the pointer on the gear
cover.
NOTE
The number 1 cylinder is at the front end of the
engine.
¾ Check the clearances of the valves of
cylinder 1.
Valve clearance when warm or cold:
Inlet valve ......... 0.2 mm
Exhaust valve ......... 0.5 mm
¾ Adjust the valve clearances, if required.

5 Maintenance
Engine
¾ Turn the crankshaft in the normal direction

of rotation and check and adjust, if required,
the valve clearances in the following se-
quence:
Pulley Set Cylinder
Start
position injector valve
Advance
A 1 1
to
Advance
B 5 5
to
Advance
C 3 3
to
Advance
A 6 6
to
Advance
B 2 2
to
Advance
C 4 4
to
Firing
order
153624
¾ Install the rocker arm cover.

¾ Carry out a functional test of the engine.
Check the intake and exhaust

systems for leaks and tightness
CAUTION
Work on the truck on level ground.
CAUTION
Engine and exhaust system may be hot.
Danger of burns.
¾ Inspect the air intake hoses, renew if

damaged. d3571085

Maintenance 5
Engine
¾ Inspect hose clips for security, tighten if

necessary.
¾ Check the overall condition of the exhaust
system, replace any pipes or the silencer If
badly corroded.
¾ Check that the exhaust mounting flange
nuts are tight.
¾ Check that the exhaust clamps are tight.
¾ Check that the silencer mountings are
secure.
¾ Torque ......... 56 Nm (41 lb. ft.)
¾ Check that the tail pipe mounting bolts are
secure. d3571086
¾ Torque ......... 56 Nm (41 lb. ft.)
Check the cooling system for leaks

and tightness
CAUTION
Work on the truck on level ground. Lower the mast
and handler, stop the engine and put the parking
brake on when working.
CAUTION
Engine and radiator may be at operating tempera-
ture. Danger of scalds and burns.
¾ Check the condition of the radiator top and

bottom hoses, replace if deteriorated. d3561145
¾ Check that hose clamps are secure.
WARNING
Do not run the engine with the thermostat removed

5 Maintenance
Engine
Flush the cooling system
CAUTION
Do not remove the pressure cap, while the engine
is hot. Wait until the coolant temperature is below
50°C before removing the pressure cap. Danger of
scalds or burns.
d3561163
CAUTION
Coolant is toxic. Keep away from children and
animals. Dispose of waste coolant according to
local regulations.
¾ Drain the cooling system, do not allow the

cooling system to dry out.
¾ Do not remove the coolant filter.
¾ Use cooling system cleaner to flush the
cooling system.
¾ Operate the engine at normal operating
temperatures for at least one hour.
¾ Switch off the engine, allow to cool, and
drain the cooling system.
¾ Fill the cooling system with clean water,
operate the engine for 5 minutes. d3561164
¾ Shut off the engine, allow to cool and drain

the system, if the drained water is still dirty,
repeat the process until drained water is
clean.
¾ Fill the cooling system with pre-mixed
coolant/water mixture - see Fuel and oil
recommendations.

Maintenance 5
Engine
Change engine coolant 1
CAUTION
Follow the precautions for fluids and lubricants.
CAUTION
Do not remove the radiator cap or drain plugs
when the radiator Is hot or with the engine running.
2
CAUTION
The radiator drain plug Is fitted at the base of

d3561152
the radiator. It is reached from under the truck
through an access hole on the Immediately In
front of the steer axle.
¾ Remove radiator cap (1).

¾ Place a container of at least 45 lts capacity
under radiator drain plug (2).
¾ Remove the engine undertray.
¾ Place a container of at least 45 lts capacity

under engine drain plug (3).
¾ Remove the drain plugs and allow the
coolant to drain.
¾ Flush out the radiator through the filler cap
aperture.
¾ Refit radiator drain plug (2).
¾ Refit engine drain plug (3). 3
¾ Fill the cooling system with a water-an-
tifreeze mixture.
¾ Refit the radiator cap (1).
¾ Run the engine for 5 minutes.
d3561153
¾ Check the coolant level, replenishing
coolant if required.
¾ Check the cooling system for leaks.
¾ Fit the undertray.

5 Maintenance
Engine
NOTE
Capacity of cooling system ......... 44 lts

Maintenance 5
Engine
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.
¾ Check the vibration damper for evidence of
loss of fluid, dents, and wobble.
¾ Inspect the vibration damper thickness for
any deformation or raising of the damper
front cover plate.
¾ If any deformations or variations are de- d3561157
tected, please contact your authorised
dealer.
Check drive belt tension
CAUTION
Danger of burns.
The engine and radiator may be at operating tem-
perature.
Examine the drive belt for tension and exces-

sive wear, cracks and traces of oil. Renew
damaged drive belts.
¾ This belt drive system is equipped with an
automatic belt tensioner which CANNOT
be adjusted. Only visual inspection of belt
tensioner is required.
¾ If the belt tensioner is hitting either of the d3561110
cast stops (limiters), check the mounting
brackets and belt length.

5 Maintenance
Engine
Check the fan drive idler pulley

assembly
¾ Remove fan drive belt (1).
d3561158
¾ Inspect the idler pulley for:

¾ Freedom of rotation,
¾ Damaged or broken pulley groove.
d3561159

Maintenance 5
Engine
¾ Measure the idler pulley end clearance.

¾ Min ......... 0.025mm
¾ Max ......... 0.250mm
¾ If end clearances are not within these
measurements, contact your authorised
dealer.
d3561160
Fan hub, belt driven

¾ Remove fan drive belt (1).
d3561158

5 Maintenance
Engine
¾ Inspect the idler pulley for:

¾ Freedom of rotation,
¾ Damaged or broken pulley groove.
d3561161
¾ Measure the idler pulley end clearance.

¾ Min ......... 0.08mm
¾ Max ......... 0.41mm
dealer.
d3561162

Maintenance 5
Engine
Check the turbocharger

¾ Remove the air intake and exhaust piping.
¾ Check the turbocharger as follows:
¾ Look for damaged or cracked compressor
or turbine blades.
¾ Check that the turbocharger shaft spins
freely.
If any of the above are detected, contact your
authorised dealer.
d3561165
Check the radial bearing clearance

¾ Remove the intake and exhaust piping from
the turbocharger.
d3561166

5 Maintenance
Engine
¾ Use a wire type feeler gauge to measure the

clearance between the compressor wheel
and housing.
¾ Gently push the compressor wheel toward
the compressor housing and gauge.
Record this clearance
d3561167
¾ With the feeler gauge in the same location,

gently push the compressor wheel away
from the compressor housing and measure
the clearance between the compressor
wheel and housing.
Record this clearance
¾ Subtract the smaller clearance from the
larger clearance, this is the radial bearing
clearance.
¾ Min ......... 0.15mm
¾ Max ......... 0.64mm
dealer. d3561168

Maintenance 5
Gearbox
Check the Axial clearance

¾ Use a dial depth gauge.
¾ Push the rotor assembly away from the
gauge.
¾ Set the gauge to zero.
¾ Push the rotor assembly toward the gauge,
and record the reading.
¾ Min ......... 0.038mm
¾ Max ......... 0.089mm
¾ If clearances are not within these measure-
ments, contact your authorised dealer.
¾ Re-fit the intake and exhaust piping. d3561169
Gearbox
Change the transmission oil and
clean the filter screen
CAUTION
CAUTION
temperature. Danger of burns and scalding.
¾ Open the engine compartment front cover. 2

¾ Remove the engine compartment front 1
under trays.
¾ Place a catch tray of at least 60 lts capacity
under drain plug (1). d3561141
¾ Remove drain plug (1) and allow the oil to

drain. Remove and discard the plug seal
ring.
¾ Remove plug (2) from the housing with the
filter screen attached.
¾ Remove and discard the seal ring on drain
plug (1).
¾ Wash the screen assembly in paraffin
derivatives such as benzene and dry with
compressed air (max. 5 bar).

5 Maintenance
Gearbox
¾ Fit drain plug (1) with a new seal ring and

tighten.
¾ Install screen assembly and plug (2) with

new seal ring.
¾ Torque to 13 - 20 Nm (10 - 15 lb. ft.)
¾ Remove transmission filler cap (3) and fill
transmission oil.
¾ Capacity ........ 60 lts
¾ Start the engine and check for leaks at the 3
seal faces.
¾ Check the transmission oil level, replenish-
ing oil If required.
¾ Fit the engine compartment front under
trays.
¾ Close the engine compartment front cover. d3561142
Change transmission oil filters
CAUTION
2
lubricants.
3 1
CAUTION
Filters and oil may be hot. Danger of burns and
scalding.
¾ Open the engine compartment front cover.

¾ Place a catch tray of at least 11 pints
capacity under the filters (1).
¾ Loosen filters using a filter wrench and
remove by hand d3561121
¾ Clean the filter head.
¾ Fill the new filter with transmission oil.
¾ Lubricate filter seals (2) with transmission
oil.
¾ Install new filters and tighten by hand only.
¾ Start the engine and check for leaks at the
seal faces
¾ Check the transmission oil level and replen-
ish oil if necessary.

Maintenance 5
¾ Close the engine compartment front cover.
Check transmission mountings
CAUTION 1
brake on when working..
CAUTION
2
Check the condition of the rubber mounts.
Renew the rubber mounts, if damaged.
3
¾ Torque ......... 175 Nm (129 lbf- ft.) d3561140
¾ Torque ......... 195 Nm (145 lbf- ft.)
¾ Torque ......... 100 Nm (75 lbf- ft.)
¾ Torque ......... 250 Nm (185 lbf- ft.)

Clean the truck
NOTE
The frequency of cleaning depends on the
use of the truck. If used with very aggressive
media like salt water, fertilizer, chemicals,
cement, etc., a thorough cleaning is required
after the completion of work.

5 Maintenance
CAUTION
Use hot steam or intensive degreasing solutions
with the 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.
Follow the precautions for handling lubricants and
fluids.
CAUTION
Wear protective clothing and eye protectors.
When cleaning with a pressure washer, do not
expose electrical components or air filter intake
lines to the direct jet, cover them first.
Before lubrication, clean the grease nipples,

oil filler openings and surrounding areas.
Remove stubborn dirt with a cold cleaner when
cleaning with an air jet.
NOTE
If the truck is cleaned frequently, increase
lubrication intervals accordingly.
When cleaning with degreasing cleaning
solutions, allow sufficient time for the cleaner
to soak in and then flush with a strong water
jet.
After cleaning the engine, allow it to run warm
to dry it in order to prevent any malfunctions
due to the ingress of water.

Maintenance 5
Check seat belt for condition and 1

correct operation*
NOTE
For safety reasons the condition and proper 3
operation of the retention system should be
inspected regularly (monthly).
Under extreme operating conditions this
check is required daily before taking the truck 2
into operation.
¾ Pull belt (1) out fully and inspect for fraying.
¾ Check lock (2) for correct operation and the
retractor for proper return of the belt.
d3591093
¾ Check covers for damage.
¾ Check the automatic lock.
¾ Park the truck on level ground.
¾ Pull out the belt with a jerk. The automatic
lock should prevent the belt from unrolling
from retractor (3).
¾ Slide the seat fully forward.
¾ 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 adjust-

ments 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

5 Maintenance
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.
Tighten wheel nuts
CAUTION
On new trucks, or if a wheel has been removed and
replaced, the wheel nuts must be checked before
use and daily for two weeks.
Check wheel nuts every 100 hours.
¾ Torque all wheel nuts to: approx. 350 Nm.
d3561020

Maintenance 5
Check the tyres for damage and

foreign objects
¾ Secure the truck against rolling (apply
parking brake).
¾ Chock a wheel that will not be raised.
¾ Raise the truck with a jack at the locating
points until the wheels are clear of the
ground.
¾ Secure the truck with squared timbers.
¾ Check the wheels for ease of movement
and remove any debris hindering their free
rotation.
¾ Renew worn or damaged tyres.
Check the cab mountings

Check the front cab mountings
1
NOTE
Access to front cab mounting bolts (1) is from
under the cab floor mat.
¾ Check that the front cab mounting bolts (1)
are secure;
¾ Tighten to 115 Nm (85 lb. ft.) if required.
NOTE
2
Access to front mounting bolts (2) is from
below.
¾ Check that the front cab mounting bolts (2) d3561128
are secure;
¾ Tighten to 56 Nm (41 lb. ft.) if required.

5 Maintenance
Check the rear cab mountings
NOTE
1
Access to rear cab mounting bolts (1 & 2)
Is from under the cab behind the cab rear
compartment door.
¾ Check that cab mounting bolts (1) are
secure;
¾ Tighten to 115 Nm (85 lb. ft.) If required.
¾ Check that cab mounting bolts (2) are
2
secure;
¾ Tighten to 56 Nm (41 lb. ft.) If required.
d3561129
NOTE
It is very important that these inspections are
carried out as specified in daylight or with
adequate artificial lighting, to allow close
examination of the welds. Please follow the
guidelines below:
CAUTION
These maintenance procedures may need to be
carried out at heights of more than 2 metres. Use
suitable access equipment.
In line with the recommended maintenance

schedules for the regular inspection of the
boom and lifting equipment, please follow
these procedures for the full inspection of the
inner and outer boom.
¾ Wash the truck thoroughly and allow to dry.
¾ Corrosion and/or deposits should be
removed to facilitate the inspection.
¾ Park the machine with the boom extended
fully and lowered to allow close examination
of the inner boom.

Maintenance 5
¾ Examine both sides of the inner boom as

shown.
It is advisable to check regularly for signs of
metal fatigue. These areas are indicated.
In order to carry out the inspection most
efficiently, ensure that the boom is cleaned
of dust water and grease before inspection.
Initially, removal of any paint will not be
necessary to identify whether cracks are
present.
¾ Carry out a visual inspection of the areas of
the boom as indicated.
¾ Carry out a visual inspection of the areas of

the chassis as indicated.
NOTE
Should evidence of cracks be detected
contact Linde Heavy Truck Division Limited
immediately. Details of cracks detected
and their position, also machine usage and
site conditions should be relayed to the
Linde Heavy Truck Division Limited Service
Manager - Tel: +44 1443 624345 Fax: +44
1443 624302

5 Maintenance
Chassis frame
Chassis frame
CAUTION
lubricants.
1
CAUTION
Work on the truck on level ground. Retract and
lower the boom, stop the engine and put the parking 2
¾ Ensure that oil filler plug (1) is in the 3 o clock

position and drain plug (2) is in the 7 o clock
position.
d3571011
¾ Remove oil filler plug (1).
¾ Check oil is visible at the base of hub filler
hole (1).
¾ If required, replenish oil to the base of the
filler hole (1).
¾ Replace oil filler plug (1).

Maintenance 5
Chassis frame
Clean and lubricate steer axle, check

the mounting
1
CAUTION
2
CAUTION
and handler, stop the engine and put the parking 5
brake on when working. 3
¾ Clean the steer axle.

¾ Check steer axle mounting bolts (3) for
damage and wear 4
¾ Check nut (2) torque loading. d3561106
Torque...............2300 Nm (1700 lb. ft).

¾ Lubricate kingpin grease points (1&5), (4
positions).
¾ Lubricate the drag link grease points (4), (4
positions).
¾ Press the grease gun until clean lubricating
grease emerges at the bearings.
CAUTION
brake on when working. 1
CAUTION
temperature.
¾ Open the engine compartment front cover.

¾ Examine drive shaft coupling bolts (1) for 2
damage or signs of fretting.
d3561107
¾ Check bolt torque loading.
Torque..............80 Nm (60 lb. ft)
¾ Lubricate drive shaft grease points (2) (3
points)

5 Maintenance
Chassis frame

Check the drive axle mounting
CAUTION
Work on the truck on level ground. Lower the mast, 1
stop the engine and put the parking brake on when
working.
¾ Check drive axle securing bolts (2) and nuts

(1) for damage or signs of fretting.
¾ Check the torque loading of bolts.
Torque ........... 2300 Nm (1680 lbf- ft).
d3561118

Maintenance 5
Chassis frame
Check the drive axle centre differen-

tial oil level
CAUTION
Work on the truck on level ground. Lower the mast, 1
working.
CAUTION
lubricants.
¾ Remove filler plug (1).

¾ Check that the oil is visible at the base of the
filler hole.
d3561119
¾ If required, replenish with oil to base of filler
hole.
Capacity ................... max. approx 75 lts
¾ Fit filler plug (1).

5 Maintenance
Chassis frame
Check the drive axle hub differential

1
oil level
CAUTION
Work on the truck on level ground. Lower the mast,
OIL
working.
CAUTION
2
lubricants.
¾ Position the truck so that the drive axle hub

level indicator mark (1) is horizontal.
d3561120
¾ Check that the oil is visible at the base of the
hub filler hole.
¾ If required, replenish with oil to the base of
the filler hole.
Capacity ................. max. approx. 7 lts
¾ Fit filler plug (2).
¾ Repeat for the other hub.
Change the drive axle hub differen- 1 2

tial oil
CAUTION
Follow the precautions for fluids and lubricants. OIL
CAUTION
Work on the truck on level ground. Lower the mast 3
¾ Position the truck so that the drive axle hub

level indicator mark (2) is horizontal and
drain plug (3) is down.
under drain plug (3). d3561151

¾ Remove drain plug (3) and allow the oil to
drain completely.
¾ Remove and discard the plug seal rings.

Maintenance 5
Controls
¾ Fit drain plug (3) with a new seal ring.

¾ Fill the differential with gear oil to the base
of the filler hole.
¾ Fit filler plug (1) with a new seal ring.
¾ Repeat for the other hub.
NOTE
Maximum oil capacity each side ......... 7 lts

Correctly adjusted hub bearings must not
allow any perceptible end float, but allow the
wheel to rotate freely without binding.
NOTE
The bearing play can only be checked with the
wheel raised.
¾ Using a jack of sufficient capacity, raise the
truck on the side on which the bearing play
is to be checked and secure the truck with
squared timbers.
In case of bearing play, contact your autho-
rised dealer.
Controls
Check the steering lock
NOTE
Please contact your authorised dealer for this
check.

5 Maintenance
Electrics
Check the parking brake condition

and mounting 2 1
CAUTION
¾ Examine brake disc (3) for wear and dam-

age.
¾ Check the thickness of lining material on
brake pads (2) . Renew pads if thickness is
less than 2 mm.
3
¾ Examine calliper bolts (1) for wear, renew if
required. Check that the nuts and split pins d3561146
are secure.
Check the brake disc wear
NOTE
Please contact your authorised dealer for
renewal of the brake discs.
Electrics
The battery is fitted in the left hand chassis
compartment (1) with the air filter and fuel
system water separator.
1
¾ Check the battery, for cracks in the casing
and leakage of electrolyte.
¾ Remove corrosion on battery terminals and
check the connections are tight.
¾ Smear the terminals with non acid grease.
d3561023

Maintenance 5
Electrics
Check electric cables, connectors and connections for condition and tightness
¾ Examine cable connections for looseness
NOTE
and corrosion.
Corroded connections and cracked cables
¾ Inspect the earth lead for loose connection.
lead to a drop in voltages, which may cause
¾ Examine the electrical wiring for chaffing starting difficulties.
and loose connections.
¾ Remove corrosion and replace cracked
cables.

5 Maintenance
Hydraulics
Hydraulics
Check the hydraulic system, pumps, valves and lines
¾ Check all connections between the oil ¾ Renew any cracked hoses.
tank, pumps and control valves for leaks.
¾ Check the hoses for damage and chaffing,
If necessary, tighten any loose joints.
renew if necessary.
¾ Check the lift, tilt and steer cylinders for
leaks.

Maintenance 5
Hydraulics
Change the working hydraulic

system oil suction filters
CAUTION
lubricants. Danger of burns.
The oil tank, filter and hydraulic oil may be at
operating temperature.
¾ De-pressurise the tank by rotating the filler

cap slowly until air is heard escaping from
the tank, keep rotating the filler cap until no
more air is heard.
WARNING
The hydraulic tank accumulates stored pressure.
Take care when removing the filler cap.
¾ Remove nuts (1) from filter cover (2).

2
¾ Press retainer down, rotate through 90° and
lift out to allow removal and replacement of 1
filters (3).
d3571088

5 Maintenance
Hydraulics
¾ Lift out filters (3).

¾ Replace filters (3) and seals.
¾ Check oil level and replenish, if required 3
Dispose of used filters according to local

authority guidelines.
d3571089
Change the brake hydraulic system

oil suction filter
CAUTION
lubricants. Danger of burns.
The oil tank, filter and hydraulic oil may be at
Brake oil filtration consists of a suction strainer

(3) in the brake oil tank, and an in-line pressure
filter (10). The in-line filter (10) is situated
on the left hand side of the chassis near the
transmission.
¾ Chock the wheels of the truck and deplete
any stored pressure in the brake circuit.

Maintenance 5
Hydraulics
¾ Unscrew filter case (12).

¾ Remove and discard filter element (12) and
seal ring (11).
¾ Fit new seal ring (11) to filter element (12).
¾ Check that seal ring (11) is correctly seated
and lubricated with oil.
¾ Prime new filter element (12) with new oil.
¾ Engage new filter element (12) into the filter
head (10) and tighten. 10
11
12
d3571090
¾ To replace suction strainer (3), remove and

retain union nuts (2). 1
2
¾ Lift filter cover (1) and strainer (3) from tank
¾ The strainer (3) can be cleaned using
compressed air unless damaged, in which
case it can be removed by unscrewing by
hand and replaced by repeating the above 4
procedure. 3
¾ Start the engine and check the joints for
leakage, tighten nuts (2), if required.
NOTE
The hydraulic system is self priming when the
engine is running. d3571091
¾ Stop the engine and check the brake

hydraulic system oil level, replenishing
hydraulic oil if required.

5 Maintenance
Hydraulics

oil pressure filter
CAUTION
CAUTION
1
CAUTION
Oil filter and hydraulic oil may be at operating
The filter is fitted on the left side of engine d3561137

compartment.
¾ Place a catch tray of at least 2 L capacity
under the filter assembly.
¾ Unscrew filter case (1).
¾ Remove and discard filter element (2) and

seal ring (5).
¾ Check that seal ring (3) in new filter element
(2) is fitted correctly and lubricate with
hydraulic oil.
3
2
¾ Fit new seal ring (5) to filter case (4) and
lubricate with hydraulic oil.
¾ Fit filter element (2) to filter head. 5
¾ Engage filter case (4) into filter head and
tighten.
4
¾ Start the engine and check the joint for leak-
age, tightening the filter case if necessary.
¾ Stop the engine and check the brake system
d3561138
hydraulic oil level, replenishing hydraulic oil
if necessary.

oil
CAUTION
lubricants.

Maintenance 5
Hydraulics
CAUTION
Hydraulic oil and hydraulic oil tank may be at
CAUTION
NOTE
Note the addition of 6% Lubrizol to the hydrau-
lic oil.
The drain plugs on the hydraulic oil tank for the
working hydraulic system and braking system
are located at the base of the tank immediately
in front of the right-hand steer wheel. The
drain plug for the hydraulic braking system is
located behind the drain plug for the working
hydraulics.
under the drain plug.
¾ Remove the drain plug and allow the
hydraulic oil to drain completely.
¾ Remove and discard the drain plug sealing
ring.
¾ Install the drain plug with a new sealing ring.
d3571092

5 Maintenance
Hydraulics
¾ Fill hydraulic oil into the tank checking the

sight glass (1), frequently to check the oil
level.
Capacity ......... 100 lts
¾ Start the engine and carry out a functional
test of the breaking system hydraulics.
¾ Stop the engine and check the oil level in
the hydraulic oil tank on sight glass (1). If
required, fill the oil tank with clean hydraulic
oil until the oil level is between the HIGH and
LOW marks.
d3571092

Maintenance 5
Hydraulics
Change the hydraulic oil - working

system
CAUTION
lubricants.
CAUTION
Hydraulic oil and hydraulic 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. (Refer to analysis of
hydraulic oil.)
The drain plugs on the hydraulic oil tank for the
working hydraulic system and braking system
are located at the base of the tank immediately
in front of the right-hand steer wheel. The
drain plug for the working hydraulic system is
nearest to the front end of the truck.

under the drain plug.
¾ Remove the drain plug and allow the
hydraulic oil to drain completely.
1
¾ Remove and discard the seating ring on the
plug. Refit the drain plug with a new sealing
ring.
¾ Remove the dipstick with breather valve (1)
and fill the tank with hydraulic oil.
Capacity ......... 800 lts
¾ Start the engine and carry out a functional
test of the working hydraulics.
¾ Stop the engine and check the oil level
d3561155
in the hydraulic oil tank with the dipstick. If

5 Maintenance
Load lift system
required, add hydraulic oil up to the between

the HIGH and LOW marks on the dipstick.
Load lift system

Check and lubricate boom cylinder, boom pivot and sliding bearings
A 3
1 2 5
2
2
d3571012
CAUTION
lower the boom, stop the engine and put the parking
CAUTION
This maintenance procedure requires to be carried
out at heights of more than 2 metres. Use suitable
access equipment.
¾ Check that all stop plates (4) on the inner

and outer boom are fitted and tight (4
plates).

Maintenance 5
Load lift system
¾ Check pin (5) for tightness.

¾ Check pin (2) for tightness.
¾ Lubricate all grease points with grease (14
grease points).
¾ For lubrication use a grease gun until fresh
Lubricate slewing ring bearing and

gear
1
CAUTION
lubricants.
CAUTION
2
CAUTION
d3571010
access equipment.
¾ Lubricate the bearing grease points (1) (4

points).
¾ Using a brush, apply grease to the ring gear
(2).

5 Maintenance
Load lift system
Slew gearbox and brake oil level

check 1
CAUTION
lubricants.
CAUTION
CAUTION
d3571007

access equipment.
¾ Remove level/filler plug (1).

¾ The hydraulic oil level must be at the lower
edge of filler hole (1).
¾ If necessary, fill hydraulic oil to the base of
the hole.
¾ Fit level/filler plug (1).
Check and lubricate the twistlocks
CAUTION
Work on the truck on level ground. Lower the mast,
working.
WARNING
The twistlocks (2) are wearing parts. These must be
inspected regularly for damage, correct operation
and wear. Do not operate the truck if damage,
malfunctions or heavy wear are evident.
¾ Check twistlocks (2) in area (4) by measur-

ing between (A) and (B).
¾ This measurement must not be smaller than d3561117
1 inch, (the wear limit).
¾ Renew the twistlocks if the wear limit is
exceeded.

Maintenance 5
Load lift system
¾ Lubricate grease nipples (1 & 3) (3 on each

twistlock).
grease emerges at the bearings. 1
d3561116
Check and lubricate feet at the

bottom of each leg
CAUTION
lubricants.
1
CAUTION 2

¾ Lubricate the nipple in the centre shaft (1).

¾ Lubricate the nipples at the rear of each foot d3571009
(2) (3 points).

5 Maintenance
Special equipment, accessories
Change the twistlocks
WARNING
The twistlocks are wearing parts and must be
replaced for safety reasons after maximum 5000
service hours.
Contact your authorised dealer for renewal of

the twistlocks.

Check the central lubrication*
lubricating points
NOTE
This check is required only once after the first
50 hours.
¾ Check that enough grease is emerging from
all central lubrication lubricating points.
¾ If there is not enough or too much grease,
adjust the central lubrication time relay.
¾ Please contact your authorised dealer in
this regard.
Fill central lubrication* canister with

grease
NOTE
The central lubrication canister is located
behind the battery/air filter cover on the
left-hand side of the truck.
¾ Open the battery/air filter cover (2).
¾ Remove dust cap (3) on the canister filler 3
nipple.
¾ Clean the filler nipple and install the filler
tube of the grease gun.
¾ Fill grease up to the maximum level indica- d3561105
tor on the canister.
¾ Remove the filler tube and fit dust cap (3).

Maintenance 5
NOTE
If filling is difficult, clean the filter in the cani-
ster.
¾ Close the battery/air filter cover (2).
* Option

5 Maintenance
Troubleshooting
Troubleshooting
Troubleshooting guide Diesel engine
Trouble Possible cause Correction

Engine will not start Fuel tank empty Refill the tank
Fuel filter clogged Renew the fuel filter, use
winter fuel
Water in fuel system filter Drain, clean the fuel filter
Fuel shut off solenoid fails to Check for electric current with
open test lamp. If there is no current,
check fuse and switch
Fuel line leakage Check all pipe connections for
leaks and tighten fittings
Battery charging indicator light Tighten terminal clamps
not illuminated although lamp at battery, check cable
is ok connections
Preheating system defective Check the power supply.
Check the cables and connec-
tions at the preheat/starting
switch. If the fault cannot be
remedied, contact your autho-
rised dealer.
Fuel pump defective These faults should always be
Injection nozzles defective checked correctly by skilled
Injection pump defective staff. Please contact your
authorised dealer
Engine starting performance is Battery power is too low. Check battery, clean battery
poor Battery terminal loose or terminals, tighten clamps and
oxidised, causing the starter to cover with non-acidic grease
turn only slowly
Fuel supply insufficient Renew the fuel filter. Check
the fuel line connections for
leaks, and tighten fittings
Restriction or air in fuel system
due to parrafin deposits in
winter
Particularly in winter: Use engine oil appropriate for
Filled engine oil viscosity too the ambient temperature
high
Engine running and buzzer Oil pressure in hydraulic Let engine continue to run until
sounding braking system below minimum pressure is reached
operating pressure

Maintenance 5
Troubleshooting
Engine running unevenly with Fuel supply insufficient. Renew the fuel filter. Check
poor performance the fuel line connections for
leaks and tighten fittings.
Restriction or air in fuel system Use winter fuel in the cold
due to paraffin deposits in season.
winter.
Injection pump overflow valve Contact your authorised
not functioning correctly dealer.
Valve clearances not as Adjust valve clearances.
specified. Contact your authorised
Injection nozzles defective. dealer.
Engine oil level too high. Drain oil to the high mark on
the dipstick.
Excessive exhaust smoke Poor compression due to Adjust valve clearances.
burned-in or broken piston Contact your authorised
rings or incorrect valve dealer.
clearances.
Idle running trouble Fuel system not in order Clean and inspect fuel filter
renew if necessary. Clean the
fuel pump. Check fuel return
lines and injection lines for
leaks.
Engine speed setting incorrect May only be adjusted by skilled
staff. Contact your authorised
dealer.
Engine overheating, red Coolant level low. Check cooling system for
warning light in instrument leaks, seal if necessary. Add
panel illuminated. Stop the coolant.
engine immediately. Fan V-belt either slack or Tighten or renew the V-belt.
broken.
Radiator fins restricted due to Clean the radiator.
dirt or foreign objects.
Injection system setting Contact your authorised
incorrect. dealer.
Engine oil pressure too low. Leaks in the lubricating Contact your authorised
Stop the engine immediately. system. dealer.
Oil level too low. Add lubricating oil.
Battery charging indicator light Alternator RPM too low. Check V-belt tension.
illuminated during operation
Alternator not charging the Contact your authorised
battery because alternator or dealer.
relay defective.

5 Maintenance
Troubleshooting
Troubleshooting guide hydraulic system
Trouble Possible cause Correction

Abnormal noise Suction filter restricted. Renew the suction filter.
Suction hoses leaking, oil Tighten lines. Check oil level, top
foaming. up if necessary.
Hydraulic pump or motor failure, Have hydraulic unit inspected by
seals defective, causing air your authorised dealer.
intake.
Incorrect oil viscosity, low oil Change oil, be sure to use the
level in tank or in hydraulic correct viscosity, replenish oil.
pump.
No or too low pressure in Pump suction defective, noise. Change oil, replenish oil.
system
Pump failure, leakages, Contact your authorised dealer.
pressure valves do not close,
valve seat damage.
Pipe broken or leaky. Replace or tighten line.
Oil of low viscosity, causing high Change oil, be sure to use oil of
leakage losses. correct viscosity.
Oil temperature warning lamp Check oil level, clean oil cooler.
illuminated.
Oil pressure fluctuating Cause as under abnormal See under abnormal noise.
noise.
Pressure relief valves or boost Contact your authorised dealer.
pressure valves sticking.
Lift and tilt cylinders have tight Contact your authorised dealer.
spots.
Boom does not extend Replenish hydraulic oil.
completely or retracts slightly
after being extended.
No oil flow or low oil flow Suction filter restricted (if Clean or replace suction filter.
accompanied by noise).
Pump faulty, leakage, pressure Contact your authorised dealer.
relief valves do not close, valve
seat damaged.
Pipe broken or leaky Replace or tighten line.
Valves restricted. Contact your authorised dealer.
Hydraulic system overheating. Check oil level, use specified oil,
clean oil cooler, if needed.
Hydraulic oil temperature Pump failure, valves leaky. Contact your authorised dealer.
too high
Oil level too low or oil cooler Check oil level, if necessary top
defective. up oil. Clean cooler and check for
leaks. If defective, contact your
authorised dealer.

Maintenance 5
User manual feedback

User manual improvement record.
As part of Linde Heavy Truck Divisions
commitment to continuous improvement
please complete the form below to let us
know if there are any discrepancies within
this technical publication.
NOTE
Please be aware that amendments will be
assessed for validity, collated and updates will
be made according to scheduled updates.
Page
Proposed content
num-Existing content
amendment
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5 Maintenance

Index
g
NUMBERS AND SYMBOLS Check and lubricate boom cylinder,

boom pivot and sliding bearings . 176
1000 h Service plan . . . . . . . . . . . . . . . 114
Check and lubricate feet at the bottom
2000 h Service plan . . . . . . . . . . . . . . . 117 of each leg . . . . . . . . . . . . . . . . . 179
3000 h Service plan . . . . . . . . . . . . . . . 120 Check and lubricate the drive shaft . . . . 161
500 h Service plan . . . . . . . . . . . . . . . . 111 Check and lubricate the twistlocks . . . . 178
5000 h Service plan . . . . . . . . . . . . . . . 123 Check battery condition . . . . . . . . . 36, 166
6000 h Service plan . . . . . . . . . . . . . . . 126 Check brake hydraulic system oil level . . 38
A Check coolant level in header tank . . . . . 43
Check drive belt tension . . . . . . . . . . . . 145
Accident prevention check . . . . . . . . . . . 15 Check electric cables, connectors and
Adjusting the drivers seat . . . . . . . . . . . . 34 connections for condition and
tightness . . . . . . . . . . . . . . . . . . 167
B Check engine oil level . . . . . . . . . . . 39, 128
Before lifting a load . . . . . . . . . . . . . . . . . 80 Check seat belt for condition and
Boom and handler controls . . . . . . . . . . . 77 correct operation* . . . . . . . . . . . . 155
Check steer axle hub oil level . . . . . . . . 160
C Check the air filter . . . . . . . . . . . . . . . . 134
Cab door opening and closing . . . . . . . . . 30 Check the brake disc wear . . . . . . . . . . 166
Cabin door - closing . . . . . . . . . . . . . . . . 30 Check the cab mountings . . . . . . . . . . . 157
Change engine coolant . . . . . . . . . . . . 143 Check the central lubrication*
Change the air filter element - check lubricating points . . . . . . . . . . . . 180
the vacuum switch . . . . . . . . . . . 135 Check the condition of structured
Change the air filter safety element . . . . 137 components . . . . . . . . . . . . . . . . 104
Change the brake hydraulic system oil . 172 Check the cooling system for leaks and
tightness . . . . . . . . . . . . . . . . . . 141
pressure filter . . . . . . . . . . . . . . . 172 Check the drive axle centre differential
oil level . . . . . . . . . . . . . . . . . . . 163
suction filter . . . . . . . . . . . . . . . . 170 Check the drive axle hub differential oil
level . . . . . . . . . . . . . . . . . . . . . . 164
Change the drive axle hub differential
oil . . . . . . . . . . . . . . . . . . . . . . . 164 Check the drive axle mounting . . . . . . . 162
Change the engine oil . . . . . . . . . . . . . . 129 Check the engine mountings . . . . . . . . 138
Change the engine oil filters . . . . . . . . . 130 Check the fan drive idler pulley
assembly . . . . . . . . . . . . . . . . . . 146
Change the fuel filter . . . . . . . . . . . . . . 133
Check the front cab mountings . . . . . . . 157
Change the hydraulic oil - working
system . . . . . . . . . . . . . . . . . . . . 175 Check the hydraulic system, pumps,
valves and lines . . . . . . . . . . . . . 168
Change the transmission oil and clean
the filter screen . . . . . . . . . . . . . . 151 Check the injection nozzles . . . . . . . . . 139
Change the twistlocks . . . . . . . . . . . . . 180 Check the intake and exhaust systems
for leaks and tightness . . . . . . . . 141
Change the working hydraulic system
oil suction filters . . . . . . . . . . . . . 169 Check the parking brake condition and
mounting . . . . . . . . . . . . . . . . . . 166
Change transmission oil filters . . . . . . . 152
Check the rear cab mountings . . . . . . . 158
Check and adjust hub bearings . . . . . . . 165
Check the steering lock . . . . . . . . . . . . 165

Index
g
Check the transmission oil level . . . . . . . 41 E

Check the turbocharger . . . . . . . . . . . . 149
EC declaration of conformity . . . . . . . . . . 11
Check the tyres for damage and foreign Electrical Circuit . . . . . . . . . . . . . . . . . . 201
objects . . . . . . . . . . . . . . . . . . . . 157
Electronic control module System . . . . . . 46
Check the vibration damper . . . . . . . . . 145
Check transmission mountings . . . . . . . 153 F
Check tyre condition and pressure . . . . . 37
Fan hub, belt driven . . . . . . . . . . . . . . . 147
Check valve clearances . . . . . . . . . . . . 139
Fill central lubrication* canister with
Check windscreen washer reservoir grease . . . . . . . . . . . . . . . . . . . . 180
fluid level . . . . . . . . . . . . . . . . . . . 43
Filling fuel . . . . . . . . . . . . . . . . . . . . . . . 40
Check working hydraulic system oil level . 38
First 50 h . . . . . . . . . . . . . . . . . . . . . . . 109
Checking the fuel level . . . . . . . . . . . . . . 40
Flush the cooling system . . . . . . . . . . . 142
Checking the twistlocks and warning
lights for proper operation . . . . . . . 44 Frequency characteristic for human
body vibrations . . . . . . . . . . . . . . . 18
Checks prior to first operation* . . . . . . . . 15
Fuel and oil recommendations . . . . . . . 103
Clean and lubricate steer axle, check
the mounting . . . . . . . . . . . . . . . 161 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Clean the radiator and check for leaks . . 138 G
Clean the truck . . . . . . . . . . . . . . . . . . . 153
Gear shift control . . . . . . . . ......... . 62
Closing the battery and air filter
compartment door . . . . . . . . . . . . 33 General information . . . . . . ......... . 98
Closing the brake hydraulic system oil General view of the handler ......... . 23
tank cover . . . . . . . . . . . . . . . . . . 33 General view of the truck . . ......... . 22
Closing the cabin rear compartment
door . . . . . . . . . . . . . . . . . . . . . . . 32 H
Closing the engine cover . . . . . . . . . . . . 31 Handling Fuel, Lubricants and
Closing the fuse box cover . . . . . . . . 34, 74 Coolant . . . . . . . . . . . . . . . . . 15 – 16
Closing the transmission cover . . . . . . . . 31 Hoisting the truck . . . . . . . . . . . . . . . . . 100
Closing the working hydraulic system Hydraulic Circuit . . . . . . . . . . . . . . . . . . 221
oil tank cover . . . . . . . . . . . . . . . . 32
Cold Start . . . . . . . . . . . . . . . . . . . . . . . 47 I
Improper use . . . . . . . . . . . . . . . . . . . . . . 8
D
Inspection and maintenance data . . . . . 102
Daily checks . . . . . . . . . . . . . . . . . . . . 106 Isolating the battery . . . . . . . . . . . . . . . . 36
Daily checks* . . . . . . . . . . . . . . . . . . . . . 16
Danger notices L
Graduation . . . . . . . . . . . . . . . . ..... 9 Lubricate slewing ring bearing and
Declaration of conformity . . . . . . . . . . . . 11 gear . . . . . . . . . . . . . . . . . . . . . . 177
Depositing the load . . . . . . . . . . . . . . . . 89
Drain the fuel filter . . . . . . . . . . . . . . . . 132
M
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Malfunctions during operation . . . . . . . . . 57
Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Index
g
N S
Normal start . . . . . . . . . . . . . . . . . . . . . . 45 Safety Precautions . . . . . . . . . . . . . . . . . 14
Securing the open cabin door . . . . . . . . . 30
O Service brake . . . . . . . . . . . . . . . . . . . . . 66
Opening the battery and air filter Service plan . . . . . . . . . . . . . . . . . . . . . 107
compartment door . . . . . . . . . . . . 33 Slew gearbox and brake oil level check . 178
Opening the brake hydraulic system oil Stability . . . . . . . . . . . . . . . . . . . . . . . . . 18
tank cover . . . . . . . . . . . . . . . . . . 33
Start-up indications . . . . . . . . . . . . . . . . 60
Opening the cabin door from the inside . . 30
Starting the engine . . . . . . . . . . . . . . . . . 45
Opening the cabin rear compartment
Steering . . . . . . . . . . . . . . . . . . . . . . . . . 64
door . . . . . . . . . . . . . . . . . . . . . . . 32
Stopping the engine . . . . . . . . . . . . . . . . 47
Opening the engine cover . . . . . . . . . . . . 31
Stopping the truck . . . . . . . . . . . . . . . . . 65
Opening the fuse box cover . . . . . . . 34, 74
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . 9
Opening the transmission cover . . . . . . . 31
Opening the working hydraulic system T
oil tank cover . . . . . . . . . . . . . . . . 32
Operating the hazard warning lights . . . . 69 Taking the truck out of operation . . . . . . . 98
Operating the horn . . . . . . . . . . . . . . . . . 69 Technical Data . . . . . . . . . . . . . . . . . . . 197
Operating the spreader . . . . . . . . . . . . . 80 Tighten wheel nuts . . . . . . . . . . . . . 37, 156
Operating transmission dump . . . . . . . . . 65 To operate the cab pre-heater system * . . 72
Operation of container handlers in the Towing . . . . . . . . . . . . . . . . . . . . . . . . . 93
plant area . . . . . . . . . . . . . . . . . . 15 Trailer coupling . . . . . . . . . . . . . . . . . . . 91
Overload safety switch . . . . . . . . . . . . . . 60 Travelling with loads . . . . . . . . . . . . . . . . 87
Troubleshooting guide Diesel engine . . 182
P Troubleshooting guide hydraulic
Parking brake . . . . . . . . . . . . . . . . . . . . 66 system . . . . . . . . . . . . . . . . . . . . 184
Parking the truck . . . . . . . . . . . . . . . . . . 91 Truck lighting and turn indicators . . . . . . . 67
Picking up a container . . . . . . . . . . . . . . 82 Truck status display . . . . . . . . . . . . . . . . 48
Picking up a container CH model . . . . . . 84 Truck welds inspection . . . . . . . . . 105, 158
Picking up a container TL model . . . . . . . 82 Turning on the front windscreen wiper . . . 70
Prime the fuel system . . . . . . . . . . . . . . 133 Tyre Specifications - Drive and Steer
Axle . . . . . . . . . . . . . . . . . . . . . . . 37
R
W
Residual risks . . . . . . . . . . . . . . . . . . . . 17
Wheel change . . . . . . . . . . . . . . . . . . . . 92
Running-in Instructions . . . . . . . . . . . . . 15
Work on the boom and the front part of
the truck . . . . . . . . . . . . . . . . . . . . 99

Linde Material Handling GmbH
3578011501 EN – 2010/01/27
Reachstacker
Original instructions
C4230 - C4540 TL /5,

Annex C4026 - C4535 CH /5
3578011501 EN – 2010/01/27
6
Technical Data
6 Technical Data

Technical Data 6
Datasheet
Datasheet
Technical Data
LINDE Reachstacker 357 05 Data sheet for material handling equipment DFG VDI 2198
Designation acc. To VDI 3586 Registration note to VDI 3586
October 2008
1.1 Manufacturer Linde Linde Linde Linde Linde Linde Linde Linde Linde Linde Linde Linde Linde
1.2 Model designation C4230 TL / 5 C4531 TL / 5 C4234 TL / 5 C4535 TL / 5 C4540 TL / 5 C4540 TL / 5 (2nd Rail) C4026 CH / 5 C4127 CH / 5 C4527 CH / 5 C4030 CH / 5 C4531 CH / 5 C4535 CH / 5 C4535 CH / 5 (2nd Rail)
1.3 Power unit: battery, diesel, LP gas, mains power Diesel Diesel Diesel Diesel Diesel Diesel Diesel Diesel Diesel Diesel Diesel Diesel Diesel
1.4 Operation: manual,pedestrian,stand-on,seated,order picker Rider seated Rider seated Rider seated Rider seated Rider seated Rider seated Rider seated Rider seated Rider seated Rider seated Rider seated Rider seated Rider seated
1.5 Load capacity (L1,L2,L3) Q (kg) 42 / 30 / 16 45 / 31 / 16 42 / 34 / 17 45 / 35 / 19 45 / 40 / 21 45 / 40 / 21 40 / 26 / 12 41 / 27 / 12 45 / 27 / 12 40 / 30 / 13 45 / 31 / 15 45 / 35 / 16 45 / 35 / 16
Load capacity With stabilisers applied (L1,L2,L3) Q (kg) 42 / 34 / 20 45 / 36 / 22 42 / 38 / 21 45 / 40 / 25 45 / 45 / 31 45 / 45 / 31 43 / 30 / 16 41 / 31 / 16 45 / 31 / 16 40 / 34 / 17 45 / 35 / 21 45 / 40 / 26 45 / 40 / 26
1.6 Load centre First row (L1) c (mm) 1760 1760 1760 1670 1800 1800 1760 1760 1760 1760 1670 1800 1800
Load centre Second row (L2) c (mm) 3810 3810 3810 3810 3860 3860 3810 3810 3810 3810 3810 3860 3860
Load centre Third row (L3) c (mm) 6250 6250 6250 6250 6400 6400 6250 6250 6250 6205 6250 6400 6400
1.8 Axle centre to fork face (L1 - 1 / 2 high) x (mm) 2800 / 2600 2800 / 2600 2800 / 2600 2800 / 2600 2800 / 2600 2800 / 2600 2800 / 2600 2800 / 2600 2800 / 2600 2800 / 2600 2800 / 2600 2800 / 2600 2800 / 2600
1.9 Wheelbase y (mm) 6400 6400 6400 6400 7000 7000 6400 6400 6400 6400 6400 7000 7000
2.1 Service weight kg 70400 71400 73200 76300 77000 77700 73950 74900 74900 76700 81250 81970 83470
2.2 Axle load with load, front/rear (L1) kg 97180 / 15220 101900 / 14500 97030 / 18170 103250 / 18050 103950 / 18050 104025 / 18675 99000 / 14950 102270 / 13630 102270 / 13630 98870 / 17830 110100 / 16150 110320 / 16650 111820 / 16650
Axle load without load, front/rear (L2) kg - -
2.3 Axle load without load, front/rear (L1) kg 35900 / 34500 36400 / 35000 36100 / 37100 38500 / 37800 38700 / 38300 38900 / 38800 41320 / 32630 41780 / 33120 41780 / 33120 41450 / 35250 44320 / 36920 44550 / 37420 46050 / 37420
Axle load without load, front/rear (L2) kg - -
3.1 Tyres, front/rear. SE = (superelastic), P = (pneumatic) P/P P/P P/P P/P P/P P/P P/P P/P P/P P/P P/P P/P P/P
3.2 Tyre size, front 18.00 x 25 / 40pr 18.00 x 25 / 40pr 18.00 x 25 / 40pr 18.00 x 33 / 40 pr 18.00 x 33 / 40 pr 18.00 x 33 / 40 pr 18.00 x 25 / 40pr 18.00 x 25 / 40pr 18.00 x 25 / 40pr 18.00 x 25 / 40pr 18.00 x 33 / 40pr 18.00 x 33 / 40pr 18.00 x 33 / 40pr
3.3 Tyre size, rear 18.00 x 25 / 40pr 18.00 x 25 / 40pr 18.00 x 25 / 40pr 18.00 x 33 / 40 pr 18.00 x 33 / 40 pr 18.00 x 33 / 40 pr 18.00 x 25 / 40pr 18.00 x 25 / 40pr 18.00 x 25 / 40pr 18.00 x 25 / 40pr 18.00 x 33 / 40pr 18.00 x 33 / 40pr 18.00 x 33 / 40pr
3.5 Wheels, number, front/rear (x = driven) 4x / 2 4x / 2 4x / 2 4x / 2 4x / 2 4x / 2 4x / 2 4x / 2 4x / 2 4x / 2 4x / 2 4x / 2 4x / 2
3.6 Track width, front b10 (mm) 3030 3030 3030 3030 3030 3392 3030 3030 3030 3030 3030 3030 3392
3.7 Track width, rear b11 (mm) 2786 2786 2786 2786 2786 2786 2786 2786 2786 2786 2786 2786 2786
4.1 Telescopic boom lift angle, Raised/lowered a/ß (º) 61 / 0 61 / 0 61 / 0 61 / 0 61 / 0 60 / 0 61 / 0 61 / 0 61 / 0 61 / 0 61 / 0 61 / 0 60 / 0
4.2 Height telescopic boom lowered h1 (mm) 5115 5115 5115 5215 5215 5555 5115 5115 5115 5115 5215 5215 5555
4.4 Lift (L1,L2,L3) h3 (mm) 15900 / 14100 / 11350 15900 / 14100 / 11350 15900 / 14100 / 11350 16000/14200/11550 16000/14200/11550 16000/14200/11550 16000/15200/11550 15420/13620/10870 15420/13620/10870 15420/13620/10870 15520/13720/11070 15520/13720/11070 15520/13720/11070
4.5 Height , telescopic boom extended h4 (mm) 18900 18900 18900 19000 19000 19100 18900 18900 18900 18900 19000 19000 19100
4.7 Height of overhead guard (cabin) h6 (mm) 3900 3900 3900 4000 4000 4400 3900 3900 3900 3900 4000 4000 4400
4.8 Height, operators seat/stand-on platform h7 (mm) 2840 2840 2840 2940 2940 3340 2840 2840 2840 2840 2940 2940 3340
4.12 Towing coupling height h10 (mm) 600 600 600 700 700 700 600 600 600 600 700 700 700
Cabin travel movement h12 (mm)
4.15 Twistlock height lowered h13 (mm) 1885 1885 1885 1985 1985 1985 1885 1885 1885 1885 1985 1985 1505
Twistlock height lowered (with over-ride activated) h13 (mm)
4.19 Overll length with attachment l1 (mm) 11618 11618 11618 11618 12220 12220 11618 11618 11618 11618 11618 12220 12220
4.20 Overall length l2 (mm) 8408 8408 8408 8408 9008 9008 8408 8408 8408 8408 8408 9008 9008
4.21 Overall width b1/b2 (mm) 4180 / 3400 4180 / 3400 4180 / 3400 4180 / 3400 4180 / 3400 4570 / 3400 4180 / 3400 4180 / 3400 4180 / 3400 4180 / 3400 4180 / 3400 4180 / 3400 4570 / 3400
4.24 Width of attachment 20' / 40' b3 (mm) 6050 / 12150 6050 / 12150 6050 / 12150 6050 / 12150 6050 / 12150 6050 / 12150 6050 / 12150 6050 / 12150 6050 / 12150 6050 / 12150 6050 / 12150 6050 / 12150 6050 / 12150
4.31 Ground clearance, minimum m1 (mm) 345 345 345 345 345 345 345 345 345 345 345 345 345
4.32 Ground clearance, centre of wheelbase m2 (mm) 300 300 300 400 400 400 300 300 300 300 400 400 400
4.33 Stacking aisle 20' container Ast (mm) 10225 10225 10225 10225 13980 13980 10225 10225 10225 10225 10225 13980 13980
4.34 Stacking aisle 40' container Ast (mm) 13050 13050 13050 13050 14510 14510 13050 13050 13050 13050 13050 14510 14510
4.35 Turning radius Wa (mm) 8605 8605 8605 8605 9275 9275 8605 8605 8605 8605 8605 9275 9275
4.36 Minimum pivoting point distance b13 (mm) 3400 3400 3400 3400 3620 3620 3400 3400 3400 3400 3400 3620 3620
5.1 Travel speed, with/without load km/h 21 / 25 21 / 25 21 / 25 21 / 25 23 / 25 23 / 25 21 / 25 21 / 25 15 / 25 21 / 25 21 / 25 23 / 25 23 / 25
5.2 Lift speed, with/without load m/s 0.28 / 0.39 0.28 / 0.39 0.28 / 0.39 0.28 / 0.39 0.28 / 0.39 0.28 / 0.39 0.28 / 0.39 0.28 / 0.39 0.28 / 0.39 0.28 / 0.39 0.28 / 0.39 0.28 / 0.39 0.28 / 0.39
5.3 Lowering speed, with/without load m/s 0.39 / 0.39 0.39 / 0.39 0.39 / 0.39 0.39 / 0.39 0.39 / 0.39 0.39 / 0.39 0.39 / 0.39 0.39 / 0.39 0.39 / 0.39 0.39 / 0.39 0.39 / 0.39 0.39 / 0.39 0.39 / 0.39
5.5 Tractive force, with/without load 1 kph N 346 346 346 346 382 382 346 346 346 346 382 383 382
5.6 Maximum tractive force, with/without load N 392 392 392 392 425 425 392 392 392 392 425 425 425
5.7 Climbing ability, with/without load 1 kph % 28 28 28 28 31.5 31.5 28 28 28 28 31.5 31.5 31.5
5.8 Maximum climbing ability, with/without load % 32.5 32.5 32.5 32.5 35.0 35.0 32.5 32.5 32.5 32.5 35.0 35.0 35.0
5.9 Acceleration time, with/without load s - - - - - - - - - - - - -
5.10 Service brake Wet disc Wet disc Wet disc Wet disc Wet disc Wet disc Wet disc Wet disc Wet disc Wet disc Wet disc Wet disc Wet disc
6.4 Battery voltage, rated capacity V/Ah 24V (2x 12 / 143) 24V (2x 12 / 143) 24V (2x 12 / 143) 24V (2x 12 / 143) 24V (2x 12 / 143) 24V (2x 12 / 143) 24V (2x 12 / 143) 24V (2x 12 / 143) 24V (2x 12 / 143) 24V (2x 12 / 143) 24V (2x 12 / 143) 24V (2x 12 / 143) 24V (2x 12 / 143)
7.1 Engine manufacturer/type Cummins QSM 11 Cummins QSM 11 Cummins QSM 11 Cummins QSM 11 Cummins QSM 11 Cummins QSM 11 Cummins QSM 11 Cummins QSM 11 Cummins QSM 11 Cummins QSM 11 Cummins QSM 11 Cummins QSM 11 Cummins QSM 11
7.2 Engine performance according to ISO 1585 kW 250 250 250 250 280 280 250 250 250 250 250 280 280
7.3 Rated speed 1/min 2100 2100 2100 2100 2100 2100 2100 2100 2100 2100 2100 2100 2100
7.4 Number of cylinders/displacement / cm³ 6 / 10820 6 / 10820 6 / 10820 6 / 10820 6 / 10820 6 / 10820 6 / 10820 6 / 10820 6 / 10820 6 / 10820 6 / 10820 6 / 10820 6 / 10820
7.5 Fuel consumption according to VDI cycle l/h 15-28 15-28 15-28 15-28 15-28 15-28 15-28 15-28 15-28 15-28 15-28 15-28 15-28
8.1 Type of drive control Torque converter 4 / 4 Torque converter 4 / 4 Torque converter 4 / 4 Torque converter 4 / 4 Torque converter 4 / 4 Torque converter 4 / 4 Torque converter 4 / 4 Torque converter 4 / 4 Torque converter 4 / 4 Torque converter 4 / 4 Torque converter 4 / 4 Torque converter 4 / 4 Torque converter 4 / 4
8.2 Working pressure for attachments bar 160 160 160 160 160 160 160 160 160 160 160 160 160
8.3 Oil flow for attachments l/min - - - - - - - - - - - - -
8.4 Noise level, at operator's ear, Overhead guard/Cab dB(A) 74 74 74 74 74 74 74 74 74 74 74 74 74
8.5 Trailer coupling, design/type DIN Ø (mm) 50 50 50 50 50 50 50 50 50 50 50 50 50
C4230 TL / 4 C4531 TL / 4 C4234 TL / 4 C4535 TL / 4 C4540 TL / 4 C4540 TL / 4 C4026 CH / 4 C4127 CH / 4 C4527 CH / 4 C4030 CH / 4 C4531 CH / 4 C4535 CH / 4 C4535 CH / 4
2nd Rail 2nd Rail
4.1 Telescopic boom lift angle, Raised/lowered m/s 56 / 0 56 / 0 56 / 0 56 / 0 56 / 0 56 / 0 56 / 0 56 / 0 56 / 0 56 / 0 56 / 0 56 / 0 56 / 0
4.2 Height telescopic boom lowered N 5115 5115 5115 5215 5215 5555 5115 5115 5115 5115 5215 5215 5555
4.4 Climbing ability, with/without load (L1,L2,L3) % 13400 / 11120 / 6850 13400 / 11120 / 6850 13400 / 11120 / 6850 13500/11220/6950 13500/11220/6950 13500/11220/6950 13075 / 10800 / 6550 13075 / 10800 / 6550 13075 / 10800 / 6550 13075 / 10800 / 6550 13175 / 10900 / 6650 13175 / 10900 / 6650 13175 / 10900 / 6650
4.5 Height , telescopic boom extended % 16560 16560 16560 16660 16660 16760 16560 16560 16560 16560 16660 16660 16760

6 Technical Data
Datasheet
Dimensional illustration
Ast
TL
a
2
L1
Wa
a
2
b13
h4
L2 L1
b11
b3 b1 b2
h3/L1
b10 L3 L2 L1
h3/L2
h3/L3
20’
L3 L2 L1
1495
9’ 6"
L3 L2 L1
40’
1790
x
3840
6280
AST Travelling aisle Q Q Q
4 5
20' 10225 10225 / 13980
40' 13050 13050 / 14 510
h4
Rotation 30° 45° 30° 45°
Ast CH
Model capacity 42000 kg 42000 kg 45000 kg 45000 kg
40’
Distance (a) 4200 mm 4100 mm 4200 mm 4100 mm h3/L1
L1
Capacity (a) 25000 kg 25000 kg 28000 kg 28000 kg
Distance (b) – 5300 mm – 5300 mm
20’
Capacity (b) – 20000 kg – 20000 kg
h3/L2
L2 L1
b11
h3/L3
L3 L2 L1
b3 b1 b2
a
b10 2
b13 h13
9’ 6"
L3 L2 L1
1790
Wa
3840
6280
?/? Q Q Q
a
500
2
h1
h6
h7
h13 h10 9’6” 9’6”
m2
y
m1
l2
l1 L1
L3
d3571003

7
Circuit Diagrams
7 Circuit Diagrams

Circuit Diagrams 7
Electrical Circuit Diagram

Electrical Circuit
Page 1
24v (BAT +) :60
Aircon clutch X105 pin 6 Pg10: (764)

24v (BAT +) Isolator :30
24v (IGN +) Isolator :15
FM2 :29 :30
C1
30-1A/30-1B
45
45-A 45-B
916
24v (IQAN +) E/S :45
28
30-1A/30-1B
30-1A/30-1B
120A :26
15-1/15-2
:25
15-1/15-2
F9 28-A 28-B 24v (IQAN +) E/S :28
:8
S5
30
F1 30A
X10B
:1 :1
:2 :5 30A :2 :3 :4
B19
F17 F34 F21 F18 F19 K16 Pin 4Pg1: (30) F20 F33
5A 3A 20A 10A 10A 5A 5A
:13 :14 :17 :14 :15 :16 :13
X97
:15 :8 :7
IQAN XS2-A1 Pin 9
30-11
497
496
409
X4
11-21
11-21B
25
Pg3: (180)
29
30-15
IQAN XS2-A1 Pin 11Pg3: (163)
110
250
:6 :7 :5 :3 :2
09-2
916
:30
:87
X10B X10A
R32
:30
0
K1
:86
:2 K8
11-2
FM1 S1 :87
:85
30
1A I
S1
:85
:86
900-AC
900-AG
210
:7
50A
16-A
S2 0 0 I II15/54
16
X10A
:8 :4 :7
I II :6
S1-A :7 :8 :5 :2 :1
XT2-A0 Pin 7 Pg4: (249)
K16 X1
10 1
11-21A
:1
497
496
11
409
X2A X10B Pin 5 Pg1: (64)
29
409
25
K15
4 :4 :3 :4 SP SP
X1 X4
S3 X
0-07
12 14 13 9
X
496b
496c
497b
497a
496a
130
:85
06-2
900-K
:86
XS2-A1 Pin 6 Pg3: (196)

OEM2
210
110 7 8 17 18 28 38
:87
:30
124 250 BAT1 BAT2 IGN

463 A1 S2
5
D
BAT IGN
464 7
C
125 Cummins engine QSM Tier3 DANA CLARK
Management System
412 TE27 TRANS
19
A B
+ 122 411 6
- A3 B4 S3
G2
B+ I+ B+ EX B3
G :1
+24V
114 4
M1 G1 3
:1 X9
S4
29 30 39 40 37
GND GND
+
OEM1
506 507 SP Y37 M9
- X
129b
129d
129e
129a
129c
:115/129/137
:2 150
XSP
353
115
137
129
Chassis Ground 0v
1 3 5 7 9 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80
Non harness wiring Linde engine harness Chasis harness Cab harness

81
202
83
Page 2
F3
15A
900 900-C 28-1 28-B
+BAT 28-1
:2
:28
:14
:15
85
28-1A
X SP900
(D
INPUTS
O
O (D
R
87
I
S34
S33
SWN- 35-1A
-BAT OUTPUTS
IT T)
C 35-1
:35
H
)
89
Cab floor ground 0v
7 Circuit Diagrams
(S
LH
+24v Ign & E/Stop (28)
Non harness wiring

RH
(D
90
PR
O
:8
(S EA
PA UT D
X88
ER (D
R -A
92
( D E) ) LO IN
C -S 21-1
:9
(S O U (S K )
:21
:2
PA T PR ED
R -B EA )
E) )
94
(
D D
ER
(S O U
(D
H9 H10
:22
Cab harness
PA UT N IN
R -C -L -R 34-1
O
C
96
( D E) ) K )
:3
:34
ED
:23
(S O U
PA T )
R -
98
(D E) D)
:36
(S OU
PA T (L
R -E G
X93
S (D
(D E) ) U
100
N IN
I 0 II
C 20-1
:37
(S OU
I
PA T LA -Q
M )
:20
:3
S56
R -F P)
0
102
(D E) ) (L (D
G
:2
:01 :07
(S OU S IN
:03
II
C 33-1
PA T -P
R -G LA )
:33
M
:6
( D E) )
104
P)
:3
(S O U
:10
PA T
:09
R -
(D E) H)
106
:4
Container Handler adaptor harness

(S OU
PA T
R -I
( D E) ) (R
108
(D
:5
(S O U EA
R IN
I 0 II
PA T
- LG -O 19-1
I
( D RE) J ) S )
:19
U
:2
(R
S57
110
:6
(S O U EA P)
0
PA T R (D
:01 :07
R -K LG IN
:03
II
(D E) ) S -N 32-1
D
112
:7 W )
:32
:5
(S OU N
PA T )
R -L
E) )
:10
:09
114
116
(F
R (
N D
T I
I 0 II
LG N
S -M 18-1
I
118
U )
:18
:1
S58
(F P)
R
0
N (D
:01 :07
T I
:03
LG N
II
31-1
120
S -L
D )
W
:31
:4
N
)
122
:10
:09
:1
X94
:2
124
:7
900-FM
100-AJ
(-V
42-1B
126
R
(+ EF 29-1 29-1A
)
:29
5V
R
3A
128
ILF2
42-1
EF
X
)
:42
:1
SP42-1
(S (V 29-1B
R
130
IN
:3
EA
D
ER A)
- 10-1
XSP29-1A
:10
:2
JS
42-1A
132
(S (V )
R
:4
IN
N2
EA
D - 11-1
JS-6
ER B)
134
:11
JS
)
136
B31
(S (V
R
:5
138
EA IN
D - 12-1
ER C)
:12
(S (V JS
R )
:6
IN
140
EA
(D D - 13-1
IN ER D)
:13
-G JS
)
142
)(JS
JS-10
PB
1) 38-1 42-1D
:4
:38
(D
:10
144
IN
-
(D F) (
I N JS
146
(D -H PB
IN )(JS 2) 25-1
:25
:5
-I) P
(D (J B 3
S 39-1
148
02-0 I )
:6
PB
:39
MDL Pin 27 Pg:6 (470) (C

16-1
(D N-J
IQAN-XS2-(A0) CAB FRONT
A IN ) (J 4)
03-0
:7
MDL Pin 41 Pg:6 (470) (C N-H -K P S

150
A ) )(J B
N S 5 30-1
:8
02-0A (C -L (S PB )
XS2-A1 Pin 27 Pg:3 (232) A ) R 6) 17-1
N EA
152
:9
:16 :30 :17
XS2-A1 Pin 41 Pg:3 (234) 03-0A (C -H D

ER
:1
(V
Address resistor
A ) 29-1C
:3
:26 :40 :27 :41
N PR IN
24-1
-L (A O -E
) (A P )
154
D
:24
D D R
O
:2
R D 42-1C
-H R T)
-L
)
CAN-bus
)
156
PB6
:1
PB5
:14
PB2
14-1
PB3
01-1
158
PB4
PB1
XS2-0
160
R21
Operating Instructions – 3578011501 EN – 2010/01/27

161
+BAT 28-2
F4
15A
( 28-B
:28
163
:3
(IgDIN
:15
n - 11-2
Page 3
sw B
S1
( ) )
Pg1: (28)
:11
900 (S DI
165
900-D
ea N-
-BAT
ts M 18-2
:15
INPUTS
w )
X SP900
:01
( 1) 28-2A
:18
(S DI
ea N
167
t s -N 32-2 :03
w )
S7
2
:02
)
:32
169
X108
Non harness wiring

0
OUTPUTS
36-2
170
(D I
Cab floor ground 0v

+24v
:2
(P
:36
(U OU
0
ar (D
PA T k IN
O -E br 10-2
172
/P ) ak -A
L
) e
I
sw) 28-2D
:10
S8
)
900-FB
100-A
174
:49a :58
:31
Cab harness
K4
CBFB
900 900-AA 08-2
:85
(D
:86
176
O
:8
(R
ev U T
X SP900
er -A
(D SP900
F42
se )
IN
:2
lig
178
h (U - 38-2
X110
ts PA G)
)
3
:38
) 28-2G

K8
(D
180
:1
IN
:3
(U
900-AC 09-2
:85
39-2
:86
(D PA -H
:9
(B O 3 )
)
:39
ra U T
900-FH
182
ke -
100-AE
:4
:5
coB)
ol
er
)
184
K9
900-AD 22-2
:85
:86
(D (D
(2
186
(H O U 0' IN
:22
I 0 II
or T R -J
et 30-2
I
n -C
re ) ra
ct
)
la
S10
)
:30
y (4 28-2I
188
)
0
0' (D
:01 :07
Ex IN
:03
II
te 16-2
ns -I)
io
K10
n
:16
190
) 900-FJ
100-AG
900-AE 23-2
:85
:86
(D
:10
:09
(U U
O
:23
192
PA T
/ p -D
ro )
g
lig (3
O
194
ht '/ (D
) 35 IN
I 0 II
'S -
21-2
I
(3 to S)
O p
S11
196
in
:21
'/
(D ) 28-2H
0
35 (D
900-K 06-2
:13
:14
' S IN
:01 :07
(IG OU
:03
II
N T to -
35-2
:06
SW -K p T)
198
ou
IT ) t)
:35
C 900-FI
H 100-AF
O
:10
:09
FF
K16
200
X105-A
05-2 (D
:1
O
:05
(E
202
N U (P (
G T-
R owDI
I 0 II
PMJ) er N-
:1
05-2A ) sl K 17-2
I
204
op )
e
S12
:17
) 28-2E
0
X108
(P (D
:01 :07
ow IN
:03
II
er -L 31-2
206
N3
:2
sl )
B7
:1
op
900-FC
:31
37-2 e
(D ) 900-FD
100-AA
BUZZER
:37
:10
(W OU
:09
208
ar T
ni -F
ng )
bu
z ze
210
r)
(D
IN
:2
I 0 II
(U
B8
:1
-Q 20-2
212
900-EH
PA
901-E 02-2
I
(D 2 )
)
S13
:20
BUZZER
(A O
:02
U 28-2F
0
la (D
rm T- (U I
:01 :07
X SP901-E
214
:03
II
PA N-
buG)
2 R) 34-2
zz
e )
:34
r)
900-FE
100-AB
216
:10
:09
218
:10
(D
:9
(R O
03-2 ES UT (D
:03
(J I
I 0 II
ET -H
220
ac N-
12-2
S20 Pg: (236)
P/ )
I
B ks C
up)
S18
LA
:12
M ) 28-2J
0
P (J (D
07-2 )
222
ac
:01 :07
(D IN
:03
II
ks - 13-2
:07
( R OU dw D)
EA T n
:13
R -L )
A ) 900-FK
224
U 100-AH
:10
:09
TO
/M
04-2 (D A
N
(TO W
226
:04
O UT IP
IQAN-XS2-(A1) CAB (FUSEBOX)
P - ER
A I)
U O
TO /P (
/M ) (C DI
228
A
I 0 II
ab N
S30 Pg:11 (842) S31 Pg:11 (864)
N 24-2
W Fw-E)
I
02-0A IP d
)
S19
:24
XS2-A0 Pin 27 Pg: (152) (C ER

28-2K
0
A O
(D
230
03-0A /P (C I
:01 :07
) (S
:03
XS2-A0 Pin 41 Pg: (152)

II
(C N-H ab N-
A ) pr R F) 25-2
N ea ev
0-27 de )
:25
100-A
232
(C -L)
XT2-A0 Pin 27 Pg: (312) 900-FL
A r o (D
:11
X94
N ve IN
:10
:09
0-41 100-AJ
rid -P
XT2-A0 Pin 41 Pg: (314) (C -H 33-2
:1
A ) e )
p
:12
(O
:26 :40 :27 :41
N
0
234
:33
/ri (D b )
I
-L (A (A
Address resistor
de I
) D D
0
X10C
D ke N-
R D y O 19-2
OVERIDE
-H R sw )
236
I
-L ) 28-2B
) )
CAN-bus
:19
S20
900-F 03-2
XS2-A1 PIN 03
:9
:10
:1
:14
Cab floor ground 0v
28-2C
238
14-2
01-2
R24
900-FM
2
X94
XS2-1
S21
240
Circuit Diagrams 7
203
241
204
F6
X11
20A
X10C
SP
0-28 28-B
243
Page 4
X
X
0-15 0-28A 0-28
:1
:9
:4
:16
SP
:15
:28
-BAT
0-29
+BAT
SP
245
0-42
:29
126a
:42
Pg:4 (306)
K15
+24V
X 0-42A1
247
INPUTS
Chassis Ground 0v
OUTPUTS
130 0-07
:85
:86
(D
:1
O
:7
(E U
249
7 Circuit Diagrams
ng T-
in
Pg:4 (306)
e F )
250
st
ar
tr (B
X2A
el ra (VI
ay ke N
:1
K1 Pg: (14)
)
:3
252
oi -A 0-28B
lf )
ilt 0-21
Non harness wiring Cylinder harness

:21
er
)
0-03
254
171 (D
:2
:1
O
:3
(H U
an T- S14
db B
256
ra
ke
)
so
le
no (P
258
id IL
:1
) O 0-28C
T (
Y3
:3
PR VI
ES N-
SU J)
260
0-39
R12
R
bar
:2
:39
E)
Y1
PLT
0-13G
262
24 0-04 (D
:2
:1
O
:4
264
(M U
O
:1
T-
VI
N C ( 0-28F
G ) (L VI
IF N
:3
C
A T -F
Linde engine harness Chasis harness

266
B TO )
R P
R9
0-35
bar
EV
:2
1)
:35
268
0-13C
42 0-05 (D
:5
:2
O
:1
(M U
270
O T-
Cab harness
VI
N D
G )
:1
C ( 0-28G
A
272
B
Y2
(L VI
:3
FW IF N
T -G
D TO )
) 0-36
R8
P
bar
:2
:36
2)
274
(-V
R 0-13D
EF 0-13
)
E3
276
0-13H
:13
Jacks harness
3A
ILF3
0-06 (D
:6
278
(B OU
Pg8: (636)
ra T
Pg:4(294)
ke -
ligE)
E4
ht
s)
280
X51
282
:1
:3
(L
IF
T (V
:3
B IN
O - 0-24 0-28D
TT D
284
O )
M
R10
:6
:2
bar
:24
1)
:4
286
288
:1
:7
(L
IF (V
T
:3
290
B IN 0-25 0-28E
O -
TT E
O )
R11
:2
M
bar
:2
:8
:25
292
0-17 C
2)
O
:17
(S U
T
pr (F (V
:2
:1
ea -A ue IN
0-18
294
C de ) l l -I
R rp ev ) 0-38
Pg:4(274)
(S E
:18
:38
ro el
p )
R4
pr T
N4
ea -A su
296
:1
C der +) ppl
O pr y) 120 Ω
U
:31
:1
T- op s
A 0-13B
R6
C
298
) uppl (B
R y)
Y13
ra (V
:32
ET ke IN
-A oi -H
-) lt
em )
0-37
300
:37
p)
R5
0-19 C
:1
(
O
302
M U 120 Ω
:19
ov T
:2
(+
:1
:2
in -B 0-13A
0-20 C g ) 5V
R7
R c
(M E ab R
304
:20
pr 0-12
ov T- EF
in B op )
IQAN-XT2-(A0)
:12
Pg:4 (247)
C g ca+) sup
O pl
:33
306
U b pr y)
T-
B op s
C )
126a
up
0-421a
R
Y10
pl
:5
:5
:34
ET y)
308
-B
-)
(J (V
CHASSIS LEFT
A 0-42B
C IN
310
K
1 -B
U ) 0-22
:5
P)
I
:22
0-27 (C
S54
312
XS2-A1 Pin 16 Pg: (232)

A 126D
0-41 (C N-H
XS2-A1 Pin 30 Pg: (234) A )
N (J (
A V
314
0-16 (C -L) C IN
XT2-A1 Pin 27 Pg:5 (390) K 0-42C
:10
A 2 -C
N U )
0-30 (C -H P)
XT2-A1 Pin 41 Pg:5 (390) 0-23
Address resistor
A )
316
I
:27 :41 :16 :30
N
:23
126F
S55
-L (A (A
) D D
D D
R
Chassis Ground 0v
R
318
-H -L
) )
CAN-bus
X-SPARE
Pg:5 (382)
Pg:5 (382)
:14
320
0-14
0-01
:1 R20
XT2-0

321
:15
F7
X11
20A
X10C
1-15 28-B
323
1-28
1-28A
:2
1-28
:5
Page 5
:10
:17
:28
:29
-BAT
1-29
+BAT
325
1-42
O
:42
U
TP
1-17
+24V
327
(C
INPUTS
Non harness wiring

TS
Chassis Ground 0v
:17
(L OU
ow
Y5
erT-A :1
(L
pr ) 1-28D
329
op S (V
:3
va PR IN
:2
:1
lv ES
330
1-18 (C e) -J
SU ) 1-39
S15
R R
bar
:18
(L
:2
:39
owET E)
LS
er -A
332
pr + 1-13H
op )
Chasis harness
va
l ve
)
334
:1
(P 1-28C
:2
:1
PR (V :3
1-31
336
(C ES IN
O SU -I)
:31
(li U 1-38
S16
R
bar
ft
:38
:2
T-
Cab harness
E)
pr A
P
338
op )
va 1-13G
Y6
lv (H
e) YD
1-32 (C TA

R N (V
K
340
:32
(li IN
ft ET O
pr
o -A
IL -
LE H)
p -) 1-37
1-20
:37
(C va VE
lv L )
120 Ω
342
R
R18
(E e)
:20
XT ET
:3
p -B
Y7
Jacks harness
ro
p +) 632
t
:2
344
va
lv
:2
:1
e)
1-19 1-28B
R23
(C
5 sec
:1
(E OU (-V
:19
R
346
XT T
1-13
pr -B (+ EF
op ) 5V )
:13
va
l ve R
348
) 1-12
EF
)
:12
350
:2
:1
1-33 (C (H
YD (
(R OU
:33
O VI
ET T IL N
352
pr -B TE -G
M )
op ) P 1-36
)
:36
va
Y8
l
R17
ve
) 1-12A
1-34
354
(C
:1
(R R
:34
ET ET
470 Ω
:2
pr -B 1-13J
356
op -)
°C
S17
Y4
va
lv
e)
126B 1-02
358
(P
:2
:1
:02
(P W
U M
M -A
P ) (B
:3
C O
360
O O 1-13B
N M
(V
:2
TR LE IN
O 1-21
L N -A
G )
VA
362
TH
:1
LV 1-12B
:21
1)
E ) (B
O
:6
O
R13
M
(V 1-13C
:5
364
LE IN
N -B 1-22
644 1-05 (D G )
TH
:2
:1
2)
:4
:22
:05
(P OU 1-12C
366
IL T
O -
T D
W )
D
O
)
368
x cm
(B
:1
Y9
O (V 1-13E
O
370
M
:2
IN
A
N -D
G ) 1-24
LE
:3
2)
372
1-12D
:24
(B
Y38
O
:4
R14
O (V 1-13D
:5
M I
X-SPARE
A N
N
374
G
-C 1-23
126A 1-04 LE )
(D
N5
:2
1)
:1
:6
:23
O 1-12E
:04
(J U
:08
A
C
376
K
T-
S C
U )
P)
378
x°
Pg:4 (320)
Pg:4 (320)
380
CHASSIS RIGHT
382
126B 1-06 (D 0-42A

:2
:1
O (J (V
:07
:06
(J U A
A C IN 1-25
C T K
384
K -E 1 -E
S D )
:3
) W
I
D N 126C
W
IQAN-XT2-(A1T)
S52
:25
N )
)
386
Y39
388
(V 0-42D
(J
A
:4
0-16 C IN
XT2-A0 Pin 16 Pg: (314) (C K - 1-35
2 F
A D )
W
390
0-30 N
I
:35
XT2-A0 Pin 30 Pg: (316) )

(C N-H
A ) 126F
S53
N
(C -L)
392
A
N
(C -H
Address resistor
A )
:27 :41 :26 :40
N
394
-L (A (A
X-SPARE
) D D
D D
R R
-H -L
396
) )
CAN-bus
Chassis Ground 0v
:1
:14
1-14
1-01
398
R19
400
XT2-A1
Circuit Diagrams 7
205
7 Circuit Diagrams
Page 6
24v (IQAN +) E/S :28 + 24v + 24v
+5v SP14-0 +5v
24v (BAT +) :60 X 24v (IQAN +) E/S :28
28-B
0v 0v
X
28-0C
28-B
01-0F
SP01-0A
01-0D
01-0E
28-0D
01-0C
14-0A
01-0A
28-0BA
01-0B
14-0C
28-0E
:1
14-0B
28-0B
:5 :9 :H
:1
F2
916-A
R1-A
S22 R1 R26 R3 R2
F8
X104
15 15 :C :A :2
10A S6 ILF1 R1-A
:5 :2 :1 :2 :1
3A
3A
:13 R
F 13 21 :8
bar
1
R1
N bar
28-0A
2
R31 3
4 6 1
3
R F (S25 Pg:11 (830)
XSP28-0 14 22
:A :C
1 2 3 4 S22 (S25 Pg:11 (830)
KD 53B 53 31B J F R
42-0
:B :B :3 :3
28-8
:3
:6 :1 :2 :3 :4 :7 :8 :2 :3
28-0
35-0
01-0
33-0
21-0
37-0
34-0
14-0
32-0
36-0
22-0
25-0
18-0
23-0
20-0
39-0
24-0
38-0
19-0
:42 :22 :23 :36 :37 :18
:28 :25 :39 :24 :38 :34 :35 :14 :1 :20 :19 :21 :32 :33
)
+RTC
)
2)
T)
VI IN )
D
INPUTS
1)
IN D)
2)
+BAT
(D D)M)
(DIN- )
R )
)
K )
PS
I )
)
)
PO )
T)
)
(DIN- )
T)
SE )
O (D B 1
PS )
H
)
-E
C )
C
TE
(-V EF
EF
A -F
(D -A
C )
-K
-D
L -B
-L
(D N-B
L -C
ER -N
)
-E
G O
C
G P
B
IT
C
(FIN-
E
A
PO
PO
B IN
A
IN
N -
IN
IN
IN
N -
XE IN
XE IN
EV IN
IN
LE
:4
SW
VR
VI DIN
W
E V
SE
K
(D
(D
K
(D
(V
(E (V
(E V
(D
(V
N
X102
R
A
C (
(+
(
R
S
R
(
R
(R
O
ER
(B
(B
(H
RS232
IP
(M
(M
(W
VI
RPM
B14
ER
:1
16-0
(S
Y )
:16
D
X100
H ) G ) F ) E ) D ) C ) B ) A)
TA O EA
A
:2
N1 IQAN-MDL 30-0
T- AREUT- AREUT- AREUT- ARE T- ARE T- ARE T- RE T-
)
TA -R
T
P U P U P U PA U
:30
U
- D A 32
:3
O
:3
13-0 31-0
)
(D
32 2-D S2
)
N
(S
:31
S2 23 (R
:5
I
:4 :13
B
O
27-0
)
A
(D
SPARE OUTPUTS
:27
(S
(R RS
O
(
(D
:41 C
(S
02-0
XS2-A0 PIN 26
L) H L) H) L) H)
O
:02
-
)
(D
-D -D N-C N-C -B -B -A -A
03-0 XS2-A0 PIN 40
A A A AN
:12
(S
:03
-
O
(C (C (C (C (C (C (C (C
)
(D
04-0
N N N
P
J1939 ENG / TRANS (X90)
S
(S
:26
U
:04
-
B
O
05-0
)
N
(D
J1939 ENG / TRANS (X90)
A
P
(S
:40
IQ
:05
-
06-0
O
LFM CONT (X97)
)
9
)
(D
93
:06
-
P
(S
:11
J1
U
07-0
E)
O
LFM CONT (X97)
A
R
(D
PA
:07
-
(S
:10 08-0
N
J1939 SPREADER / UPA
CAN-bus L) H)
A AN A
PE
:08
-
_O
F1 F2 F3 F4 F5
09-0
J1939 SPREADER / UPA
N
:09
-
A
C
N
9
93
J1
-BAT
:15
X-MDL
900-B
900-EI
X SP900 X SP900-E
900
900-E
Fusebox ground 0v
401 403 405 407 409 410 412 414 416 418 420 422 424 426 428 430 432 434 436 438 440 442 444 446 448 450 452 454 456 458 460 462 464 466 468 470 472 474 476 478 480
Cab harness

Circuit Diagrams 7
Page 7
N1 MDL N2 XS2-(A0) N3 XS2-(A1) N4 XT2-(A0) N5 XT2-(A1T)
(Cab) (cab front) (Cab fuse box) (Chassis LHS) (Chassis RHS)
C3 XS2 XS2 XA2 XA2
(R11) RS232 IQAN prigram / diagnostic interface plug
C1 C1 C1 C1 C1
:01
X-MDL XS2-0
:01
XS2-1 :01 XT2-0 XT2-1 :01
ADDRESS
ADDRESS
ADDRESS
ADDRESS
R21 R24 R20 R19
)
)
)
)
)
)
)
)
-H
-H
-H
-H
-L
-L
-L
-L
)
)
)
)
)
)
)
)
-H
)
)
-H
)
-L
)
-L
)
-H
-H
)
-H
-B
-H
-B
-D
-D
-A
-A
-L
-L
-C
-C
-L
-L
-H
-H
-L
-L
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
:14
N
N
N
:14 :14
A
A
A
:14
A
A
A
A
A
A
A
A
A
A
A
A
A
A
(C
(C
(C
(C
(C
(C
(C
(C
(C
(C
(C
(C
(C
(C
(C
(C
(C
(C
(C
(C
(C
(C
(C
(C
:09 :08 :07 :06 :05 :04 :03 :02 :26 :40 :27 :41 :26 :40 :27 :41 :26 :40 :16 :30 :27 :41
02-0A
03-0A
03-0
02-0
02-0A
0-41
0-30
0-16
0-30
02-0
06-0
0-16
03-0A
04-0
0-27
08-0
05-0
09-0
03-0
07-0
0-27
0-41
IQAN-BUS
J1939 Printer
:03
:01
0-27 :11 :01 0-27
X10-C
X100
IQAN-BUS
X11
SP08-0
08-0A
X IQAN-BUS IQAN-BUS IQAN-BUS
:1
:06
:02
09-0A
X 0-41 :12 :02 0-41
CAN OPEN LHC BUS
:2
SP09-0
SCREEN :C SCREEN
XXX J1939 ENGINE / TRANS BUS

R25
X90
05-0 :B 05-0
CAN 2.0B J1939 BUS
SCREEN 1 :C :C SCREEN 1
:A 04-0
04-0B
05-0B
04-0
SCREEN 1
X112
X112
J1939 ENGINE / TRANS BUS 05-0A :B :B 05-0A
X19
P10
05-0B :B :B CAN-L
04-0A :A :A 04-0A
06-0
07-0
:14 :13 04-0B :A :A CAN-H
(P10) DANA Transmission harness CAN interface plug

X97
08-0B
09-0B
:A :B DANA PRE-WIRED TRANSMISSION HARNES
X89 J1939 BUS SCREEN

GRND POINT ENGINE ECU
3 P1 (R11) RS232 Dana transmission controller prigram / diagnostic

B3 Engine ECM unit J2
J1939 Spreader
1 2 interface plug R11

6 P2
4
5
8
9
AC
B
(Connector J2) :37 SCREEN 1
7 :47 05-0A
J2
0
* :46 04-0A
Transmission controller
M
N8 LINDE LFM B4
S
(DANA SPICER TE-17)

481 483 485 487 489 490 492 494 496 498 500 502 504 506 508 510 512 514 516 518 520 522 524 526 528 530 532 534 536 538 540 542 544 546 548 550 552 554 556 558 560
Non harness wiring Linde engine harness Chasis harness Cab harness

7 Circuit Diagrams
Page 8
24v (Bat +) Isolator (30) 24v (Bat +) Isolator (30)
24v Ign + (:15)
30-1A/30-1B
24v Ign + (:15)
15-3/15-4
15-1/15-2
30-1/30-1A
24v switch illumination
15-3/15-4
:9 :7 :2
:1 :6
F41 F23 F50
F49 F22 15A 15A 10A
5A 5A
:21 :19 :14
:13 :18 Pg8: (592)
100-BC
15-32
30-16
15-31
15-21A
400
30-17A
30-17
15-21
IQAN XS2-A1 Pin 8
:15 :30 :01 :02 :09 Pg2: (90)
1 0 9 5
S23
0 I II 0 I II 0 I II 15/1 56
0 I I 0
08-2
:30 :30 K4
I 0 II
:86
K3
0 I II 0 :85
:87 :87
S24 S25
56A 56B
S25-B
900-AA
:31 :L :R :49A :49 :03 :06 :10 7 6
320-A H7 327-A
900-EC
347
400
345
X 320-C 327-C
X
49A1
49
IQAN XT2-AO Pin 6

327-B
Pg8: (616)
320-B
Pg4: (278)
:1 :4 :49
S25-B
L R
317A
317
346
II 0 I K5
346A
:12 :10
t
06-B
06-A
:11 :29 :31 :25 :27
F43 F44 F42 F47 F48 F45 F46
:8 3A 3A 1A 10A 10A 5A 5A E3 E4
S25 49A 49A
:22
919
:49A :23 :24 :30 :32 :26 :28
327
320
317L
317R
345L
346R
345R
346L
:31 :9 :9
:11 :12 :1 :2 :10 :3 :4 X10B
X10A X10B X10A X10B
:14
:12 :11 :16
:6 :7 :8 :9 :13
X4 X4 X4 X4 X4
345L
345R
327
320
347
347-A
X X X
317R
X X
317L
346L
346R
309
321
324
325
326
308
:3 :3 :2 :2
X35R
X35L H6 K3 X35L X35L
900-AB
X35L
E20 E21 E14 E15 E1 E2 B11

:86
E16 E17 E18 E19 E10 E11 E12 E13 :85
I 0 II X
900-FA
900
333/339
900-A
344
334/339
343
357
334/339
355
333/339
900-ED
Chassis Grnd 0v Chassis Ground 0v
561 563 565 567 569 570 572 574 576 578 580 582 584 586 588 590 592 594 596 598 600 602 604 606 608 610 612 614 616 618 620 622 624 626 628 630 632 634 636 638 640
Non harness wiring Chasis harness Cab harness Light harness

Circuit Diagrams 7
Page 9
24v Ign + (:15) 24v Ign + (:15)
15-1/15-2
15-3/15-4
15-3/15-4
15-3/15-4
15-3/15-4
24v switch illumination 24v switch illumination
:8 :3 :4 :5 :6
F40 F51 F52 F53 F54
5A 20A 20A 10A 20A
:20 :15 :16 :17 :18
100-BA
100-BD
100-BB
100-B
12
15-34A
15-36A
15-35A
15-33A
15-34
15-33
15-36
15-35
:05 :06 :09 :05 :06 :09 :05 :06 :09 :05 :06 :09
0 I 0 I 0 I 0 I 0 I 0 I 0 I 0 I 0 I 0 I 0 I 0 I
S26 S27 S28 S32
:01 :02 :10 :01 :02 :10 :01 :02 :10 :01 :02 :10
900-EA
900-EB
900-EE
900-E
924A
194
925
145
193
189
148
59
:1 :8 :9 :5 :6 :10 :11 :1 :1
X10A X88 X10A X10B E23:1 E23A:1
:1 :5 :7 :2 :3 :1 :2
X4 X109 X4 X4A
12-A
12
E7 E6 E8 E9 E22 E23
X SP900
X SP900
X SP900 E23:2 E23A:2 X SP900
:1 :1
900
900
900
900
901-EE
901-ED
Chassis Ground 0v
641 643 645 647 649 650 652 654 656 658 660 662 664 666 668 670 672 674 676 678 680 682 684 686 688 690 692 694 696 698 700 702 704 706 708 710 712 714 716 718 720
Non harness wiring Chasis harness Cab harness

7 Circuit Diagrams
Page 10
24v Bat + (:30) 24v Bat + (:30)
15-1/15-2
24v Ign + (:15) 24v Ign + (:15)
30-1A/30-1B
30-1A/30-1B
:3
:8 :12
F35
F24 F28 30A
5A 15A :15
:20 :24
15-13
30-18
30-27
X105
:1 :2 :3 :4 :5 :7 :6 :8
251/252
253
254
256
250
255
257
IQAN XS2-A1 Pin 22
Pg3: (186)
22-2
Pg1: (36)Aircon clutch
:30 K9
:86
:85
:87
252
251
900-AD
:1 :2 :3 :4 :5 :6 :7
X43
:1
E5
E5
329-A
329
B16
251
252
263
262
261
E5
:2 0
M
901-EB
901-C
901-B
S46 M2
X
SP901-E
SP901
X
901-E
264
Chassis Ground 0v Chassis Ground 0v
721 723 725 727 729 730 732 734 736 738 740 742 744 746 748 750 752 754 756 758 760 762 764 766 768 770 772 774 776 778 780 782 784 786 788 790 792 794 796 798 800
Non harness wiring Cab harness Heater / blower harness

Circuit Diagrams 7
Page 11
24v Bat + (:30) 24v Bat + (:30)
24v Ign + (:15) 24v Ign + (:15)
30-1A/30-1B
30-1A/30-1B
15-1/15-2
:5 :10 :11
F37 F26 F27
15A 10A 10A
:17 :22 :23
(IQAN XS2-A1)Pin 4 Pg 3 (226)
15-15
(IQAN XS2-A1)Pin 7 Pg 3 (222)
X SP15-15
04-2
15-15B
07-2
:6
15 S25-A
S25 100-AD
Pg.2 (234) 100-AC
Pg.2 (234)
04-2A
07-2A
:05 :11 :08 :05 :11 :08
0 I 0 I
+24v +24v +24v +24v
J
t t
+24v Wash/wipe o/p
+24v Wash/wipe o/p

0
1
+24v wipe o/p
+24v wipe o/p

2
2
24v wash
24v wash
1 0 J
o/p
o/p
H
0v
0v
:2
I VII S30 I VII S31
S25-B
53B 53 31B J 53C
35-0
:3 :1 :4 :7 :8 :02 :07 :03 :06 :09 :02 :07 :03 :06 :09
240
229
226
1004-A
57
58
1004
1002-A
1002
SP240
X
1003
1001
30-22
30-23
SP226
X (IQAN MDL Pin 35 Pg 6 (444)
D1
240-A R30
900-FG
900-FF
58-A D2 :87 :87a :87 :87a
X D3 X :86 :86
X
SP58
57-A K6 K7
SP34-0A
:85 :85
50
86
SP57
34-0
226-A
240-B
229
:30 :30
56
15-15A
:3 :2 :4 :6 :5
84
47
85
48
15-15C
I 86 S 31B 15
226-B
58-B
57-B
(IQAN MDL Pin 34 Pg 6 (442)

56
:3 :2 :5 X14 :2 :3 X14 :2 :3
:6 M5 M7
:2
X14 :1 :4
M6 M5 M8 M7
M4 M3
K2 M M M M
M M
31
K2
:1
900-AF
X14 X14
M4 X14 :3 :4 :1 :3 :4 :1
XSP900 :1 :3 X SP900
901-F
30-22A
30-23A
901
901-A
901-D
901-A
901-A
900
900
SP901
X SP901
X SP901
X SP901
X SP901
X X SP901
Cab floor Ground 0v Cab floor ground 0v
801 803 805 807 809 810 812 814 816 818 820 822 824 826 828 830 832 834 836 838 840 842 844 846 848 850 852 854 856 858 860 862 864 866 868 870 872 874 876 878 880
Cab harness

7 Circuit Diagrams
Page 12
24v Ign + E/stop (:45) 24v (IQAN +) E/S :45
24v Bat + (:30)
15-3/15-4
24v (BAT +) Isolator :30
30-1A/30-1B
15-3/15-4
15-3/15-4
15-1/15-2
30-2A
30-2C
30-2B
15-1/15-2
24v Ign + (:15) 24v (IGN +) Isolator :15
45-B
:4 :11 :11 :27 :25 :9 :7 :10 :29 :7 24v (BAT +) :60
F36 F15 F59 F30 F29 F25 F55 F58 F31 F39
30A 5A 1A 10A 5A 3A 3A 5A 5A 5A
Pg:2 (124)
:16 :23 :23 :28 :26 :21 :19 :22 X94 Pin 1 :30 :19
15-310
100-AK
15-411
916-B
15-17
30-31
30-29
30-21
30-30
15-37
15-14
45-6
:06 :08
0 I 0 I
S29
P7 SP08-0 P7 SP09-0
(495) (495) :4
:05 :07
:1 :2 :3
Pg:1 (26)
Pg:1 (24)
15-311
:1 :2 :3
X94 Pin 2
08-0A
09-0A
X101
11-21B
11-21
:6 :5 :1 :2
X100 :1 :2 :7 :8
B22 B25 B23

L inde
24v
B20
M B19
B26
GND
24v
B27 RADIO
GND
12v
12v
CAN-L
CAN-H
:13 :14
X97
:3
06-0
07-0
+VE
-VE
MDL Pin 6 Pg 6 (474)
MDL Pin 7 Pg 6 (474)

:4
900-G
901-EC
900-H
901-J
SP901-E SP900 SP900
X X X
B21
901-E
900
900
Cab floor ground 0v Cab floor Ground 0v
881 883 885 887 889 890 892 894 896 898 900 902 904 906 908 910 912 914 916 918 920 922 924 926 928 930 932 934 936 938 940 942 944 946 948 950 952 954 956 958 960
Non harness wiring Cab harness Options harness

Circuit Diagrams 7
Page 13
24v Bat + (:30) 24v Bat + (:30)
15-1/15-2
30-2D
24v Ign + (:15) 24v Ign + (:15)
15-3/4
:6 :31 :31
F38 F32 F60
5A 5A 5A
:18 :32 :32
15-412
15-16
:01 :09
30-28A
1010
30-28
0 I
:01 :09 S37
0 I
S35
:8
I 0
X10-C
:03 :05 :10
I 0
1005
:03 :05 :10
:1 :1
:1 :2 X113
X91 X106 X106
1005
1011
1012
:12
1010
1009
1008
:6 :7 X10-B
15-16
X10-C X10-C
:3 :4 :5
X10-C
:1
:1 :2 X103
X95 X95
:4 :5 :6
X91
:1
:03 :05 :09

B24 0 I 0 I
B28 HR FWD B29 B30
S36
:01 :10
X92
:4 :2 :3
X91
:2 :3
X10-C
:1 :2
1007
1006
H16 H17 E24

900-EF
900-EG
900-EF
999
998
SP900
X SP900
X
Chassis Ground 0v Chassis Ground 0v
961 963 965 967 969 970 972 974 976 978 980 982 984 986 988 990 992 994 996 998 1000 1002 1004 1006 1008 1010 1012 1014 1016 1018 1020 1022 1024 1026 1028 1030 1032 1034 1036 1038 1040
Non harness wiring Cab harness Options harness

7 Circuit Diagrams
Page 14
+24v Ign & E/Stop (45) +24v Ign & E/Stop (45)
24v Ign + (:15) 24v Ign + (:15)
X109 A
45-B
45-B
45-B
45-B
(CORE 16) 45-5 :16
15
:+24V E/stop (10A)
:7 :8 :9 :10 :31 (CORE 16) 45-5 :16 A&B 16 Pin Harting Socket on ELME spreader
(CORE 16) :15
(CORE 15) 45-4
:+24V E/stop (10A)
F10 F11 F12 F14 F13 (CORE 15) 45-4 :15
(CORE 15) :14
10A 10A 10A 10A 3A (CORE 14) 45-3
:+24V E/stop (10A)
(CORE 14) 45-3 :14
(CORE 14) :13
:19 :20 :21 :22 :32 16 x 1.5mm core Lapp cable
(CORE 13) 45-2
:+24V E/stop (10A)
(CORE 13) 45-2 :13 (CORE 13) :12
ELME Combi Can Bus Spreader

(CORE 12) 15-8
:+24V IGN (3A)
45-4
45-5
45-2
45-3
15-8
X88
(CORE 12) 15-8 :12
(CORE 12) H9-H11 H18-H25 :11
(CORE 11) :0V
:11
(CORE 11) (CORE 11) :10
(CORE 10) :0V
15-8 :1 (CORE 12)
:10
(CORE 10) (CORE 10) :9
(CORE 9) :0V
45-5
:7
(CORE 16) :9
(CORE 9) (CORE 9) :8
(CORE 11)
(CORE10)
900-I
(CORE 1)
(CORE 2)
(CORE 3)
(CORE 6)
(CORE 8)
G/Y
(CORE 5)
(CORE 7)
(CORE 9)
(CORE 4)
(CORE 8) :GND CAN
45-4 :6
(CORE 15) :8
(CORE 8) 900-I (CORE 8)
189 :7
(CORE 7) :Work light RH
:5
12 x 1.5mm multicore cable

45-3 (CORE 14)
(CORE 7) 189 :7
(CORE 7) :6
(CORE 6) :0V
45-2 :4 (CORE 13)
(CORE 6) :6
(CORE 6) :5
(CORE 5) 59
:2 :Work light LH
21-1
IQAN XS2-A0 Pin 21Pg2: (92) (CORE 1)
59 :5
16 x 1.5mm core Lapp cable (CORE 5) (CORE 5) :4
(CORE 4) :0V
34-1 :3
(CORE 4) :4
(CORE 4) :3
(CORE 3) 34-1 :H2 Not locked
59 :8
S26 Pin 1 Pg9: (656) (CORE 5)
34-1 :3
(CORE 3)
D 8 Pin Cannon plug (CORE 2)
(CORE 3)
:9
E 7 Pin Cannon plug :2
:H3 Seated
189 (CORE 7)
S26 Pin 2 Pg9: (662) :2
(CORE 2) :1
(CORE 1) 21-1
:H1 locked
(CORE 11)
(CORE 10)
:10
(CORE 6)
(CORE 7)
(CORE 8)
(CORE 4)
(CORE 2)
(CORE 1)
(CORE 9)
(CORE 5)
(CORE 3)
G/Y
900-I (CORE 8) GY
21-1 :1
:11
(CORE 1) (CORE 1)
GY
E :7
D
(CORE 2)/G/Y :1 :4 :6 :7 :1 :2 :3 :4 :5 :6 :8
:12 :14
B
(CORE 14)
(CORE 12)
(CORE 13)
(CORE 14)
(CORE 10)
(CORE 11)
:Legs frnt dwn
(CORE 1)
(CORE 8)
(CORE 9)
(CORE 4)
(CORE 7)
(CORE 2)
(CORE 3)
(CORE 13) :13
:Legs frnt up
(CORE 12) :12

(CORES (2/4/6/9/10/11) :Clamped RH
(CORE 11)
:11
:Clamped LH
(CORE 10)
:10
:Seated foot rear RH
:9
(CORE 9) :Seated foot front RH
4 x 1.5mm multicore cable 12 x 1.5mm multicore cable
(CORE 8)
:8
:Seated foot rear LH
X89
(CORE 7)
:7
:Seated foot front LH
F 3 Pin Deutsch
:A
2 CORE 0.5 mm twisted pair cable :A
2 CORE 0.5 mm twisted pair cable :1
C
IQAN MDL Pin 8 Pg6: (472) 08-0B :Can high (j1939)
09-0B :B :B :2
IQAN MDL Pin 9 Pg6: (472) :Can low (j1939)
F :C :3
:Screen
C 6 pin Harting plug on ELME spreader
X111
1041 1043 1045 1047 1049 1050 1052 1054 1056 1058 1060 1062 1064 1066 1068 1070 1072 1074 1076 1078 1080 1082 1084 1086 1088 1090 1092 1094 1096 1098 1100 1102 1104 1106 1108 1110 1112 1114 1116 1118 1120
Non harness wiring Cab harness

Circuit Diagrams 7
Page 15
+24v Ign & E/Stop (45) +24v Ign & E/Stop (45)
24v Ign + (:15) 24v Ign + (:15)
X109 A
45-B
45-B
45-B
45-B
(CORE 16) 45-5 :16
15
:+24V E/stop (10A)
:7 :8 :9 :10 :31 (CORE 16) 45-5 :16 A 16 Pin Harting Socket on ELME spreader
(CORE 16) :15
(CORE 15) 45-4
:+24V E/stop (10A)
F10 F11 F12 F14 F13 (CORE 15) 45-4 :15
(CORE 15) :14
10A 10A 10A 10A 3A (CORE 14) 45-3
:+24V E/stop (10A)
(CORE 14) 45-3 :14
(CORE 14) :13
:19 :20 :21 :22 :32 16 x 1.5mm core Lapp cable
(CORE 13) 45-2
:+24V E/stop (10A)
(CORE 13) 45-2 :13 (CORE 13)
15-8 :12
(CORE 12) :+24V IGN (3A)
45-4
45-5
45-2
45-3
15-8
X88
(CORE 12) 15-8 :12
(CORE 12) :11
(CORE 11) :0V
:11
(CORE 11) (CORE 11) :10
ELME Can Bus Spreader

(CORE 10) :0V
15-8 :1 (CORE 12)
:10
(CORE 10) (CORE 10) :9
(CORE 9) :0V
45-5
:7
(CORE 16) :9
900-I
(CORE 8) :GND CAN
45-4 :6
(CORE 15) :8
(CORE 8) 900-I (CORE 8)
189 :7
(CORE 1)
(CORE 2)
(CORE 3)
(CORE 4)
(CORE 7) :Work light RH
45-3 :5 (CORE 14)
(CORE 7) 189 :7
(CORE 7) :6
(CORE 6) :0V

45-2 :4 (CORE 13)
(CORE 6) :6
(CORE 6) :5
(CORE 5) 59
:2 :Work light LH
21-1
59 :5
16 x 1.5mm core Lapp cable (CORE 5) (CORE 5) :4
(CORE 4) :0V
34-1 :3
(CORE 4) :4
(CORE 4) :3
(CORE 3) 34-1 :H2 Not locked
59 :8
S26 Pin 1 Pg9: (656) (CORE 5)
34-1 :3
(CORE 2) :H3 Seated
189 :9
S26 Pin 2 Pg9: (662) (CORE 7)
:2
(CORE 2) :1
(CORE 1) 21-1
:10 :H1 locked
(CORE 2)
(CORE 1)
(CORE 3)
(CORE 4)
900-I (CORE 8) GY
(CORE 1) 21-1 :1 :0V
:11 (CORE 2)/G/Y
(CORE 1)
GY
E :1 :4 :6 :7 E 7 Pin Cannon plug
:12
(CORE 1)
(CORE 4)
(CORE 2)
(CORE 3)
(CORES (2/4/6/9/10/11)
C 6 Pin Harting Socket on ELME spreader

X89
F 3 Pin Deutsch
:A
2 CORE 0.5 mm twisted pair cable :A
2 CORE 0.5 mm twisted pair cable :1
C
IQAN MDL Pin 8 Pg6: (472) 08-0B :Can high (j1939)
09-0B :B :B :2
IQAN MDL Pin 9 Pg6: (472) :Can low (j1939)
:C
F :C :3
:Screen
C 6 pin Harting plug on ELME spreader
X111
1121 1123 1125 1127 1129 1130 1132 1134 1136 1138 1140 1142 1144 1146 1148 1150 1152 1154 1156 1158 1160 1162 1164 1166 1168 1170 1172 1174 1176 1178 1180 1182 1184 1186 1188 1190 1192 1194 1196 1198 1200
Non harness wiring Cab harness

7 Circuit Diagrams
Page 16
PAGE LEFT INTENTIONALLY BLANK
1201 1203 1205 1207 1209 1210 1212 1214 1216 1218 1220 1222 1224 1226 1228 1230 1232 1234 1236 1238 1240 1242 1244 1246 1248 1250 1252 1254 1256 1258 1260 1262 1264 1266 1268 1270 1272 1274 1276 1278 1280

Circuit Diagrams 7
Page 17

7 Circuit Diagrams
Page 18
DESCRIPTION PAGE DESCRIPTION PAGE DESCRIPTION PAGE DESCRIPTION PAGE

B3 B ENGINE ECM 1 H5 H AIR CON LP/HP FAIL 16 R1 R THROTTLE PEDAL 8 S23 S HAZARD WARNING P/B SWITCH 8
B4 B TRANSMISSION MODULE 1 H8 H MAIN BEAM INDICATOR LAMP 8 R2 R HYD BRAKE PRESSURE TRANSDUCER 6 S24 S SIDE LIGHTS / HEADLIGHTS ROCKER SWITCH 8
B7 B WARNING BUZZER 3 H7 H INDICATOR/ HAZARD WARNING LAMP 8 R3 R HYD SERVICE BRAKE PRESSURE TRANSDUCER 8 S25 S H/LIGHTS DIP.FRONT WIPER. IND.HORN STALK SWITCH 8,11
B8 B ALARM BUZZER 3 H9 H SPREADER LOCKED GREEN LAMP 2.14.15 R4 R 1200 RESISTOR 4 S26 S D
SPREADER UGHTS ROCKER SWITCH 9
B11 B REVERSE SOUNDER 8 H10 H SPREADER UN-LOCKED RED LAMP 2.14,15 R5 R 1200 RESISTOR 4 S27 S BOOM LIGHTS ROCKER SWITCH 9
E14 B EXTERNAL MODEM 6 H11 H SPREADER SEATED AMBER LAMP 2.14.15 R6 R FUEL LEVEL SENDER S28 S UGH LIGHTS ROCKER SWITCH
SIDE 9
E 18 B HORNS 10 H12 H AIR CON POWER ON LAMP 16 R7 R BRAKE TEMP SENDER S29 S HEATED SEAT ROCKER SWITCH 12
BIH B LFM CONTROLLER 12 HIS H AIR CON CLUTCH ON LAMP 16 R8 R LIFT TOP 2 PRESSURE TRANSDUCER S30 S REAR WASH WIPE SPEED SELECT SWITCH 11
E20 B 24/12V POWER CONVERTER 12 H14 H AIR CON CONDENSER ON LAMP 16 R9 R LIFT TOP 1 PRESSURE TRANSDUCER S31 S TOP WASH WIPE SPEED SELECT SWITCH 11
B21 B 24V/12V CIG LIGHTER/ POWER OUTLET 12 H15 H AIR CON TRINARY ON LAMP 16 R10 S32 S CAB ROOF LIGHTS 9
B22 B J1939 PRINTER/ UPA DEVICE 12 HI8 H CENTRAL GREASING ON LAMP 13 R11 R LIFT BOTTOM 1 PRESSURE TRANSDUCER S33 S RH DOOR SWITCH 2
B23 B RADIO H17 H CENTRAL GREASING EMPTY LAMP 13 R12 R PILOT PRESSURE TRANSDUCER S34 S LH DOOR SWITCH 2
B24 B CENTRAL GREASING UNIT 13 H13 H COMBI SPREADER LEGS FRONT DOWN LAMP 14 R13 R BOOM LEGTH SENSOR 5 S35 S STEP LIGHTNG SWITCH CAB 13
B25 B DIESEL CAB HEATER 12 H19 H COMBI SPREADER LEGS FRONT UP LAMP 14 R14 R BOOM ANGLE SENSOR 5 S36 S STEP LIGHTING SWITCH BATTERY BOXSWITCH 13
B26 B COMPRESSOR SEAT 12 H20 H COMBI SPREADER CLAMPED RH LAMP 14 R17 R 470 OHM RESISTOR 5 S37 S HEATED MIRROR SWITCH 13
B27 B HEATED SEAT 12 H21 H COMBI SPREADER CLAMPED LH LAMP 14 R18 R 120 OHM RESISTOR 5 S46 S BLOWER SPEED SELECT SWITCH 10 16.17
B28 B B ATTERY BOX RUN HOUR METER 13 H22 H COMBI SPREADER SEATED FOOT REAR RH LAMP 14 R19 R XT2-(A1T) 768 OHM ADDRESS RESISTOR 5,7 S47 S AMBIENT TEMP STAT 16
B29 B FORWARD SOUNDER 13 H23 H COMBI SPREADER SEATED FOOT FRONT RH LAMP 14 R20 R XT2-(AO) 287 OHM ADDRESS RESISTOR 4,7 S52 3 JACK 1 DOWN SENSOR 5
B30 B HEATED VIRRORS 13 H24 H COMBI SPREADER SEATED FOOT REAR LH LAMP 14 R21 R X52-(AO) 287 OHM ADDRESS RESISTOR 7 S53 S JACK 1 DOWN SENSOR 5
B31 B CONTAINER HANDLER JOYSTICK 2 H25 H COMBI SPREADER SEATED FOOT FRONT LH LAMP 14 R22 R AIR CON TEMP PROBE 6 S54 S JACK 2 UP SENSOR 4
E1 B REVERSE LIGHT L Kl K IGNITION RELAY 1 R23 R HYDOILTEMP 5 S55 S JACK 2 UP SENSOR 4
E2 E REVERSE LIGHT R 8 K2 K TIMER RELAY 11 R24 R XS2-(A1) 590 OHM ADDRESS RESISTOR 7 S56 S CH LEGS CLAMP/UNCLAMP SWITCH 2
E3 E BRAKE LIGHT L 4& 8 K3 K HEADLIGHTS RELAY 8 R25 R ENGINE ECU TERMINATING RESISTOR 120 OHM 7 S57 S CH LEGS REAR UP/DWN SWITCH 2
E4 b BRAKE LIGHT R 4& 8 K4 K REVERSE LIGHTS 3,8 R28 R BRAKE PEDAL 8 S58 S CH LEGS FRONT UP/DWN SWITCH 2
E5 E INTERIOR LIGHT 10 K5 K INDICATOR FLASHER 8 R30 R IQAN INPUT PROTECTION RESISTOR 11 Yl Y MOVING CAB FWD VALVE 4
E6 E ROTATING BEACON CAB 9 K8 K REAR WIPER R31 R IQAN INPUT PROTECTION RESISTOR 8 Y2 Y MOVING CAB REV VALVE 4
E7 E ROTATING BEACON BOOM 9 K7 K TOP WIPER R32 R IQAN INPUT PROTECTION RESISTOR 1 Y3 Y HANDBRAKE SOLENOID 4
E8 E SPREADER LIGHTS 9 K8 K BRAKE COOLER 1,3 SI S IGNITION SWITCH 1,3 Y4 Y PUMP CONTROL VALVE 5
E9 E BOOM LIGHTS 9 K9 K HORN RELAY 3,10 52 S ISOLATOR SWITCH 1 Y5 Y LOWER PROP VALVE 5
E10 E SIDE LIGHTS- FRONT L 8 K10 K UPA RELAY 1 3 S3 S COOLANT LEVEL SWITCH 1 Y8 Y LIFT PROP VALVE 5
E11 E SIDE LIGHTS REAR L 8 K15 K STARTER MOTOR RELAY 1,4 S4 S AIR INTAKE SWITCH 1 Y7 Y EXTEND PROP VALVE 5
E12 E SIDELIGHTS FRONT R 8 K1S K IGN AUTO SWITCH OFF RELAY 1,3 S5 S EMERGENCY STOP 1 Y8 Y RETRACT PROP VALVE 5
E13 E SIDE LIGHTS REAR R 8 K17 K IGNITION RELAY AIR CON BOARD (ACB) 16 SB S MOVING CAB UMIT SWITCH 8 Y9 Y PILOT WD VALVE 5
E14 E HEADLIGHTS DIPPED L 8 K13 K CLUTCH RELAY AIR CON BOARD (ACB) 16 SI S SEAT SWITCH 3 Y10 Y MOVING CAB PROP SUPPLY VALVE 4
E15 E HEADLIGHTS DIPPED R 8 K13 K CONDENSER RELAY AIR CON BOARD (ACB) 16 S8 S PARK BRAKE P/B SWITCH 3 Y13 Y SPREADER PROF SUPPLY VALVE 4
E16 E INDCATOR LIGHT FRONT R 8 K20 K TRINARY RELAY AIR CON BOARD (ACB) 16 310 S 20' RETRACT 40' EXTENSION ROCKER SWITCH 3 Y37 Y AIR CON COMPRESSSOR CLUTCH
E17 E INDICATOR LIGHT REAR R 8 M1 M STARTER M OTOR 1 311 S 301/ 35 ' STOPS IN/OUT ROCKER SWITCH 3 Y38 Y JACKS UP VALVE 5
E13 E INDICATOR LIGHT FRONT L 8 M2 M HEATER BLOWER MOTOR 10,16.17 312 5 POWER SLOPE ROCKER SWITCH 3 Y39 Y JACKS DOWN VALVE 5
E19 E INDICATOR LIGHT REAR L 8 M3 M FRONTWINDSCREEN WASH PUMP MOTOR 11 313 S UPA ROCKER SWITCH 2 3
E20 E HEADLIGHTS MAIN BEAM L 8 M4 M FRONT WIPER MOTOR 11 314 S BREAK OIL FILTER DRTY SWITCH 4
E21 E HEADLIGH S MAIN BEAM R 8 M5 M REAR WINDSCREEN WIPER MOTOR 11 315 S HYD LS PRESSURE 5
E22 E SIDE SPOT LlGHTS 9 M8 M REAR WINDSCREEN WASH PUMP MOTOR 11 316 S HYD P PRESSURE 5
E23 E CAB ROOF LIGHTS 9 M7 M TOP WIPER MOTCR 11 317 S HYD OIL TEMPERATURE 5
E24 E STEP LIGHTING 13 M8 M TOP ROOF WINDOW WASH PUMP MOTOR 11 316 S JACKS UP/DOWN ROCKER SWITCH 3
G1 G ALTERNATOR 1 M9 M BRAKE COOLER PUMP MOTOR 1 S19 S CAB FWD/REV ROCKER SWITCH 3
G2 G BATTERY 1 M30 M AIR CON CONDENSER MOTOR 1 16 320 S SPREADER RESET P/B 3
M 11 M AIR CON CONDENSER MOTOR 2 16 321 S OVERIDE KEY SWITCH 3
322 S GEAR SEL.FWD/REV .P/B STALK SWITCH 6
Inspection dim.
Auxillary dim. ( )
13.10.08 P HARLING MK5 Re-issue T10985
Date Name Date Checked Alteration Change No
Drawn
357 MK5
13.10.08 G J REES
Checked 14.10.08 P HARLING Title:
Auth'd ELECTRICAL SCHEMATIC
M.check
Scale:
Drawing number
Page:
HEAVY TRUCK DIVISION
S: 357 802 0261 18 of 19
Confidential document A:
Refer to protection notice ISO
Repl. Orig.
16016
A3

Circuit Diagrams 7
Page 19
K3 K4 K5 K6
PAGE
DESCRIPTION K2
F1 F IGN 30A TRUCK IQAN ES SUPPLY 1
F2 F ES 10A IQAN CAB MDL UINT 6 K7 K8 K9 K10
F3 F ES 15A IQAN CAB FRONT XS2-AO UNIT 2
F4 F ES 15A IQAN CAB FUSEBOX XS2-A1 UNIT 3
F5 F ES / SPARE
F6 F ES 20A IQAN CHASSIS LEFT XT2-0 UNIT 4
F7 F ES 20A IQAN CHASSIS RIGHT XT2-1 UNT 5 FC1
F8 F ES 3A EXTERNAL MODEM 6 1 2 3 4 5 6 7 8 9 10 11 12
F16
F15
F14
F10
F12
F11
F2
F7
F4
F6
F8
F3
F9 F IGN 30A ELME IQAN ES SUPPLY 1
F10 F ES 10A ELME SPREADER SUPPLY 1 14 & 15 13 14 15 16 17 18 19 20 21 22 23 24
F11 F ES 10A ELME SPREADER SUPPLY 2 14 & 15

F12 F ES 10A ELME SPREADER SUPPLY 3 14 & 15 25 F1 26 27 F5 28 29 F9 30 31 F1332
F13 F ES 10A ELME IGN SUPPLY 14 & 15
FC2
F14 F ES 10A ELME SPREADER SUPPLY 4 14 & 15 1 2 3 4 5 6 7 8 9 10 11 12
F15 F ES 5A J1939 PRINTER /UPA 12
F23
F22
F28
F24
F25
F21
F26
F19
F17
F20
F27
F18
F16 F ES / SPARE
F17 F BAT+ 5A IGNITION SWITCH 1
K1 13 14 15 16 17 18 19 20 21 22 23 24
F18 F BAT+ 10A ENGINE ECM 1 1

25 F2926 27 F3028 29 F3130 31 F3232
F19 F BAT+ 10A ENGINE ECM 2 1
F20 F BAT+ 5A TRANSMISSION 1 FC3
F21 F BAT+ 20A BRAKE COOLER MOTOR 1 1 2 3 4 5 6 7 8 9 10 11 12
F41
F39
F38
F22 F BAT+ 5A HAZARD WARNING LIGHTS 8
F44
F40
F37
F42
F35
F33
F36
F43
F34
F23 F BAT+ 15A HEADLIGHTS FLASHER 8 13 14 15 16 17 18 19 20 21 22 23 24
F24 F BAT+ 5A INTERIOR LIGHT 10
F25 F BAT+ 5A LFM BAT+ SUPPLY 12 F4628
25 F4526 27 29 F4730 31 F4832
F26 F BAT+ 10A REAR WIPER 11
F27 F BAT+ 10A TOP WIPER 11 K16 FC4
F28 F BAT+ 5A HORN SUPPLY 10 1 2 3 4 5 6 7 8 9 10 11 12
F55
F54
F60
F56
F57
F53
F58
F51
F49
F52
F59
F50
F29 F BAT+ 10A DIESEL CAB HEATER 1 12
F30 F BAT+ 10A DIESEL CAB HEATER 2 12 13 14 15 16 17 18 19 20 21 22 23 24
F31 F BAT+ 5A COMPRESSOR SEAT 12

F32 F BAT+ 5A STEP LIGHTING 12 25 F6126 27 F6228 29 F6330 31 F6432
F33 F IGN 5A TRANSMISSION 1
F34 F IGN 3A ALTERNATOR EXCITATION 1
F35 F IGN 30A HEATER BLOWER 10.16,17,18
F36 F IGN 20A 24/1 2V CONVERTER
F37 F IGN 15A FRONT WIPER/HORN DESCRIPTION PAGE
F38 F IGN 10A CENTRAL GREASING
F39 F IGN 5A RADIO K1 K IGNITION RELAY 1
F40 F IGN 5A ROTATING BEACON K2 K WIPER RELAY 11
F41 F IGN 15A SIDE LIGHTS / DIP LIGHTS K3 K HEADLIGHTS RELAY 8
F42 F IGN 1A SWITCH ILLUMINATION K4 K REVERSE LIGHTS 3&8
F43 F IGN 3A SIDE LIGHTS LEFT K5 K INDICATOR FLASHER 8
F44 F IGN 3A SIDE LIGHTS RIGHT K6 K REAR WIPER 11
F45 F IGN 5A DIP LIGHTS LEFT K7 K TOP WIPER 11
F46 F IGN 5A DIP LIGHTS RIGHT K8 K BRAKE COOLER 1&3
F47 F IGN 10A HEAD LIGHTS LEFT K9 K HORN RELAY 3 & 10 ACB
F48 F IGN 10A HEAD UGHTS RIGHT K10 K UPA RELAY 1 3
F49 F IGN 5A INDICATORS K15 K STARTER MOTOR RELAY 1&4
F50 F IGN 10A REVERSE LIGHTS / SOUNDER K16 K IGN AUTO SWITCH OFF RELAY 1&3
F51 F IGN 20A SPREADER LIGHTS K17 K IGNITION RELAY AIR CON BOARD (ACB) 16
F52 F IGN 20A BOOM LIGHTS K18 K CLUTCH RELAY AIR CON BOARD (ACB) 16
F53 F IGN 10A SIDE SPOT LIGHTS K19 K CONDENSER RELAY AIR CON BOARD (ACB) 16
F54 F IGN 20A CAB ROOF LIGHTS K20 K TRINARY RELAY AIR CON BOARD (ACB) 16
F55 F IGN 3A LFM IGN
F56 F IGN 15A RED DOT AIR CON UMT 1
F57 F IGN 15A RED DOT AIR CON UNT 2
F58 F IGN 5A HEATED SEAT
Inspection dim.
F59 F IGN 1A HEATED SEAT
F60 F IGN 5A HEATED MIRRORS Auxillary dim. ( )
13.10.08 P HARLING MK5 Re-issue T10985
F61 F IGN / SPARE Date Name Date Checked Alteration Change No
F62 F IGN / SPARE Drawn 13.10.08 G J REES
F63 F IGN / SPARE Checked14.10.08 P HARLING Title: 357 MK5
F64 F IGN / SPARE
Auth'd ELECTRICAL SCHEMATIC
M.check
Scale:
Drawing number
NONE
Page:
HEAVY TRUCK DIVISION
S: 357 802 0261 19 of 19
Confidential document A:
Refer to protection notice ISO
Repl. Orig.
16016
A3

7 Circuit Diagrams

Circuit Diagrams 7
Hydraulic Circuit Diagram
Hydraulic Circuit Diagram

Hydraulic Circuit
Page 1
225/180*2918 LWB 225/180*2918 LWB
200/160*2*272 200/180*2918 SWB 200/180*2918 SWB
MB
380bar
EXTENTION CYLINDER
170/150*7583
1.4mm
STEERING
B A
CYLINDER LIFT CYLINDER M
P
CL CR
JACKS CYL.RHS
JACKS CYL.LHS
L
100/60X380
100/60X380
0.3mm
1mm E E 1mm
0.1bar
1mm 1mm
19.7bar+0.1 MX
260bar 260bar
19.8bar+0.1
200bar
0.3mm
420bar
420bar
DN30 B1 B
LS
DN19
X
MX X
DN38 A1 A
X L A A L
110Lit/min
R R
70Lit/min
A A DN25
3bar
L L B B
0.1bar
200bar 3bar
P P pmax=210bar
L2 L1
p max
=32bar
T T xE B1 A1 E MB L
SPREADER HYDR. SCHEMATIC
SHOULD BE SUPPLIED BY
lower SPREADER MANUFACTURER
DN8
P DN6
100lit/min spreader
9lit/min pressure
B2
A2
lift
B1
A1
DN6
405bar+20 380bar+20 380bar+20
Z Z
EF retr. 110lit/min 27lit/min 110lit/min 70lit/min
DN6
max. max. max. max.
ext.
DN6
LS=210 bar
p=
LS=180bar
LS=180bar
440mA-1350mA=min.7.5bar-max.28.5bar
HT LS HP
PS 1bar
1bar
LS
OPTION
3+-0.6bar
5-1bar
310+10bar
hydraulic leak
60+6bar moving cab
spreader
DN8
xLS
X1 A
P1
xP
P2
DN25-30
T
K
LS1
DN25-30
5bar
LS2 p=34bar X DN25-30
DN38
DN30
DN8
P DN18
DN15
35bar pres.
FOR SPREADER
DUMP CYLINDER
1 3 24lit/min n=2200rpm
V=0.75 Lit
pNitr.
=15bar
19ccm 11ccm
105ccm T M B
0.5bar
T
L p=35bar
p=160bar
WDO VALVE
DN50
300mA=8.5bar DN25 3B6

10 m
P SP DN8
P R
X1 A Y
DN18 pmax= 1.5bar pmax=1.5bar DN25
LS1
7 m
DN50 Tank return spreader

LS2 p=24bar X turbo pressure of engine 1.15+0.03bar abs.
1.35bar abs.
L 1.1-2.7bar abs. 0.95bar abs.
P to brake system
10 m
10 m 10 m
2.5bar 2.5bar 1.5bar
19ccm
105ccm
from brake tank

Linde Material Handling GmbH
3578011501 EN – 2010/01/27

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Reachstacker

C4230 - C4540 TL /5,

Linde - Your Partner

Operating Instructions – 3578011501 EN – 2010/01/27 I

Operating Instructions – 3578011501 EN – 2010/01/27 III

Opening the cabin rear compartment door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

IV Operating Instructions – 3578011501 EN – 2010/01/27

Operating the horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Operating Instructions – 3578011501 EN – 2010/01/27 V

VI Operating Instructions – 3578011501 EN – 2010/01/27

Change the drive axle hub differential oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

Operating Instructions – 3578011501 EN – 2010/01/27 VII

VIII Operating Instructions – 3578011501 EN – 2010/01/27

Your Linde truck

2 Operating Instructions – 3578011501 EN – 2010/01/27

Operating Instructions – 3578011501 EN – 2010/01/27 3

4 Operating Instructions – 3578011501 EN – 2010/01/27

into a container actual load weight, maximum Steering

Operating Instructions – 3578011501 EN – 2010/01/27 5

6 Operating Instructions – 3578011501 EN – 2010/01/27

Operating Instructions – 3578011501 EN – 2010/01/27 7

Operating Procedures Summary

8 Operating Instructions – 3578011501 EN – 2010/01/27

the correct operating procedures. NEVER

WARNING ENVIRONMENT NOTE

Operating Instructions – 3578011501 EN – 2010/01/27 9

In order to avoid later complaints and incon- • Truck model:

10 Operating Instructions – 3578011501 EN – 2010/01/27

Linde Heavy Truck Division Limited

We declare that the machine

Industrial truck according to these operating instructions

complies with the most recent version of machinery directive 2006/42/EC.

Personnel authorised to compile the technical documents:

see EC declaration of conformity

Linde Heavy Truck Division Limited

Operating Instructions – 3578011501 EN – 2010/01/27 11

12 Operating Instructions – 3578011501 EN – 2010/01/27

WARNING • information related to starting, driving and

! Follow these Stay

Safety precautions WARNING

14 Operating Instructions – 3578011501 EN – 2010/01/27

Accident prevention check

NOTE The accident prevention rules in some coun-

Handling fuel, lubricants and coolant Operation of container handlers in the

CAUTION Checks prior to ﬁrst operation*

Operating Instructions – 3578011501 EN – 2010/01/27 15

• Drive motors oil volume Daily checks*

Do not operate with guards removed

Handling Fuel, Lubricants and Coolant

16 Operating Instructions – 3578011501 EN – 2010/01/27

come into contact with hot objects or naked CAUTION

Clean the area surrounding the part in ques- CAUTION

Operating Instructions – 3578011501 EN – 2010/01/27 17

• Human error, • Risk caused by insufﬁcient maintenance or

Frequency characteristic for human body vibrations

Noise emission data

18 Operating Instructions – 3578011501 EN – 2010/01/27

• While driving LPc = 75dB(A)

Operating Instructions – 3578011501 EN – 2010/01/27 19