357_en_0110

Reachstacker

Original instructions

C4230 - C4540 TL /5,C4026 - C4535 CH /53578011501 EN – 2010/01/27

Prefaceg

Linde - Your PartnerLinde, an enterprise operating worldwide inthe investment and service sector, is one ofthe large industrial enterprises in the EC withits three business segments and six divisions.

The Linde Material Handling division is a lead-ing manufacturer of industrial trucks andhydraulics. It includes eight manufacturingplants in the Federal Republic of Germany,France and Great Britain, as well as sub-sidiaries and branches in all economicallyimportant countries.

Linde industrial trucks enjoy a worldwidereputation - thanks to their high quality inengineering, performance and service.

Wishing you satisfactory operation,

Linde Heavy Truck Division LimitedLinde Industrial ParkMerthyr TydfilSouth Wales, UKCF48 4LATel: +44 (0)1443 624300Fax: +44 (0) 1443 624302

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

Table of contentsg

1 IntroductionYour 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 SafetySafety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Do not operate with guards removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Handling Fuel, Lubricants and Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Frequency characteristic for human body vibrations . . . . . . . . . . . . . . . . . . . . . . . . . . 18Frequency characteristic for human body vibrations . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Noise emission data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Noise emission data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3 OverviewGeneral view of the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

General view of the handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Gauges, switches and warning lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4 OperationMirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Cab door opening and closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Opening the engine cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Opening the transmission cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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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 MaintenanceGeneral remarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98Taking the truck out of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98Work on the boom and the front part of the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99Hoisting the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100Inspection and maintenance data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102Fuel and oil recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103Check the condition of structured components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104Truck welds inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Inspection and maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106Daily checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106As required Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10750 h Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109500 h Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1111000 h Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1142000 h Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1173000 h Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1205000 h Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1236000 h Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

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Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128Check engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128Change the engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129Change the engine oil filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130Drain the fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132Change the fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133Prime the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133Check the air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134Change the air filter element - check the vacuum switch . . . . . . . . . . . . . . . . . . . . . . . . 135Change the air filter safety element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137Check the engine mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138Clean the radiator and check for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138Check the injection nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139Check valve clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139Check the intake and exhaust systems for leaks and tightness . . . . . . . . . . . . . . . . . . . 141Check the cooling system for leaks and tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141Flush the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142Change engine coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143Check the vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145Check drive belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145Check the fan drive idler pulley assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146Fan hub, belt driven . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147Check the turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151Change the transmission oil and clean the filter screen . . . . . . . . . . . . . . . . . . . . . . . . 151Change transmission oil filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152Check transmission mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Chassis, bodywork and fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153Clean the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153Check seat belt for condition and correct operation* . . . . . . . . . . . . . . . . . . . . . . . . . . . 155Tighten wheel nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156Check the tyres for damage and foreign objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157Check the cab mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157Truck welds inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

Chassis frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160Check steer axle hub oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160Clean and lubricate steer axle, check the mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . 161Check and lubricate the drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161Check the drive axle mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162Check the drive axle centre differential oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163Check the drive axle hub differential oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

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Change the drive axle hub differential oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164Check and adjust hub bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165Check the steering lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165Check the parking brake condition andmounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166Check the brake disc wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

Electrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166Check battery condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166Check electric cables, connectors and connections for condition and tightness . . . . . . . 167

Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168Check the hydraulic system, pumps, valves and lines . . . . . . . . . . . . . . . . . . . . . . . . . 168Change the working hydraulic system oil suction filters . . . . . . . . . . . . . . . . . . . . . . . . 169Change the brake hydraulic system oil suction filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 170Change the brake hydraulic system oil pressure filter . . . . . . . . . . . . . . . . . . . . . . . . . . 172Change the brake hydraulic system oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172Change the hydraulic oil - working system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

Load lift system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176Check and lubricate boom cylinder, boom pivot and sliding bearings . . . . . . . . . . . . . . 176Lubricate slewing ring bearing and gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177Slew gearbox and brake oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178Check and lubricate the twistlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178Check and lubricate feet at the bottom of each leg . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179Change the twistlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

Special equipment, accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180Check the central lubrication* lubricating points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180Fill central lubrication* canister with grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182Troubleshooting guide Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182Troubleshooting guide hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

User manual feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185User manual improvement record. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

Annex

6 Technical DataDatasheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

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

Table of contentsg

7 Circuit DiagramsElectrical Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201Electrical Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

Hydraulic Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

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

1

Introduction

1 IntroductionYour Linde truck

Your Linde truckLinde lift trucks offer the best in economy,safety and driving convenience. Therefore itis mainly in the hands of the operator to pre-serve the qualities of the trucks for a long andprofitable service life and to make full use oftheir benefits on the job. For attachments, theproprietary operating instructions suppliedwith them are applicable. Follow all hints foroperating the lift truck and carry out the main-tenance and care prescribed in the inspectionand maintenance schedule regularly, on timeand with the specified lubricants. This manualtells you all you need to know about start-ing, running, servicing and maintaining yourlift truck. The terms “front”, “rear”, “left” and“right” refer to the position in which the itemconcerned is installed in the truck, looking for-ward in the travel direction.

Approved applications Linde lift trucks aredesigned for transporting and lifting the loadsstated in the load capacity diagram. In partic-ular, we refer to the attached VDMA booklet"Safety rules for industrial trucks" and acci-dent prevention rules of your trade associationand the special measures required for drivingon public roads in accordance with the trafficregulations. The safety rules for the use ofindustrial trucks must be followed under allcircumstances by the responsible persons,especially by the operator and service person-nel. The user, and not Linde, is responsiblefor any danger arising from applications notauthorised by the manufacturer. If you desireto use the truck for applications not mentionedin the manual and convert or supplement it forthis purpose, please first contact your autho-rised dealer. No changes, especially conver-sions or modifications, may be made on yourtruck without the prior permission of the man-ufacturer. Only qualified persons authorisedby Linde are allowed to service the trucks. Tokeep your warranty valid, keep a record of allmaintenance services.

Technical note These operating instructionsor excerpts thereof may only be copied, trans-lated or transmitted to third parties after prior

written approval by the manufacturer. Lindepursues a policy of continuous progress in thedesign and construction of its products. As aresult, the illustrations and technical detailsreferring to design, fittings and engineeringof lift trucks are subject to change if progresswarrants it. Therefore, the manufacturer willnot accept any claims based on the specifica-tions, illustrations and descriptions containedin this operating manual. Please submit allenquiries concerning your truck and all ordersfor spare parts to your authorized distributor,making sure to state your correct shippingaddress. For repairs, use only genuine Lindespare parts to ensure that your Linde truck willmaintain its original technical standard.

• Lift truck model:......................................• Serial no./year built:...............................• Handing-over date:................................

When ordering parts for the engine, mast,drive motors, drive pumps, steer axle, hy-draulic pump and transmission, also state theserial number of the assembly. When takingover the lift truck, transfer the details from theassembly type plates into this operating man-ual.

Truck takeover Every truck undergoes carefulinspection before leaving the factory in orderto make sure that it will be in satisfactorycondition and fully equipped as orderedwhen delivered to the customer. Authoriseddistributors are under obligation to re-inspectthe truck before delivery and to hand it over ingood order. In order to avoid later complaintsand inconvenience to customers, you arerequested to ascertain that the truck is insatisfactory condition and fully equippedat the time of delivery and to acknowledgeorderly handing/taking over of the truck in themanufacturer’s certificate of conformity.

The following technical documents are sup-plied with each truck:

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

Introduction 1Your Linde truck

• 1 Operating instructions• 1 EC certificate of conformity (The man-ufacturer certifies that the industrial truckconforms 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 IntroductionTechnical Description

Technical DescriptionGeneralType 357 reachstackers are designed to liftand transport containers between 20 ft and40 ft in lenght and at weights up to 45 tonnes.Maximum travel speed is 25 k.p.h. loaded,28 k.p.h. unloaded, and maximum climbinggradient is 30.9%. The handler has automaticself-levelling and sway damping, 95°/185°rotation and +/- 800 mm sideshift.

EngineThe trucks are fitted with a Cummins 11 litreliquid cooled, 6 cylinder turbocharged directinjection diesel engine which develops a ratedoutput of 250 kW maximum engine torqueis attained at 1100 rpm. The engine drawsfuel from two tanks fitted in the chassis lefthand compartment and fuel consumption isbetween 15-28 l/h (according to VDI cycle).Engine lubricating oil is filtered by a twinelement oil filter and a rotary bypass filter.

The oil cooler is of the plate type and is locatedunder a cast-iron cover on the right-hand sideof the engine block. A combined cooler forengine air, water and transmission oil is fittedin the engine compartment.

Cooling air is drawn through the radiator by theengine cooling fan and is discharged throughthe engine compartment and under the driveaxle.

TransmissionAn automatic, electronically controlled four-speed powershift transmission is driven bythe engine. Manual pre-selection of gears canalso bemade. The driving direction is selectedwith a control lever mounted on the steeringcolumn.

Transmission Disconnect (De-clutch)De-clutch is the standard transmission setting,controlled by the APC unit and is activated bydepressing the brake pedal. The transmissionoil is filtered through a twin element filter fitted

to the left hand side of the chassis in the enginecompartment.

Driving cabin, controls, switches andinstrumentsThe driving cab frame forms the load guard; itconforms to International safety standards.

The cab is fitted to a rolling platformand lockedat the rear of the chassis. (CH versions areprovided with an automated hydraulicallypowered moving cabin as standard). To gainaccess for maintenance services, it can beunlocked and moved.

Steps and a walkway on the left hand side ofthe truck are provided for normal access. Theright hand door can be used in an emergency.On CHmodels an emergency exit is situatedat the rear of the cabin.

The cab and doors have large glazed areasto allow the driver maximum visibility duringoperations. Screen wipers and washers arefitted to the front, top and rear screens withdemist functions as part of the heater systemto maintain visibility.

The boom positioning and container handlerfunctions are controlled by a central controllever mounted on the driver’s control centre.

Operational travel speed of the truck is re-stricted to 5 km/hr when: -

- the load lifted exceeds 70% of the truckcapacity at the given mast position.

- the boom is extended to 930 cms abovenormal travel position height.

System faults are indicated on the truck statusdisplay screen fitted in the cab to the rightof the operator. Working light switches aremounted in a panel fitted on the left of thesteering column at the front windscreen lowercorner.

Also indicated on the truck status displayscreen when driving is the actual gear se-lected, engine revs (selectable) and the fuellevel in litres. When the twistlocks are locked


Introduction 1Technical Description

into a container actual load weight, maximumload weight, boom angle and boom lengthare displayed. The truck status display unitalso logs all lifting and driving activities, andall error codes and fault codes along with theoperators actions when error and fault codesare displayed.

The gearchange control unit and combinedelectrical control switch are fitted on either sideof the steering column. The switches for thetop and rear windscreen wipers and washersare fitted on the driver’s control centre.

The windscreen washer reservoir is fitted tothe right rear of the cab, with access to the fillercap from the outside of the cab.

The ventilation switch and temperatureregulator is fitted to the rear right of the cab.The right rear skin panels of the cab can beremoved to allow access to the windscreenwasher reservoir.

The heater / fresh air unit is fitted behindthe rear access door. This can be pivotedoutwards to allow access for maintenance.

The fuel filler cap is located within a compart-ment in the left side of the chassis behind alockable door.

Drive AxleThe drive (load) axle is driven by the trans-mission through a propeller shaft. The axleis a double reduction type with spiral bevelprimary and hub planetary reduction gears.The half shafts are fully floating, with the hubsrunning on adjustable taper roller bearings.

Steer AxleThe steer (rear) axle is mounted on bushes,which allow sufficient wheel movementfor stability over uneven ground. Steeringmovement is provided by a double actinghydraulic cylinder, acting on fixed lengthsteering links. The steering stub axles pivoton adjustable roller bearings and the steeringlinks are fitted with spherical bearings.

SteeringThe steering is a hydrostatic power system,which operates the rear wheels with thesteering wheel via the steering cylinder. Thesteering system can also be operated whenthe engine is stopped, but a greater effort isrequired to turn the steering wheel.

Braking SystemThe truck braking system is hydraulically op-erated. It is designed as a Fail Safe systemwhich will not release unless hydraulic pres-sure in the system is correct. Audible warningof low pressure in the brake hydraulic systemis given by a buzzer fitted in the drivers caband a visual warning on the truck status dis-play unit.

The service brake is controlled by connectedfoot pedals, one fitted on either side of thesteering column.

The parking brake by an electrical push buttonfitted on the drivers control centre and isautomatically applied after the truck has beenstationary for 4 seconds.

An engine mounted oil pump draws oil from atank in the right hand chassis compartment.The oil passes through a pressure filter andis circulated through the brake chambers inthe drive axle to provide brake cooling andlubrication, with a high pressure bleed to thebrake system pressure accumulator.

The service brakes are of the oil immerseddisc type. The disc type parking brake is fittedto the drive axle differential.

The service brake is controlled by valves fitteddirectly under the service brake pedals whichare mechanically connected to each otherusing a rigid bar. The pedal control valve isconnected directly to the main brake systemcontrol valve fitted on the top of the brakesystem oil filter block on the chassis.

Transmission disconnect is activated wheneither of the brake pedals are depressed andthrottle selected.


1 IntroductionTechnical Description

Working and Steering HydraulicsThe working hydraulic and steering hydraulicsystems are supplied by a single pump andtwo pumps mounted in tandem which arefitted to the transmission.

The pumps draw oil through positive suctionfilters from a tank built into the right hand chas-sis compartment anddeliver at regulated pres-sure to the flow selection valves and steeringpriority valve. With the truck stationary and noworking or steering function selected, pres-sure in the pump control system is maintainedbetween 435 and 725 p.s.i., with all other flowsreturned to the hydraulic oil tank.

The flow selection, steering priority andhydraulic control valves for the mast andhandler are mounted under the centre enginecompartment cover on the right hand side ofthe chassis. They are operated by the centralcontrol lever, and switches mounted on thedrivers control centre and the steering handpump.

A bleed from each control valve operatesthe engine speed-up control cylinder onthe fuel injection pump. In operation thesteering system demand is given priority withthe working hydraulic functions selected asdemand requires.

When there is no steering demand all steeringpump delivery is diverted if required, to theworking system. Pressure relief valvesare fitted in all hydraulic circuits to preventoverloading.

Telescopic BoomThe telescopic boom comprises two squaresection tubes. It is raised and lowered bytwo single-acting hydraulic lift cylinders fittedbetween the chassis and the boom, and it isextended and retracted by a double actinghydraulic cylinder fitted inside the boom.

Movement of the inner boom within the outeris guided by heavy-duty main and side thrustbearing pads. The boom assembly pivots ontwo large bearings fitted to the outer section,with the head of the inner section having

bearings for the handler turntable and levellingcylinders.

The hydraulic service lines to the lift andextension cylinders have lock valves fittedto prevent sudden lowering of the boom uponloss of hydraulic pressure .

The extension cylinder is attached to the innerand outer boom sections.

Container HandlerThe container handler has a hydraulic ro-tator and a spreader beam assembly. Thehydraulic rotator is attached to the boom bybearings fitted at the turntable top plate. Twohydraulic brake drive units are fitted on theturntable top plate and both units are meshedto a slewing gear fitted on the turntable bottomplate.

The spreader beam has a centre sectionmanufactured from two square tubes in whichthe beam extensions slide. Two hydrauliccylinders for extending the beam extensionsto the container length are attached to eachbeam extension and to the centre beam.

The electrical control boxes for the beamfunctions are fitted on the top of the beam,together with the hydraulic hoses. A beamlocking hydraulic cylinder (optional on TLmodels standard on CH models), is fitted oneach end of the centre section, each cylinderhas a sliding bolt which engages in a slot at the24’ and 30’ extension positions.

The twistlock mechanisms are fitted in eachend of the cross beams. They engage in thecorner castings of the container andare lockedor unlocked with a cross shaft. When thecontainer is raised, it is suspended on thesefour twistlocks.

The positions of the twistlocks are indicatedby a three colour light display fitted under theboom head and duplicated in a repeater unitmounted on the top left-hand side of the frontcab windscreen rail.

Additionally mechanical flags are fitted to therear twistlocks to show the positions. Interlock


Introduction 1Intended use

switches cut out the boom lift function if all fourtwistlocks are not locked properly.

Electrical SystemThe truck has a 24 V DC electrical systemsupplied by the alternator. Two 12 V 143Ah heavy-duty batteries connected in seriesare fitted in the leftside chassis compartmentbeside the air filter. A battery isolator facility isincluded with safety in mind, as well as actingas an anti-theft device.

The battery isolator is located between the twolockable compartments on the left side of thechassis.

The electrical fuse box for main truck systems,is located at the rear right of the cab.

The truck is fitted with basic road lighting, in-cluding sidemarker and tail lights, headlights,stop lights and turn indicator lights, and re-verse warning buzzer. The working lights, 8chassis, 4 boom, are fitted to illuminate thearea around the truck.

Safety Systems and Shut Down DevicesThe truck safety system uses sensors fitted onthe boom, chassis and lift cylinders to detectoverload. The system gives a visual indicationof the safety state to the driver using a seriesof green, yellow and red colour lights.

When operating conditions are safe, the greenindicators illuminate.

If hazardous operating conditions are de-tected, the yellow indicators illuminate pro-gressively as the condition becomes less safe.

If unsafe operating conditions occur, the redindicators illuminate and the safety systemprevents further unsafe operation. Any furthermovement of the boom or handler is allowedonly if it gives a safe load state.

When the red indicators illuminate an audi-ble buzzer sounds within the cabin. A secondbuzzer is fitted andwill emit an audiblewarningwhen the load exceeds 75% of the truck ca-pacity. The frequency of this buzzer increasesuntil 100% of the load is reached.

These indications are also displayed on thetruck status display screen in the cab. A loadsafety status bar is displayed whenever aload is locked onto the spreader which gives avisual indication of the safety of the load.

Automatic lubrication system*The truck is fitted with an electrically operatedautomatic lubrication system which suppliesgrease to key points around the truck indicatedbelow.

Measured quantities of new grease aresupplied at regular pre-programmed timedintervals to ensure efficient operation of wearpads, bearings etc..

Indicator lights are fitted inside the drivers cabwhich inform the operator of the status of thelubrication system.

* option

Intended useLinde trucks are designed for transporting andstacking the loads stated in the load capacitydiagram. In particular;

• we refer to the VDMA Guidelines for thenormal and proper use of industrial trucks(or BITA for UK market),

• the safety rules of your trade association,

• the special measures required for driving onpublic roads in accordance with the C.U.R.,

• other local regulations.

The rules for the intended and approveduse of industrial trucks must be followedunder all circumstances by the responsiblepersons, especially by the operator andservice personnel.


1 IntroductionImproper use

The user, and not Linde, is responsible forany danger arising from applications notauthorised by the manufacturer.

If you desire to use the truck for applicationsnot mentioned in this manual, please firstcontact your authorised dealer.

No changes, particularly no modifications andadditions, may be made to the truck withoutthe approval of the manufacturer.

Improper useThe operating company or driver, and not themanufacturer, is liable if the truck is used in amanner that is not permitted.

WARNING

One of the major causes of accidents involving lifttrucks is the operator ignoring, or being unaware ofbasic safe operating practices.In order to ensure the safety of the operator andothers, a fewbasic safe operating practicesoutlinedbelow must be followed.

Never operate the truck in a potentially explo-sive atmosphere.

Never carry passengers (unless a ’buddy seat’is fitted).

Do not overload the truck beyond it’s ratedcapacity as stated on the capacity plate.

Do not carry off centre loads.

Do not turn or stack loads on a slope.

Do not operate the truck on loose or greasysurfaces.

Do not travel on uneven or obstructed ground.

Do not park the truck in front of fire extinguish-ers, emergency exits or gangways where itcan cause an obstruction.

Never alight from a moving truck.

Never leave the truck unattendedwith a raisedload.

Operating ProceduresAlways adapt your driving style to the condi-tions of the roadway, particularly hazardouswork areas and the load being transported.

Prior to, and whilst travelling, ALWAYS look inthe direction of travel.

Be aware of pedestrians, and avoid situationswhere they could become trapped betweenthe truck and a fixed object.

When approaching blind corners, alwayssound the horn.

Only use the truck and any attachments forauthorised applications.

When transporting a load, follow the directionsin the user manual.

On a ramp or incline: • Ensure the truckhas adequate ground clearance to clear thecamber • Raise the load sufficiently to clearthe camber

Travel uphill with the load leading

Travel downhill with the load trailing

When raising the load lift device, ensure thereis adequate clearance.

When working near overhead electric cables,observe the safe distance established by theresponsible authorities.

Make sure the surface on which you are trav-elling is capable of supporting the combinedweight of the truck and load.

Before leaving the operator’s driving position,always turn the ignition off and ensure the parkbrake is applied.

SummaryA safe, competent operator is one who takespride in the way they operate their truck,respects the goods they handle, and follows


Introduction 1Truck takeover

the correct operating procedures. NEVERTAKE CHANCES.

Symbols usedThe precautions Danger, Warning, Caution,Note und Environment Note in this manualare provided to indicate special hazardsor unusual information requiring specialidentification:

DANGER

indicates hazards that may result in personal injuryor death and/or substantial damage to the product.

WARNING

indicates hazards that may result in personal injuryand/or substantial damage to the product.

CAUTION

indicates hazards that may result in damage to ordestruction of the product.

NOTE

Identifies technical information requiringspecial attention because the connection maynot even be obvious to skilled personnel.

ENVIRONMENT NOTE

The information contained herein must beobserved, otherwise environmental damagemay occur.

For your safety other symbols are also used.Please note the different symbols.

CommissioningCheck the engine oil level

Check coolant level in expansion reservoir

Refuel the truck

Check the condition of the battery

Check the tyre inflation pressure

Tighten the wheel nuts

Working hydraulic system: Check the oillevel

Check the braking system

Check the steering system

Check the lifting device and attachments

Regenerate the soot filter (option)

The truck can be operated at full speed im-mediately. Avoid sustained high loads onthe working hydraulic system and transmis-sion system in the first 50 hours of operation.Re-tighten wheel nuts daily prior to startingoperation until they are seated firmly, i.e. untilno further tightening is possible.

Tighten opposite wheel nuts to a torque of680 Nm.

Truck takeoverEvery container handler undergoes carefulinspection before leaving the factory in orderto make sure that it will be in satisfactorycondition and fully equipped as ordered

when delivered to the customer. Authoriseddistributors are under obligation to reinspectthe truck before delivery and to hand it over ingood order.


1 IntroductionTruck takeover

In order to avoid later complaints and incon-venience to customers, you are requested toascertain that the truck is in satisfactory condi-tion and fully equipped at the time of deliveryand to acknowledge orderly handing/takingover of the truck in the manufacturer’s certifi-cate of conformity.

Linde pursues a policy of continuous improve-ment in the design and manufacture of itsproducts. The illustrations and technical de-tails referring to design, fittings and engineer-ing of lift trucks are subject to change or mod-ification as a result of technological progressby Linde.

Linde is therefore unable to consider anyclaims based on the specifications, illustra-tions and descriptions contained in this Oper-ating Instructions manual.

Please submit all enquiries concerning Lindecontainer handling truck orders for spare partsto your local Linde representative, makingsure to give the correct delivery address.

For repairs use only original Linde spare parts.Only in this way can it be guaranteed that yourLinde truck maintains its original technicalstandard.

These operating instructions or excerptsthereof may only be copied, translated ortransmitted to third parties after prior writtenapproval by the manufacturer.

When ordering spare parts, please specify thepart number and state the following truck data:

• Truck model:• Serial number/year of manufacture:• Hand over date:

Additionally, specify the serial number of theengine, mast, hydrostatic hydraulic pump,drive pump and drive motors when orderingparts for these assemblies.

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

This information can be found on the typeplates on the truck. We recommend that youtransfer this information to this manual forease of future reference.

The following technical documents are sup-plied with each fork truck:

• 1 Operating Instructions• 1 EC certificate of conformity (The man-ufacturer certifies that the industrial truckconforms to EC guidelines for machines)

• Safety rules for the use of industrial trucks(VDMA)

We wish you satisfactory operation.

Linde Material Handling


Introduction 1EC declaration of conformity

EC declaration of conformityThe manufacturer declares that the truckcomplies with the requirements of the ECdirectives valid at the timeofmarketing. This isconfirmed by the EC declaration of conformityand by the CE labelling on the nameplate. Seealso the following explanation.

An independent structural change or additionto the truck can compromise safety, thusinvalidating the EC declaration of conformity.

The EC declaration of conformity must becarefully stored and made available to theresponsible authorities.

Declaration

Linde Heavy Truck Division Limited

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

Linde Heavy Truck Division Limited


1 IntroductionEC declaration of conformity


2

Safety

2 SafetySafety rules

Safety rulesSafety rules

WARNING

Exercise care when operating your machine inwind velocities of 24 knots / 28 mph / 45 km h orgreater, handling characteristics may be affected,specifically, high lifting and lowering operations.Further information should be sought from themanufacturer, or local statutory authorities.

The responsible persons, particularly the truckoperator and servicing personnel, must beinstructed in the safety rules for the normaland proper use of the trucks included withthese operating instructions.

The employer must ensure that the operatorhas understood all safety information.

Please observe the guidelines and safetyrules therein for example:

• information on the operation of containerhandling trucks

• rules for roadways and work areas• rights, duties and safety rules for theoperator

• operation in special areas

• information related to starting, driving andbraking

• service and repair information• recurrent inspections, accident preventioncheck

• disposal of grease, oil and batteries• remaining risks

The operator (employer) or the responsibleperson must ensure that all the guidelinesand safety rules applicable for your truckare observed. When instructing a trainedoperator, acquaint him with the:

• special features of the truck• optional attachments• special operating and working area char-acteristics, by training and practice driving,shifting and steering operations until theyare completely mastered.

Only then start to train for stacking operations.The stability of the truck in the work is ensuredif employed properly. Should the truck tipover during unauthorised application or dueto incorrect operation, always follow theinstructions depicted below.

!WARNING

Follow these

InstructionsStay

buckled up Don't jump Hold on tight Brace feet lean away

In case of tip-over

Safety precautionsThe precautions WARNING, CAUTION, AT-TENTION and NOTE in this manual are pro-vided to indicate special dangers or unusualinformation requiring special identification:

DANGER

Indicates hazards that may result in personal injuryor death and/or substantial damage to the product

WARNING

Indicates hazards that may result in personal injuryand/or substantial damage to the product

CAUTION

Indicates hazards that may result in damage to ordestruction of the product


Safety 2Safety rules

CAUTION

This note is found on variouspositions of the truck where specialattention is required. Read theappropriate section of your operatinginstructions.

NOTE

Identifies technical information requiringspecial attention because the connection maynot even be obvious to skilled personnel.

Handling fuel, lubricants and coolantAlways handle fuel, lubricants and coolant asrequired andas specified by themanufacturer.Only store fluids and lubricants in approvedcontainers at specified storage places, as theycould be inflammable. Do not allow them tocome into contact with hot objects or nakedflame.

Only use clean containers when replenishingfluids and lubricants.

Follow the manufacturer’s safety and disposalinstructions when using fluids, lubricants andcleaning compounds. Avoid spilling fluids andlubricants.

Remove any spillage immediately with a suit-able binding agent anddisposeof as specified.Also dispose of used or contaminated fluidsand lubricants as specified.

Follow laws and regulations.

Clean the area surrounding the part in ques-tion before lubrication, filter renewal or repairsin the hydraulic system. Discard parts in anenvironmentally friendly way.

CAUTION

Medical aid is required if such an injury occurs.Do not allow hydraulic oil under pressure, forexample at a leak, to penetrate the skin.

CAUTION

Improper handling of coolant and coolant additivesputs your health and the environment at risk.Always handle fuel, lubricants and coolant asrequired and as specified by the manufacturer.

Accident prevention checkThe accident prevention rules in some coun-tries prescribe that the forklift truck must bechecked at least once a year for proper work-ing condition by trained personnel. Pleasecontact your authorised dealer in this regard.

Operation of container handlers in theplant area

WARNING

Many plant areas are so-called limited public trafficareas. We advise you to check if your companyliability insurance covers any damages occurringwith your truck against third parties on “limited”public traffic areas.

Running-in InstructionsThe truck can be operated at full speed im-mediately. Avoid sustained high loads onthe working hydraulic system and transmis-sion system in the first 50 hours of operation.Re-tighten wheel nuts daily prior to startingoperation until they are seated firmly, i.e. untilno further tightening is possible.

Tighten opposite wheel nuts to a torque of 350Nm.

NOTE

Observe the tightening instructions on the tagattached to the steering column.

Checks prior to first operation*• Coolant level in reservoir• Engine oil level• Fuel level• Working hydraulic system oil level• Tightness of wheel nuts• Tyre pressure


2 SafetySafety rules

• Drive motors oil volume• Battery terminals• Boom and spreader• Function of braking system• Function of steering system• Regenerate the soot filter (option)

Daily checks*• Coolant level in reservoir• Engine oil level• Hydraulic system oil level• Tyre pressure• Windscreen washer fluid level• Clean, check and adjust mirrors

*A description of the services can also belocated in the alphabetical index.

Do not operate with guards removed

CAUTION

Do not operate the truck with guards removedDanger of injury.

NOTE

Guards and covers are fitted to prevent injury,and should only be removed for maintenancepurposes. They should be refitted beforereturning the truck to service.

Park Brake

CAUTION

Always check that the park brake (manual andautomatic), is applied before leaving the truck.Automatic park brake - option.

MalfunctionsIn the event of a malfunction park the truck in asafe condition, lower the load and shut off theengine.

If fitted the truck override systemmay be usedto make the truck safe and in some cases a’limphome’mode is available to allow the truckto bemoved to a safe location for investigationinto the malfunction.

CAUTION

Some safety features are disabled when the over-ride function is activated. Exercise extreme cau-tion.Do not continue to operate the truck.

Handling Fuel, Lubricants and CoolantAlways handle fuel, lubricants and coolant asrequired and as specified by themanufacturer.

Only store fluids and lubricants in approvedcontainers at specified storage places, as theycould be inflammable. Do not allow them to


Safety 2Safety rules

come into contact with hot objects or nakedflame.

Only use clean containers when replenishingfluids and lubricants. Follow the manufac-turer’s safety and disposal instructions whenusing fluids, lubricants and cleaning com-pounds.

Avoid spilling fluids and lubricants. Removeany spillage immediately with a suitablebinding agent and dispose of as specified.Also dispose of used or contaminated fluidsand lubricants as specified.

Follow laws and regulations.

Clean the area surrounding the part in ques-tion before lubrication, filter renewal or repairsin the hydraulic system.

Discard parts in an environmentally friendlyway.

CAUTION

Do not allow hydraulic oil under pressure, forexample at a leak, to penetrate the skin.Medical aid is required if such an injury occurs.

CAUTION

Improper handling of coolant and coolant additivesputs your health and the environment at risk.Always handle fuel, lubricants and coolant asrequired and as specified by the manufacturer.

Accident prevention check

The accident prevention rules in some coun-tries prescribe that the forklift truck must bechecked at least once a year for proper work-ing condition by trained personnel. Pleasecontact your authorised dealer in this regard.

Operation of forklift trucks in the plant area

CAUTION

Many plant areas are so-called limited public trafficareas.We advise you to check if your company liabilityinsurance covers any damages occurring with yourfork truck against third parties on “limited” publictraffic areas.

Residual risksDespite careful working and compliance withall applicable standards and regulations, thepossibility of other dangers when using thetruck cannot be entirely excluded.

The truck and its possible attachments complywith current safety regulations. Nevertheless,even when the truck is used for its properpurpose and all instructions are followed,some residual risk cannot be excluded.

Even beyond the narrow danger areas of thetruck itself, a residual risk cannot be excluded.Persons in this area around the truck mustexercise a heightened degree of awareness,so that they can react immediately in the eventof any malfunction, incident or breakdown.

DANGER

Persons in the vicinity of the truck must be instruc-ted regarding these dangers that arise through useof the truck.These operating instructions also contain additionalsafety regulations.

Residual dangers can include:

• Escape of consumables due to leakages orthe rupture of lines, hoses or containers,

• Risk of accident when driving over difficultground such as gradients, smooth orirregular surfaces, or poor visibility,

• Risk of falling, tripping, slipping etc. whenmoving on the truck, especially in thewet, with leaking consumables or on icysurfaces,

• Risk of fire and explosion due to the batteryand electrical voltages,


2 SafetyNoise emission data

• Human error,• Disregarding the safety regulations,• Risk caused by unrepaired damage,

• Risk caused by insufficient maintenance ortesting,

• Risk caused by using the wrong consum-ables.

StabilityStability is guaranteed if your truck is usedproperly and according to its intended pur-pose. Common reasons for a loss of truckstability include:

• cornering at excessive speeds,• moving with the load raised,• moving with a load that is protruding to theside (e.g. sideshift),

• turning and driving diagonally acrossslopes,

• driving on slopes with the load on thedownhill side,

• loads that are too wide,• swinging loads,• ramp edges or steps.

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 vibrationsFrequency characteristic for human body vibrationsThe values are determined in conformancewith EN 13059 on trucks with standard equip-ment according to the technical data sheet(driving over test course with bumps).

Frequency characteristics acc. to EN 12096

Measured frequency characteristic aw, ZS =0.4 m/s² Uncertainty K = 0.1 m/s²

Frequency characteristic for hand arm vibra-tions

NOTE

The frequency characteristic for the humanbody cannot be used to determine the actualfrequency load during operation. This load de-pends on theworking conditions (conditions ofroadway, type of operation, etc) and must the-refore be determined at the site, if necessary.The specification of hand and arm vibration isrequired by law, even if the values, as in thiscase, do not indicate any danger.

Noise emission dataNoise emission dataDetermined in the test cycle according to EN12053 from the weighted data in the operatingmodes DRIVING, LIFTING, IDLE.

Noise level at the driver’s station• 357 LPAZ = 72 dB(A)• While lifting Lpa = 75 dB(A)• While Idling LPb = 61 dB(A)


Safety 2Noise emission data

• While driving LPc = 75dB(A)• Uncertainty KPA = 4 dB(A)


2 SafetyNoise emission data


3

Overview

3 OverviewGeneral view of the truck

General view of the truck

1 Lift cylinder2 Boom3 Boom extension cylinder4 Levelling cylinder5 Rotator head6 Indicator lights7 Container handler8 Transmission cover9 Drive axle10 Transmission11 Variable displacement pumps12 Engine

13 Exhaust system14 Steer axle15 Cooling system radiator16 Bonnet17 Heater / Climate control* system18 Air intake system19 Driver’s cab20 Fuse and relay box21 Battery and air filter access door22 Battery isolator23 Fuel filler access door


Overview 3General view of the handler

* option

General view of the handler1

2

34

5

67

8

910

11

1213

14

15

1 Inner boom2 Levelling cylinder3 Rotator drive motor4 Handler electrical box5 Handler centre beam6 Sideshift sliding bearings7 Sideshift cylinder8 Twistlocks

9 Extension sliding bearings10 Twistlocks guides11 Handler extension12 Hydraulic system control valves13 Rotator gearbox14 Rotator brake15 Handler mountin pin


3 OverviewControls and Indicators

Controls and Indicators

F

RN

d3571000

6

4

8

1

2 3

9

10

11

12

13

14

1516

5

7

1 Left hand display unit (LHD)2 Electronic gear shift control lever (EGS)3 Turn indicator lamp4 Steering wheel5 Multiple function electrical control lever6 Ignition key switch7 Display screen8 Central control lever (joystick)

9 Driver’s control centre (DCC)10 Parking brake switch11 Hazard warning light switch12 Emergency shutdown switch13 Emergency override key14 Heater control15 Accelerator pedal16 Service brake pedals


Overview 3Gauges, switches and warning lights

Gauges, switches and warning lights

SC

RHPLHP

1

2

1

3

2

1

2

F

R

N

d3571001

Left hand control panel (LHP)1 Left hand panel2 Headlampmain beam indicator light

Right hand control panel (RHP)1 Right hand panel

2 Truck status display

Steering column (SC)1 Electronic gear shift control lever (EGS)2 Turn indicator lamp3 Multiple function electrical control lever


3 OverviewGauges, switches and warning lights

DCC 1

345

6

7

LSSP

3

TI2

1

CHI

8

CRB 11 2 3

4

5

2

d3571002

12

1

1 1

1

Driver’s control centre (DCC)1 Central control lever (joystick)2 Twistlock switch3 Top screen wiper and washer switch4 Rear screen wiper and washer switch5 Parking brake button6 Hazard warning indicator light switch7 Emergency stop button8 Override switch

Load safety system panel (LSSP)1 Load state indicator

Twistlock indicators (TI)1 Truck status display indicator lights2 Boom indicator lights3 Flag indicators on handler

Combi-Handler indicators (CHI)1 Handler indicator lights2 Boom indicator lights

Cab rear bulkhead (CRB 1)1 Climate control unit2 Fan speed switch3&4 Temperature regulation switches5 Climate control switch


Overview 3Gauges, switches and warning lights

NOTE

A warning buzzer will sound if brake systemhydraulic pressure is low. A warning buzzerwill also sound if maximum load/position isapproached (red illuminated LED’s).


3 OverviewGauges, switches and warning lights


4

Operation

4 OperationCab door opening and closing

Mirrors

CAUTION

Rear view mirrors should be cleaned and adjustedto suit the operator before commencement ofoperation, and it should be noted that they areonly provided for checking the vicinity of the truckbefore moving off, and to monitor the rear trafficarea. Reversing is only allowed with a direct view inthe reverse direction of travel.

1

2

3

4

d3561006

Cab door opening and closingPress button (1) on handle (2) and pull thedoor.

Opening the cabin door from the insideHold handle (3) and press lever (4) andpush the door.

1

2 3

d3561007

Securing the open cabin doorOpen the cab door.

Open door fully rearward until spring loadedplunger (2) locks into retainer (3).

Cabin door - closingLift lever (1)inside the cabin, or pull downthe lever on the door retainer (3) to release(2). Pull the door outwards.

Close the door.

NOTE

Lock the cabin door with the key when leavingthe truck unattended.


Operation 4Opening the transmission cover

1 2

d3571013

Opening the engine cover

WARNING

The engine cover is raised by gas struts whichoperate as it is released. When opening, the enginecover passes close to the cab support frame withpossibility of trap injury.Do not hold the front edge of the engine cover as itrises.

Check that engine cover (1) is free fromobstruction. .

Insert key (2) and turn it fully anticlockwise

Engine cover (1) opens when released.

Closing the engine coverPull engine cover (1) down against gas strutpressure.

Insert key (2) into the lock and turn it fullyclockwise.

1

2

d3571014

Opening the transmissioncover

WARNING

The front deck cover opens forward leaving openaccess to the transmission compartment from bothsides of the truck.Danger of injury due to slips and falls.

Check that cover (1) is free fromobstruction.

Insert key (2) into the lock and turn it fullyanticlockwise.

The transmission cover opens as it isreleased.

Closing the transmission cover

Pull transmission cover (1) down againstgas strut pressure.

Insert key (2) into the lock and turn it fullyclockwise.


4 OperationOpening the working hydraulic system oil tank cover

3

2

1

4

d3561012

Opening the cabin rearcompartment doorRelease catches (1&2) on door (3).

Open the door under control until the strut(4) engages.

Closing the cabin rear compartment doorRaise door (3) to unlock strut (4) and thenlower the door to the closed position.

Push door inward until the catches (1&2)engage.

WARNING

Danger of injury due to trapped fingersTake care when closing door (2).

1

2

3

d3561013

Opening the working hydraulicsystem oil tank coverCheck that cover (1) is free fromobstruction.

Fit deck key (2) into each lock (3) and turnanticlockwise to open the lock.

Raise cover (1).

Closing the working hydraulic system oiltank coverCheck that all tank covers and fillers areclosed.

Lower cover (1).

Fit deck key (2) into lock (3) and turnclockwise to close the lock.


Operation 4Opening the battery and air filter compartment door

1

2

3

d3561014

Opening the brake hydraulicsystem oil tank coverCheck that cover (1) is free fromobstruction.

Fit deck key (2) into lock (3) and turnanticlockwise to open the lock.

Raise cover (1).

Closing the brake hydraulic system oiltank coverCheck that all tank covers and fillers areclosed.

Lower cover (1).

Fit deck key (2) into lock (3) and turnclockwise to close the lock.

1

2

d3561015

Opening the battery and airfilter compartment doorCheck that door (1) swing area is free fromobstruction.

Insert key (2) and turn it anticlockwise toopen the lock.

Pull door (1) open fully.

Closing the battery and air filter compart-ment doorCheck that door (1) swing area is free fromobstruction.

Close the door and turn key (2) clockwise toclose the lock.


4 OperationAdjusting the drivers seat

1

2

d3571015

Opening the fuse box coverThe fuse box (1) is situated inside the cabin,to the rear of the driver’s seat.

Check that fuse box door (2) lowering areais free from obstruction.

Insert key (or coin), into lock and turnanticlockwise to open the lock.

Lower the door to open.

Closing the fuse box coverCheck that door raising area is free fromobstruction.

Close door (2), insert key (or coin) into lockand turn fully clockwise.

d3561033

Adjusting the drivers seat

NOTE

Maximum driving comfort is obtained andvibrations are reduced by setting the seat tothe correct weight of the driver.

Setting the drivers weightSit on the driver’s seat.

Rotate the weight setting adjuster (1) untilthe drivers weight shows in the window.


Operation 4Adjusting the drivers seat

1

5

d3561034

Adjusting the seat positionFor a horizontal adjustment of the seat liftlever (5).

Slide the seat forward until the desiredposition to the steering wheel and pedalsis achieved.

Re-engage the lever (5).

2

3

4

d3561035

Setting the seat height

To raise the seat cushion:Raise both levers (3&4) and lift the cushionto the required height.

Re-engage the levers.

To lower the seat cushion:Raise both levers (3&4) and push thecushion down to the desired height.


Adjusting the seat cushion angleLift both levers (3&4) individually and raiseor lower the cushion to the desired angle.


Adjusting the seat backrest anglePush handle (2) forwards and set thebackrest to the desired angle.

Re-engage the handle.

NOTE

Long sitting puts excessive strain on the spinalcolumn. Prevent strain with regular, lightexercising.


4 OperationCheck battery condition

ISOLATOR

+_

1

1

d3571081

Isolating the battery

NOTE

In case of an electrical fire isolate the battery toensure any recovery work can be carried outsafely.The battery Isolator does not shut downthe engine, but isolates the truck electricallyand should be used only for maintenancepurposes or in the case of emergency.

To isolate the battery rotate isolator handle(1) fully anti clockwise.

To reconnect the battery rotate isolatorhandle (1) fully clockwise.

1

d3561023

Check battery conditionThe battery is fitted in the left hand chassiscompartment (1) with the air filter and fuelsystem water separator.

Check the battery, for cracks in the casingand leakage of electrolyte.

Remove corrosion on battery terminals andcheck the connections are tight.

Smear the terminals with non acid grease.


Operation 4Tighten wheel nuts

2

2

1

d3561019

Check tyre condition andpressure

NOTE

Low tyre pressure reduces the tyre service lifeand the stability of the truck.

Check tyres for damage or excessive wear.

Remove any foreign objects from thetreads.

Check tyres for specified pressure.

Inflate tyres according to stickers (1) on thechassis.

If necessary add air at filler valves (2), Driveaxle, two valves each side, Steer axle, onevalve each side.

Tyre Specifications - Drive and SteerAxleFront 18.00 x 25 / 40 pr 145 p.s.i.

Rear 18.00 x 25 / 40 pr 145 p.s.i.

d3561020

Tighten wheel nuts

CAUTION

On new trucks, or if a wheel has been removed andreplaced, the wheel nuts must be checked beforeuse and daily for two weeks.Check wheel nuts every 100 hours.

Torque all wheel nuts to: approx. 350 Nm.


4 OperationCheck brake hydraulic system oil level

1

2

3

d3571004

Check working hydraulicsystem oil level

CAUTION

The hydraulic oil and tank may be at workingtemperature.Danger of scalding

Fully lower the boom.

Close the spreader to the 20’ position.

Stop the engine and put the parking brakeon.

Check sight glass (3) located on the RHS ofthe truck.

If required, replenish with hydraulic oil to thehigh mark on the dipstick.

Open tank cover.

Rotate breather cap (1) until escaping air isno longer heard.

Remove filler cap (2).

Fill to upper level in sight glass (3).

Refit filler cap (2), tighten breather cap (1)and close tank cover.

23

4

d3571005

Check brake hydraulic systemoil level

CAUTION

The hydraulic oil and tank may be at workingtemperature.Danger of scalding

Fully lower and retract the boom.

Close the spreader to the 20’ position.

Stop the engine and put the parking brakeon.

Check sight glass (4) located on the LHS ofthe truck.

If required, replenish with hydraulic oil to thehigh mark on the dipstick.


Operation 4Check engine oil level

Open tank cover (2).


Fill to upper level in sight glass (4).

Refit filler cap (2) and close tank cover (2).

WARNING

The oil level must not drop below the lowmarking orthe brake may malfunction.Maintain correct oil level.

Check engine oil level

CAUTION

The bonnet opens forward leaving open accessto the engine compartment from both sides of thetruck.Danger of injury due to slips and falls.

CAUTION

The engine may be at operating temperature.Danger of scalding.

CAUTION

Follow the precautions for handling fluids andlubricants.

Park the truck on firm level ground, put theparking brake ON and stop the engine.


4 OperationFilling fuel

1

d3571018

2

3

Behind the cab, remove dipstick (2) andwipe with a clean cloth.

Fully re-insert dipstick (2) and remove itagain.

The oil level should be between the Highand LOWmarks on dipstick (2).

If necessary, unscrew filler cap (3) and fillengine oil as far as the high mark.

Insert dipstick (2), refit the filler cap.

NOTE

Filling capacity between HIGH and LOW levelmarks is approximately 5 lts.

Total filling capacity ............ approx. 35 lts.

d3571021

1

2

3

4

Checking the fuel levelTurn ignition key (1) to position II.

Check the fuel level displayed on truck sta-tus monitor (2) on the right-hand instrumentpanel (RHP).

Filling fuel

CAUTION

Stop the engine before filling fuel. No smoking ornaked lights when filling fuel.Do not spill or allow fuel to contact hot parts. Followlocal regulations for handling diesel fuel.Do not allow the fuel tank to run dry to preventdamage to the fuel system.

Turn the ignition off.


Operation 4Check the transmission oil level

d3571073

1

The fuel tank filler cap (1) located in the frontaccess panel on the left side of the truck.

d3571074

2

3

Remove fuel cap (1), (if the fuel cap islockable, rotate flap (2) and use the keyprovided in lock (3) to unlock).

Fill the tank with clean diesel fuel.

Fit the tank filler cap (1) (lock the fuel cap iffitted).

NOTE

Maximum fuel capacity - 800 L

Check the transmission oillevel

CAUTION

The engine must be running when making the oillevel check. Ensure that the truck is parked onfirm level ground with the parking brake on and thetransmission in neutral.


4 OperationCheck the transmission oil level

CAUTION

The engine and transmission will be at workingtemperature. Danger of burns and scalds.Follow the precautions for handling fluids andlubricants.

Start the engine and run it until the transmis-sion oil is at operating temperature.

Open the transmission cover.

1

2

d3571075

Remove filler cap (1) on the left handchassis wall.

Remove dipstick (2) and wipe it with a cleancloth.

Replace dipstick (2) and remove it again.

d3571076

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DA

DD

FU

LL

FU

LL

1

2

3

Check that the oil level is between the HIGHand LOWmark on the dipstick.

If necessary, replenish oil through filler cap(3), up to the high mark on dipstick (2).

Refit the dipstick

Fit the transmission filler cap.

Close the transmission cover.

NOTE

Filling capacity between HIGH and LOW levelmarks is approximately approx. 10 lts.

Total filling capacity ......... 60 lts.


Operation 4Check windscreen washer reservoir fluid level

1

d3571018

2

3

Check coolant level in headertank

CAUTION

Danger of scalding.Do not remove the header tank cap when theradiator is hot or with the engine running.

Check that coolant level is between low andhigh marks.


If required, replenish with coolant mixture.

Refit filler cap (1).

NOTE

In hot climates check the coolant level twicedaily.

1

2

d3561176

Check windscreen washerreservoir fluid level

NOTE

The windscreen washer reservoir is fittedunder a flexible cover in the cab right rear bulk-head. The reservoir should be replenishedusing a good quality washer fluid/water mixedto the fluid manufacturer’s specifications.

Lift flexible cover (1).

Open reservoir cap (2).

Fill the reservoir to the base of the filler neckwith washer fluid/water mixture.

Close reservoir cap (2).

Fit flexible cover (1).


4 OperationChecking the twistlocks and warning lights for proper operation

d3571016

4

1

1 1

1

2, 3

2, 3

123

Checking the twistlocks andwarning lights for properoperation

NOTE

A container is required for this inspection. Theoperation of the controls is described in thesection on the lifting device and handler.

Position the handler over a container andlower the twistlocks into the corner castings.

When the twistlocks are seated, yellow lights(2), and red lights (3) will illuminate on theboom twistlock indicators and on the truckstatus display screen. Indicator flags (4) onthe handler are in the “not locked” position

If the twistlocks are not correctly seated, lights(2) will flash.

Lock the twistlocks.

Yellow lights (2) will remain illuminated. Redlights (3) will extinguish, and green lights(1) will illuminate on the boom twistlockindicators and on the truck status displayscreen. 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 displayscreen will indicate which twistlock is notcorrectly locked.

Lift the handler slightly.

Yellow indicator lights (2) extinguish.

Handler and indicator lights are workingproperly.

CAUTION

Contact your authorised dealer if one of the functi-ons and indicator lights does not operate as descri-bed above.


Operation 4Normal start

Normal startNOTE

The engine is equipped with a start-stopsystem controlled by the engine oil pressure.When the engine does not reach or holdoperating pressure when starting or duringoperation, the engine is shut off. Pleasecontact your authorised dealer.

CAUTION

If this start-stop system is activated, discontinuethe starting procedure to prevent damage to theengine.

WARNING

Danger of carbon monoxide poisoning!Do not let the engine run in unventilated enclosedspaces.

CAUTION

Do not operate the starter with the engine running!This will damage the engine and starter.

1

0 I

IIIII

d3571020

Starting the engine

NOTE

The directional lever to the left of the steeringcolumnmust be in the neutral position.

Sit on the drivers seat.

Insert ignition key (1).

Turn the key clockwise to position (I). Theelectrical system is now energised, and anaudible buzzer sounds while hydraulic andengine oil pressures are checked by theECM and found to be within specifications.

The red indicator lights on the mast and inthe cabin are illuminated.

On the truck displaymonitor, enter thedriverpin code by pressing buttons A, B, C & Duntil the correct code is shown.

Press F2 to enter.


4 OperationNormal start

NOTE

Driver pin code is optional.

The truck can then be started normally.

Ensure the truck is in neutral, and that theparking brake is applied.

After the buzzer has stopped, turn thekey clockwise to position (III), the enginewarning lights illuminate.

As soon as the engine starts, release theignition key.

The engine warning lights extinguish.

NOTE

If the engine does not start after 20 seconds,wait at least 2 minutes before repeating thestarting procedure. If the engine fails to startafter the third attempt, check the fluidity ofthe diesel fuel and the battery charge levelsagainst the recommended values.

Electronic control module systemThe Cummins engine is fitted with an ad-vanced electronic monitoring and fuel injec-tion system controlled by the ECM (electroniccontrol module). This unit will indicate faults orpotential problems on display screen.

NOTE

Do not start the engine if an engine fault isdisplayed on the truck status display.

On start up all of the lights will illuminate, andextinguish after a few seconds in the orderyellow, red, blue. When a fault is detected bythe ECM the enginewill be shut downor powerwill be reduced.

There is a fault analysis procedure available -please contact your authorised Linde dealerfor further information.

CAUTION

Failure to observe the warning lights could lead toserious engine damage.


Operation 4Normal start

CAUTION

On start up, the truck must always be in neutral.If forward or reverse gears are selected beforeswitching on the ignition, start up is isolated, andthe truck cannot be started.

d3571021

1

2

3

4

Cold StartTurn ignition key to position II and hold for15 - 20 seconds.

On the truck displaymonitor, enter thedriverpin code by pressing buttons A, B, C & Duntil the correct code is shown.

Press F2 to enter.

NOTE

Driver pin code is optional.

Turn key clockwise to position (III).

As soon as the engine starts, release theaccelerator pedal and return the key toposition (II).

Release ignition key.

NOTE

Do not warm up the engine at idle speed.Always allow time for the engine to warm upbefore using maximum speed, especiallyin cold climates. The engine will attain itsoperating temperature after running brieflywith a moderate load and at various revs.

Stopping the engine

NOTE

Do not stop the engine at full speed, allow toidle for at least 3 minutes before shutting off.

Release accelerator pedal (4).

Bring the truck to a controlled stop.

Press parking brake button (3).

Shift the electronic gear shift control lever toneutral and let the engine idle for 3 minutesto achieve a temperature balance.


4 OperationTruck status display

CAUTION

With engines fitted with a turbocharger there is alsothe danger of the shaft bearing running dry andbecoming damaged due to the high speed of theturbocharger shaft (approx. 100,000 rpm at fullspeed).

Turn ignition key anticlockwise to the zeroposition.

Remove the ignition key when leaving thetruck.

CAUTION

Do not disconnect or isolate the batteries for at least3 minutes after the engine has been switched off.Danger of possible damage to the engine manage-ment system.

Truck status displayThe drive monitors purpose is to efficientlycontrol the trucks hydraulic system anddrive line by utilising both analog and digitalinformation from various sensors. This willgive the driver a complete overview of thetrucks status and activities during operation,and give a complete history of the trucksactivities. It also provides truck informationsuch 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 4Truck status display

Start-up menu

d3571023

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2 3

4

5

7

8

9

1011121314

6

16

15

1 Selected gear2 Speedometer3 Clock4 Engine menu5 Transmission menu6 Hydraulics menu7 Spreader menu8 Measure and adjustment menus9 Scroller knob10 Return key

11 F5 key. In main screen (shown) this buttonalternates automatic / manual wiper opera-tion

12 F4 key. In main menu screen resets the tripcounter

13 F3 key. In main menu screen resets the tripfuel counter

14 F2 key. In main menu screen turns enginerpmmonitor on / off

15 F1 key. In main menu screen togglesbetween first / second gear start

16 Fuel level indicator

The scroller knob



To step up/down in the menu, turn scrollerknob(8). The selected function is highlighted.Press scroller knob (8) to activate the selectedfunction.

NOTE

Menu content may vary depending on whichscreen is open.

Driver pin code (optional)When the ignition is switched on this screen isdisplayed.

Enter the driver pin code by pressingbuttons A, B, C & D until the correct codeis shown.

Press F2 to enter

The truck can then be started normally.

Main screenWhen the truck has been started the mainscreen 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

Press (F1) to toggle between first andsecond gear startup.

Press (F2) to toggle between engine rpm on/ off.

Press (F3) to reset the trip fuel.

Press (F4) to reset the trip distance.

Press (F5) to toggle between automatic /manual wiper operation.

Press (A) to open the engine menu



Press (B) to open the transmission menu

Press (C) to open the hydraulics menu

Engine menuWith 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

Thismenu screenwill be displayed for a presettime and will then return to the main screen.

Press (A) again to view truck history statis-tics.

Press (←) to return to the main screen.

Press (←) once to exit and return to themainmenu.



Transmission menuWith the main screen displayed, press (B)to go to the engine screen.


• 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

Press (←) to return to the main screen.


Hydraulics menuWith the main screen displayed, press (C)to go to the engine screen.


• gear selected• truck speed• fuel level• joystick position (X & Y axis)• hydraulic oil temperature




Spreader menuWith the main screen displayed, press (D)to go to the engine screen.


• status of the load on the spreader• status of each leg

Press (D) again to display the spreaderinformation menu.


Adjust & measure menuPress (≡) in main screen.

Press (F1) to go to sub-menu Adjust.

Press (F2) to go to sub-menuMeasure.

Press (F3) to go to sub-menu Settings.

Press (F4) to go to sub-menu Info.

Press (≡) to return to the Start-up menu.

Sub-menu AdjustPress (F1) to enter the adjust list.

Rotate scroller knob to select requiredsetting.



Press scroller knob.

Press (A) to adjust setting.

Press (←) once to return to the previousmenu, and again to return to the Adjust &measure main screen.

Sub-menu MeasurePress (≡) in main screen.

Press (F2) to go to sub-menu Measure.

Rotate scroller knob to select requiredsetting.


Press (A) to toggle between raw value andscaled value.

Press (←) once to return to the previousmenu, and again to return to the Adjust &measure main screen.



Sub-menu PreferencesPress (F3) in the Adjust & measure mainmenu.

Press (A) to set Date/time.

Press (B) to select Display settings.

Press (C) to select Language.

Press (←) to return to the previous menu.

Press (F1) to return to Adjust & measuremain menu.


Third menu Date/timePress (A) to set date.

Press (B) to set time.

Select the required value by turning thescroller knob.

Press the scroller knob to save the value.




Third menu DisplaySelect settings by pressing buttons (A - D).

Change settings by pressing the scrollerknob.

Save settings by pressing the scroller knob.






Third menu LanguageSelect the required language by turning thescroller knob.

Save settings by pressing the scroller knob.




Sub menu InfoPress (F4) in the Adjust & measure mainmenu.

Press (A) to view modules status.


Operation 4Malfunctions during operation

Press (B) to view modem information andstatus.

Press (C) to view truck logs

Rotate scroller knob to required log.

Press scroller knob to view log data.


Press (≡) to return to the main screen.

Malfunctions during operation

CAUTION

If a fault is detected and displayed on the truckstatus display screen, take necessary action toeliminate the malfunction.Do not continue to operate the truck if critical faultsare indicated.

There are four types of message, MessageAlarm, Warning and Critical.

Message

These are messages indicating faults whichmay not require immediate action, andmay berectified at the next scheduled service interval.

Warning

These are messages which should be actedupon as soon as it is safe to do so.

Alarm


4 OperationMalfunctions during operation

These are messages which must be actedupon immediately.

Critical

These are messages which indicate a faultwhichmay cause seriousmechanical damageto 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 faultcode. A full list of fault codes can be found inthe annex.

An example of a message which may notrequire immediate attention is water in fuelmessage.

When this message is shown, the operatormay decide to temporarily ignore themessage until the next scheduled serviceinterval.

An example of a warning which requiresimmediate attention is engine oil temperaturewarning.


Operation 4Malfunctions during operation

When this message is shown, immediateaction is required to rectify the fault.

An example of an alarm message whichrequires attention as soon as possible isspreader lock/unlock which indicates a hard-wire fault on the truck.

When this message is shown, action isrequired as soon as it is safe to do so torectify the fault.

An example of a critical message whichrequires immediate attention is hydraulic oilpressure difference at the lift cylinders.

When this message is shown, immediateaction is required to rectify the fault toprevent serious mechanical damage tothe truck.

CAUTION

Failure to act accordingly when warnings aredisplayed may result in serious damage.Do not continue to operate the truck if critical faultsare indicated.


4 OperationStart-up indications

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RN

1

Overload safety switchOperating overload safety switch (1) willenable the handler lowering function as longas the switch is operated so that the handlercan be lowered along with the load.

NOTE

Overload safety switch (1) may only be usedby authorised persons who can estimate andbear responsibility for the safety risk whenlowering the load. Some safety features aredisabled when the overload safety switch isactivated - exercise extreme caution.

When the Overload safety switch (1) is oper-ated, the truck display unit will also warn thedriver that this activity will be logged.

Override options are displayed.

Start-up indicationsThe load safety system has an automaticself-test function, which operates wheneverthe truck electrical system is energised. Aftera successful self-test (duration approx. 10sec), the green LEDs will illuminate.

WARNING

Contact your authorised dealer in case of defect.Do not operate the truck if the load safety systemself-test is not correct, i.e. no illumination of greenLEDs and sounding of the buzzer.


Operation 4Driving

Driving

WARNING

Exercise care when operating your machine inwind velocities of 24 knots / 28 mph or 45 km/h orgreater, handling characteristics may be affected,specifically, high lifting and lowering operations.Further information should be sought from themanufacturer, your authorised distributor, or localstatutory authorities

CAUTION

Travel on slopes over 15% is not allowed as a ruledue to the prescribed minimum brake applicationsand truck stability characteristics. Before drivingon steeper slopes you should contact your dealer.The climbing ability rates given in the data sheetwere derived from the tractive force of the truck andthey apply only for crossing obstacles and for smalldifferences in level.

Always accommodate your driving style to suitthe conditions of the roadway (rough surfacesetc.) especially hazardous work areas and theload.

CAUTION

Always look in the direction of travel and have anadequate overview of the road ahead, includingto the sides when steering. When driving, ensurethat the road ahead is clear. If goods obstructingvision are being transported, drive the truck withthe load trailing. If this is not possible, a secondperson shallwalk in front of the truckasaguide. Thetruck should then only be driven at walking speedwith particular caution being exercised. If visibilityaids are required (e.g. mirrors, camera/monitor),to ensure adequate sight, then training shouldbe given for driving with these aids. Reversingwith a mirror for example, shall be exercised withparticular care.


4 OperationGear shift control

F

R

N

1

d3561053

Gear shift controlThe gear control (APC200) is an electronicallycontrolled system which detects truck speedthrough the transmission and selects theappropriate gear for a driving condition.

The system will default to second gear start(as factory setting, first gear start is available).The anti-reverse facility prevents the trans-mission from engaging reverse direction driveuntil the truck is stopped. The operating leveris fitted to the left of the steering column andhas a dual function control lever (1), (directionand gear selector).

The control lever has threemovements, two ofwhich select the drive direction (fore / aft), withthe third selecting gears (rotate).

Selecting the travel directionForward travel

Push electronic gear shift control lever (1)forward. The transmission will shift into 2ndforward gear.

Reversing

Pull electronic control lever (1) back.

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2

3

Moving offGently depress accelerator pedal (3) toprevent jerky starting.

NOTE

The parking brake will release automatically.

The truck will move in the selected direction oftravel.

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


Operation 4Gear shift control

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F

RN

1

Slowing down and stoppingRelease accelerator pedal (2).

Operate brake pedal (3).

Controlled transmission drive dump willtake place during the depression of brakepedal (4), when accelerator pedal (3) isdepressed.

Transmission drive is re-engaged upondepression of accelerator pedal (3).

Manual 1st gear selection when stoppedTo select forward 1st gear

Push electronic gear shift control lever (5)forward.

Rotate the gear selector knob clockwise.Gear selection will be displayed on theMDM display screen.

To select reverse 1st gear

Pull electronic gear shift control lever (5) tothe rear.

Rotate the gear selector knob clockwise.Gear selection will be displayed on theMDM display screen.

Preselection of 1st gear when travelling

NOTE

1st gear can be preselected for manoeuvringand on the approach to steep gradients whentravelling.

CAUTION

Danger of incorrect transmission operation causingsevere damage.Do not hold gear change lever (5) in the rotatedposition after selecting the gear.

To preselect 1st gear

From 4th gear - Rotate gear selector lever(5) clockwise three times.

From 3rd gear - Rotate gear selector lever(5) clockwise twice.


4 OperationSteering

From 2nd gear - Rotate gear lever (5)clockwise once.

NOTE

After pre-selectionof 1st gear the transmissionwill remain in 1st gear until speed increasesabove the preset speed or until the truckis stopped and NEUTRAL is selected. Onreversion to automatic gear change, 1stgear is available only by manual selectionor pre-selection.

SteeringStart the engine and drive the truck.

Turn the steering wheel to the left and rightthrough 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 steeringwheel. This is especially beneficial when ope-rating in narrow aisles. To avoid unnecessarytyrewear, turn the steering onlywhen the truckis moving.

WARNING

Contact your authorised dealer if steering requirestoo much effort or if there is too much play in thesteering.


Operation 4Operating transmission dump

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RN

1

23

4

Stopping the truckRelease accelerator pedal (2).

Depress brake pedal (3) to slowly brake thetruck to a standstill.

Press parking brake button before releasingbrake pedal (3).

Move electronic gear shift control lever (4)to neutral.

NOTE

The transmission will automatically disengagegear when brake pedal (3) is depressed.

Lower the handler and ground any load.

Allow the engine to idle for at least 3minutesto stabilise the turbocharger, lubricating oiland coolant temperatures.

Stop the engine.

Remove ignition key (1).

Operating transmission dumpOperating either brake pedal (3) disconnectsthe transmission from the drive and appliesthe brakes in a controlled sequence.

CAUTION

Danger of damage to the transmission if engagedat high engine speed.Allow the engine to idle before releasing brakepedal (3).

NOTE

Active steering system is installed whichvaries steering resistance dependant uponthe operation of the machine.


4 OperationParking brake

F

RN

d3571039

3

1

2

Service brakeTo operate the service brake:

Release accelerator pedal (2) and allow it toreturn to its rest position.

Depress either brake pedal (3).

d3571037

2

3

Parking brakeThe parking brake button (2) for applying theparking brake ismounted in the driver’s controlcentre located to the right of the seat.

This is illuminated for low light recognition.

To release the parking brake, depressparking brake button (2). The parking brakewarning symbol in the truck display monitorwill extinguish.

To apply the parking brake manually,depress parking brake button (2) again.The parking brake warning symbol in thetruck display monitor will illuminate.

During operation, should the truck becomestationary for 4 seconds or more in neutral(no gear is selected), the parking brake willautomatically switch on.


Operation 4Truck lighting and turn indicators

To release the parking brake depressparking brake button (2). The parking brakewarning symbol in the truck display monitorwill extinguish.

During operation, should the truck becomestationary for 5 seconds or more while ingear (forward or reverse gear selected), theparking brake will automatically switch on.

To release the parking brake gently depressaccelerator pedal (3). The parking brakewarning symbol in the truck display monitorwill extinguish.

WARNING

If the braking system is becoming faulty or worn,contact your authorised dealer.Do not drive your truck with faulty brakes.

d3571019

LHP1

2

3

4

5

SC 7

F

R

N

Truck lighting and turnindicatorsLight switches (3, 4&5) are located on theleft-hand panel (1).

To illuminate the side marker lights:

Push light switch (3) to the first position.

To illuminate the side marker lights and dipbeam headlights:

Push light switch (3) to the second position.

The side marker lights and dip beam head-lights are on.

The indicator lamp in the light switch willilluminate when the side marker and dip beamheadlights are illuminated.

To illuminate theworking lights* on the handlerand boom:

Depress light switch (4) fully.

To illuminate additional working lights* :

Depress light switch (5) fully.

* option


4 OperationTruck lighting and turn indicators

O I II

6

d3561060

Turning on the main beam headlightsPush multiple function electrical lever (6)away from the steering wheel to illuminatethe main beam headlights permanently.Headlight main beam indicator light (2) willbe illuminated.

Pull multiple function electrical lever (6)towards the steering wheel to flash theheadlights.

NOTE

The main beam headlight can only be turnedon permanently when switch (3) is turned on.

O I II

6

d3561061

Turning on the turn indicator lightsFor left turn indication push the multiplefunction electrical control lever (6) on theright-hand side of the steering column up.Turn indicator warning light (7) will flash.

For right turn indication pull the multiplefunction electrical control lever (6) on theright-hand side of the steering columndown. Turn indicator warning light (7) willflash.

NOTE

To stop turn indicator lights flashing multiplefunction electrical lever must be returned to itscentral position manually.


Operation 4Operating the horn

1

2

d3561069

Operating the hazard warninglightsThe hazard warning light switch (2) is locatedin the driver’s central control panel (1).

Push button (2) to operate the hazardwarning lights.

Push button (2) again to turn the hazardwarning lights off.

NOTE

The indicator light in RHP illuminates.

O I II

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12

Operating the hornThe horn is used as a warning signal at e.g.blind corners and junctions.

To sound the horn, press horn button (2) atthe end ofmultiple function electrical controllever (1).


4 OperationTurning on the front windscreen wiper

O I II

d3561063

1 2 3

5 4

Turning on the front wind-screen wiperThe front windscreen wiper switch (3) is part ofmultiple function electrical control lever (1).

For slow wiping: Turn switch (3) from thezero position one step back to position (5).

For fast wiping: Turn switch (3) from thezero position back two steps to position (4).

For intermittent wiping turn switch (3)from the zero position one step forwardto position (2).

NOTE

The wiper motor is fitted with a thermal cut-outwhich, during operation, will switch off thewipers to prevent overheating of the motor,when the windscreen is dry.

O I II

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12

Turning on the front windscreen washerThe windscreen washer switch (2) is locatedon the end of multiple function electricalcontrol lever (1) . It is the collar surroundingthe horn button.

Push switch (2).

NOTE

The washer stops automatically when theswitch is released.


Operation 4Turning on the front windscreen wiper

1

2 3

d3561065

To operate rear screenwiper andwasherThe rear screen wiper/washer switch (2) isfitted in the drivers central control panel (1).

To operate the wiper.

Push switch (2) to the first position.

To operate the wiper and washer.

Push switch (2) all the way down and hold.

NOTE

The washer stops automatically when switchis released. The wiper continues to operateuntil the switch is returned to the startingposition.

NOTE

The wiper motor is fitted with a thermal cut-outwhich, during operation, will switch off thewipers to prevent overheating of the motor,when the windscreen is dry.

To operate top screen wiper and washerThe top screen wiper/washer switch (3) isfitted in the drivers central control panel (1).

To operate the wiper.

Push switch (3) to the first position.

To operate the wiper and washer.

Push switch (3) all the way down and hold.

NOTE

The washer stops automatically when switchis released. The wiper continues to operateuntil the switch is returned to the startingposition.


4 OperationTo operate the cab pre-heater system *

d3571023

1

2 3

4

5

7

8

9

1011121314

6

16

15

Automatic wiper functionPress button (F5) to operate automaticwipers.

When the automatic wiper function is acti-vated, the front wipers will operate at all timesunless turned off manually.

In addition, when reverse gear is selected therear wipers will operate and will stop whenreverse is de-selected.

Also, whenever the boomangle is greater thana pre-set height the top wipers will operate,and will stop when the boom is lowered belowthe pre-set height.

NOTE

Switch positions may differ.

NOTE

The wiper motors are fitted with a thermalcut-out which, during operation, will switch offthe wipers to prevent overheating of the motorwhen the windscreen is dry.

d3571084

P

1

2

34567

P

To operate the cab pre-heatersystem *The cab pre-heater (1) is fitted in the cab rearright corner. The heater operates for 120minutes (default setting).

• (1) Cab pre-heater• (2) Temperature controller (rotate to in-crease / decrease cab temperature)

• (3) Forward• (4) Backward• (5) Heating (depress to activate / deactivateheating)

• (6) Preselection• (7) Clock time

NOTE

The cab pre-heater must not be used indoors.


Operation 4To operate the cab pre-heater system *

NOTE

Always shut off the heater when refuelling thetruck.

* Option

1 2 3

4

5

d3561067

To operate climate control *

NOTE

Do not operate the system with all ventsclosed. Heating and cooling systems willoperate only while the engine is running andthe batteries are charging.

Switch the fan on and select required fanspeed by rotating switch (2).

NOTE

The indicator display (3) shows the currentcab temperature in normal operating mode.

Select temperature by depressing up/downbuttons (4), a single press increases/de-creases the temperature by one degree.

NOTE

Temperature is selectable between 5 and30°C.

When frost button (5) is selected (switchillumination changes from yellow to green),additional cooling is obtained.

NOTE

Where maximum heating effect is required,the air conditioning should be disengaged.

Adjust vents to suit.

NOTE

Maximum heating/cooling effect will be achie-ved with lower vents open.


4 OperationFuses

1

2

d3571015

Opening the fuse box coverThe fuse box (1) is situated inside the cabin,to the rear of the driver’s seat.

Check that fuse box door (2) lowering areais free from obstruction.

Insert key (or coin), into lock and turnanticlockwise to open the lock.

Lower the door to open.

Closing the fuse box coverCheck that door raising area is free fromobstruction.

Close door (2), insert key (or coin) into lockand turn fully clockwise.

1

2

d3561068

FusesThe truck and handler electrical circuits areprotected by fuses in fuse box (1) fitted behindthe cab rear compartment door.

WARNING

If fuses fail continuously, stop the truck, ground theload and stop the engine. Contact local authoriseddealer. Danger of fire and severe damage toequipment.Do not continue to operate with faulty electricalcircuits.

To check the fuses, open the cab rear com-partment door and take off fuse box covers(2).

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 4Fuses

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 OperationFuses

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 4Boom and handler controls

d3571065

DCC

1

Boom and handler controlsThe standard control for mast and handler isthe central control lever (1) (joystick).

NOTE

The symbol of the control lever movementsare shown on a label attached to the wind-screen pane to the right of the driver. Observethe 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 handlingof containers, the boom and handlerDo not operate this machine if you are not trained.

NOTE

The central control lever has been calibratedto allow 5%movement in all directions beforefunction is activated.

The central control lever (1) is mounted onthe driver’s control centre to the right of theseat. Always shift the control lever gently andslowly. The control lever returns to its initialposition automatically when released.

NOTE

When operating central control lever (1), theengine speed will increase automatically tothe power required for operating the rotation,sideshifting and telescoping the handler.

Operating accelerator pedal for higher speedsdoes not have any effect on the speed ofthese work cycles. Central control lever (1)is provided for lifting and lowering, rotatingand slewing the handler.


4 OperationBoom and handler controls

d3571066

DCC

1

To lift the boomPull central control lever (1) back.

To lower the boomPush central control lever (1) forward.

d3571067

DCC

1

To extend the boomPush central control lever (1) to the right.

To retract the boomPush central control lever (1) to the left.


Operation 4Boom and handler controls

d3571068

1

2

3

Operating the sideshift

CAUTION

Do not operate the sideshift with a container in thehandler and the container grounded.Danger of severe damage to the equipment.

If necessary, raise the load slightly.

NOTE

The handler beam centre line is indicated by awhite fluorescent marking on the REAR face.When the beam is central, the line coincideswith a white fluorescent centring mark on therear face of the rotator.

To sideshift left

Press and hold (2) on central control lever (1).

To sideshift right

Press and hold (3) on central control lever (1).

d3571069

1

4

Rotating the handler

CAUTION

A foul condition can occur between the truck,load and handler, while rotating the handler. Thiscondition can occur with or without load. ALWAYSobserve the load and handler while rotating thehandler.Do not slew the handler if fouling of the load canoccur. Danger of severe damage to the handler.

Rotating the handler clockwise

Press and hold the left side of button (4) oncentral control lever (1).

Rotating the handler anticlockwise

Press and hold the right side of button (4) oncentral control lever (1).

NOTE

The front face of the handler is identified byyellow and black high visibility markings on thesideshift bearing mountings. The rear face ofthe handler is identified by white fluorescentmarkings and the beam sideshift centringmarks.


4 OperationBefore lifting a load

Operating the spreaderOperating the spreaderThe beam spreader opens and closes to 20 ftand 40 ft for standard containers.

Setting the spreader to container width 40 ft

d3571070

1

5

6

78

9

Press and hold button (5) on central controllever (1).

Setting the spreader to container width 20 ft

Press and hold button (7) on central controllever (1).

Twistlock autolock*

* option

To operate twistlock autolock, depressbutton (6).

Vertical lift*

* option

To operate vertical lift, depress button (8)and pull back central control lever (1).

Power pump lock*

* option

To operate power pump lock, depressbutton (9).

Machine Serial Number CC

000.000.00.00

Before lifting a load

WARNING

Exercise care when operating your machine inwind velocities of 24 knots / 28 mph or 45 km / h orgreater, handling characteristics may be affected,specifically, high lifting and lowering operations.Further information should be sought from themanufacturer, your authorised distributor, or localstatutory authorities.

Before lifting a load, check the load capacitydiagram.

The load table can also be viewed on the truckstatus display unit.


Operation 4Before lifting a load

In the main screen, press (≡).

Press F4 (info).

Rotate scroller knob until load table ishighlighted.



4 OperationPicking up a container

Press scroller knob to view load tableinformation.

To return to themain screen, press (←) threetimes.

WARNING

The values stated on the load capacity diagram andthe handler apply for the standard containers andtowed loads.These values must not be exceeded as this willreduce the stability of the truck and the strength ofthe handler.

NOTE

Maximum capacity is governed by the heightof lift and the load centre distance.

Picking up a containerPicking up a container TL model

WARNING

Do not attempt to lift a load or continue to lift if thetwistlocks do not seat and lock correctly.

WARNING

No person is allowed to stand underneath theelevated load.

d3571016

4

1

1 1

1

2, 3

2, 3

123

The twistlocks must be unlocked and redindicator lamps (3)must be illuminated.

Approach the container to be lifted ascarefully and accurately as possible.

Raise and extend the mast sufficiently toallow the handler to clear the load andintervening stacks.


Operation 4Picking up a container

40'

20'

A

d3571053

Stop the truck centred and as close aspossible to the container.

NOTE

After a period of approx 5 seconds * theparking brake is applied, and the directioncontrol lever shifts to the neutral positionautomatically. In this condition, lift speed isregulated by throttle.

d3571054

Lower the handler over the container usingthe sideshift, slew, outreach and inreachand mast for final positioning.

NOTE

The levelling system will automatically setthe handler with a 5° tilt up. As the handleris lowered on the container, the levellingcylinders reset allowing the twistlocks to enterinto the front container pockets first.

Lock the twistlocks.

Elevate the boom until the container is clearof 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 iswithin a stack.

Release the parking brake.

Move the truck and rotate the load asnecessary until it is free of obstructions.



d3571055

Raise or lower the load to travelling height.

Picking up a container CHmodel

WARNING

Do not attempt to lift a load or continue to lift if thelegs do not seat and lock correctly.

WARNING

No person is allowed to stand underneath theelevated load.

WARNING

When operated, legs must not foul the truck orground.

d3571016

4

1

1 1

1

2, 3

2, 3

123

The twistlocks must be unlocked and redindicator lamps (3)must be illuminated.

Approach the container to be lifted ascarefully and accurately as possible.

Raise and extend the mast sufficiently toallow the handler to clear the load andintervening stacks.


Operation 4Picking up a container

40'

20'

A

d3571053

Stop the truck centred and as close aspossible to the container.

NOTE


If necessary move the cab so that the backlegs can be observed.

Position the legs in front of the load usingboom raise/lower and extend/retract con-trols.

d3571056

12

34

5 6

For sloping trailers, use slope pyle* tocompensate, (* option).

NOTE

The levelling system will automatically setthe handler with a 5° tilt up. As the handleris lowered on the container, the levellingcylinders reset allowing the twistlocks to enterinto the front container pockets first.

NOTE

When the container handler legs are activatedthe handler is set horizontal automatically.



d3571078

1

CHI

2

3

4

5

6

Lower the front legs. Indicators (2 & 4)illuminate, and indicator (6) extinguishes.

NOTE

Indicator (5)will flash while legs are in motion.

Lower the back legs. Indicators (1 & 3)illuminate.

NOTE

When all legs are lowered, indicator (5)illuminates.

Clamp the legs. The load status is indicatedon the truck status display screen.

Raise the load slightly, indicators (1,2,3,& 4) illuminate to indicate that all legs areseated correctly.

CAUTION

The load being lifted my be unevenly balanced, inthis case use the sideshift to stabilise the load.Reposition the truck where the unbalanced load iswithin a stack.

Elevate the boom until the container is clearof the ground or transport vehicle.

Release the parking brake.

Move the truck and rotate the load asnecessary until it is free of obstructions.


Operation 4Travelling with loads

d3571055

Raise or lower the load to travelling height.

Automatic parking brake operationWhen stationary, with the footbrake appliedand in gear, following a period of 5 seconds*,the handbrake will engage and neutral will beselected automatically.

NOTE

During this time the working hydraulics speedis regulated by the throttle pedal.

Upon gear selection (forward/reverse), enginerevs falling below 950 r.p.m, and activation ofthe throttle pedal thehandbrakewill disengageand selected travel direction will commence.

(* variable 0.5 - 5 seconds)

d3571062

Travelling with loads

WARNING

Do not stand underneath an elevated load.


4 OperationTravelling with loads

d3571060

Travel with the container centred (nosideshift).

d3571055

Transport the load as low as possible whilstmaintaining forward visibility.

NOTE

If the travel lift height is exceeded, truck speedwill be automatically reduced to 3 m.p.h. (5kph). Lower the load to the travel height toreturn to normal truck speed.

CAUTION

Always look in the direction of travel and have anadequate overview of the road ahead, includingto the sides when steering. When driving, ensurethat the road ahead is clear. If goods obstructingvision are being transported, drive the truck withthe load trailing. If this is not possible, a secondpersonshall walk in front of the truckasaguide. Thetruck should then only be driven at walking speedwith particular caution being exercised. If visibilityaids are required (e.g. mirrors, camera/monitor),to ensure adequate sight, then training shouldbe given for driving with these aids. Reversingwith a mirror for example, shall be exercised withparticular care.


Operation 4Depositing the load

d3571062

Depositing the load

WARNING

Do not stand underneath an elevated load.

d3571063

Approach the stack or device receivingthe load as carefully and as accurately aspossible.

Lift the handler to the correct height.

Carefully move into the stack.

NOTE



4 OperationDepositing the load

d3571064

Lower the load onto the stack using thesideshift and rotate for final positioning.

TL model

Slowly lower the handler until the twistlocksare loose in the load and the yellow indicatorlamps are illuminated in addition to thegreen indicator lamps.

Unlock the twistlocks. The yellow and redlampswill illuminate and no flags are visible.

NOTE

For sloping trailers use Slope pyle * to com-pensate (* option).

Lift the handler up out of the corner castings.

The yellow lamps extinguish, the red lampscontinue to illuminate and no flags arevisible.

CH model

Slowly lower the handler until the legs areno longer seated. Indicators (1,2,3, & 4) willextinguish.

Unclamp the legs.

Raise the front legs. Indicators (2 & 4)extinguish.

Raise the back legs indicators (1 & 3)extinguish.

Select reverse gear.

NOTE

Selection of reverse gear will automaticallyrelease the parking brake as soon as theaccelerator pedal is pressed.

Reverse the truck away from the stack.

Lower the handler to driving height.

WARNING

Do not leave the truck unattended with the loadelevated.


Operation 4Trailer coupling

Parking the truckLower the boom and ground the load.

Apply the parking brake.

NOTE

The parking brake will be applied automati-cally if neutral is selected and after the truckhas been stationary for approx 5 seconds.

Stop the engine and remove the ignition keyfrom the key switch.

Lock the cabin door and remove the doorkey.

NOTE

When parking the CH model, take care notto damage the front and rear legs on thecontainer handler.

1

d3561088

Trailer coupling

NOTE

The trailer coupling should be used only fortowing light trailers inside the plant workingarea (refer to the technical data for nominaltowing capacity).

Lift tow pin (1).

Place the tow bar in coupling recess in thelower retaining hole.

Push tow pin (1) down to engage thedrawbar.


4 OperationWheel change

1 2 3 4 5 6

d3181051

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 wheelDrive axle outer wheels:

Remove wheel nuts (6) and lugs (5).

Release the outer wedge band (4) fromwheel (3) by striking the rim using a hammerand drift.

Remove wheel.

Drive axle inner wheels:

Release the inner wedge band (2) from thehub.

Remove wheel (1) from hub.

Steer axle wheels

Remove the wheel nuts and lugs.

Remove the wheel.

Wheel mounting

CAUTION

When awheel has been removed and replaced, thewheel nuts must be checked before use and dailyfor two weeks.

Drive axle inner wheels:

Fit wheel (1) to the hub. Ensure that thetyre inflation valve extension is positionedcorrectly in the hub cutaway.

Fit centre wedge band (2).

Drive axle outer wheels:

Fit wheel (3). Ensure the tyre inflation valveis correctly located in the hub cutaway.

Fit outer wedge band (4).


Operation 4Towing

NOTE

Tighten opposite wheel nuts sequentiallyspanner tight then torque to the correct torquesetting.

Fit wheel lugs (5) and nuts (6).

Tighten the nuts.

Steer axle wheels:

Fit the wheel.

Fit the wheel lugs and nuts Tighten the nuts.

NOTE

The steer axle wheels fit directly to the hub.Wheel nut torque = 680 Nm.

Inflate tyres to 10 bar (145 psi)

TowingIf the truck must be towed, first release thehydraulic parking brake and remove thepropeller shaft.

NOTE

Disconnect the propshaft at the drive axle endonly.

WARNING

Care must be taken to ensure the propshaft issuspended clear of the roadway.

CAUTION

The truckmust only be towedwith a rigid towbar andby a vehicle with sufficient tractive braking power tostop both vehicles.

NOTE

With the engine stopped, the truck can still besteered, although with much increased effortat the steering wheel.

Towing procedureLower and release the load.


4 OperationTowing

Attach the towing vehicle to the towing pinwith a rigid tow bar (tractive and brakingpower are sufficient).

Chock the drive axle wheels.

1

2

3

4

5

d3561091

Releasing the parking brakeRemove cover (2) from brake calliper (4).

Turn bolt (3) anti-clockwise to release thebrake until the brake disc is clear.

Removing the propeller shaftRemove bolts, nuts and spacers (5) on thecoupling joints.

Take off propeller shaft (1) and suspend itwith a chain, for example, to prevent it fromtouching the ground during towing.

CAUTION

Because of a lack of hydraulic power during towing,increased effort is required when steering.Tow the truck only with great caution and at a speedof not over 3-5 kph.

After towing and repairChock the wheels.

Reset the parking brake.

Resetting the parking brakeTurn bolt (3) clockwise to reset the brakeuntil the brake disc is tight again.

Fit cover (2) to brake calliper (4).

Refitting the propeller shaftDetach the propeller shaft, position it and fitthe axle.

Fit bolts, nuts and spacers (5) on thecoupling joints.

Tighten the bolts.

Torque approx ..... 135 Nm


Operation 4Towing

CAUTION

Bolts may be used 2 times maximum.

Remove the chocks.

Check the function of the brakes after carryingout repairs.


4 OperationTowing


5

Maintenance

5 MaintenanceGeneral remarks

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

Measures before taking the truck out ofoperationThoroughly clean the truck.

Rotate,Slew and sideshift the spreader.Extend and retract the boom.

Raise, lower and tilt the boom several timesthrough the full cycle.

Check the hydraulic oil level and add oil ifneeded.

Add diesel fuel.

Apply a thin film of oil or grease on allunpainted mechanical parts.

Lubricate the vehicle.

Check the condition of the battery. Coatthe battery terminals with non-acid grease(follow the instructions of the battery manu-facturer).

Spray all open electrical contacts with asuitable contact spray.

NOTE

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

NOTE

Do not use plastic foil to cover the trucks asthis enhances the formation and collection ofcondensation water.

Putting the truck back into operationThoroughly clean the truck.

Lubricate the truck.

Coat the battery terminals with non-acidgrease.

Check the condition of the battery.

Check the engine oil for condensation waterand change the oil if necessary.

Perform the same services as for commis-sioning.

Take the truck into service.

If the vehicle is to be taken out of operation forover 6 months, contact your authorised dealerfor further measures.

General informationYour truck will remain operational only if themaintenance and checks are carried outregularly and according to the informationand instructions in the operating manual.The maintenance may only be performed byqualified authorised personnel. This work canbe carried out by your authorised distributorunder a service contract.

We recommend reserving a special servicearea for the truck with a container or supportonto which the handler can be lowered to gaineasy and safe access to the service points.

If you wish to do the work yourself, we rec-ommend that the first three customer servicechecks be carried out by your distributor’smechanic in the presence of the responsiblemechanic in your workshop, so that your staffcan receive the appropriate instruction.

For all servicing, the truck must be placed ona level surface and the wheels secured. Stopthe engine and remove the ignition key.

When working on the truck with the mast ele-vated, secure it against inadvertent lowering.


Maintenance 5General remarks

For work on the front end of the truck, securethe mast against tilting back. No changes,particularly no modifications and additions,may be made to the truck without the approvalof the manufacturer.

NOTE

Missing or damaged type and/or adhesivelabels must be replaced. See the PartsCatalogue for location and order numbers.

Perform a functional check and trial run afterevery servicing.

NOTE

When operating the truck under extremeconditions (i.e. extreme heat or cold, intensivedust concentration, etc.), the intervals given inthe maintenance schedule should be reducedaccordingly.

CAUTION


Work on the boom and the front partof the truck

CAUTION

These safety precautions are only sufficient forthe general servicing of the truck (inspections andlubrication). When carrying out repairs (e.g. boomcylinder removal), additional safety precautionsare required. Please contact your authoriseddistributor.Do not carry out any work on the boom or thefront part of the truck with the boom raised withoutsecuring it as described below.

Park the truck on firm level ground andchock the wheels.

Support the handler (on a container).

Turn the ignition key to the zero position andremove it.

Lock all cab doors and remove the key.



1

2

3

4

d3571071

Hoisting the truck

DANGER

When loading the truck by crane, make sure nopersons are within the working range of the crane!Do not step under the elevated load!

CAUTION

The weight of the unladen truck is between 70 & 84tonnes.Only use a crane and slinging gear with sufficientlifting capacity.

CAUTION

Safety lock (4) must close after attaching the slingsto lifting hook (3).

When the truck is hoisted, the lifting sling must notrub against any attachment fitted.

Attach the lifting slings at the four pointsshown.

Attach two hooks to rear sling points (2) infront of the boom bearings.

Attach two lifting hooks to front sling points(1) in front of the boom cylinders.

Attach the slings to crane hook (3).

Handler removal

WARNING

This work may only be performed by the qualifiedstaff 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 kgC 4540 TL / 5 (2ndrail) 77700 kg



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 kgC 4535 CH / 5 (2ndrail 83470 kg



Inspection and maintenance data

No. Assembly Aids/oils and lubrication Filling capacities/ratedvalues

1 Engine Engine oil approx. 35 lts

2 Fuel tank Diesel approx. 800 lts

3 Cooling system Water and antifreezemixture approx. 45 lts

4 Working hydraulic systemoil tank Hydraulic oil approx. 800lts

5 Braking system oil tankHydraulic oilOil additive (mixed at ratio6%)

approx. 100 ltsapprox. 6lts

6 Brake relay hydraulicsystem Hydraulic oil as required

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

14 Grease points on boom,handler and chassis Lubricating grease as required

15 Temperature sensor Oil Engine oil temperature to130°C

16 Valve clearances Inlet 0.2 mmExhaust 0.5 mm

17 Fuel injection nozzle Diesel Operating pressure 246 barPressure setting 264 bar



Fuel and oil recommendationsEngine oils

API classification: CCMCD5, API-CE specifi-cation oils may be used but must be renewedat 250 hour service intervals. API classifica-tion: CH-4 or ACEA E5 may be used for up to500 hour service intervals.

Oil grades

Engine oils of API classification CD or less arenot recommended due to the extended draincycle given for this engine application.

During engine operation, part of the oil servingas a lubricant for the piston is combusted(“consumed”). The products of combustionand the high temperatures combined leadto “wear”, particularly of the chemical oiladditives. For this reason the oil must bechanged at certain intervals.

Since this oil wear depends on the operatingconditions and the quality of the oil (oil perfor-mance) and fuel used, oil change intervals ofdifferent lengths result.

Oil additives of any kind must not be used withany of the recommended engine oils. Use ofadditives will invalidate the warranty.

The longest possible oil change interval forlubricating oil in the engine is one year. Thismeans that the oil must be renewed at leastonce every year, regardless of the oil changeintervals.

Gear oil

MIL-L2105B, API GL5, SAE 90 or multigrade oils for normal external temperatures,recommended - 75w 90.

Sae 140 ormulitgrade oils for external temper-atures over 30° C

Transmission oil

Only Dexron III oil is approved for use.

Handler slew gearbox and brake

SAE 90 Gear oil to with additives to specifica-tion J306a.

e.g. Esso compressor oil G150

e.g. Mobil Glygoyle 22

Hydraulic oil for working hydraulics

ISO VG 46 (factory filling)

Hydraulic oil analysis

The working hydraulic system has a capacityof approx. 800 ltrs. To reduce the high levelof expenditure required if the oil is renewed atthe 3000 hour service, the operator may use areputable oil analysis company to determinethe state of the hydraulic oil. This analysisshould be made between 2750 and 3000hours run.

The results of the analysis should be recordedto support any warrant claim which may arisefrom defects in the working hydraulic systemsubsequent to the analysis. Where oil analysisis not available, the recommended 3000 houroil renewal is mandatory.

Hydraulic oil (brake system, brake cylinder)

ISO VG 46 (factory filling)

Hydraulic oil additives (brake system)

Use only pre-mixed Lubrizol solution.

Electrical contact grease

For use on all electrical connections.

Lubricating grease

Lindeheavy duty greasewith additives EPandMOS2. Designation acc. to DIN 51825-KPF2K-20 (see the Parts Catalogue for the ordernumber). Any mixing with grease types otherthan lithium-based greases is not allowed.

Battery grease

Non-acidic grease (terminal grease).

Chain spray

Linde chain spray (see the Parts Catalogue forthe order number).

Central lubrication

The grease must be an EP grade NLGI-0grease with a lithium/calcium base. It must



not contain any additives such as graphite orPTFE.

A grease from Greenlube is recommended.If difficult to obtain, please contact yourauthorised dealer.

Coolant

Only use coolants with a monoethylene glycolbase and containing a rust inhibitor.

Do not mix with antifreeze containingethanolamine.

Mixing ratio for lower temperatures:

Temperaturedown to

Antifreeze%

Mixture ratiowater:an-tifreeze

-12°C 25 1:3

-18°C 33 1:2

-22°C 40 1:1.5

-37°C 50 1:1

-60°C 66 2:1

Diesel fuel

Use only Diesel fuel to DIN EN 590 with acetane number not lower than 45.

The sulphur content should not exceed 0.5 %.

If the sulphur content is 0.5 to 1%, the oilchange intervals must be halved.

If the values are higher, contact the manu-facturer of the lift truck or the supplier of thelubricant.

NOTE

As the ambient temperature decreases, sodoes the fluidity of Diesel fuel due to theprecipitation of paraffin. If “summer grade”diesel fuel is used, malfunctions can result.For this reason, “winter grade” diesel fuel thatfunctions reliably at temperatures down toapproximately -15°C is available in the coldseason of the year.

The addition of any form of additive will invali-date the engine manufacturer’s warranty.

In winter, fill only winter diesel fuel to preventany clogging caused by paraffin precipitation.At very low temperatures youmust reckonwithdisturbing precipitations even if winter dieselfuel is used.

NOTE

These are only recommendations. In caseof doubt we recommend you contact yourauthorised dealer.

NOTE

The digital clock display must be reset whenever the battery isolator has been used for more thanfour days.

Check the condition of structured components

CAUTION

Work on the truck on level ground. Lower thecarriage, stop the engine and put the parking brakeon when working.

CAUTION

This maintenance procedure requires to be carriedout at heights of more than 2 metres. Use suitableaccess equipment. Danger of fall injuries.

Examine the structural components of thetruck to assure their integrity. Inspectionshould cover all areas of themain structuresand their connections. Attention should begiven towelds andmaterial adjoiningwelds,



particularly at changes of section, boltedinterfaces and sliding pad pressure points.

Examine the mast, lift and tilt cylinders,anchor and bearing points for damage,wear, missing lock bolts, metal fatigue, etc.

Examine the bearings for damage, missingretaining rings and abnormal wear.

Truck welds inspection

NOTE

It is very important that these inspections arecarried out as specified in daylight or withadequate artificial lighting, to allow closeexamination of the welds. Please follow theguidelines below:

CAUTION

These maintenance procedures may need to becarried out at heights of more than 2 metres. Usesuitable access equipment.Danger of fall injuries.

Wash the truck thoroughly and allow to dry.

Corrosion and/or deposits should beremoved to facilitate the inspection.

Carry out a detailed inspection of all weldedjoints on the chassis, load lifting device andattachment.

If there is any visible abnormality whichsuggests that a crack is present, carryout a more detailed inspection using nondestructive methods.

Please forward copies of any existing struc-tural inspection reports (as advised in theservice operators manual) to LHTD.

Reports including any photographs shouldbe sent to Mr. Andrew Dickson, (email:[email protected]) as soon asthey are available.


5 MaintenanceInspection and maintenance schedule

Inspection and maintenance scheduleDaily checksCheck the tyres for damage and foreignobjects

Check the working hydraulics oil level

Check the brake hydraulic system oil level

Check the hydraulic oil level in the brakesystem reservoir

Check the transmission oil level

Check the coolant level in the heater tank

Check the engine oil level

Check the fluid level in the washer fluidreservoir

Check the fuel level

Check the handler for visible damage

Check the operation of the twistlocks andindicator lights

Clean, check and adjust mirrors

Check the central warning system


Maintenance 5Inspection and maintenance schedule

As required Service plan

At operating hours Carriedout

Asrequired

CommentDepending on application, environmental conditions and driving style, the followingprocedures 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 engine oil level

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




AsrequiredCheck 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



50 h Service plan


50h

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

Check the transmission oil level

Chassis, bodywork and fittings

Clean and lubricate all pivots and joints


Check cab mountings

Check steer axle, check mounting

Check drive axle mounting

Change transmission oil filter canisters






50h

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




500 h Service planAt operating hours

500 1500 2500 3500 4500

5500 6500 7500 8500 9500

10500 11500 12500 13500 14500Carriedout

15500 16500 17500 18500 19500

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




At operating hours

500 1500 2500 3500 4500

5500 6500 7500 8500 9500

10500 11500 12500 13500 14500Carriedout

15500 16500 17500 18500 19500



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



At operating hours

500 1500 2500 3500 4500

5500 6500 7500 8500 9500

10500 11500 12500 13500 14500Carriedout

15500 16500 17500 18500 19500

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





1000 7000 11000 13000 17000Carriedout

19000

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





At operating hours

1000 7000 11000 13000 17000Carriedout

19000

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







At operating hours

1000 7000 11000 13000 17000Carriedout

19000


Subsequent tasks





2000h 4000h 8000 10000 14000Carriedout

16000 20000

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



At operating hours

2000h 4000h 8000 10000 14000Carriedout

16000 20000



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




At operating hours

2000h 4000h 8000 10000 14000Carriedout

16000 20000

Load lift device

Inspect load lifting device for proper operation


Lubricate tilt cylinder bearings





Subsequent tasks




3000 h Service plan


3000 9000 15000

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






3000 9000 15000

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






3000 9000 15000

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 boommountings





Subsequent tasks

General overall check




5000 h Service plan


5000 10000 15000 20000

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










5000 10000 15000 20000

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





5000 10000 15000 20000

Change the twistlocks


Check the handler extension cylinder bearing pads






Subsequent tasks





6000 h Service plan


6000 12000 18000

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






6000 12000 18000

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 brake hydraulic system oil

Change the working hydraulic system oil




5 MaintenanceEngine


6000 12000 18000



Load lift device


Change the handler slewing gearbox and brake oil


Check the handler extension cylinder bearing pads






Subsequent tasks



EngineCheck engine oil level

CAUTION

The bonnet opens forward leaving open accessto the engine compartment from both sides of thetruck.Danger of injury due to slips and falls.

CAUTION

The engine may be at operating temperature.Danger of scalding.


Maintenance 5Engine

CAUTION


Park the truck on firm level ground, put theparking brake ON and stop the engine.

1

d3571018

2

3

Behind the cab, remove dipstick (2) andwipe with a clean cloth.

Fully re-insert dipstick (2) and remove itagain.

The oil level should be between the Highand LOWmarks on dipstick (2).

If necessary, unscrew filler cap (3) and fillengine oil as far as the high mark.

Insert dipstick (2), refit the filler cap.

NOTE

Filling capacity between HIGH and LOW levelmarks is approximately 5 lts.

Total filling capacity ............ approx. 35 lts.

1 d3561122

Change the engine oil

CAUTION


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 operatingtemperature.

Open the engine cover.

Put a catch tray with a capacity of at least 35lts under drain plug (1).

Remove oil drain plug (1) and drain theengine oil.


5 MaintenanceEngine

Clean drain plug (1) and install with a newwasher.

Torque drain plug (1) to 60 Nm (45 lb. ft.).

Remove oil filler cap (3) on the filler neck.

Fill engine oil.

Capacity ............... approx. 35 lts.

Fill engine oil.

Check the engine oil level. The oil levelshould be between the high and low marks.The oil level must not exceed the highmark.

Start the engine and check drain plug (1) forleakage.

Stop the engine and wait at least 5 minutesfor the oil level to stabilise.

Check the oil level again and replenishengine oil, if necessary.

d3561124

2

Change the engine oil filters

CAUTION


CAUTION

Engine and engine oil may be at operating tempe-rature. Danger of burns and scalding.

Open the bonnet.

Put a catch tray with a capacity of at least 10lts under oil filters (2).

Loosen filters (2) using a filter wrench andremove by hand.

Clean filter housing (1).


Maintenance 5Engine

d3561125

2

2

2

3

Check filter seal rings (3) in new filters forproper seating.

Fill new fillers slowly with oil.

Lubricate seal rings (3) of new filters withengine oil.

Install filters (2) by hand until seal rings(3)mate with the filter head, then tightenby quarter turns using a filter wrench withtightening band.

Start the engine and check the seal facesfor leakage.

Stop the engine and wait for at least 5minutes for the engine oil level to stabilise.

Check the engine oil level and replenishengine oil if necessary.


5 MaintenanceEngine

Drain the fuel filter

1

2d3561097

CAUTION


The fuel filter is located in the air filter/batterycompartment on the left-hand side of thechassis.

Visual check for any water in the waterseparator, draining it if required.

Place a catch tray of approximately 11 pintscapacity under sediment bowl (1).

Release drain screw (2) and drain thesediment/water.

Tighten drain screw (2) as soon as cleanfuel flows.


Maintenance 5Engine

d3561126

1

2


CAUTION


CAUTION

Engine and engine oil may be at operating tempe-rature. Danger of burns and scalding.

Place a catch tray of at least 6 ltrs capacityunder filter element (2) to catch the fuel.

Using filter wrench, remove filter, and sealring (1).

Clean all components with paraffin deriva-tives (washing petrol) and dry with com-pressed air.

Fit a new seal ring (1) to the filter head.

Fill the new filter with fuel before fitting.

Rotate filter by hand until the gasket con-tacts filter head surface, then ½ to ¾ of aturn further, maximum.

Prime the fuel system

d3561098

CAUTION


CAUTION

The engine may be at operating temperature.Danger of scalds and burns

Remove filler cap from the top of the fuelpump (1).

Fill the pump with clean fuel.

Refit filler cap (1).


5 MaintenanceEngine

Check the air filter

NOTE

This service is only required once after the first50 service hours. Further service intervals asrequired.

WARNING

This work may only be performed by the qualifiedstaff 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 thefilter element. Follow precautions for handlingfluids and lubricants. If a warning indicatorappears on the display unit located on the righthand pod, stop the engine at once and renewthe air filter.

CAUTION

A dirty filter element decreases engine perfor-mance.Careful filter servicing is essential for the engine.

12

3

d3561100

Open the air filter/battery compartmentdoor.

Unscrew nut (1) and remove the filter endcover.

Empty the dust collected in the cover andwipe it with a clean damp cloth.

Replace dust valve (3) to remove anycollected dust. If necessary, clean the dustvalve with a damp cloth.

Replace dust valve if split or torn.

Unscrew wing nut (4) and carefully removefilter element (5).

Wipe the inside of filter casing (6) using adamp cloth.

Examine the filter.


Maintenance 5Engine

Replace the filter element if it is damaged,after 1000 service hours or at least every 12months.

Before installing a new filter element, examineit for damage with an inspection lamp heldinside the element.

4

5

6

d3561101

Examine the seals for damage.

Renew the filter or seals if damaged.

Examine the safety element. Renew ifdamaged.

Install filter element (5) into filter casing (6)and secure it with wing nut (4).

Refit end cover (2), ensuring that dust valve(3) is positioned through the deck plate, andsecure with the wing nut.

Close the air filter/battery compartmentdoor.

12

3

d3561100

Change the air filter element - checkthe vacuum switchAt least every 12 months or after 5 cleanings.

CAUTION

Work on the truck on level ground.Lower the mast and handler, stop the engine andput the parking brake on when working.

CAUTION

Stop engine before servicing the air Intake system.Do not start the engine with the filter elementremoved. Wear a protective mask for all serviceson the air Intake system.

CAUTION

Clean the filter case with a damp cloth.Do not wet clean the filter element.

Open the air filter/battery compartmentdoor.


5 MaintenanceEngine

Unscrew nut (1) and remove filter end cover(2).

Empty the dust collected in the cover andwipe clean with a damp cloth.

Remove dust valve (3) and clean with adamp cloth.

Renew dust valve (3) if damaged.

7

8

d3561102

Unscrew wing nut (4), remove element (5)and discard it.

Wipe filter casing (6) with a damp cloth.

Examine the new filter element for damagebefore installation.

Install filter element (5) into filter casing (6)and secure with wing nut (4).

Refit end cover (2) and secure with nut (1).Ensure that dust valve (3) is positionedthrough the casing hole.

Ensure that dust valve (3) is pointingdownwards.

Remove the intake hose from the air filterintake.

Close the air filter Intake when the engineis running. The Air filter restriction warningindicator will be visible on the truck displayunit.

NOTE

If air filter restriction indicator is not shown onthe truck display unit, contact your authoriseddealer.

Refit the intake hose.

Close the air filter/battery compartmentdoor


Maintenance 5Engine

d3561156

8

76

54

3

2

1


WARNING

Stop the engine before servicing the air intakesystem.

WARNING

Under no circumstances must the safety elementbe cleaned, or an attempt made to start the truckwith the safety element removed.

CAUTION

Clean the filter casing with a damp cloth. Do notclean the filter element.

The use of cleaning agents will destroy thefilter element. Follow the precautions forhandling fluids and lubricants.

Unscrew nut (1) and remove filter end cover(2).

Empty the dust collected in the cover andwipe clean with a damp cloth.

Remove dust valve (3) and clean with adamp cloth.

Renew the dust valve if damaged.

12

3

d3561100

Refit dust valve (3).

Unscrew wing nut (4) and remove mainair filter element (5). Inspect and renew ifdamaged.

Unscrew nut (6) and remove safety element(7).

Examine the new safety element for signsof damage, before installation.

Fit safety element (5) into filter casing (8)and secure with nut (6).

Refit main air filter (5) into filter casing (8)and secure with wing nut (4).

Refit end cover (2) and secure with nut (1).Ensure that dust valve (3) is positionedthrough casing hole (9).


5 MaintenanceEngine

d3561139

1

2 3


CAUTION

Engine and transmission may be at operatingtemperature. Danger of burns and scalding.

Check the engine mountings and spherelasticmounts for condition. Renew the rubbermounts, if damaged.

Check mounting bolts (1).

Torque ......... 68 Nm (50 lbf- ft.)

Check mounting bolt (2).

Torque ......... 195 Nm (145 lbf- ft.)


Torque ......... 100 Nm (75 lbf- ft.)

Clean the radiator and check forleaks

CAUTION

Clean the radiator only when the engine is stoppedand cool.

CAUTION


Remove radiator grille (1) and clear theradiator and oil cooler of any debris.

Clean the radiator and oil cooler fins withcompressed air or use a cold cleaner orsteam jet if necessary.

Start the engine and let it idle to allow waterto evaporate quickly.

Check the cooling system for leaks with theengine at operating temperature.

Install the radiator grille.


Maintenance 5Engine

Check the injection nozzlesServicing of the Injection nozzles before thenormal interval is indicated if the engine is:

Misfiring

Knocking in one or more cylinders

Overheating

Losing power

Emitting smoky black exhaust

Using more fuel

NOTE

Technical skill and knowledge are requiredfor this adjustment. Please contact yourauthorised dealer

d3561144


CAUTION

Lower the mast and handler, stop the engine andput the parking brake on when working.

CAUTION

Engine and radiator may be at operating tempera-ture.Danger of scalds and burns.

Isolate the battery.

Remove the rocker arm cover nuts and sealrings.

Remove the rocker arm covers and gas-kets.Rotate the accessory drive clockwise untilthe ‘A’ valve setmark on the accessory drivepulley is aligned with the pointer on the gearcover.

NOTE

The number 1 cylinder is at the front end of theengine.

Check the clearances of the valves ofcylinder 1.

Valve clearance when warm or cold:

Inlet valve ......... 0.2 mm

Exhaust valve ......... 0.5 mm

Adjust the valve clearances, if required.


5 MaintenanceEngine

Turn the crankshaft in the normal directionof rotation and check and adjust, if required,the valve clearances in the following se-quence:

Start Pulleyposition

Setinjector

Cylindervalve

Advanceto A 1 1

Advanceto B 5 5

Advanceto C 3 3

Advanceto A 6 6

Advanceto B 2 2

Advanceto C 4 4

Firingorder153624

Install the rocker arm cover.

Carry out a functional test of the engine.

d3571085

Check the intake and exhaustsystems for leaks and tightness

CAUTION

Work on the truck on level ground.Lower the mast and handler, stop the engine andput the parking brake on when working.

CAUTION

Engine and exhaust systemmay be hot.Danger of burns.

Inspect the air intake hoses, renew ifdamaged.


Maintenance 5Engine

d3571086

Inspect hose clips for security, tighten ifnecessary.

Check the overall condition of the exhaustsystem, replace any pipes or the silencer Ifbadly corroded.

Check that the exhaust mounting flangenuts are tight.

Check that the exhaust clamps are tight.

Check that the silencer mountings aresecure.

Torque ......... 56 Nm (41 lb. ft.)

Check that the tail pipe mounting bolts aresecure.

Torque ......... 56 Nm (41 lb. ft.)

d3561145

Check the cooling system for leaksand tightness

CAUTION

Work on the truck on level ground. Lower the mastand handler, stop the engine and put the parkingbrake on when working.

CAUTION

Engine and radiator may be at operating tempera-ture. Danger of scalds and burns.

Check the condition of the radiator top andbottom hoses, replace if deteriorated.

Check that hose clamps are secure.

WARNING

Do not run the engine with the thermostat removed


5 MaintenanceEngine

d3561163

Flush the cooling system

CAUTION

Do not remove the pressure cap, while the engineis hot. Wait until the coolant temperature is below50°C before removing the pressure cap. Danger ofscalds or burns.

d3561164

CAUTION

Coolant is toxic. Keep away from children andanimals. Dispose of waste coolant according tolocal regulations.

Drain the cooling system, do not allow thecooling system to dry out.

Do not remove the coolant filter.

Use cooling system cleaner to flush thecooling system.

Operate the engine at normal operatingtemperatures for at least one hour.

Switch off the engine, allow to cool, anddrain the cooling system.

Fill the cooling system with clean water,operate the engine for 5 minutes.

Shut off the engine, allow to cool and drainthe system, if the drained water is still dirty,repeat the process until drained water isclean.

Fill the cooling system with pre-mixedcoolant/water mixture - see Fuel and oilrecommendations.


Maintenance 5Engine

d3561152

1

2

Change engine coolant

CAUTION

Follow the precautions for fluids and lubricants.

CAUTION

Do not remove the radiator cap or drain plugswhen the radiator Is hot or with the engine running.Danger of scalds and burns.

CAUTION


The radiator drain plug Is fitted at the base ofthe radiator. It is reached from under the truckthrough an access hole on the Immediately Infront of the steer axle.

Remove radiator cap (1).

Place a container of at least 45 lts capacityunder radiator drain plug (2).

Remove the engine undertray.

d3561153

3

Place a container of at least 45 lts capacityunder engine drain plug (3).

Remove the drain plugs and allow thecoolant to drain.

Flush out the radiator through the filler capaperture.

Refit radiator drain plug (2).

Refit engine drain plug (3).

Fill the cooling system with a water-an-tifreeze mixture.

Refit the radiator cap (1).

Run the engine for 5 minutes.

Check the coolant level, replenishingcoolant if required.

Check the cooling system for leaks.

Fit the undertray.


5 MaintenanceEngine

NOTE

Capacity of cooling system ......... 44 lts


Maintenance 5Engine

d3561157

Check the vibration damper

NOTE

Silicone fluid inside the vibration damper willbecome solid after extensive service, whichmakes the vibration damper inoperative.This could cause major engine or drivelineproblems.

Check the vibration damper for evidence ofloss of fluid, dents, and wobble.

Inspect the vibration damper thickness forany deformation or raising of the damperfront cover plate.

If any deformations or variations are de-tected, please contact your authoriseddealer.

d3561110

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. Renewdamaged drive belts.

This belt drive system is equipped with anautomatic belt tensioner which CANNOTbe adjusted. Only visual inspection of belttensioner is required.

If the belt tensioner is hitting either of thecast stops (limiters), check the mountingbrackets and belt length.


5 MaintenanceEngine

d3561158

Check the fan drive idler pulleyassemblyRemove fan drive belt (1).

d3561159

Inspect the idler pulley for:

Freedom of rotation,

Damaged or broken pulley groove.


Maintenance 5Engine

d3561160

Measure the idler pulley end clearance.

Min ......... 0.025mm

Max ......... 0.250mm

If end clearances are not within thesemeasurements, contact your authoriseddealer.

d3561158

Fan hub, belt drivenRemove fan drive belt (1).


5 MaintenanceEngine

d3561161

Inspect the idler pulley for:

Freedom of rotation,

Damaged or broken pulley groove.

d3561162

Measure the idler pulley end clearance.

Min ......... 0.08mm

Max ......... 0.41mm



Maintenance 5Engine

d3561165

Check the turbochargerRemove the air intake and exhaust piping.

Check the turbocharger as follows:

Look for damaged or cracked compressoror turbine blades.

Check that the turbocharger shaft spinsfreely.

If any of the above are detected, contact yourauthorised dealer.

d3561166

Check the radial bearing clearanceRemove the intake and exhaust piping fromthe turbocharger.


5 MaintenanceEngine

d3561167

Use awire type feeler gauge tomeasure theclearance between the compressor wheeland housing.

Gently push the compressor wheel towardthe compressor housing and gauge.

Record this clearance

d3561168

With the feeler gauge in the same location,gently push the compressor wheel awayfrom the compressor housing and measurethe clearance between the compressorwheel and housing.

Record this clearance

Subtract the smaller clearance from thelarger clearance, this is the radial bearingclearance.

Min ......... 0.15mm

Max ......... 0.64mm



Maintenance 5Gearbox

d3561169

Check the Axial clearanceUse a dial depth gauge.

Push the rotor assembly away from thegauge.

Set the gauge to zero.

Push the rotor assembly toward the gauge,and record the reading.

Min ......... 0.038mm

Max ......... 0.089mm

If clearances are not within these measure-ments, contact your authorised dealer.

Re-fit the intake and exhaust piping.

Gearbox

d3561141

21

Change the transmission oil andclean the filter screen

CAUTION


CAUTION


Open the engine compartment front cover.

Remove the engine compartment frontunder trays.

Place a catch tray of at least 60 lts capacityunder drain plug (1).

Remove drain plug (1) and allow the oil todrain. Remove and discard the plug sealring.

Remove plug (2) from the housing with thefilter screen attached.

Remove and discard the seal ring on drainplug (1).

Wash the screen assembly in paraffinderivatives such as benzene and dry withcompressed air (max. 5 bar).


5 MaintenanceGearbox

Fit drain plug (1) with a new seal ring andtighten.

d3561142

3

Install screen assembly and plug (2) withnew seal ring.

Torque to 13 - 20 Nm (10 - 15 lb. ft.)

Remove transmission filler cap (3) and filltransmission oil.

Capacity ........ 60 lts

Start the engine and check for leaks at theseal faces.

Check the transmission oil level, replenish-ing oil If required.

Fit the engine compartment front undertrays.

Close the engine compartment front cover.

d3561121

1

2

3

Change transmission oil filters

CAUTION


CAUTION

Filters and oil may be hot. Danger of burns andscalding.


Place a catch tray of at least 11 pintscapacity under the filters (1).

Loosen filters using a filter wrench andremove by hand

Clean the filter head.Fill the new filter with transmission oil.

Lubricate filter seals (2) with transmissionoil.

Install new filters and tighten by hand only.

Start the engine and check for leaks at theseal faces

Check the transmission oil level and replen-ish oil if necessary.


Maintenance 5Chassis, bodywork and fittings

Close the engine compartment front cover.

d3561140

1

2

3

Check transmission mountings

CAUTION

Work on the truck on level ground. Lower the mastand handler, stop the engine and put the parkingbrake on when working..

CAUTION


Check the condition of the rubber mounts.Renew the rubber mounts, if damaged.


Torque ......... 175 Nm (129 lbf- ft.)


Torque ......... 195 Nm (145 lbf- ft.)


Torque ......... 100 Nm (75 lbf- ft.)


Torque ......... 250 Nm (185 lbf- ft.)

Chassis, bodywork and fittingsClean the truck

NOTE

The frequency of cleaning depends on theuse of the truck. If used with very aggressivemedia like salt water, fertilizer, chemicals,cement, etc., a thorough cleaning is requiredafter the completion of work.


5 MaintenanceChassis, bodywork and fittings

CAUTION

Use hot steam or intensive degreasing solutionswith the utmost care. The grease in sealed for-life bearings may dissolve and leak out. Sincere-greasing is not possible, thiswill result in damageto the bearing.Follow the precautions for handling lubricants andfluids.

CAUTION

Wear protective clothing and eye protectors.When cleaning with a pressure washer, do notexpose electrical components or air filter intakelines 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 cleanerwhencleaning with an air jet.

NOTE

If the truck is cleaned frequently, increaselubrication intervals accordingly.

When cleaning with degreasing cleaningsolutions, allow sufficient time for the cleanerto soak in and then flush with a strong waterjet.

After cleaning the engine, allow it to run warmto dry it in order to prevent any malfunctionsdue to the ingress of water.



2

1

3

d3591093

Check seat belt for condition andcorrect operation*

NOTE

For safety reasons the condition and properoperation of the retention system should beinspected regularly (monthly).

Under extreme operating conditions thischeck is required daily before taking the truckinto operation.

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

Check lock (2) for correct operation and theretractor for proper return of the belt.

Check covers for damage.

Check the automatic lock.

Park the truck on level ground.

Pull out the belt with a jerk. The automaticlock should prevent the belt from unrollingfrom retractor (3).

Slide the seat fully forward.

Tilt the backrest fully forward.

* option

CAUTION

Have a defective seat belt replaced immediately byyour authorised dealer.Do not operate the truck with a faulty seat belt.

To prevent accidents, check that all adjust-ments are properly engaged before operatingthe truck.

Do not operate the seat adjusting deviceswhile operating the truck.

Seat belts must be applied before operation ofthe truck.

After an accident, the seat belt must berenewed. In the case of seat belts attachedto the operator seat, the seat and mounting ofthe seat must also be inspected by qualifiedpersonnel.

Nuts and bolts should be checked regularlyfor tightness. An unstable seat can indicate



loose bolts or other faults. If malfunctions inthe operation of the seat are detected (eg seatcushioning), contact your authorised dealerimmediately to eliminate the cause.

If the seat belt is not checked, you put yourhealth in danger and there is a higher risk ofaccidents.

d3561020

Tighten wheel nuts

CAUTION

On new trucks, or if a wheel has been removed andreplaced, the wheel nuts must be checked beforeuse and daily for two weeks.Check wheel nuts every 100 hours.

Torque all wheel nuts to: approx. 350 Nm.



Check the tyres for damage andforeign objectsSecure the truck against rolling (applyparking brake).

Chock a wheel that will not be raised.

Raise the truck with a jack at the locatingpoints until the wheels are clear of theground.

Secure the truck with squared timbers.

Check the wheels for ease of movementand remove any debris hindering their freerotation.

Renew worn or damaged tyres.

Check the cab mountings

1

2

d3561128

Check the front cab mountings

NOTE

Access to front cab mounting bolts (1) is fromunder the cab floor mat.

Check that the front cab mounting bolts (1)are secure;

Tighten to 115 Nm (85 lb. ft.) if required.

NOTE

Access to front mounting bolts (2) is frombelow.

Check that the front cab mounting bolts (2)are secure;

Tighten to 56 Nm (41 lb. ft.) if required.



d3561129

1

2

Check the rear cab mountings

NOTE

Access to rear cab mounting bolts (1 & 2)Is from under the cab behind the cab rearcompartment door.

Check that cab mounting bolts (1) aresecure;

Tighten to 115 Nm (85 lb. ft.) If required.

Check that cab mounting bolts (2) aresecure;

Tighten to 56 Nm (41 lb. ft.) If required.


NOTE

It is very important that these inspections arecarried out as specified in daylight or withadequate artificial lighting, to allow closeexamination of the welds. Please follow theguidelines below:

CAUTION

These maintenance procedures may need to becarried out at heights of more than 2 metres. Usesuitable access equipment.Danger of fall injuries.

In line with the recommended maintenanceschedules for the regular inspection of theboom and lifting equipment, please followthese procedures for the full inspection of theinner and outer boom.

Wash the truck thoroughly and allow to dry.

Corrosion and/or deposits should beremoved to facilitate the inspection.

Park the machine with the boom extendedfully and lowered to allow close examinationof the inner boom.



Examine both sides of the inner boom asshown.

It is advisable to check regularly for signs ofmetal fatigue. These areas are indicated.In order to carry out the inspection mostefficiently, ensure that the boom is cleanedof dust water and grease before inspection.Initially, removal of any paint will not benecessary to identify whether cracks arepresent.

Carry out a visual inspection of the areas ofthe boom as indicated.

Carry out a visual inspection of the areas ofthe chassis as indicated.

NOTE

Should evidence of cracks be detectedcontact Linde Heavy Truck Division Limitedimmediately. Details of cracks detectedand their position, also machine usage andsite conditions should be relayed to theLinde Heavy Truck Division Limited ServiceManager - Tel: +44 1443 624345 Fax: +441443 624302


5 MaintenanceChassis frame

Chassis frame

1

2

d3571011


CAUTION


CAUTION

Work on the truck on level ground. Retract andlower the boom, stop the engine and put the parkingbrake on when working.

Ensure that oil filler plug (1) is in the 3 o clockposition and drain plug (2) is in the 7 o clockposition.

Remove oil filler plug (1).

Check oil is visible at the base of hub fillerhole (1).

If required, replenish oil to the base of thefiller hole (1).

Replace oil filler plug (1).


Maintenance 5Chassis frame

1

2

35

4

d3561106

Clean and lubricate steer axle, checkthe mounting

CAUTION


CAUTION


Clean the steer axle.

Check steer axle mounting bolts (3) fordamage and wear

Check nut (2) torque loading.

Torque...............2300 Nm (1700 lb. ft).

Lubricate kingpin grease points (1&5), (4positions).

Lubricate the drag link grease points (4), (4positions).

Press the grease gun until clean lubricatinggrease emerges at the bearings.

2

1

d3561107


CAUTION


CAUTION

Danger of scalds and burns.Engine and transmission may be at operatingtemperature.


Examine drive shaft coupling bolts (1) fordamage or signs of fretting.

Check bolt torque loading.

Torque..............80 Nm (60 lb. ft)

Lubricate drive shaft grease points (2) (3points)




2

1

d3561118

Check the drive axle mounting

CAUTION

Work on the truck on level ground. Lower the mast,stop the engine and put the parking brake on whenworking.

Check drive axle securing bolts (2) and nuts(1) for damage or signs of fretting.

Check the torque loading of bolts.

Torque ........... 2300 Nm (1680 lbf- ft).


Maintenance 5Chassis frame

1

d3561119

Check the drive axle centre differen-tial oil level

CAUTION


CAUTION


Remove filler plug (1).

Check that the oil is visible at the base of thefiller hole.

If required, replenish with oil to base of fillerhole.

Capacity ................... max. approx 75 lts

Fit filler plug (1).



OIL

1

2

d3561120

Check the drive axle hub differentialoil level

CAUTION


CAUTION


Position the truck so that the drive axle hublevel indicator mark (1) is horizontal.


Check that the oil is visible at the base of thehub filler hole.

If required, replenish with oil to the base ofthe filler hole.

Capacity ................. max. approx. 7 lts

Fit filler plug (2).

Repeat for the other hub.

d3561151

1 2

3

OIL

Change the drive axle hub differen-tial oil

CAUTION


CAUTION


Position the truck so that the drive axle hublevel indicator mark (2) is horizontal anddrain plug (3) is down.

Place a catch tray of at least 7 lts capacityunder drain plug (3).


Remove drain plug (3) and allow the oil todrain completely.

Remove and discard the plug seal rings.


Maintenance 5Controls

Fit drain plug (3) with a new seal ring.

Fill the differential with gear oil to the baseof the filler hole.

Fit filler plug (1) with a new seal ring.

Repeat for the other hub.

NOTE

Maximum oil capacity each side ......... 7 lts

Check and adjust hub bearingsCorrectly adjusted hub bearings must notallow any perceptible end float, but allow thewheel to rotate freely without binding.

NOTE

The bearing play can only be checked with thewheel raised.

Using a jack of sufficient capacity, raise thetruck on the side on which the bearing playis to be checked and secure the truck withsquared timbers.

In case of bearing play, contact your autho-rised dealer.

ControlsCheck the steering lock

NOTE

Please contact your authorised dealer for thischeck.


5 MaintenanceElectrics

d3561146

2

3

1Check the parking brake conditionand mounting

CAUTION


Examine brake disc (3) for wear and dam-age.

Check the thickness of lining material onbrake pads (2) . Renew pads if thickness isless than 2 mm.

Examine calliper bolts (1) for wear, renew ifrequired. Check that the nuts and split pinsare secure.

Check the brake disc wear

NOTE

Please contact your authorised dealer forrenewal of the brake discs.

Electrics

1

d3561023

Check battery conditionThe battery is fitted in the left hand chassiscompartment (1) with the air filter and fuelsystem water separator.

Check the battery, for cracks in the casingand leakage of electrolyte.

Remove corrosion on battery terminals andcheck the connections are tight.

Smear the terminals with non acid grease.


Maintenance 5Electrics

Check electric cables, connectors and connections for condition and tightnessExamine cable connections for loosenessand corrosion.

Inspect the earth lead for loose connection.

Examine the electrical wiring for chaffingand loose connections.

NOTE

Corroded connections and cracked cableslead to a drop in voltages, which may causestarting difficulties.

Remove corrosion and replace crackedcables.


5 MaintenanceHydraulics

HydraulicsCheck the hydraulic system, pumps, valves and linesCheck all connections between the oiltank, pumps and control valves for leaks.If necessary, tighten any loose joints.

Check the lift, tilt and steer cylinders forleaks.

Renew any cracked hoses.

Check the hoses for damage and chaffing,renew if necessary.


Maintenance 5Hydraulics

Change the working hydraulicsystem oil suction filters

CAUTION

Follow the precautions for handling fluids andlubricants. Danger of burns.The oil tank, filter and hydraulic oil may be atoperating temperature.

De-pressurise the tank by rotating the fillercap slowly until air is heard escaping fromthe tank, keep rotating the filler cap until nomore air is heard.

WARNING

The hydraulic tank accumulates stored pressure.Take care when removing the filler cap.

1

2

d3571088

Remove nuts (1) from filter cover (2).

Press retainer down, rotate through 90° andlift out to allow removal and replacement offilters (3).



3

d3571089

3

Lift out filters (3).

Replace filters (3) and seals.

Check oil level and replenish, if required

Dispose of used filters according to localauthority guidelines.

Change the brake hydraulic systemoil suction filter

CAUTION

Follow the precautions for handling fluids andlubricants. Danger of burns.The oil tank, filter and hydraulic oil may be atoperating temperature.

Brake oil filtration consists of a suction strainer(3) in the brake oil tank, and an in-line pressurefilter (10). The in-line filter (10) is situatedon the left hand side of the chassis near thetransmission.

Chock the wheels of the truck and depleteany stored pressure in the brake circuit.



10

11

12

d3571090

Unscrew filter case (12).

Remove and discard filter element (12) andseal ring (11).

Fit new seal ring (11) to filter element (12).

Check that seal ring (11) is correctly seatedand lubricated with oil.

Prime new filter element (12) with new oil.

Engage new filter element (12) into the filterhead (10) and tighten.

d3571091

3

1

4

2

To replace suction strainer (3), remove andretain union nuts (2).

Lift filter cover (1) and strainer (3) from tank

The strainer (3) can be cleaned usingcompressed air unless damaged, in whichcase it can be removed by unscrewing byhand and replaced by repeating the aboveprocedure.

Start the engine and check the joints forleakage, tighten nuts (2), if required.

NOTE

The hydraulic system is self priming when theengine is running.

Stop the engine and check the brakehydraulic system oil level, replenishinghydraulic oil if required.



1

d3561137

Change the brake hydraulic systemoil pressure filter

CAUTION


CAUTION


CAUTION

Oil filter and hydraulic oil may be at operatingtemperature. Danger of burns and scalding.

The filter is fitted on the left side of enginecompartment.

Place a catch tray of at least 2 L capacityunder the filter assembly.

Unscrew filter case (1).

d3561138

5

2

4

3

Remove and discard filter element (2) andseal ring (5).

Check that seal ring (3) in new filter element(2) is fitted correctly and lubricate withhydraulic oil.

Fit new seal ring (5) to filter case (4) andlubricate with hydraulic oil.

Fit filter element (2) to filter head.

Engage filter case (4) into filter head andtighten.

Start the engine and check the joint for leak-age, tightening the filter case if necessary.

Stop theengine andcheck thebrake systemhydraulic oil level, replenishing hydraulic oilif necessary.

Change the brake hydraulic systemoil

CAUTION




CAUTION

Hydraulic oil and hydraulic oil tank may be atoperating temperature.Danger of scalds and burns.

CAUTION


NOTE

Note the addition of 6% Lubrizol to the hydrau-lic oil.

The drain plugs on the hydraulic oil tank for theworking hydraulic system and braking systemare located at the base of the tank immediatelyin front of the right-hand steer wheel. Thedrain plug for the hydraulic braking system islocated behind the drain plug for the workinghydraulics.

d3571092

Place a catch tray of at least 100 lts capacityunder the drain plug.

Remove the drain plug and allow thehydraulic oil to drain completely.

Remove and discard the drain plug sealingring.

Install the drain plug with a new sealing ring.



d3571092

Fill hydraulic oil into the tank checking thesight glass (1), frequently to check the oillevel.

Capacity ......... 100 lts

Start the engine and carry out a functionaltest of the breaking system hydraulics.

Stop the engine and check the oil level inthe hydraulic oil tank on sight glass (1). Ifrequired, fill the oil tank with clean hydraulicoil until the oil level is between theHIGHandLOWmarks.



Change the hydraulic oil - workingsystem

CAUTION


CAUTION

Hydraulic oil and hydraulic oil tank may be atoperating temperature. Danger of scalds andburns.

CAUTION


NOTE

The operator can have the hydraulic oilanalysed after about 2750 service hours todetermine if the hydraulic oil must be changedat 3000 service hours. (Refer to analysis ofhydraulic oil.)

The drain plugs on the hydraulic oil tank for theworking hydraulic system and braking systemare located at the base of the tank immediatelyin front of the right-hand steer wheel. Thedrain plug for the working hydraulic system isnearest to the front end of the truck.

d3561155

1

Place a catch tray of at least 800 lts capacityunder the drain plug.

Remove the drain plug and allow thehydraulic oil to drain completely.

Remove and discard the seating ring on theplug. Refit the drain plug with a new sealingring.

Remove the dipstick with breather valve (1)and fill the tank with hydraulic oil.

Capacity ......... 800 lts

Start the engine and carry out a functionaltest of the working hydraulics.

Stop the engine and check the oil levelin the hydraulic oil tank with the dipstick. If


5 MaintenanceLoad lift system

required, addhydraulic oil up to the betweenthe HIGH and LOWmarks on the dipstick.

Load lift systemCheck and lubricate boom cylinder, boom pivot and sliding bearings

2

2

2

13

5

6

4

A

A

A

d3571012

CAUTION


CAUTION

This maintenance procedure requires to be carriedout at heights of more than 2 metres. Use suitableaccess equipment.Danger of fall injuries.

Check that all stop plates (4) on the innerand outer boom are fitted and tight (4plates).


Maintenance 5Load lift system

Check pin (5) for tightness.

Check pin (2) for tightness.

Lubricate all grease points with grease (14grease points).

For lubrication use a grease gun until freshgrease emerges at the bearings.

1

2

d3571010

Lubricate slewing ring bearing andgear

CAUTION


CAUTION


CAUTION


Lubricate the bearing grease points (1) (4points).


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


5 MaintenanceLoad lift system

1

d3571007

Slew gearbox and brake oil levelcheck

CAUTION


CAUTION


CAUTION


Remove level/filler plug (1).

The hydraulic oil level must be at the loweredge of filler hole (1).

If necessary, fill hydraulic oil to the base ofthe hole.

Fit level/filler plug (1).

d3561117

Check and lubricate the twistlocks

CAUTION


WARNING

The twistlocks (2) arewearing parts. Thesemust beinspected regularly for damage, correct operationand wear. Do not operate the truck if damage,malfunctions or heavy wear are evident.

Check twistlocks (2) in area (4) by measur-ing between (A) and (B).

Thismeasurementmust not be smaller than1 inch, (the wear limit).

Renew the twistlocks if the wear limit isexceeded.


Maintenance 5Load lift system

1

3

d3561116

Lubricate grease nipples (1 & 3) (3 on eachtwistlock).


1 2

d3571009

Check and lubricate feet at thebottom of each leg

CAUTION


CAUTION


Lubricate the nipple in the centre shaft (1).

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



5 MaintenanceSpecial equipment, accessories

Change the twistlocks

WARNING

The twistlocks are wearing parts and must bereplaced for safety reasons after maximum 5000service hours.

Contact your authorised dealer for renewal ofthe twistlocks.

Special equipment, accessoriesCheck the central lubrication*lubricating points

NOTE

This check is required only once after the first50 hours.

Check that enough grease is emerging fromall central lubrication lubricating points.

If there is not enough or too much grease,adjust the central lubrication time relay.

Please contact your authorised dealer inthis regard.

3

d3561105

Fill central lubrication* canister withgrease

NOTE

The central lubrication canister is locatedbehind the battery/air filter cover on theleft-hand side of the truck.

Open the battery/air filter cover (2).

Remove dust cap (3) on the canister fillernipple.

Clean the filler nipple and install the fillertube of the grease gun.

Fill grease up to the maximum level indica-tor on the canister.

Remove the filler tube and fit dust cap (3).


Maintenance 5Special equipment, accessories

NOTE

If filling is difficult, clean the filter in the cani-ster.

Close the battery/air filter cover (2).

* Option


5 MaintenanceTroubleshooting

TroubleshootingTroubleshooting guide Diesel engine

Trouble Possible cause CorrectionFuel tank empty Refill the tank

Fuel filter clogged Renew the fuel filter, usewinter fuel

Water in fuel system filter Drain, clean the fuel filter

Fuel shut off solenoid fails toopen

Check for electric current withtest lamp. If there is no current,check fuse and switch

Fuel line leakage Check all pipe connections forleaks and tighten fittings

Battery charging indicator lightnot illuminated although lampis ok

Tighten terminal clampsat battery, check cableconnections

Preheating system defective Check the power supply.Check the cables and connec-tions at the preheat/startingswitch. If the fault cannot beremedied, contact your autho-rised dealer.

Engine will not start

Fuel pump defectiveInjection nozzles defectiveInjection pump defective

These faults should always bechecked correctly by skilledstaff. Please contact yourauthorised dealer

Battery power is too low.Battery terminal loose oroxidised, causing the starter toturn only slowly

Check battery, clean batteryterminals, tighten clamps andcover with non-acidic grease

Fuel supply insufficient Renew the fuel filter. Checkthe fuel line connections forleaks, and tighten fittings

Restriction or air in fuel systemdue to parrafin deposits inwinter

Engine starting performance ispoor

Particularly in winter:Filled engine oil viscosity toohigh

Use engine oil appropriate forthe ambient temperature

Engine running and buzzersounding

Oil pressure in hydraulicbraking system belowoperating pressure

Let engine continue to run untilminimum pressure is reached


Maintenance 5Troubleshooting

Fuel supply insufficient. Renew the fuel filter. Checkthe fuel line connections forleaks and tighten fittings.

Restriction or air in fuel systemdue to paraffin deposits inwinter.

Use winter fuel in the coldseason.

Injection pump overflow valvenot functioning correctly

Contact your authoriseddealer.

Engine running unevenly withpoor performance

Valve clearances not asspecified.Injection nozzles defective.Engine oil level too high.

Adjust valve clearances.Contact your authoriseddealer.Drain oil to the high mark onthe dipstick.

Excessive exhaust smoke Poor compression due toburned-in or broken pistonrings or incorrect valveclearances.

Adjust valve clearances.Contact your authoriseddealer.

Fuel system not in order Clean and inspect fuel filterrenew if necessary. Clean thefuel pump. Check fuel returnlines and injection lines forleaks.

Idle running trouble

Engine speed setting incorrect May only be adjusted by skilledstaff. Contact your authoriseddealer.

Coolant level low. Check cooling system forleaks, seal if necessary. Addcoolant.

Fan V-belt either slack orbroken.

Tighten or renew the V-belt.

Radiator fins restricted due todirt or foreign objects.

Clean the radiator.

Engine overheating, redwarning light in instrumentpanel illuminated. Stop theengine immediately.

Injection system settingincorrect.


Leaks in the lubricatingsystem.


Engine oil pressure too low.Stop the engine immediately.

Oil level too low. Add lubricating oil.

Alternator RPM too low. Check V-belt tension.Battery charging indicator lightilluminated during operation

Alternator not charging thebattery because alternator orrelay defective.



5 MaintenanceTroubleshooting

Troubleshooting guide hydraulic system

Trouble Possible cause CorrectionSuction filter restricted. Renew the suction filter.

Suction hoses leaking, oilfoaming.Hydraulic pump or motor failure,seals defective, causing airintake.

Tighten lines. Check oil level, topup if necessary.Have hydraulic unit inspected byyour authorised dealer.

Abnormal noise

Incorrect oil viscosity, low oillevel in tank or in hydraulicpump.

Change oil, be sure to use thecorrect viscosity, replenish oil.

Pump suction defective, noise. Change oil, replenish oil.No or too low pressure insystem

Pump failure, leakages,pressure valves do not close,valve seat damage.

Contact your authorised dealer.

Pipe broken or leaky. Replace or tighten line.

Oil of low viscosity, causing highleakage losses.

Change oil, be sure to use oil ofcorrect viscosity.

Oil temperature warning lampilluminated.

Check oil level, clean oil cooler.

Cause as under abnormalnoise.

See under abnormal noise.

Pressure relief valves or boostpressure valves sticking.


Lift and tilt cylinders have tightspots.


Oil pressure fluctuating

Boom does not extendcompletely or retracts slightlyafter being extended.

Replenish hydraulic oil.

Suction filter restricted (ifaccompanied by noise).

Clean or replace suction filter.No oil flow or low oil flow

Pump faulty, leakage, pressurerelief valves do not close, valveseat 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.

Pump failure, valves leaky. Contact your authorised dealer.Hydraulic oil temperaturetoo high

Oil level too low or oil coolerdefective.

Check oil level, if necessary topup oil. Clean cooler and check forleaks. If defective, contact yourauthorised dealer.


Maintenance 5

User manual feedbackUser manual improvement record.As part of Linde Heavy Truck Divisionscommitment to continuous improvementplease complete the form below to let usknow if there are any discrepancies withinthis technical publication.

NOTE

Please be aware that amendments will beassessed for validity, collated and updates willbe made according to scheduled updates.

Pagenum-ber

Existing content Proposed contentamendment


5 Maintenance


Indexg

NUMBERS AND SYMBOLS1000 h Service plan . . . . . . . . . . . . . . . 1142000 h Service plan . . . . . . . . . . . . . . . 1173000 h Service plan . . . . . . . . . . . . . . . 120500 h Service plan . . . . . . . . . . . . . . . . 1115000 h Service plan . . . . . . . . . . . . . . . 1236000 h Service plan . . . . . . . . . . . . . . . 126

AAccident prevention check . . . . . . . . . . . 15Adjusting the drivers seat . . . . . . . . . . . . 34

BBefore lifting a load . . . . . . . . . . . . . . . . . 80Boom and handler controls . . . . . . . . . . . 77

CCab door opening and closing . . . . . . . . . 30Cabin door - closing . . . . . . . . . . . . . . . . 30Change engine coolant . . . . . . . . . . . . 143Change the air filter element - check

the vacuum switch . . . . . . . . . . . 135Change the air filter safety element . . . . 137Change the brake hydraulic system oil . 172Change the brake hydraulic system oil

pressure filter . . . . . . . . . . . . . . . 172Change the brake hydraulic system oil

suction filter . . . . . . . . . . . . . . . . 170Change the drive axle hub differential

oil . . . . . . . . . . . . . . . . . . . . . . . 164Change the engine oil . . . . . . . . . . . . . . 129Change the engine oil filters . . . . . . . . . 130Change the fuel filter . . . . . . . . . . . . . . 133Change the hydraulic oil - working

system . . . . . . . . . . . . . . . . . . . . 175Change the transmission oil and clean

the filter screen . . . . . . . . . . . . . . 151Change the twistlocks . . . . . . . . . . . . . 180Change the working hydraulic system

oil suction filters . . . . . . . . . . . . . 169Change transmission oil filters . . . . . . . 152Check and adjust hub bearings . . . . . . . 165

Check and lubricate boom cylinder,boom pivot and sliding bearings . 176

Check and lubricate feet at the bottomof each leg . . . . . . . . . . . . . . . . . 179

Check and lubricate the drive shaft . . . . 161Check and lubricate the twistlocks . . . . 178Check battery condition . . . . . . . . . 36, 166Check brake hydraulic system oil level . . 38Check coolant level in header tank . . . . . 43Check drive belt tension . . . . . . . . . . . . 145Check electric cables, connectors and

connections for condition andtightness . . . . . . . . . . . . . . . . . . 167

Check engine oil level . . . . . . . . . . . 39, 128Check seat belt for condition and

correct operation* . . . . . . . . . . . . 155Check steer axle hub oil level . . . . . . . . 160Check the air filter . . . . . . . . . . . . . . . . 134Check the brake disc wear . . . . . . . . . . 166Check the cab mountings . . . . . . . . . . . 157Check the central lubrication*

lubricating points . . . . . . . . . . . . 180Check the condition of structured

components . . . . . . . . . . . . . . . . 104Check the cooling system for leaks and

tightness . . . . . . . . . . . . . . . . . . 141Check the drive axle centre differential

oil level . . . . . . . . . . . . . . . . . . . 163Check the drive axle hub differential oil

level . . . . . . . . . . . . . . . . . . . . . . 164Check the drive axle mounting . . . . . . . 162Check the engine mountings . . . . . . . . 138Check the fan drive idler pulley

assembly . . . . . . . . . . . . . . . . . . 146Check the front cabmountings . . . . . . . 157Check the hydraulic system, pumps,

valves and lines . . . . . . . . . . . . . 168Check the injection nozzles . . . . . . . . . 139Check the intake and exhaust systems

for leaks and tightness . . . . . . . . 141Check the parking brake condition and

mounting . . . . . . . . . . . . . . . . . . 166Check the rear cab mountings . . . . . . . 158Check the steering lock . . . . . . . . . . . . 165


Indexg

Check the transmission oil level . . . . . . . 41Check the turbocharger . . . . . . . . . . . . 149Check the tyres for damage and foreign

objects . . . . . . . . . . . . . . . . . . . . 157Check the vibration damper . . . . . . . . . 145Check transmission mountings . . . . . . . 153Check tyre condition and pressure . . . . . 37Check valve clearances . . . . . . . . . . . . 139Check windscreen washer reservoir

fluid level . . . . . . . . . . . . . . . . . . . 43Checkworking hydraulic system oil level . 38Checking the fuel level . . . . . . . . . . . . . . 40Checking the twistlocks and warning

lights for proper operation . . . . . . . 44Checks prior to first operation* . . . . . . . . 15Clean and lubricate steer axle, check

the mounting . . . . . . . . . . . . . . . 161Clean the radiator and check for leaks . . 138Clean the truck . . . . . . . . . . . . . . . . . . . 153Closing the battery and air filter

compartment door . . . . . . . . . . . . 33Closing the brake hydraulic system oil

tank cover . . . . . . . . . . . . . . . . . . 33Closing the cabin rear compartment

door . . . . . . . . . . . . . . . . . . . . . . . 32Closing the engine cover . . . . . . . . . . . . 31Closing the fuse box cover . . . . . . . . 34, 74Closing the transmission cover . . . . . . . . 31Closing the working hydraulic system

oil tank cover . . . . . . . . . . . . . . . . 32Cold Start . . . . . . . . . . . . . . . . . . . . . . . 47

DDaily checks . . . . . . . . . . . . . . . . . . . . 106Daily checks* . . . . . . . . . . . . . . . . . . . . . 16Danger notices

Graduation . . . . . . . . . . . . . . . . . . . . . 9Declaration of conformity . . . . . . . . . . . . 11Depositing the load . . . . . . . . . . . . . . . . 89Drain the fuel filter . . . . . . . . . . . . . . . . 132Driving . . . . . . . . . . . . . . . . . . . . . . . . . . 61

EEC declaration of conformity . . . . . . . . . . 11Electrical Circuit . . . . . . . . . . . . . . . . . . 201Electronic control module System . . . . . . 46

FFan hub, belt driven . . . . . . . . . . . . . . . 147Fill central lubrication* canister with

grease . . . . . . . . . . . . . . . . . . . . 180Filling fuel . . . . . . . . . . . . . . . . . . . . . . . 40First 50 h . . . . . . . . . . . . . . . . . . . . . . . 109Flush the cooling system . . . . . . . . . . . 142Frequency characteristic for human

body vibrations . . . . . . . . . . . . . . . 18Fuel and oil recommendations . . . . . . . 103Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . 74

GGear shift control . . . . . . . . . . . . . . . . . . 62General information . . . . . . . . . . . . . . . . 98General view of the handler . . . . . . . . . . 23General view of the truck . . . . . . . . . . . . 22

HHandling Fuel, Lubricants and

Coolant . . . . . . . . . . . . . . . . . 15 – 16Hoisting the truck . . . . . . . . . . . . . . . . . 100Hydraulic Circuit . . . . . . . . . . . . . . . . . . 221

IImproper use . . . . . . . . . . . . . . . . . . . . . . 8Inspection and maintenance data . . . . . 102Isolating the battery . . . . . . . . . . . . . . . . 36

LLubricate slewing ring bearing and

gear . . . . . . . . . . . . . . . . . . . . . . 177

MMalfunctions during operation . . . . . . . . . 57Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . 30


Indexg

NNormal start . . . . . . . . . . . . . . . . . . . . . . 45

OOpening the battery and air filter

compartment door . . . . . . . . . . . . 33Opening the brake hydraulic system oil

tank cover . . . . . . . . . . . . . . . . . . 33Opening the cabin door from the inside . . 30Opening the cabin rear compartment

door . . . . . . . . . . . . . . . . . . . . . . . 32Opening the engine cover . . . . . . . . . . . . 31Opening the fuse box cover . . . . . . . 34, 74Opening the transmission cover . . . . . . . 31Opening the working hydraulic system

oil tank cover . . . . . . . . . . . . . . . . 32Operating the hazard warning lights . . . . 69Operating the horn . . . . . . . . . . . . . . . . . 69Operating the spreader . . . . . . . . . . . . . 80Operating transmission dump . . . . . . . . . 65Operation of container handlers in the

plant area . . . . . . . . . . . . . . . . . . 15Overload safety switch . . . . . . . . . . . . . . 60

PParking brake . . . . . . . . . . . . . . . . . . . . 66Parking the truck . . . . . . . . . . . . . . . . . . 91Picking up a container . . . . . . . . . . . . . . 82Picking up a container CHmodel . . . . . . 84Picking up a container TLmodel . . . . . . . 82Prime the fuel system . . . . . . . . . . . . . . 133

RResidual risks . . . . . . . . . . . . . . . . . . . . 17Running-in Instructions . . . . . . . . . . . . . 15

SSafety Precautions . . . . . . . . . . . . . . . . . 14Securing the open cabin door . . . . . . . . . 30Service brake . . . . . . . . . . . . . . . . . . . . . 66Service plan . . . . . . . . . . . . . . . . . . . . . 107Slew gearbox and brake oil level check . 178Stability . . . . . . . . . . . . . . . . . . . . . . . . . 18Start-up indications . . . . . . . . . . . . . . . . 60Starting the engine . . . . . . . . . . . . . . . . . 45Steering . . . . . . . . . . . . . . . . . . . . . . . . . 64Stopping the engine . . . . . . . . . . . . . . . . 47Stopping the truck . . . . . . . . . . . . . . . . . 65Symbols . . . . . . . . . . . . . . . . . . . . . . . . . 9

TTaking the truck out of operation . . . . . . . 98Technical Data . . . . . . . . . . . . . . . . . . . 197Tighten wheel nuts . . . . . . . . . . . . . 37, 156To operate the cab pre-heater system * . . 72Towing . . . . . . . . . . . . . . . . . . . . . . . . . 93Trailer coupling . . . . . . . . . . . . . . . . . . . 91Travelling with loads . . . . . . . . . . . . . . . . 87Troubleshooting guide Diesel engine . . 182Troubleshooting guide hydraulic

system . . . . . . . . . . . . . . . . . . . . 184Truck lighting and turn indicators . . . . . . . 67Truck status display . . . . . . . . . . . . . . . . 48Truck welds inspection . . . . . . . . . 105, 158Turning on the front windscreen wiper . . . 70Tyre Specifications - Drive and Steer

Axle . . . . . . . . . . . . . . . . . . . . . . . 37

WWheel change . . . . . . . . . . . . . . . . . . . . 92Work on the boom and the front part of

the truck . . . . . . . . . . . . . . . . . . . . 99


Linde Material Handling GmbH

3578011501 EN – 2010/01/27

Reachstacker

Original instructions

AnnexC4230 - C4540 TL /5,C4026 - C4535 CH /53578011501 EN – 2010/01/27

6

Technical Data

6 Technical Data


Technical Data 6Datasheet

DatasheetTechnical Data

LINDE Reachstacker 357 05 Data sheet for material handling equipment DFG VDI 2198Designation 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 DataDatasheet

Dimensional illustration

L1L1

L2L2 L1L1

L3L3 L2L2 L1L1

L3L3 L2L2 L1L19’ 6"

h3/L3

h3/L2

h3/L1

h4

Q

6280

QQ

1790

3840

h13

CH

? / ?

h13 h10

h7

h6

h1

m1

m2

l2

y

l1

a2

b1 b2b11

Ast

b10

b13

b3

500

Wa

20’

40’

a2

1495

TL

9’ 6"

h3/L3

h3/L2

h3/L1

h4

Q

6280

QQ

1790

3840

L1L1

L2L2 L1L1

L3L3 L2L2 L1L1

L3L3 L2L2 L1L1

L3L3 L2L2 L1L1

30°

42000 kg

4200 mm

Rotation

Model capacity

Distance (a)

25000 kgCapacity (a)

–Distance (b)

–

45°

42000 kg

4100 mm

25000 kg

5300 mm

20000 kg

30°

45000 kg

4200 mm

28000 kg

–

–

45°

45000 kg

4100 mm

28000 kg

5300 mm

20000 kgCapacity (b)

5

10225 / 13980

13050 / 14 510

4

10225

13050

20'

40'

AST Travelling aisle

x

40’

20’

b11b1 b2

b10

b13

Ast

a2

a2

b13

b3

Wa

9’6”9’6”9’6”9’6”

L1L1L3L3

d3571003


7

Circuit Diagrams

7 Circuit Diagrams


Circuit Diagrams 7Electrical Circuit Diagram

Electrical Circuit DiagramElectrical Circuit

Page 1

Cummins engine QSM Tier3 Management System

K15

:30 :87

:86

:85

B19

7 8 17 18 28 38

29 30 39 40 37

A1 S2

A3 S3

BAT1 BAT2 IGN

BAT IGN

BA

463

CD

464

412411

4

619

7

5

114

150

129e

129d

129

129a

129c

496

497

409

115

137

29 25

496

497

29 25409

:115

/129

/137

129b

916

XSP

XSP

496c

496b

496a

XSP

497b

497a

OEM2

B3

S3

OEM

1

S4M1 G1

506

:7 :8 :5 :2 :1

F205A

F335A

:6 :7 :5 :3 :2

I0

S2

+24V

+

+

-

-

G2

FM11A

B+ I+

GND

122

124

125

G3

B+

GND

EX

XSP507

130

0-07

X2A:1

III00 I II

S1

F175A

:30

:87

:86 :85

K1C

1FM2120A

B4

S5

250

F343A

:4

110

X1

Chassis Ground 0v

409

F130A

F930A

F1810A

F1910A

4528 45-A

28-A

30-1

A/30

-1B

30 15-1

/15-

2

:13

:1

:14

:2

:15

:3

:16

:4

:13

:1

30-1

A/30

-1B

15-1

/15-

2

30-1

1

11-2

16

24v (IGN +) Isolator :15

24v (BAT +) Isolator :30

24v (IQAN +) E/S :45

24v (IQAN +) E/S :28

:14

:2

DANA CLARKTE27 TRANS

X10B

916

X4:15

:8X10B

X1

X10A

X10A

:4

250

:1

Y37

110

F2120A

30-1

A/30

-1B

:17

:5

:86

:85

IQAN XS2-A1 Pin 9Pg3: (180)

09-2

900-

AC

:87

:30

30-1

5

210

:7:8

:4 :3X4

M9

210

353

:1

:2

X9

K8

11-2

1

:29 :30

:25 :26

900-

AG

IQA

N X

S2-

A1

Pin

11 P

g3: (

163)

X10B Pin 5 Pg1: (64)

K16 Pin 4 Pg1: (30)

30

50A

15/54

:2

:7

:6

S1

S1-AXT2-A0 Pin 7 Pg4: (249)

X97:8 :7

24v (BAT +) :60

Airc

on c

lutc

h X

105

pin

6 P

g10:

(764

)

16-A

K16

XS2-A1 Pin 6 Pg3: (196)

11-2

1A10 1

4

11

91312 14

900-K06-2

R32

11-2

1B

45-B

28-B

5652 54 58 60 7062 64 66 68 72 74 76 78 801 3 5 7 9 10 2012 14 16 18 22 24 26 483430 32 36 38 40 42 44 46 5028

Cab harnessChasis harnessLinde engine harnessNon harness wiring


7 Circuit DiagramsElectrical Circuit Diagram

Page 2

Cab floor ground 0v

:15

IQAN-XS2-(A0) CAB FRONT

:14

:2

+24v Ign & E/Stop (28)

(VIN

-A)

(SREADER JS

)

14-1

01-1:1

OUTPUTS CAN-bus

Address resistor

+B

AT

-BAT (CA

N-H

)

(CA

N-L

) (C

AN

-H)

(CA

N-L

) (A

DD

R-L

)

(AD

DR

-H)

F315A

INPUTS

XS2-0

R21N2


28-1

28-B

(-V

RE

F) (+

5V R

EF)

ILF23A

(VIN

-B)

(SREADER JS

)

(VIN

-C)

(SREADER JS

) (V

IN-D

)

(SREADER JS

)

:28

29-1

42-1

10-1

11-1

12-1

13-1

38-1

25-1

39-1

16-1

30-1

17-1

:29 :42 :10 :11 :12 :13 :38 :25 :39 :16 :30 :17 :24

(DIN

-G) (J

S PB 1)

(VIN

-E)

(SREADER PROP R

OT)

24-1

(DIN

-H) (J

S PB 3)

(DIN

-I) (J

S PB 4)

(DIN

-J) (J

S PB 5)

(DIN

-K) (J

S PB 6)

(DIN

-F)

I II0

I II0

:03 :09

:01 :07 :10

I II0

I II0

:03 :09

:01 :07 :10

S56 S57 I II0

I II0

:03 :09

:01 :07 :10

S58

XSP42-1X

(DIN

-M)

(FRNT LGS UP)

(DIN

-T)

(DOOR SWITCH)

(DIN

-L)

(FRNT LGS DWN)

(DIN

-N)

(REAR LGS D

WN)

(DIN

-O)

(DIN

-P)

(DIN

-Q)

(DIN

-S)

(DIN

-R)

:21 :34 :20 :33 :19 :32 :18 :31:35

31-1

18-132

-1

19-1

33-1

20-1

(DO

UT-

A)

(SPARE) (D

OU

T-B

)

(SPARE) (D

OU

T-C

)

(SPARE) (D

OU

T-D

)

(SPARE) (D

OU

T-E

)

(SPARE) (D

OU

T-F)

(SPARE) (D

OU

T-G

)

(SPARE) (D

OU

T-H

)

(SPARE) (D

OU

T-I)

(SPARE) (D

OU

T-J)

(SPARE) (D

OU

T-K

)

(SPARE) (D

OU

T-L)

(SPARE)

:8 :9 :22 :23 :36 :37 :2 :3 :4 :5 :6 :7

900-

C

:26 :40 :27 :41

MD

L P

in 2

7 P

g:6

(470

)

02-0

A

03-0

A

MD

L P

in 4

1 P

g:6

(470

)

XS

2-A

1 P

in 2

7 P

g:3

(232

)

XS

2-A

1 P

in 4

1 P

g:3

(234

)

02-0

03-0

SP29-1A

29-1

A

42-1B

X93 :3 :6 :2 :5 :1 :4

S33

S34

35-1

28-1

A

28-1

:7

:1100-AJ

900-FM

:14

H9 H10

( SPREADER LOCKED)

( SPREADER U

N-LOCKED)

:2

X94

XSP900

900

X88

21-1

34-1

:2 :3

35-1

A

RH

LH

JS-10:4 :1 :2

:10 :5 :6 :7 :8 :9 :3

:1 :2

:3 :4 :5

JS-6

29-1

B

42-1

A

42-1

D

29-1

C

42-1

C

(JS PB 2)

(REAR LGS U

P)

( LGS U

NCLAMP) ( L

GS CLAMP)

:6

PB6 PB2 PB1

PB5 PB4

PB3

B31

81 83 90 10085 87 89 92 94 96 98 102 104 106 108 112 114 116 118 122 124 126 128 132 134 136 138 142 144 146 148 152 154 156 158150140130110 120 160

Cab harnessNon harness wiring Container Handler adaptor harness



Page 3

Cab floor ground 0v

:28

IQAN-XS2-(A1) CAB (FUSEBOX)

:15

(DIN

-A)

28-2

:1414-2

01-2:1

:26 :40 :27 :41

OUTPUTS

CAN-bus

Address resistor

(Park

brake s

w )

900-

D

+B

AT

-BAT (CA

N-H

)

(CA

N-L

) (C

AN

-H)

(CA

N-L

) (A

DD

R-L

)

(AD

DR

-H)

38-2

INPUTS

+24v

N3

R24

F415A

XS2-1

XS

2-A

0 P

in 2

7 P

g: (1

52)

02-0

A

03-0

AX

S2-

A0

Pin

41

Pg:

(152

)


:3

28-B

:1 :4

:5

39-2

I II0

I II0

:03 :09

:01 :07 :10

I II0

I II0

:03 :09

:01 :07 :10

I II0

I II0

:03 :09

:01 :07 :10

I II0

I II0

:03 :09

:01 :07 :10

S10 S11 S12 S13

XT2

-A0

Pin

27

Pg:

(312

)0-

27

0-41

XT2

-A0

Pin

41

Pg:

(314

)

I0 I0

:49a :58

L :31

S8

:38 :39 30-2

16-2

:30 :16 21-2

35-2

:21 :35 17-2

31-2

:17 :31 20-2

34-2

:20 :34:10

(DIN

-G)

(DIN

-H)

(DIN

-J)

(20' R

etrac

t )

(DIN

-S)

(3O' /

35' S

top in )

(DIN

-T)

(DIN

-K)

(UPA 2

)

(DIN

-L)

(DIN

-Q)

(DIN

-R)

10-2

(DIN

-I)

(40' E

xtensio

n )

(3O' /

35' S

top out )

(UPA 2

)

(DIN

-C)

(Jack

s up)

(DIN

-E)

(Cab

Fwd )

(DIN

-D)

(Jack

s dwn )

(DIN

-F)

I II0

I II0

:03 :09

:01 :07 :10

S18

12-2

13-2

:12 :13

I II0

I II0

:03 :09

:01 :07 :10

S19

24-2

25-2

:24 :25

(Cab

Rev

)

S7

18-2

32-2

(DIN

-M)

(Sea

t sw1 )

(D

IN-N

)

(Sea

t sw 2

)

:03

:01 :02

S21

19-2

(DIN

-O)

(O/rid

e key

sw )

:15

:86

:85

:86

:85

:86

:85

K4 K8 K9

CBFB

:86

:85

K10

:8 :9 :22 :23

X

(DO

UT-

A)

(Rev

erse l

ights )

(DO

UT-

B)

(Brak

e cooler

)

(DO

UT-

C)

(UPA/ p

rog lig

ht )

(DO

UT-

D)

(Horn

relay

)

(DO

UT-

F)

(Warn

ing buzzer

) BUZZER

B7

:1

:2

28-2

A

08-2

(DIN

-P)

(Sprea

der ove

ride p

b )

:18 :32 :33 :19

(DIN

-B)

(Ign sw

)

:11

11-2

(DO

UT-

G)

(Alar

m buzzer

)

BUZZER

B8

:1

:2

09-2

22-2

23-2

37-2

02-2

:37 :02

X10C

(DO

UT-

I)

( TOP AUTO/M

AN WIPER O

/P)

04-2

:04

I0 I0

S20

OVERIDE

33-2

03-2

:03

(DO

UT-

H)

(RESET P/B

LAMP )

XS2-

A1

PIN

03

03-2

:11 :12

900-

AA

900-

AC

900-

AD

900-

AE

SP900

100-

A

100-

AE

100-

AG

100-

AF

100-

AA

100-

AB

100-

AH

100-

A

900-

FH

900-

FJ

900-

FI

900-

FD

900-

FE

900-

FK

900-

FL

X94:1

2

28-2

D

28-2

G

28-2

I

28-2

H

28-2

E

28-2

F

28-2

J

28-2

K

28-2

B

28-2

C

XSP900

900

900-

FB

100-

AJ

900-

F

900-FM

SP90

0

F42

S1

Pg1: (28)

S20 Pg: (236)

S30 Pg:11 (842)

Cab floor ground 0v

900

900-

FC

X94

XSP901-E

901-

E90

0-EH

:9

:10

:9

:10

(DO

UT-

J)

(ENG R

PM ) 05

-2

:05

07-2

:07

(DO

UT-

L)

( REAR AUTO/M

AN WIPER O

/P )

S31 Pg:11 (864)

(DO

UT-

E)

(UPA O

/P)

36-2

:36

X108:2

X105-A:1 :1

X108

05-2

A

06-2

(DO

UT-

K)

(IGN SWITCH O

FF )

:06

:14

:13

K1690

0-K

(Power

slope )

(UPA 3

) (U

PA 3 )

X110

:2 :3


(Power

slope )

161 163 165 167 169 170 172 174 176 178 180 182 184 186 188 190 192 194 196 198 200 202 204 206 208 210 212 214 216 218 220 222 224 226 228 230 232 234 236 240238

Cab harnessNon harness wiring



Page 4

Chassis Ground 0v Chassis Ground 0v

:28

IQAN-XT2-(A0)

(VIN

-A)

0-28

(DO

UT-

F)

(Engine s

tart r

elay)

:140-14

0-01

:1

:27 :41 :16 :30

INPUTS

OUTPUTS CAN-bus

Address resistor

(Brak

e oil f

ilter)

0-15

+BAT

-BAT (CA

N-H

)

(CA

N-L

) (C

AN

-H)

(CA

N-L

) (A

DD

R-L

)

(AD

DR

-H)

0-38

F620A

S14

R6

:1 :1

R20

N4 CHASSIS LEFT

XT2-0

:1

+24V :4

:16

+24v Ign & E/Stop (28) +24v Ign & E/Stop (28)

X10C:9

28-B

0-28

A0-

28

:42

0-42

0-28

B

bar

:1 :2

:3

R12

bar

:1 :2

:3

R9

bar

:1 :2

:3

R8

bar

:1 :2

:3

R10

bar

:1 :2

:3

R11

0-28

C

0-28

F

0-28

G

(VIN

-J)

(PILOT PRESSURE)

(VIN

-D)

(LIFT BOTTOM 1)

(VIN

-E)

(LIFT BOTTOM 2)

(VIN

-F)

(LIFT TOP 1)

(VIN

-G)

(LIFT TOP 2)

(-V

RE

F)

(+5V

RE

F)

ILF33A

0-13

0-12

0-13

H

0-37

R7

:1 :2

0-13

D

0-13

C

0-13

G

0-13

B

0-13

A

R4 R5

(VIN

-I)

(VIN

-H)

(Brak

e oil t

emp)

:21 :39 :24 :25:35 :36 :13 :12:38 :37

0-21

0-39

0-35

0-36

0-24

0-25

:15 :29

0-29

(VIN

-B)

(JACK1 U

P) :22

Y3:86

:85

0-07

:7

K15

130

:3

(DO

UT-

B)

(Han

dbrake s

olenoid)

171

0-03

(DO

UT-

C)

(MOVIN

G CAB R

EV)

(DO

UT-

D)

(MOVIN

G CAB FWD)

0-04

0-05

:4 :5

24 42

Y1 Y2

(DO

UT-

E)

(Brak

e lights)

:6

Pg8: (636)

0-06

CR

ET-

A+)

(Sprea

der pro

p supply)

CO

UT-

A)

CR

ET-

A-)

:18 :31 :32 :19 :20 :33

CO

UT-

A)

(Sprea

der pro

p supply)

:17 :34

CR

ET-

B+)

(Movin

g cab pro

p supply)

CO

UT-

B)

CR

ET-

B-)

CO

UT-

B)

(Movin

g cab pro

p supply)

(VIN

-C)

(JACK2 U

P)

:23

0-22

0-23

E3 E4

PLT

:1

:2

Y13

0-17

0-18

:1

:2

Y10

0-19

0-20

X11:1

XS

2-A

1 P

in 1

6 P

g: (2

32)

0-27

0-41

XS

2-A

1 P

in 3

0 P

g: (2

34)

XT2

-A1

Pin

27

Pg:

5 (3

90)

0-16

0-30

XT2

-A1

Pin

41

Pg:

5 (3

90)

K1 Pg: (14)

I

S55

X-SPARE

I

S54

0-42

B

126D

0-42

C

126F

Pg:5 (382)

Pg:5 (382)

:6 :2

X51 0-28

D

0-28

E

:3

Pg:4(294)

Pg:4(274)

:3 :7

:4 :8

(Fuel lev

el)

120Ω

120Ω

X2A:1

:1

:2

:1

:2

:1

:2

:5 :10X

SP

XSP 0-42A1

:5

:5

Pg:4 (306)

XSP

126a

Pg:4

(306

)

126a

0-421a

Pg:4

(247

)

241 243 245 247 249 250 252 254 256 258 260 262 264 266 268 270 272 274 276 278 280 282 284 286 288 290 292 294 296 298 300 302 304 306 308 310 312 314 316 320318

Cab harnessChasis harnessCylinder harness Linde engine harnessNon harness wiring Jacks harness



Page 5


:28

IQAN-XT2-(A1T)

1-28

(CO

UT-

A)

(Lower pro

p valve

)

:141-14

1-01

:1

:27 :41 :26 :40

INPUTS

OUTP

UTS

CAN-bus

Address resistor

1-15

+BAT

-BAT (CA

N-H

)

(CA

N-L

) (C

AN

-H)

(CA

N-L

) (A

DD

R-L

)

(AD

DR

-H)

F720A

R19N5

CHASSIS RIGHT

XT2-A1

+24V :5

:17

+24v Ign & E/Stop (28) +24v Ign & E/Stop (28)28

-B

1-28

A1-

28

:42

1-42

bar

:1 :2

:3

S15

bar

:1 :2

:3

S16

1-28

D

1-28

C

(VIN

-J)

( LS PRESSURE)

(VIN

-I)

1-13

1-12

1-13

G

1-13

H

:39 :38 :13 :12

1-39

1-38

:15 :29

1-29

Y4

(CR

ET-

A+)

126B

1-02

1-37

R23

R18

:37

1-28

B

632

(VIN

-H)

(HYD TA

NK OIL LEVEL)

t5 sec

:2 :5

:3 :1 :6 :4

:2 :5

:1 :3 :4 :6

1-13

B

1-13

C

1-13

E

1-13

D

1-12

E

1-12

D

1-12

C

1-12

B

:1

:2

:1

:2

Y5 Y6

:1

:2

:1

:2

Y7 Y8

1-17

1-18

1-31

1-32

1-20

1-19

1-33

1-34

(Lower pro

p valve

)

:17 :18

(CO

UT-

A)

(lift p

rop va

lve)

(CR

ET-

A-)

(lift p

rop va

lve)

:31 :32 :20

(CR

ET-

B+)

(EXT pro

p valve

) (C

OU

T-B

)

(CO

UT-

B)

(RET pro

p valve

) (C

RE

T-B

-)

(RET pro

p valve

)

(EXT pro

p valve

)

:19 :33 :34

(PW

M-A

)

(PUMP C

ONTROL VALVE)

:02

Y9

644

1-05

(DO

UT-

D)

(PILOT W

DO)

:05

(VIN

-A)

(BOOM LENGTH 1)

(VIN

-B)

(BOOM LENGTH 2)

(VIN

-C)

(BOOM ANGLE 1)

(VIN

-D)

(BOOM ANGLE 2)

(VIN

-E)

(JACK1 D

WN )

(VIN

-F)

1-21

1-22

1-24

1-23

:21 :22 :24 :23 :25 :35

R13 R14

1-36

°C

S17

:1 :2

R17

( P PRESSURE)

470Ω120 Ω

x°

xcm

:36 1-25

1-35

0-42

A

0-42

D

126C

126F

(JACK2 D

WN )

I I

(VIN

-G)

(HYD O

IL TEMP )

(-V

RE

F) (+

5V R

EF)

S52 S53

LS P

(DO

UT-

C)

1-04

1-06

:04 :06

Y38 Y39

(JACKS U

P)

(JACKS D

WN)

(DO

UT-

E)

X-SPARE

X10C:10

X11:2

XT2

-A0

Pin

16

Pg:

(314

)0-

16

0-30

XT2

-A0

Pin

30

Pg:

(316

)

Pg:4 (320)

Pg:4 (320)

:1:2:3

1-13

J

1-12

A

:1

:2

:1

:2

:1

:2

:1

:2

:3 :4

:08 :07

126A 12

6B

X-SPARE

Cab harnessChasis harnessNon harness wiring Jacks harness

321 323 325 327 329 330 332 334 336 338 340 342 344 346 348 350 352 354 356 358 360 362 364 366 368 370 372 374 376 378 380 382 384 386 388 390 392 394 396 400398



Page 6

Fusebox ground 0v

F1 F2 F3 F4 F5

A

B

C

D

IQAN-MDL

CA

N-b

us

-BAT

:42

:16

:30

:31(RS

232-

RE

AD

Y)

(RS

232-

DATA

OU

T)

(RS

232-

DATA

IN)

RS232

16-0

30-0

31-0

:02

:03

:04

:05

:06

:07

:08

:09

02-0

03-0

04-0

05-0

06-0

07-0

08-0

09-0

(CA

N-A

-H)

(CA

N-A

-L)

(CA

N-B

-H)

(CA

N-B

-L)

(CA

N-C

-H)

(CA

N-C

-L)

(CA

N-D

-H)

(CA

N-D

-L)

+B

AT

+R

TC

SP28-0X

28-0

INPUTS

SP

AR

E O

UT

PU

TS

XS2-A0 PIN 26

XS2-A0 PIN 40

J1939 ENG / TRANS (X90)

J1939 ENG / TRANS (X90)

X-MDL

N1

R31

:13

:1

28-B

F210A

916-

A

(DO

UT-

A)

(SPARE)

CA

N_O

PE

N

J193

9

IQA

N B

US

J193

9

S22

F

RN

R

F

1234

1 2 3 4

bar

:1 :2

:3

R1

6 13

:C :A:5 :2

:B:B

bar

:1 :2

:3

S6

:1

:2 :3

(DIN

-B)

(VIN

-B)

(EXEL POT 1)

(VIN

-D)

(BRAKE POT)

(VIN

-C)

(EXEL POT 2)

(VIN

-E)

(BRAKE PS)

(VIN

-F)

(SERVIC

E BRAKE PS)

(-V

RE

F)

(+V

RE

F)

(DIN

-L)

(DIN

-M)

(REVERSE)

(DIN

-N)

(FWD)

(DIN

-O)

(MOVIN

G CAB 1)

:28:23 :36 :37

:25 :39 :24 :38 :34 :35 :14 :1 :20 :19 :21 :32 :33

(DIN

-C)

(DIN

-D)

(DIN

-E)

(DIN

-P)

(MOVIN

G CAB 2)

(D

IN-K

)

23-0

36-0

37-0

18-0

25-0

39-0

24-0

38-0

34-0

14-0

20-0

19-0

21-0

32-0

33-0

(DO

UT-

B)

(SPARE)

(DO

UT-

C)

(SPARE)

(DO

UT-

D)

(SPARE)

(DO

UT-

E)

(SPARE)

(DO

UT-

F)

(SPARE)

ILF13A

28-0

B

28-0

C

28-0

D

X

14-0

C

14-0

B

01-0

A

28-0

E

14-0

A

(DO

UT-

G)

(SPARE)

(DO

UT-

H)

(SPARE)

:13

:27

:41

:12

:26

:40

:11

:10

:15

(DIN

-A)

:22

22-0

35-0

01-0

(WIPERS SELECTED)

(HORN SWITCH)

R26 R3 R2

RPM

28-0

A

J1939 SPREADER / UPA

J1939 SPREADER / UPA

42-0

:18

XSP900

900

900-

B

(S25 Pg:11 (830)

(S25 Pg:11 (830)

:5 :9

:6 :1 :2 :3 :4 :7 :8

:C:A

:3KD 53B 53 31B J F R

15 15S22

28-0

BA

X

SP01

-0A

SP14-0

01-0

B

01-0

C

01-0

D

01-0

E

01-0

F

LFM CONT (X97)

LFM CONT (X97)

24v (IQAN +) E/S :28

24v (BAT +) :60

+ 24v + 24v

0v 0v +5v +5v

X104

:8

:H

28-8

900-

EI

F83A

:4

:1

:2

:3

:5

X102

X100

13-0

27-0

:3

:4

24v (IQAN +) E/S :28

B14

XSP900-E

900-

E

R1

R1-

A

R1-A

13 21

14 22

28-B

Cab harness

401 403 405 407 409 410 412 414 416 418 422 424 426 428 430 432 434 436 438 440 442 444 446 448 450 452 454 456 458 460 462 464 466 468 470 472 474 476 480478420



Page 7

XA2XS2 XA2

:26 :40 :27:14

02-0

03-0

02-0

A

(CA

N-H

)

(CA

N-L

)

(CA

N-H

)

(CA

N-L

)

:26 :40 :16 :30

(CA

N-H

)

(CA

N-L

)

(CA

N-H

)

(CA

N-L

)

:27 :41

(CA

N-H

)

(CA

N-L

)

(CA

N-H

)

(CA

N-L

)

0-27

XS2-0

X11

X10

-C

0-41

0-27

0-41

:11

:12

:03

:06

:05 :04 :03 :02

05-0

04-0

03-0

02-0

(CA

N-B

-L)

(CA

N-B

-H)

(CA

N-A

-L)

(CA

N-A

-H)

:09 :08 :07 :06

09-0

08-0

07-0

06-0

(CA

N-D

-L)

(CA

N-D

-H)

(CA

N-C

-L)

(CA

N-C

-H)

XS2-(A0) XT2-(A0) XT2-(A1T)MDL

03-0

A

0-41

0-27

0-16

0-30

0-16

0-30

(Cab) (cab front) (Chassis LHS) (Chassis RHS)

1 2 3

4 5 6

7 8 9

0*

X97

07-0

06-0

04-0

B

05-0

B

:01

:14

:01

:14

:01

AD

DR

ES

S

AD

DR

ES

S

AD

DR

ES

S

:41

J193

9 S

prea

der

C1 C1 C1 C1

C3

Transmission controller(DANA SPICER TE-17)

LINDE LFM

J1939 ENGINE / TRANS BUS

IQAN-BUS

CAN

OPE

N L

HC

BUS

CAN

2.0

B J1

939

BUS

04-0

X9005-0

04-0

05-0

SCRE

EN 1

05-0B

04-0B

XX X

N1 N2 N4 N5

B3

B4N8

R19

:C

:B

:A

CAB

M

S

X11

2

J2

:C

:B

:A 04-0A

05-0A

SCREEN 1

04-0A

05-0A

SCREEN 1:37

:47

:46

Engine ECM unit(Connector J2)

P10

:AX

19:B

X-MDL

R25

DANA PRE-WIRED TRANSMISSION HARNES

CAN-L

CAN-H

(P10) DANA Transmission harness CAN interface plug

:A

:B

P2P1 (R11) RS232 Dana transmission controller prigram / diagnostic

interface plug R11 J2

(R11) RS232 IQAN prigram / diagnostic interface plug

IQAN-BUS IQAN-BUS IQAN-BUS

IQA

N-B

US

:26 :40 :27:14

02-0

A

03-0

A

0-27

(CA

N-H

)

(CA

N-L

)

(CA

N-H

)

(CA

N-L

)

0-41

:01

AD

DR

ES

S

:41

C1

R24

(Cab fuse box)N3

J1939 ENGINE / TRANS BUS

SCREEN SCREEN

:A

:B

:C

08-0

B

09-0

B

:14 :13

:A :B

X89

05-0A

04-0A

SCREEN 1

XX

:2:1

X10

0 08-0A

09-0A

J193

9 P

rinte

r

XS2-(A1)

R20R21

:01

:02

:01

:02

XS2-1 XT2-0 XT2-1

SP08-0

SP09-0

X11

2

J1939 BUS SCREENGRND POINT ENGINE ECU

XS2

Cab harnessChasis harnessLinde engine harnessNon harness wiring

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 560558



Page 8

Chassis Ground 0v

24v Ign + (:15)

I II0 I II0 I II0

:01 :02 :09

:03 :06 :10

24v Ign + (:15)

:27

:28

:25

:26

01:15 :30

24v switch illumination

III 0

II 0

Chassis Grnd 0v

:31

:32

:29

:30I0

I0

II

30-1

7A

F4115AF49

5AF225A

:9

:21

15-1

/15-

2

15-2

1

15-2

1A

F4710A

F4810A

F455A

F465A

317L

317R

346L

346R

333/

339

334/

339

317

346

400

E10E16

:11

:23

:12

:24

F433A

F443A

345

308

F421A

:1

:13

:6

:18

15-3

1

30-1

6

15-3

/15-

4

30-1

/30-

1A

S23

S24 S25

24v (Bat +) Isolator (30)24v (Bat +) Isolator (30)

100-

BC

9

67

:14:13

:11

E20:86

:85

H6 K3

:87

:30

K3

F2315A

:7

:19

30-1

A/3

0-1B

30-1

7

:10

:22

345L

345R

309

347

400

347

347-

A

XX

:L :R :49A :49

I 0 II

I0 0I

t

H7

S25

K5

:12

:6 :7

F5010A

:2

:14

15-3

/15-

4

15-3

291

9

E1 E2 B11

:9

:86

:85


K4

08-2

900-

AA

:87

:30

:16

E3 E4

IQAN XT2-AO Pin 6Pg4: (278)

06-A

06-B

343

344

X10A

320

327

X4

X10B :1 :2

X4 :8 :9

XXX

345L

345R

X10A

X4

317L

317R

:9 :10 346L

346R

X10B:3 :4

:12X4

:11

X10B

X4

X X

:49

:49A

326

324

E17 E18 E19

320-A 327-A

320-

B

327-

B

320-C 327-C

320

327

325

321

X35R

E11 E12 E13

:31

900-

AB

4949A

1

49A

900-

A

:31

900-

FA

:4:1

:8

L R

49A

15/1 56

56A 56BS25-B

S25-B

5

E21 E14 E15

X35L:2

X35L:2

X35L:3

X35L:3

333/

339

334/

339

355

357

Pg8: (616)

Pg8: (592)

900

X

900-

EC

900-

ED

317A

346A

Cab harnessChasis harnessNon harness wiring Light harness

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 640638



Page 9

Chassis Ground 0v

24v Ign + (:15) 24v Ign + (:15)


I0 I0 I0

:05

:01 :02

:06


:09

:10

F5120A

F405A

100-

B

S26

:3

:15

15-3

/15-

4

59 189

:8

:20

15-1

/15-

212

12

E7

900-

E

X10A:1

12-A

X4:1

E8

:8 :9

X109:5 :7

I0 I0 I0

:05

:01 :02

:06 :09

:10

F5220A

100-

BA

S27

:4

:16

15-3

/15-

4

193

194

:5 :6

:2 :3

15-3

4

I0 I0 I0

:05

:01 :02

:06 :09

:10

F5310A

100-

BB

S28

:5

:17

15-3

/15-

4

924A

925

:10 :11

:1 :2

E22

15-3

3A

15-3

3

X88 X10A

X4

X10B

X4A

15-3

4A

15-3

5

15-3

5A

E6 E9

X

900

SP900

900-

EB

X

900

SP90090

0-EA

X

900

SP900

I0 I0 I0

:05

:01 :02

:06 :09

:10

F5420A

100-

BD

S32

:6

:18

15-3

/15-

4

148

145

:1 :1

E23

15-3

6

15-3

6A

X

900

SP900

900-

EE

:1 :1

901-

ED

901-

EE

E23:1 E23A:1

E23:2 E23A:2

Cab harnessChasis harnessNon harness wiring

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 720718



Page 10


24v Ign + (:15)

24v Bat + (:30) 24v Bat + (:30)

24v Ign + (:15)

F2815A

:12

:24

30-1

A/3

0-1B

B16

:86

:85


K9

22-2

:87

:30

30-2

7

329-

A

329

900-

AD

901-

B

901-

C

XSP901

F245A

:8

:20

30-1

A/3

0-1B

30-1

8

E5

E5:1

:2E5

X

901-

EB

SP901-E

901-

E

:1 :2 :3 :4 :5 :7 :6 :8

F3530A

:3

:15

15-1

/15-

215

-13

X105

X43

251/

252

:1 :2

253

254

255

256

257

:3 :4 :5 :6 :7

250

Pg1: (36)

251

252

251

252

M

263262

261

264

S46

0

Aircon clutch

M2

Cab harness Heater / blower harnessNon harness wiring

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 800798



Page 11

Cab floor Ground 0v

24v Ign + (:15)

24v Bat + (:30) 24v Bat + (:30)

24v Ign + (:15)

M

I

:08

VII

I0

M

:05 :11

:02 :07 :03 :06 :09

+24v

Was

h/w

ipe

o/p

+24v

wip

e o/

p

24v

was

h

o/p

+24v

t

:86

:85

+24v

0v

:87 :87a

:30

M

I

:08

VII

I0

M

:05 :11

:02 :07 :03 :06 :09

+24v

Was

h/w

ipe

o/p

+24v

wip

e o/

p

24v

was

h

o/p

+24v

t

:86

:85

+24v

0v

:87 :87a

:30

:2 :3

:4 :1

:2 :3

:4 :1

F2610A

F2710A

:10

:22

:11

:23

30-1

A/3

0-1B

30-1

A/3

0-1B

S30 S31

M6 M5 M8 M7M3M4

K6 K7

(IQAN XS2-A1)Pin 7 Pg 3 (222)

M

J012

57 58 229

240

226

15-1

5B

J012

M

:3

:1

XR30D1

D2D3

(IQAN MDL Pin 34 Pg 6 (442)

(IQAN MDL Pin 35 Pg 6 (444)

F3715A

:5

:17

:2 :6 :5

15-1

/15-

2

35-0

34-0

07-2

50 86

1001

1003

30-2

2

30-2

2A

30-2

3A

30-2

3

48 8547 84

Pg.2 (234)

15-1

5A

15-1

5C

K2

240-A

57-B

58-B

58-A

57-A

240-

B

226-

A

229

226-

B

56

56

900-

AF

Pg.2 (234) 100-AC100-AD

07-2

A

04-2

AS25

900-

FG

900-

FF

XSP900

900

Cab floor ground 0v

XSP900

900

1002

-A

1002

1004

-A

1004

:3 :1 :4 :7 :8

:2

:6

53CJ

H

31B5353B

15

S25

-B

S25-A

SP34

-0AX

X

XSP240

SP58

SP57

I 86 S 31B 15

31

:3 :2 :4 :6 :5

:1

M4

K2

901

X14:2

X14 X14

:1 :4

:3X14 :3

X14:3

X14

M5 M7

X

901-

A

XSP901 SP901

901-

A

XSP901

901-

A

XSP901

901-

D

XSP901

901-

F

X SP901

XSP15-15

XSP226

(IQAN XS2-A1)Pin 4 Pg 3 (226)

04-2

15-1

5

Cab harness

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 880878



Page 12

RADIO

Cab floor ground 0v Cab floor Ground 0v

24v Ign + (:15)

24v Bat + (:30)

F591A

:11

:23

F395A

:7

:19

15-3

/15-

4

15-1

/15-

2

15-4

11

15-1

7

24v24v

GND

12v

GND12v

F3630A

:4

:16

15-1

/15-

215

-14

F3010A

:27

:28

30-2

B30

-29

F295A

:25

:26

30-3

0

:1 :2 :3 :4

MB25 indeL

F253A

:9

:21

30-1

A/3

0-1B

30-2

1

F553A

:7

:19

15-3

/15-

4

15-3

7

X

:1 :2

:3

:7 :8

X97

Pg:1 (26)

11-2

1B

11-2

1

B19

Pg:1 (24)

06-0

07-0

:13 :14

MD

L P

in 6

Pg

6 (4

74)

MD

L P

in 7

Pg

6 (4

74)

CAN

-H

CAN

-L

B20

100-

AK

916-

B

X

901-

EC

SP901-E

901-

E B21

SP900

900

900-

G

F155A

:11

:23

45-B

45-6

X100:6

X

900-

H

SP900

900

:5

24v Ign + E/stop (:45)

B22

08-0

A

09-0

A

:1 :2

P7 SP08-0 (495)

P7 SP09-0 (495)

+VE

-VE

B23

:29

:30

F315A

30-2

C

B26

30-3

1

I0 I0

:06 :08

:05 :07

:10

:22

S29

F585A

15-3

/15-

415

-310

15-3

11

B27

901-

J

24v (BAT +) :60

24v (IGN +) Isolator :15

24v (BAT +) Isolator :30

24v (IQAN +) E/S :45

:1 :2 :3

:4

X101

Pg:2 (124)

30-2

A

X94 Pin 1

X94 Pin 2

Cab harness Options harnessNon harness wiring

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 960958



Page 13


24v Ign + (:15)

24v Bat + (:30) 24v Bat + (:30)

24v Ign + (:15)

F385A

:6

:1815

-1/1

5-2

15-1

6

:8

15-1

6

:1 :2X10-C

XSP900

H16

1006

1007

H17

X10-C

900-

EF

900-

EG

0 I0 I

E24

:03 :05 :09

:01 :10

S36

:2 :3X91

1008

1009

1010

:1

X91

0I

0 I S35

F325A

:31

:32

30-2

D30

-28

30-2

8A

1010

XSP900

X10-C

:01 :09

:10:03 :05

900-

EF

:3 :4 :5

B24

X91:4 :5 :6

X92:2 :3:4

:1

998

999

1011

X10-C:6

X95:1

X106:1

1012

X10-C:7

X106:2

FWD

1005

X10-B:12

X103:1

X113:1

0I

0 I S37

:01 :09

:10:03 :05

1005

X95:2

F605A

:31

:32

15-3

/4

15-4

12

B28 B29 B30HR

Cab harness Options harnessNon harness wiring

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 10401038



Page 14

24v Ign + (:15) 24v Ign + (:15)


F133A

:3215

F1010A

:19

45-B

F1110A

:20

45-B

F1210A

:21

45-B

F1410A

:22

45-B

15-8

45-2

45-3

45-4

45-5

:16

:15

:14

:13

:12

:11

:10

:9

:8

:7

:6

:5

:4

:3

:2

:1

:16

:15

:14

:13

:12

:11

:10

:9

:8

:7

:6

:5

:4

:3

:2

:1

:1

:7

:6

:5

:4

:2

:3

:9

:10

:11

:12

:8

IQAN XS2-A0 Pin 21 Pg2: (92)


21-1

34-1

S26 Pin 1 Pg9: (656) 59

189S26 Pin 2 Pg9: (662)

X88

:A

:B09-0B

08-0B

X89

45-2

45-3

45-4

15-8

45-5

IQAN MDL Pin 8 Pg6: (472)


:A

:B

:C

X111

(CORE 16)

(CORE 15)

(CORE 14)

(CORE 13)

(CORE 12)

(CORE 11)

(CORE 10)

(CORE 9)

(CORE 8)

(CORE 7)

(CORE 6)

(CORE 5)

(CORE 4)

(CORE 3)

(CORE 2)

(CORE 1)

(CORE 12)

(CORE 16)

(CORE 15)

(CORE 14)

(CORE 13)

(CORE 1)

(CORE 3)

(CORE 5)

(CORE 7)

(CORE 8)

(CORES (2/4/6/9/10/11)

(CORE 16)

(CORE 15)

(CORE 14)

(CORE 13)

(CORE 12)

(CORE 11)

(CORE 10)

(CORE 9)

(CORE 8)

(CORE 7)

(CORE 6)

(CORE 5)

:1

:2

:3

(CORE 1)

(CORE 2)/G/Y

(CORE 3)

(CORE 4)

16 x 1.5mm core Lapp cable


EL

ME

Co

mb

i C

an

Bu

s S

pre

ad

er

4 x 1.5mm multicore cable

:+24V E/stop (10A)

:+24V E/stop (10A)

:+24V E/stop (10A)

:+24V E/stop (10A)

:+24V IGN (3A)

:0V

:0V

:0V

:Work light RH

:0V

:Work light LH

:0V

:GND CAN

:H2 Not locked

:H3 Seated

:H1 locked

A&B 16 Pin Harting Socket on ELME spreader

C 6 pin Harting plug on ELME spreader

(CORE 16)

(CORE 15)

(CORE 14)

(CORE 13)

(CORE 12)

(CORE 11)

(CORE 10)

(CORE 9)

(CORE 8)

(CORE 7)

(CORE 6)

(CORE 5)

(CORE 4)

(CORE 3)

(CORE 2)

(CORE 1)

:Can high (j1939)

:Can low (j1939)

:Screen

900-I

15-8

45-2

45-3

45-4

45-5

21-1

34-1

900-I

59

189

2 CORE 0.5 mm twisted pair cable

21-1

34-1

59

189

45-2

45-3

45-4

15-8

45-5

900-I

GY

GY

X109:31:7 :8 :9 :10

:Legs frnt dwn

:Legs frnt up

:Clamped RH

:Clamped LH

:Seated foot rear RH

:Seated foot front RH

:Seated foot rear LH

:Seated foot front LH

:14

:13

:12

:11

:10

:9

:8

:7

(CORE 14)

(CORE 13)

(CORE 12)

(CORE 11)

(CORE 10)

(CORE 9)

(CORE 8)

(CORE 7)

:1 :2 :3 :4 :5 :6 :7 :8

(CO

RE 7

)

(CO

RE 8

)

(CO

RE 9

)

(CO

RE 1

0)

(CO

RE 1

1)

(CO

RE 1

2)

(CO

RE 1

3)

(CO

RE 1

4)

12

x 1

.5m

m m

ult

ico

re c

ab

le


(CO

RE 4

)

(CO

RE 5

)

(CO

RE 6

)

(CO

RE 7

)

(CO

RE 8

)

(CO

RE 9

)

(CO

RE 1

0)

(CO

RE 1

1)

(CO

RE 4

)

(CO

RE 5

)

(CO

RE 6

)

(CO

RE 7

)

(CO

RE 8

)

(CO

RE 9

)

(CO

RE10

)

(CO

RE 1

1)

A

B

C

:1 :4 :6 :7

(CO

RE 3

)

(CO

RE 2

)

(CO

RE 1

)

(CO

RE 4

)

(CO

RE 1

)

(CO

RE 2

)

(CO

RE 3

)

(CO

RE 1

)

(CO

RE 2

)

(CO

RE 3

)

G/Y

DE


G/Y

E 7 Pin Cannon plug D 8 Pin Cannon plug

F 3 Pin Deutsch

F

H9-H11 H18-H25


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 11201118



Page 15

24v Ign + (:15) 24v Ign + (:15)


F133A

:32

15

F1010A

:19

45-B

F1110A

:20

45-B

F1210A

:2145

-B

F1410A

:22

45-B

15-8

45-2

45-3

45-4

45-5

:16

:15

:14

:13

:12

:11

:10

:9

:8

:7

:6

:5

:4

:3

:2

:1

:16

:15

:14

:13

:12

:11

:10

:9

:8

:7

:6

:5

:4

:3

:2

:1

:1

:7

:6

:5

:4

:2

:3

:9

:10

:11

:12

:8



21-1

34-1

S26 Pin 1 Pg9: (656) 59

189S26 Pin 2 Pg9: (662)

X88

:A

:B

:C

09-0B

08-0B

X89

45-2

45-3

45-4

15-8

45-5



:A

:B

:C

X111

(CORE 16)

(CORE 15)

(CORE 14)

(CORE 13)

(CORE 12)

(CORE 11)

(CORE 10)

(CORE 9)

(CORE 8)

(CORE 7)

(CORE 6)

(CORE 5)

(CORE 4)

(CORE 3)

(CORE 2)

(CORE 1)

(CORE 12)

(CORE 16)

(CORE 15)

(CORE 14)

(CORE 13)

(CORE 1)

(CORE 3)

(CORE 5)

(CORE 7)

(CORE 8)

(CORES (2/4/6/9/10/11)

(CORE 16)

(CORE 15)

(CORE 14)

(CORE 13)

(CORE 12)

(CORE 11)

(CORE 10)

(CORE 9)

(CORE 8)

(CORE 7)

(CORE 6)

(CORE 5)

:1

:2

:3

(CORE 1)

(CORE 2)/G/Y

(CORE 3)

(CORE 4)



EL

ME

Can

Bu

s S

pre

ad

er


:+24V E/stop (10A)

:+24V E/stop (10A)

:+24V E/stop (10A)

:+24V E/stop (10A)

:+24V IGN (3A)

:0V

:0V

:0V

:Work light RH

:0V

:Work light LH

:0V

:GND CAN

:H2 Not locked

:H3 Seated

:H1 locked

A 16 Pin Harting Socket on ELME spreader

C 6 pin Harting plug on ELME spreader

(CORE 16)

(CORE 15)

(CORE 14)

(CORE 13)

(CORE 12)

(CORE 11)

(CORE 10)

(CORE 9)

(CORE 8)

(CORE 7)

(CORE 6)

(CORE 5)

(CORE 4)

(CORE 3)

(CORE 2)

(CORE 1)

:Can high (j1939)

:Can low (j1939)

:Screen

900-I

15-8

45-2

45-3

45-4

45-5

21-1

34-1

900-I

59

189


21-1

34-1

59

189

45-2

45-3

45-4

15-8

45-5

900-I

GY

GY :0V

X109:31:7 :8 :9 :10

A

C

:1 :4 :6 :7

(CO

RE 3

)

(CO

RE 2

)

(CO

RE 1

)

(CO

RE 4

)

(CO

RE 1

)

(CO

RE 2

)

(CO

RE 3

)

(CO

RE 1

)

(CO

RE 2

)

(CO

RE 3

)

E


(CO

RE 4

)

E 7 Pin Cannon plug

F 3 Pin Deutsch

F

(CO

RE 4

)

4 x

1.5

mm

mu

ltic

ore

c

ab

le

C 6 Pin Harting Socket on ELME spreader


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 120011981121 1123 1125 1127 1129 1130



Page 16

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 12801278

PAGE LEFT INTENTIONALLY BLANK



Page 17



Page 18

Title:

Draw

ing

num

ber

Confidential documentRefer to protection notice ISO

16016

Inspection dim.Auxillary dim. ( )

Repl. Orig.

A3

Date NameDrawn Checked Auth'd M.check

HEAVY TRUCK DIVISION

Date Checked Alteration Change No

Scale:

Page:18 of 19

357 MK5ELECTRICAL SCHEMATIC

13.10.08 G J REES 14.10.08 P HARLING

T1098513.10.08 P HARLING MK5 Re-issue

S:

A:

357 802 0261

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

D 8,11

B8 B ALARM BUZZER 3 H9 H SPREADER LOCKED GREEN LAMP 2.14.15 R4 R 1200 RESISTOR 4 S26 S 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

UGHLIGHTS ROCKER SWITCH 9

E14 B EXTERNAL MODEM 6 H11 H SPREADER SEATED AMBER LAMP 2.14.15 R6 R FUEL LEVEL SENDER S28 S SIDE LIGHTS ROCKER SWITCH 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 BATTERY 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 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 MOTOR 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

EXTEND PROP VALVE

H/LIGHTS DIP.FRONT WIPER. IND.HORN STALK SWITCH



Page 19

K3 K4 K5 K6

K7 K8 K9 K10

K1

K16

ACB

K2

F1 F9 F13

F11

F12

F14

F2

F3

F4

F5

F6

F7

F8

F15

F16

F10

25 26

1

13

2

14

3

15

4

16

5

17

6

18

7

19

8

20

9

21

10

22

11

23

12

24

F29 F31 F32

F17

F30

F18

F19

F20

F21

F22

F23

F24

F25

F26

F27

F28

F45 F47 F48

F33

F46

F34

F35

F36

F37

F38

F39

F40

F42

F43

F44

F41

F49

F50

F51

F52

F53

F54

F55

F56

F57

F58

F59

F60

F61 F62 F63 F64

FC1

FC2

FC3

FC4

27 28 29 30 31 32

25 26

1

13

2

14

3

15

4

16

5

17

6

18

7

19

8

20

9

21

10

22

11

23

12

24

27 28 29 30 31 32

25 26

1

13

2

14

3

15

4

16

5

17

6

18

7

19

8

20

9

21

10

22

11

23

12

24

27 28 29 30 31 32

25 26

1

13

2

14

3

15

4

16

5

17

6

18

7

19

8

20

9

21

10

22

11

23

12

24

27 28 29 30 31 32

Title:

Draw

ing

num

ber

Confidential documentRefer to protection notice ISO

16016

Inspection dim.Auxillary dim. ( )

Repl. Orig.

A3

Date NameDrawn Checked Auth'd M.check

HEAVY TRUCK DIVISION

Date Checked Alteration Change No

Scale:NONE

Page:19 of 19

357 MK5ELECTRICAL SCHEMATIC

13.10.08 G J REES 14.10.08 P HARLING

T1098513.10.08 P HARLING MK5 Re-issue

S:

A:

357 802 0261

DESCRIPTION

PAGE F1

F

IGN

30A

TRUCK IQAN ES SUPPLY

1

F2

F

ES

10A

IQAN CAB MDL UINT

6 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 F8

F

ES

3A

EXTERNAL MODEM

6 F9

F

IGN

30A

ELME IQAN ES SUPPLY

1 F10

F

ES

10A

ELME SPREADER SUPPLY 1

14 & 15 F11

F

ES

10A


14 & 15 F12

F

ES

10A


14 & 15 F13

F

ES

10A

ELME IGN SUPPLY

14 & 15 F14

F

ES

10A


14 & 15 F15

F

ES

5A

J1939 PRINTER /UPA

12 F16

F

ES

/

SPARE

F17

F

BAT+

5A

IGNITION SWITCH

1 F18

F

BAT+

10A

ENGINE ECM 1

1 F19

F

BAT+

10A

ENGINE ECM 2

1 F20

F

BAT+

5A

TRANSMISSION

1 F21

F

BAT+

20A

BRAKE COOLER MOTOR

1

F22

F

BAT+

5A

HAZARD WARNING LIGHTS

8

F23

F

BAT+

15A

HEADLIGHTS FLASHER

8 F24

F

BAT+

5A

INTERIOR LIGHT

10 F25

F

BAT+

5A

LFM BAT+ SUPPLY

12 F26

F

BAT+

10A

REAR WIPER

11 F27

F

BAT+

10A

TOP WIPER

11 F28

F

BAT+

5A

HORN SUPPLY

10 F29

F

BAT+

10A

DIESEL CAB HEATER 1

12 F30

F

BAT+

10A

DIESEL CAB HEATER 2

12 F31

F

BAT+

5A

COMPRESSOR SEAT

12 F32

F

BAT+

5A

STEP LIGHTING

12 F33

F

IGN

5A

TRANSMISSION

1 F34

F

IGN

3A

ALTERNATOR EXCITATION

1 F35

F

IGN

30A

HEATER BLOWER

10.16,17,18F36

F

IGN

20A

24/1 2V CONVERTER F37

F

IGN

15A

FRONT WIPER/HORN F38

F

IGN

10A

CENTRAL GREASING F39 F IGN 5A RADIO F40

F

IGN

5A

ROTATING BEACON F41

F

IGN

15A

SIDE LIGHTS / DIP LIGHTS F42

F

IGN

1A

SWITCH ILLUMINATION F43

F

IGN

3A

SIDE LIGHTS LEFT F44

F

IGN

3A

SIDE LIGHTS RIGHT F45

F

IGN

5A

DIP LIGHTS LEFT F46

F

IGN

5A

DIP LIGHTS RIGHT F47

F

IGN

10A

HEAD LIGHTS LEFT

F48 F49 F50

F F F

IGNIGN IGN

10A 5A INDICATORS 10A

HEAD UGHTS RIGHT

REVERSE LIGHTS / SOUNDER F51

F

IGN

20A

SPREADER LIGHTS F52

F

IGN

20A

BOOM LIGHTS F53

F

IGN

10A

SIDE SPOT LIGHTS F54

F

IGN

20A

CAB ROOF LIGHTS 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 F59

F

IGN

1A

HEATED SEAT F60

F

IGN

5A

HEATED MIRRORS F61

F

IGN

/

SPARE F62

F

IGN

/

SPARE F63

F

IGN

/

SPARE F64 F IGN / SPARE

-

DESCRIPTION PAGE

K1 K IGNITION RELAY 1K2K3K4K5K6K7K8K9K10K15K16K17K18K19K20

KKKKKKKKKKKKKKK

WIPER RELAYHEADLIGHTS RELAYREVERSE LIGHTSINDICATOR FLASHERREAR WIPERTOP WIPERBRAKE COOLERHORN RELAYUPA RELAY 1STARTER MOTOR RELAYIGN AUTO SWITCH OFF RELAYIGNITION RELAY AIR CON BOARD (ACB)CLUTCH RELAY AIR CON BOARD (ACB)CONDENSER RELAY AIR CON BOARD (ACB)TRINARY RELAY AIR CON BOARD (ACB)

1183 & 8811111 & 33 & 1031 & 41 & 316161616


Circuit Diagrams 7Hydraulic Circuit Diagram

Hydraulic Circuit DiagramHydraulic Circuit

Page 1

310+10barP1 P2 T

xLS

LS

60+6bar

PS

K

xP

5-1bar

1bar

3+-0.6bar

B2 A2 A

1

B1

L

P

HT

EF

HPLS

CL CR

X1

LS1

LS2

L

A

X

P

R

T

LS

LS=210 bar

pmax=210bar

260bar260bar

1

2

3

P

L

X1

LS1

LS2

A

X

P

P

T

L

R

200/160*2*272 200/180*2918 SWB

1bar

p=34bar

p=24bar

300mA=8.5bar

105ccm19ccm

19ccm105ccm

to brake system

from brake tank

DN25-30

DN25

DN18

DN25-30

DN18 pmax= 1.5bar

turbo pressure of engine1.1-2.7bar

1.15+0.03bar1.35bar

7 m

m10

2.5bar

10 m

2.5bar 1.5bar

m10

V=0.75 Litp =15barNitr.

10 m

p=35bar

pmax=1.5bar

n=2200rpm24lit/min

11ccm

p=160bar

5bar

0.5bar

DN8

DN25

DN50

DN

38

DN

30D

N50

DN15

DN25-30

DN

8

DN

8

max.max. max. max.

110lit/min 27lit/min

405bar+20 380bar+20 380bar+20

DN6

DN6

DN6

DN6

440mA-1350mA=min.7.5bar-max.28.5bar

100lit/min

9lit/min

LS=1

80ba

r

DN8

170/150*7583

0.1bar

200bar

3bar

0.3mm

1.4mm

380bar

0.3mm

420b

ar

1mm

420b

ar

1mm

0.1b

ar 200bar 3bar

XMX

LA

E

L AX

E

A

B

LMBA1B1xE

L1

A

B

L2

B1A1

BA

X

MX

L

A

MB

BLIFT CYLINDER

EXTENTION CYLINDER

STEERINGCYLINDER

DN38

DN30

DN25

DN

19

hydraulicmoving cab

spreader

Tank return spreader

leak spreader

pressure

lower

lift

retr.

ext.

OPTION

Z

P

19.7bar+0.1

19.8

bar+

0.1

abs.abs.

E

abs.

0.95bar abs.

T

RP P

T BM

SP

Y

DUMP CYLINDER

35bar pres.

WDO VALVE3B6

M

P

1mm

p =32barmax

1mm

p=

110lit/min 70lit/min

LS=1

80ba

r

Z

110L

it/m

in70

Lit/

min

JACK

S CY

L.LH

S

JACK

S CY

L.RH

S

100/

60X3

80

100/

60X3

80

225/180*2918 LWB200/180*2918 SWB225/180*2918 LWB

FOR SPREADER

SPREADER HYDR. SCHEMATICSHOULD BE SUPPLIED BYSPREADER MANUFACTURER


Linde Material Handling GmbH

3578011501 EN – 2010/01/27

357_en_0110

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