357_en_0110
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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
Operating Instructions – 3578011501 EN – 2010/01/27 III
Table of contentsg
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
IV Operating Instructions – 3578011501 EN – 2010/01/27
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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
Operating Instructions – 3578011501 EN – 2010/01/27 V
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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
4 Operating Instructions – 3578011501 EN – 2010/01/27
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.
Operating Instructions – 3578011501 EN – 2010/01/27 5
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
6 Operating Instructions – 3578011501 EN – 2010/01/27
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.
Operating Instructions – 3578011501 EN – 2010/01/27 7
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
8 Operating Instructions – 3578011501 EN – 2010/01/27
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.
Operating Instructions – 3578011501 EN – 2010/01/27 9
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
10 Operating Instructions – 3578011501 EN – 2010/01/27
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
Operating Instructions – 3578011501 EN – 2010/01/27 11
1 IntroductionEC declaration of conformity
12 Operating Instructions – 3578011501 EN – 2010/01/27
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
14 Operating Instructions – 3578011501 EN – 2010/01/27
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
Operating Instructions – 3578011501 EN – 2010/01/27 15
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
16 Operating Instructions – 3578011501 EN – 2010/01/27
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,
Operating Instructions – 3578011501 EN – 2010/01/27 17
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)
18 Operating Instructions – 3578011501 EN – 2010/01/27
Safety 2Noise emission data
• While driving LPc = 75dB(A)• Uncertainty KPA = 4 dB(A)
Operating Instructions – 3578011501 EN – 2010/01/27 19
2 SafetyNoise emission data
20 Operating Instructions – 3578011501 EN – 2010/01/27
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
22 Operating Instructions – 3578011501 EN – 2010/01/27
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
Operating Instructions – 3578011501 EN – 2010/01/27 23
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
24 Operating Instructions – 3578011501 EN – 2010/01/27
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
Operating Instructions – 3578011501 EN – 2010/01/27 25
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
26 Operating Instructions – 3578011501 EN – 2010/01/27
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).
Operating Instructions – 3578011501 EN – 2010/01/27 27
3 OverviewGauges, switches and warning lights
28 Operating Instructions – 3578011501 EN – 2010/01/27
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.
30 Operating Instructions – 3578011501 EN – 2010/01/27
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.
Operating Instructions – 3578011501 EN – 2010/01/27 31
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.
32 Operating Instructions – 3578011501 EN – 2010/01/27
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.
Operating Instructions – 3578011501 EN – 2010/01/27 33
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.
34 Operating Instructions – 3578011501 EN – 2010/01/27
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.
Re-engage the levers.
Adjusting the seat cushion angleLift both levers (3&4) individually and raiseor lower the cushion to the desired angle.
Re-engage the levers.
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.
Operating Instructions – 3578011501 EN – 2010/01/27 35
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.
36 Operating Instructions – 3578011501 EN – 2010/01/27
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.
Operating Instructions – 3578011501 EN – 2010/01/27 37
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.
38 Operating Instructions – 3578011501 EN – 2010/01/27
Operation 4Check engine oil level
Open tank cover (2).
Remove filler cap (3).
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.
Operating Instructions – 3578011501 EN – 2010/01/27 39
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.
40 Operating Instructions – 3578011501 EN – 2010/01/27
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.
Operating Instructions – 3578011501 EN – 2010/01/27 41
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
AD
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.
42 Operating Instructions – 3578011501 EN – 2010/01/27
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.
Remove filler cap (1).
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).
Operating Instructions – 3578011501 EN – 2010/01/27 43
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.
44 Operating Instructions – 3578011501 EN – 2010/01/27
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.
Operating Instructions – 3578011501 EN – 2010/01/27 45
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.
46 Operating Instructions – 3578011501 EN – 2010/01/27
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.
Operating Instructions – 3578011501 EN – 2010/01/27 47
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
48 Operating Instructions – 3578011501 EN – 2010/01/27
Operation 4Truck status display
Start-up menu
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2 3
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5
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6
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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
Operating Instructions – 3578011501 EN – 2010/01/27 49
4 OperationTruck status display
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
50 Operating Instructions – 3578011501 EN – 2010/01/27
Operation 4Truck status display
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.
Operating Instructions – 3578011501 EN – 2010/01/27 51
4 OperationTruck status display
Transmission menuWith the main screen displayed, press (B)to go to the engine screen.
This screen displays:
• 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.
Thismenu screenwill be displayed for a presettime and will then return to the main screen.
Hydraulics menuWith the main screen displayed, press (C)to go to the engine screen.
This screen displays:
• gear selected• truck speed• fuel level• joystick position (X & Y axis)• hydraulic oil temperature
Thismenu screenwill be displayed for a presettime and will then return to the main screen.
52 Operating Instructions – 3578011501 EN – 2010/01/27
Operation 4Truck status display
Spreader menuWith the main screen displayed, press (D)to go to the engine screen.
This screen displays:
• status of the load on the spreader• status of each leg
Press (D) again to display the spreaderinformation menu.
Thismenu screenwill be displayed for a presettime and will then return to the main screen.
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.
Operating Instructions – 3578011501 EN – 2010/01/27 53
4 OperationTruck status display
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 scroller knob.
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.
54 Operating Instructions – 3578011501 EN – 2010/01/27
Operation 4Truck status display
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.
Press (≡) to return to the Start-up 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.
Press (←) to return to the previous menu.
Press (F1) to return to Adjust & measuremain menu.
Press (≡) to return to the Start-up menu.
Third menu DisplaySelect settings by pressing buttons (A - D).
Change settings by pressing the scrollerknob.
Save settings by pressing the scroller knob.
Press (←) to return to the previous menu.
Press (F1) to return to Adjust & measuremain menu.
Press (≡) to return to the Start-up menu.
Operating Instructions – 3578011501 EN – 2010/01/27 55
4 OperationTruck status display
Third menu LanguageSelect the required language by turning thescroller knob.
Save settings by pressing the scroller knob.
Press (←) to return to the previous menu.
Press (F1) to return to Adjust & measuremain menu.
Press (≡) to return to the Start-up menu.
Sub menu InfoPress (F4) in the Adjust & measure mainmenu.
Press (A) to view modules status.
56 Operating Instructions – 3578011501 EN – 2010/01/27
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 previous menu.
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
Operating Instructions – 3578011501 EN – 2010/01/27 57
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.
58 Operating Instructions – 3578011501 EN – 2010/01/27
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.
Operating Instructions – 3578011501 EN – 2010/01/27 59
4 OperationStart-up indications
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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.
60 Operating Instructions – 3578011501 EN – 2010/01/27
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.
Operating Instructions – 3578011501 EN – 2010/01/27 61
4 OperationGear shift control
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R
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1
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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.
62 Operating Instructions – 3578011501 EN – 2010/01/27
Operation 4Gear shift control
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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.
Operating Instructions – 3578011501 EN – 2010/01/27 63
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.
64 Operating Instructions – 3578011501 EN – 2010/01/27
Operation 4Operating transmission dump
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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.
Operating Instructions – 3578011501 EN – 2010/01/27 65
4 OperationParking brake
F
RN
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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).
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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.
66 Operating Instructions – 3578011501 EN – 2010/01/27
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.
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LHP1
2
3
4
5
SC 7
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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
Operating Instructions – 3578011501 EN – 2010/01/27 67
4 OperationTruck lighting and turn indicators
O I II
6
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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
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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.
68 Operating Instructions – 3578011501 EN – 2010/01/27
Operation 4Operating the horn
1
2
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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).
Operating Instructions – 3578011501 EN – 2010/01/27 69
4 OperationTurning on the front windscreen wiper
O I II
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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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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.
70 Operating Instructions – 3578011501 EN – 2010/01/27
Operation 4Turning on the front windscreen wiper
1
2 3
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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.
Operating Instructions – 3578011501 EN – 2010/01/27 71
4 OperationTo operate the cab pre-heater system *
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2 3
4
5
7
8
9
1011121314
6
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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.
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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.
72 Operating Instructions – 3578011501 EN – 2010/01/27
Operation 4To operate the cab pre-heater system *
NOTE
Always shut off the heater when refuelling thetruck.
* Option
1 2 3
4
5
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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.
Operating Instructions – 3578011501 EN – 2010/01/27 73
4 OperationFuses
1
2
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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
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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
74 Operating Instructions – 3578011501 EN – 2010/01/27
Operation 4Fuses
09 Elme Iqan ES supply 30A
10 Elme spreader supply 1 10A
11 Elme spreader supply 2 10A
12 Elme spreader supply 3 10A
13 Elme ignition supply 10A
14 Elme spreader supply 4 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
Operating Instructions – 3578011501 EN – 2010/01/27 75
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
76 Operating Instructions – 3578011501 EN – 2010/01/27
Operation 4Boom and handler controls
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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.
Operating Instructions – 3578011501 EN – 2010/01/27 77
4 OperationBoom and handler controls
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DCC
1
To lift the boomPull central control lever (1) back.
To lower the boomPush central control lever (1) forward.
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DCC
1
To extend the boomPush central control lever (1) to the right.
To retract the boomPush central control lever (1) to the left.
78 Operating Instructions – 3578011501 EN – 2010/01/27
Operation 4Boom and handler controls
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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.
Operating Instructions – 3578011501 EN – 2010/01/27 79
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.
80 Operating Instructions – 3578011501 EN – 2010/01/27
Operation 4Before lifting a load
In the main screen, press (≡).
Press F4 (info).
Rotate scroller knob until load table ishighlighted.
Press scroller knob.
Operating Instructions – 3578011501 EN – 2010/01/27 81
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.
82 Operating Instructions – 3578011501 EN – 2010/01/27
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.
Operating Instructions – 3578011501 EN – 2010/01/27 83
4 OperationPicking up a container
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.
84 Operating Instructions – 3578011501 EN – 2010/01/27
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.
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.
Operating Instructions – 3578011501 EN – 2010/01/27 85
4 OperationPicking up a container
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.
86 Operating Instructions – 3578011501 EN – 2010/01/27
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.
Operating Instructions – 3578011501 EN – 2010/01/27 87
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.
88 Operating Instructions – 3578011501 EN – 2010/01/27
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
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.
Operating Instructions – 3578011501 EN – 2010/01/27 89
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.
90 Operating Instructions – 3578011501 EN – 2010/01/27
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.
Operating Instructions – 3578011501 EN – 2010/01/27 91
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).
92 Operating Instructions – 3578011501 EN – 2010/01/27
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.
Operating Instructions – 3578011501 EN – 2010/01/27 93
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
94 Operating Instructions – 3578011501 EN – 2010/01/27
Operation 4Towing
CAUTION
Bolts may be used 2 times maximum.
Remove the chocks.
Check the function of the brakes after carryingout repairs.
Operating Instructions – 3578011501 EN – 2010/01/27 95
4 OperationTowing
96 Operating Instructions – 3578011501 EN – 2010/01/27
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.
98 Operating Instructions – 3578011501 EN – 2010/01/27
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
Follow the precautions for handling fluids andlubricants.
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.
Operating Instructions – 3578011501 EN – 2010/01/27 99
5 MaintenanceGeneral remarks
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
100 Operating Instructions – 3578011501 EN – 2010/01/27
Maintenance 5General remarks
C 4226 CH / 5 73950 kg
C 4127 CH / 5 74900 kg
C 4527 CH / 5 74900 kg
C 4030 CH / 5 76700 kg
C 4531 CH / 5 81250 kg
C 4535 CH / 5 81970 kgC 4535 CH / 5 (2ndrail 83470 kg
Operating Instructions – 3578011501 EN – 2010/01/27 101
5 MaintenanceGeneral remarks
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
102 Operating Instructions – 3578011501 EN – 2010/01/27
Maintenance 5General remarks
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
Operating Instructions – 3578011501 EN – 2010/01/27 103
5 MaintenanceGeneral remarks
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,
104 Operating Instructions – 3578011501 EN – 2010/01/27
Maintenance 5General remarks
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:andrew.dickson@linde-htd.com) as soon asthey are available.
Operating Instructions – 3578011501 EN – 2010/01/27 105
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
106 Operating Instructions – 3578011501 EN – 2010/01/27
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
Operating Instructions – 3578011501 EN – 2010/01/27 107
5 MaintenanceInspection and maintenance schedule
At operating hours Carriedout
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
108 Operating Instructions – 3578011501 EN – 2010/01/27
Maintenance 5Inspection and maintenance schedule
50 h Service plan
At operating hours Carriedout
50h
General
Clean the truck (if necessary)
Check the seat belt
Check and adjust mirrors
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
Lubricate cab door hinges
Check cab mountings
Check steer axle, check mounting
Check drive axle mounting
Change transmission oil filter canisters
Check central lubrication lubricating points (option)
Fill central lubrication canister with grease (option)
Operating Instructions – 3578011501 EN – 2010/01/27 109
5 MaintenanceInspection and maintenance schedule
At operating hours Carriedout
50h
Steering and wheels
Check the wheel nuts for tightness
Check tyre pressure
Check tyres for damage and foreign objects
Clean and lubricate steering axle
Check mounting of steering axle
Check mounting of steering cylinder and steering axle swivel pins
Controls
Check 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 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
Attach maintenance sticker
110 Operating Instructions – 3578011501 EN – 2010/01/27
Maintenance 5Inspection and maintenance schedule
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
Clean the truck (if necessary)
Check the seat belt
Check and adjust mirrors
Enter the next maintenance interval
Engine
Change engine oil
Change engine oil filter
Check engine mounting
Change the fuel filter
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
Check the coolant concentration
Transmission
Change the transmission oil filter
Check and lubricate the drive shaft
Check and adjust the steer stops
Chassis
Clean and lubricate all pivots and joints
Lubricate cab door hinges
Check mounting of the steer axle, mast and drivers cabin
Check condition of the overhead guard frame
Truck welds inspection
Operating Instructions – 3578011501 EN – 2010/01/27 111
5 MaintenanceInspection and maintenance schedule
At operating hours
500 1500 2500 3500 4500
5500 6500 7500 8500 9500
10500 11500 12500 13500 14500Carriedout
15500 16500 17500 18500 19500
Check central lubrication lubricating points (option)
Fill central lubrication canister with grease (option)
Steering and wheels
Check wheel nuts for correct torque
Check tyre pressure
Check tyres for damage and foreign objects
Check the steering
Check mounting of the steer cylinder
Check and lubricate steer axle link arms and swivel pins
Check steer axle hub oil level
Check wheel hub bearing end float
Check the security of the axle clamp and drive motors
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
Check the functionality of the emergency shutdown switch
Electrical equipment
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 the hydraulic system, drive motors, pumps, valves and lines for leaks
Check condition of auxiliary hoses and replace if necessary
Load lift device
112 Operating Instructions – 3578011501 EN – 2010/01/27
Maintenance 5Inspection and maintenance schedule
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
Attach maintenance sticker
Operating Instructions – 3578011501 EN – 2010/01/27 113
5 MaintenanceInspection and maintenance schedule
1000 h Service planAt operating hours
1000 7000 11000 13000 17000Carriedout
19000
General
Clean the truck (if necessary)
Check the seat belt
Check and adjust mirrors
Enter the next maintenance interval
Engine
Change engine oil
Change engine oil filter
Change the fuel filter
Check condition and tension of drive belt
Check the engine mountings
Check the coolant concentration
Check the mounting of the turbocharger intake pipe
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 filter
Change the transmission oil
Chassis
Clean and lubricate all pivots and joints
Lubricate cab door hinges
Check cab mountings
Check mounting of the steer axle, mast and drivers cabin
Check the condition of the overhead guard frame
Check central lubrication lubricating points (option)
Fill central lubrication canister with grease (option)
114 Operating Instructions – 3578011501 EN – 2010/01/27
Maintenance 5Inspection and maintenance schedule
At operating hours
1000 7000 11000 13000 17000Carriedout
19000
Steering and wheels
Check wheel nuts for correct torque
Check tyre pressure
Check tyres for damage and foreign objects
Check the steering
Check mounting of the steer cylinder
Check and lubricate steer axle link arms and swivel pins
Check steer axle hub oil level
Check and lubricate the drive shaft
Check wheel hub bearing end float
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 electric cables, cable connectors and connections for condition and tightness
Check the batteries
Check the functionality of the electrical system
Hydraulics
Hydraulic system: Check the oil level.
Check the hydraulic tank breather filter
Check the hydraulic system, drive motors, pumps, valves and lines for leaks
Clean the radiator and hydraulic oil cooler
Load lift device
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
Operating Instructions – 3578011501 EN – 2010/01/27 115
5 MaintenanceInspection and maintenance schedule
At operating hours
1000 7000 11000 13000 17000Carriedout
19000
Lubricate the spreader
Subsequent tasks
Attach maintenance sticker
116 Operating Instructions – 3578011501 EN – 2010/01/27
Maintenance 5Inspection and maintenance schedule
2000 h Service planAt operating hours
2000h 4000h 8000 10000 14000Carriedout
16000 20000
General
Clean the truck (if necessary)
Check the seat belt
Check and adjust mirrors
Enter the next maintenance interval
Engine
Change engine oil
Change engine oil filter
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
Check the transmission mountings
Change the transmission oil filter
Change the transmission oil
Chassis
Clean and lubricate all pivots and joints
Lubricate cab door hinges
Check mounting of the steer axle, mast and drivers cabin
Check condition of the overhead guard frame
Operating Instructions – 3578011501 EN – 2010/01/27 117
5 MaintenanceInspection and maintenance schedule
At operating hours
2000h 4000h 8000 10000 14000Carriedout
16000 20000
Check central lubrication lubricating points (option)
Fill central lubrication canister with grease (option)
Steering and wheels
Check wheel nuts for correct torque
Check tyre pressure
Check tyres for damage and foreign objects
Check the steering
Check mounting of the steer cylinder
Check the condition of the steer axle
Check and lubricate steer axle link arms and swivel pins
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
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 electric cables, cable connectors and connections for condition and tightness
Check the batteries
Check the functionality of the electrical system
Hydraulics
Hydraulic system: check the oil level.
Clean the radiator and hydraulic oil cooler
Check the hydraulic tank breather filter
Renew the feed, pressure, suction and breather filter
Check the hydraulic system, drive motors, pumps, valves and lines for leaks
118 Operating Instructions – 3578011501 EN – 2010/01/27
Maintenance 5Inspection and maintenance schedule
At operating hours
2000h 4000h 8000 10000 14000Carriedout
16000 20000
Load lift device
Inspect load lifting device for proper operation
Check the condition of the tilt cylinders
Lubricate tilt cylinder bearings
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
Attach maintenance sticker
Operating Instructions – 3578011501 EN – 2010/01/27 119
5 MaintenanceInspection and maintenance schedule
3000 h Service plan
At operating hours Carriedout
3000 9000 15000
General
Clean the truck (if necessary)
Check the seat belt
Check and adjust mirrors
Enter the next maintenance interval
Engine
Change engine oil
Change engine oil filter
Change the fuel filter
Check the engine mountings
Check safety element
Check vacuum switch
Check condition and tension of drive belt
Check cooling fan belt tensioner
Check the mounting of the turbocharger intake pipe
Check the intake and exhaust system for leaks and tightness
Check coolant concentration
Check vibration damper
Check starter motor, alternator and injection pump
Transmission
Check the transmission mountings
Change the transmission oil filter
Change the transmission oil
Chassis
Clean and lubricate all pivots and joints
Lubricate cab door hinges
Check cab mountings
Check the condition of the overhead guard frame
Check central lubrication lubricating points (option)
120 Operating Instructions – 3578011501 EN – 2010/01/27
Maintenance 5Inspection and maintenance schedule
At operating hours Carriedout
3000 9000 15000
Change transmission oil filter canisters
Fill central lubrication canister with grease (option)
Check condition of structural components
Steering and wheels
Check wheel nuts for correct torque
Check tyre pressure
Check tyres for damage and foreign objects
Check the steering
Check mounting of the steer cylinder
Check and lubricate steer axle link arms and swivel pins
Check the drive axle centre and hub differential oil level
Check and adjust hub bearings
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 electric cables, cable connectors and connections for condition and tightness
Check the batteries
Check the functionality of the electrical system
Hydraulics
Change the brake hydraulic system oil
Change the working hydraulic system oil
Check the hydraulic tank breather filter
Clean the hydraulic tank pre-filter
Change hydraulic oil filter
Check the hydraulic system, drive motors, pumps, valves and lines for leaks
Clean the radiator and hydraulic oil cooler
Operating Instructions – 3578011501 EN – 2010/01/27 121
5 MaintenanceInspection and maintenance schedule
At operating hours Carriedout
3000 9000 15000
Renew the feed, pressure, suction and breather filter
Check hydraulic pump mounting bolts
Load lift device
Inspect load lifting device for proper operation
Change the handler slewing gearbox and brake oil
Check the condition of the tilt cylinders
Check the condition of the boommountings
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
General overall check
Attach maintenance sticker
122 Operating Instructions – 3578011501 EN – 2010/01/27
Maintenance 5Inspection and maintenance schedule
5000 h Service plan
At operating hours Carriedout
5000 10000 15000 20000
General
Clean the truck (if necessary)
Check the seat belt
Check and adjust mirrors
Enter the next maintenance interval
Engine
Change engine oil
Change engine oil filter
Change the fuel filter
Check the engine mountings
Change the air filter element
Change the air filter safety element
Check vacuum switch
Check the intake and exhaust system for leaks and tightness
Check condition and tension of drive belt
Check coolant concentration
Check the mounting of the turbocharger intake pipe
Check valve clearances
Transmission
Check the transmission mountings
Change the transmission oil filter
Change the transmission oil
Chassis
Clean and lubricate all pivots and joints
Lubricate cab door hinges
Check mounting of the steer axle, mast and drivers cabin
Check the condition of the overhead guard frame
Check central lubrication lubricating points (option)
Fill central lubrication canister with grease (option)
Operating Instructions – 3578011501 EN – 2010/01/27 123
5 MaintenanceInspection and maintenance schedule
At operating hours Carriedout
5000 10000 15000 20000
Steering and wheels
Check wheel nuts for correct torque
Check tyre pressure
Check tyres for damage and foreign objects
Check the steering
Check the condition of the steer axle
Clean and lubricate steer axle, check the drive axle mounting
Check and lubricate steer axle link arms and swivel pins
Check the drive axle centre and hub differential oil level
Check and adjust hub bearings
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 electric cables, cable connectors and connections for condition and tightness
Check the batteries
Check the functionality of the electrical system
Hydraulics
Check the brake hydraulic system oil
Check the working hydraulic system oil
Check the hydraulic tank breather filter
Clean the hydraulic tank pre-filter
Change hydraulic oil filter
Clean the radiator and hydraulic oil cooler
Check the hydraulic system, drive motors, pumps, valves and lines for leaks
Load lift device
Inspect load lifting device for proper operation
124 Operating Instructions – 3578011501 EN – 2010/01/27
Maintenance 5Inspection and maintenance schedule
At operating hours Carriedout
5000 10000 15000 20000
Change the twistlocks
Check the condition of the tilt cylinders
Check the handler extension cylinder bearing pads
Check the condition of the boommountings
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
General overall check
Attach maintenance sticker
Operating Instructions – 3578011501 EN – 2010/01/27 125
5 MaintenanceInspection and maintenance schedule
6000 h Service plan
At operating hours Carriedout
6000 12000 18000
General
Clean the truck (if necessary)
Check the seat belt
Check and adjust mirrors
Enter the next maintenance interval
Engine
Change engine oil
Change engine oil filter
Change the fuel filter
Check the engine mountings
Change the air filter element
Change the air filter safety element
Check condition and tension of drive belt
Check the mounting of the turbocharger intake pipe
Check the fan drive idler pulley assembly and belt
Check the turbocharger
Check valve clearances
Check the vibration damper
Check the intake and exhaust system for leaks and tightness
Flush the cooling system
Change the coolant and coolant filter
Check starter motor, alternator and injection pump
Transmission
Check the transmission mountings
Change the transmission oil filter
Change the transmission oil
Chassis
Clean and lubricate all pivots and joints
Lubricate cab door hinges
126 Operating Instructions – 3578011501 EN – 2010/01/27
Maintenance 5Inspection and maintenance schedule
At operating hours Carriedout
6000 12000 18000
Check cab mountings
Check the condition of the overhead guard frame
Change the fuel tank breather filter
Check central lubrication lubricating points (option)
Fill central lubrication canister with grease (option)
Steering and wheels
Check wheel nuts for correct torque
Check tyre pressure
Check tyres for damage and foreign objects
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
Check and lubricate the drive shaft
Check wheel hub bearing end float
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 electric cables, cable connectors and connections for condition and tightness
Check the batteries
Check the functionality of the electrical system
Hydraulics
Change the brake hydraulic system oil
Change the working hydraulic system oil
Check the hydraulic tank breather filter
Clean the hydraulic tank pre-filter
Operating Instructions – 3578011501 EN – 2010/01/27 127
5 MaintenanceEngine
At operating hours Carriedout
6000 12000 18000
Change hydraulic oil filter
Check the hydraulic system, drive motors, pumps, valves and lines for leaks
Load lift device
Inspect load lifting device for proper operation
Change the handler slewing gearbox and brake oil
Check the condition of the tilt cylinders
Check the handler extension cylinder bearing pads
Check the condition of the boommountings
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
General overall check
Attach maintenance sticker
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.
128 Operating Instructions – 3578011501 EN – 2010/01/27
Maintenance 5Engine
CAUTION
Follow the precautions for handling fluids andlubricants.
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
Follow the precautions for handling fluids andlubricants.
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.
Operating Instructions – 3578011501 EN – 2010/01/27 129
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
Follow the precautions for handling fluids andlubricants.
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).
130 Operating Instructions – 3578011501 EN – 2010/01/27
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.
Operating Instructions – 3578011501 EN – 2010/01/27 131
5 MaintenanceEngine
Drain the fuel filter
1
2d3561097
CAUTION
Follow the precautions for handling fluids andlubricants.
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.
132 Operating Instructions – 3578011501 EN – 2010/01/27
Maintenance 5Engine
d3561126
1
2
Change the fuel filter
CAUTION
Follow the precautions for handling fluids andlubricants.
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
Follow the precautions for handling fluids andlubricants.
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).
Operating Instructions – 3578011501 EN – 2010/01/27 133
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.
134 Operating Instructions – 3578011501 EN – 2010/01/27
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.
Operating Instructions – 3578011501 EN – 2010/01/27 135
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
136 Operating Instructions – 3578011501 EN – 2010/01/27
Maintenance 5Engine
d3561156
8
76
54
3
2
1
Change the air filter safety element
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).
Operating Instructions – 3578011501 EN – 2010/01/27 137
5 MaintenanceEngine
d3561139
1
2 3
Check the engine mountings
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.)
Check mounting bolts (3).
Torque ......... 100 Nm (75 lbf- ft.)
Clean the radiator and check forleaks
CAUTION
Clean the radiator only when the engine is stoppedand cool.
CAUTION
Follow the precautions for handling fluids andlubricants.
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.
138 Operating Instructions – 3578011501 EN – 2010/01/27
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
Check valve clearances
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.
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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.
140 Operating Instructions – 3578011501 EN – 2010/01/27
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
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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.
142 Operating Instructions – 3578011501 EN – 2010/01/27
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
Work on the truck on level ground. Lower the mastand handler, stop the engine and put the parkingbrake on when working.
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.
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5 MaintenanceEngine
NOTE
Capacity of cooling system ......... 44 lts
144 Operating Instructions – 3578011501 EN – 2010/01/27
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.
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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.
146 Operating Instructions – 3578011501 EN – 2010/01/27
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).
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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
If end clearances are not within thesemeasurements, contact your authoriseddealer.
148 Operating Instructions – 3578011501 EN – 2010/01/27
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.
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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
If end clearances are not within thesemeasurements, contact your authoriseddealer.
150 Operating Instructions – 3578011501 EN – 2010/01/27
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
Follow the precautions for fluids and lubricants.
CAUTION
Engine and transmission may be at operatingtemperature. Danger of burns and scalding.
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).
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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
Follow the precautions for handling fluids andlubricants.
CAUTION
Filters and oil may be hot. Danger of burns andscalding.
Open the engine compartment front cover.
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.
152 Operating Instructions – 3578011501 EN – 2010/01/27
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
Engine and transmission may be at operatingtemperature. Danger of burns and scalding.
Check the condition of the rubber mounts.Renew the rubber mounts, if damaged.
Check mounting bolts (1).
Torque ......... 175 Nm (129 lbf- ft.)
Check mounting bolts (2).
Torque ......... 195 Nm (145 lbf- ft.)
Check mounting bolts (3).
Torque ......... 100 Nm (75 lbf- ft.)
Check mounting bolts (4).
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.
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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.
154 Operating Instructions – 3578011501 EN – 2010/01/27
Maintenance 5Chassis, bodywork and fittings
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
Operating Instructions – 3578011501 EN – 2010/01/27 155
5 MaintenanceChassis, bodywork and fittings
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.
156 Operating Instructions – 3578011501 EN – 2010/01/27
Maintenance 5Chassis, bodywork and fittings
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.
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5 MaintenanceChassis, bodywork and fittings
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.
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.
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.
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Maintenance 5Chassis, bodywork and fittings
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
Operating Instructions – 3578011501 EN – 2010/01/27 159
5 MaintenanceChassis frame
Chassis frame
1
2
d3571011
Check steer axle hub oil level
CAUTION
Follow the precautions for handling fluids andlubricants.
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).
160 Operating Instructions – 3578011501 EN – 2010/01/27
Maintenance 5Chassis frame
1
2
35
4
d3561106
Clean and lubricate steer axle, checkthe mounting
CAUTION
Follow the precautions for fluids and lubricants.
CAUTION
Work on the truck on level ground. Lower the mastand handler, stop the engine and put the parkingbrake on when working.
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
Check and lubricate the drive shaft
CAUTION
Work on the truck on level ground. Lower the mastand handler, stop the engine and put the parkingbrake on when working.
CAUTION
Danger of scalds and burns.Engine and transmission may be at operatingtemperature.
Open the engine compartment front cover.
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)
Operating Instructions – 3578011501 EN – 2010/01/27 161
5 MaintenanceChassis frame
Press the grease gun until clean lubricatinggrease emerges at the bearings.
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).
162 Operating Instructions – 3578011501 EN – 2010/01/27
Maintenance 5Chassis frame
1
d3561119
Check the drive axle centre differen-tial oil level
CAUTION
Work on the truck on level ground. Lower the mast,stop the engine and put the parking brake on whenworking.
CAUTION
Follow the precautions for handling fluids andlubricants.
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).
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5 MaintenanceChassis frame
OIL
1
2
d3561120
Check the drive axle hub differentialoil level
CAUTION
Work on the truck on level ground. Lower the mast,stop the engine and put the parking brake on whenworking.
CAUTION
Follow the precautions for handling fluids andlubricants.
Position the truck so that the drive axle hublevel indicator mark (1) is horizontal.
Remove filler plug (2).
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
Follow the precautions for fluids and lubricants.
CAUTION
Work on the truck on level ground. Lower the mastand handler, stop the engine and put the parkingbrake on when working.
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 filler plug (1).
Remove drain plug (3) and allow the oil todrain completely.
Remove and discard the plug seal rings.
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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.
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5 MaintenanceElectrics
d3561146
2
3
1Check the parking brake conditionand mounting
CAUTION
Work on the truck on level ground. Lower the mastand handler, stop the engine and put the parkingbrake on when working.
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.
166 Operating Instructions – 3578011501 EN – 2010/01/27
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.
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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.
168 Operating Instructions – 3578011501 EN – 2010/01/27
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).
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5 MaintenanceHydraulics
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.
170 Operating Instructions – 3578011501 EN – 2010/01/27
Maintenance 5Hydraulics
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.
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5 MaintenanceHydraulics
1
d3561137
Change the brake hydraulic systemoil pressure filter
CAUTION
Work on the truck on level ground. Lower the mastand handler, stop the engine and put the parkingbrake on when working.
CAUTION
Follow the precautions for fluids and lubricants.
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
Follow the precautions for handling fluids andlubricants.
172 Operating Instructions – 3578011501 EN – 2010/01/27
Maintenance 5Hydraulics
CAUTION
Hydraulic oil and hydraulic oil tank may be atoperating temperature.Danger of scalds and burns.
CAUTION
Work on the truck on level ground. Lower the mastand handler, stop the engine and put the parkingbrake on when working.
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.
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5 MaintenanceHydraulics
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.
174 Operating Instructions – 3578011501 EN – 2010/01/27
Maintenance 5Hydraulics
Change the hydraulic oil - workingsystem
CAUTION
Follow the precautions for handling fluids andlubricants.
CAUTION
Hydraulic oil and hydraulic oil tank may be atoperating temperature. Danger of scalds andburns.
CAUTION
Work on the truck on level ground. Lower the mastand handler, stop the engine and put the parkingbrake on when working.
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
Operating Instructions – 3578011501 EN – 2010/01/27 175
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
Work on the truck on level ground. Retract andlower the boom, stop the engine and put the parkingbrake on when working.
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).
176 Operating Instructions – 3578011501 EN – 2010/01/27
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
Follow the precautions for handling fluids andlubricants.
CAUTION
Work on the truck on level ground. Retract andlower the boom, stop the engine and put the parkingbrake on when working.
CAUTION
This maintenance procedure requires to be carriedout at heights of more than 2 metres. Use suitableaccess equipment.Danger of fall injuries.
Lubricate the bearing grease points (1) (4points).
For lubrication use a grease gun until freshgrease emerges at the bearings.
Using a brush, apply grease to the ring gear(2).
Operating Instructions – 3578011501 EN – 2010/01/27 177
5 MaintenanceLoad lift system
1
d3571007
Slew gearbox and brake oil levelcheck
CAUTION
Follow the precautions for handling fluids andlubricants.
CAUTION
Work on the truck on level ground. Retract andlower the boom, stop the engine and put the parkingbrake on when working.
CAUTION
This maintenance procedure requires to be carriedout at heights of more than 2 metres. Use suitableaccess equipment.Danger of fall injuries.
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
Work on the truck on level ground. Lower the mast,stop the engine and put the parking brake on whenworking.
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.
178 Operating Instructions – 3578011501 EN – 2010/01/27
Maintenance 5Load lift system
1
3
d3561116
Lubricate grease nipples (1 & 3) (3 on eachtwistlock).
Press the grease gun until clean lubricatinggrease emerges at the bearings.
1 2
d3571009
Check and lubricate feet at thebottom of each leg
CAUTION
Follow the precautions for handling fluids andlubricants.
CAUTION
Work on the truck on level ground. Retract andlower the boom, stop the engine and put the parkingbrake on when working.
Lubricate the nipple in the centre shaft (1).
Lubricate the nipples at the rear of each foot(2) (3 points).
For lubrication use a grease gun until freshgrease emerges at the bearings.
Operating Instructions – 3578011501 EN – 2010/01/27 179
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).
180 Operating Instructions – 3578011501 EN – 2010/01/27
Maintenance 5Special equipment, accessories
NOTE
If filling is difficult, clean the filter in the cani-ster.
Close the battery/air filter cover (2).
* Option
Operating Instructions – 3578011501 EN – 2010/01/27 181
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
182 Operating Instructions – 3578011501 EN – 2010/01/27
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.
Contact your authoriseddealer.
Leaks in the lubricatingsystem.
Contact your authoriseddealer.
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.
Contact your authoriseddealer.
Operating Instructions – 3578011501 EN – 2010/01/27 183
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.
Contact your authorised dealer.
Lift and tilt cylinders have tightspots.
Contact your authorised dealer.
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.
Contact your authorised dealer.
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.
184 Operating Instructions – 3578011501 EN – 2010/01/27
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
Operating Instructions – 3578011501 EN – 2010/01/27 185
5 Maintenance
186 Operating Instructions – 3578011501 EN – 2010/01/27
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
Operating Instructions – 3578011501 EN – 2010/01/27 187
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
188 Operating Instructions – 3578011501 EN – 2010/01/27
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
Operating Instructions – 3578011501 EN – 2010/01/27 189
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
196 Operating Instructions – 3578011501 EN – 2010/01/27
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
Operating Instructions – 3578011501 EN – 2010/01/27 197
6 Technical DataDatasheet
Dimensional illustration
L1L1
L2L2 L1L1
L3L3 L2L2 L1L1
L3L3 L2L2 L1L19’ 6"
h3/L3
h3/L2
h3/L1
h4
Q
6280
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
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
198 Operating Instructions – 3578011501 EN – 2010/01/27
7
Circuit Diagrams
7 Circuit Diagrams
200 Operating Instructions – 3578011501 EN – 2010/01/27
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
Operating Instructions – 3578011501 EN – 2010/01/27 201
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
+24v Ign & E/Stop (28)
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
202 Operating Instructions – 3578011501 EN – 2010/01/27
Circuit Diagrams 7Electrical Circuit Diagram
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
)
+24v Ign & E/Stop (28)
: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
+24v Ign & E/Stop (28)
(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
Operating Instructions – 3578011501 EN – 2010/01/27 203
7 Circuit DiagramsElectrical Circuit Diagram
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
204 Operating Instructions – 3578011501 EN – 2010/01/27
Circuit Diagrams 7Electrical Circuit Diagram
Page 5
Chassis Ground 0v Chassis Ground 0v
: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
Operating Instructions – 3578011501 EN – 2010/01/27 205
7 Circuit DiagramsElectrical Circuit Diagram
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
206 Operating Instructions – 3578011501 EN – 2010/01/27
Circuit Diagrams 7Electrical Circuit Diagram
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
Operating Instructions – 3578011501 EN – 2010/01/27 207
7 Circuit DiagramsElectrical Circuit Diagram
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
IQAN XS2-A1 Pin 8Pg2: (90)
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
208 Operating Instructions – 3578011501 EN – 2010/01/27
Circuit Diagrams 7Electrical Circuit Diagram
Page 9
Chassis Ground 0v
24v Ign + (:15) 24v Ign + (:15)
24v switch illumination
I0 I0 I0
:05
:01 :02
:06
24v switch illumination
: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
Operating Instructions – 3578011501 EN – 2010/01/27 209
7 Circuit DiagramsElectrical Circuit Diagram
Page 10
Chassis Ground 0v Chassis Ground 0v
24v Ign + (:15)
24v Bat + (:30) 24v Bat + (:30)
24v Ign + (:15)
F2815A
:12
:24
30-1
A/3
0-1B
B16
:86
:85
IQAN XS2-A1 Pin 22Pg3: (186)
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
210 Operating Instructions – 3578011501 EN – 2010/01/27
Circuit Diagrams 7Electrical Circuit Diagram
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
Operating Instructions – 3578011501 EN – 2010/01/27 211
7 Circuit DiagramsElectrical Circuit Diagram
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
212 Operating Instructions – 3578011501 EN – 2010/01/27
Circuit Diagrams 7Electrical Circuit Diagram
Page 13
Chassis Ground 0v Chassis Ground 0v
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
Operating Instructions – 3578011501 EN – 2010/01/27 213
7 Circuit DiagramsElectrical Circuit Diagram
Page 14
24v Ign + (:15) 24v Ign + (:15)
+24v Ign & E/Stop (45) +24v Ign & E/Stop (45)
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)
IQAN XS2-A0 Pin 34 Pg2: (94)
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)
IQAN MDL Pin 9 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
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
12 x 1.5mm multicore cable
(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
2 CORE 0.5 mm twisted pair cable
G/Y
E 7 Pin Cannon plug D 8 Pin Cannon plug
F 3 Pin Deutsch
F
H9-H11 H18-H25
Cab harnessNon harness wiring
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
214 Operating Instructions – 3578011501 EN – 2010/01/27
Circuit Diagrams 7Electrical Circuit Diagram
Page 15
24v Ign + (:15) 24v Ign + (:15)
+24v Ign & E/Stop (45) +24v Ign & E/Stop (45)
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
IQAN XS2-A0 Pin 21 Pg2: (92)
IQAN XS2-A0 Pin 34 Pg2: (94)
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
IQAN MDL Pin 8 Pg6: (472)
IQAN MDL Pin 9 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
16 x 1.5mm core Lapp cable
EL
ME
Can
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 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 :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
2 CORE 0.5 mm twisted pair cable
(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
Cab harnessNon harness wiring
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
Operating Instructions – 3578011501 EN – 2010/01/27 215
7 Circuit DiagramsElectrical Circuit Diagram
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
216 Operating Instructions – 3578011501 EN – 2010/01/27
Circuit Diagrams 7Electrical Circuit Diagram
Page 17
Operating Instructions – 3578011501 EN – 2010/01/27 217
7 Circuit DiagramsElectrical Circuit Diagram
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
218 Operating Instructions – 3578011501 EN – 2010/01/27
Circuit Diagrams 7Electrical Circuit Diagram
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
ELME SPREADER SUPPLY 2
14 & 15 F12
F
ES
10A
ELME SPREADER SUPPLY 3
14 & 15 F13
F
ES
10A
ELME IGN SUPPLY
14 & 15 F14
F
ES
10A
ELME SPREADER SUPPLY 4
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
Operating Instructions – 3578011501 EN – 2010/01/27 219
7 Circuit DiagramsElectrical Circuit Diagram
220 Operating Instructions – 3578011501 EN – 2010/01/27
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
Operating Instructions – 3578011501 EN – 2010/01/27 221
Linde Material Handling GmbH
3578011501 EN – 2010/01/27
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