357 en 0110

Reachstacker
Original instructions
C4230 - C4540 TL /5,

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

Linde, an enterprise operating worldwide in
the investment and service sector, is one of
the large industrial enterprises in the EC with
its three business segments and six divisions.
The Linde Material Handling division is a leading manufacturer of industrial trucks and
hydraulics. It includes eight manufacturing
plants in the Federal Republic of Germany,
France and Great Britain, as well as subsidiaries and branches in all economically
important countries.
Operating Instructions 3578011501 EN 2010/01/27
Linde industrial trucks enjoy a worldwide

reputation - thanks to their high quality in
engineering, performance and service.
Wishing you satisfactory operation,
Linde Heavy Truck Division Limited
Linde Industrial Park
Merthyr Tydl
South Wales, UK
CF48 4LA
Tel: +44 (0)1443 624300
Fax: +44 (0) 1443 624302
Table of contents
g
Introduction
Your Linde truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Technical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Improper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Truck takeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
EC declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safety
Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Do not operate with guards removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Handling Fuel, Lubricants and Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frequency characteristic for human body vibrations
14
14
16
16
16
16
17
18
. . . . . . . . . . . . . . . . . . . . . . . . . . 18
. . . . . . . . . . . . . . . . . . . . . . . . . . 18
Noise emission data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Noise emission data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Overview
General view of the truck
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
General view of the handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Controls and Indicators
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Gauges, switches and warning lights
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Operation
Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Cab door opening and closing
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Opening the engine cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Opening the transmission cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
III
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Opening the cabin rear compartment door
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Opening the working hydraulic system oil tank cover . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Opening the brake hydraulic system oil tank cover
. . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Opening the battery and air lter 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 uid 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
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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
Maintenance
General remarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Taking the truck out of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Work on the boom and the front part of the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Hoisting the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Inspection and maintenance data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Fuel and oil recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Check the condition of structured components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Truck welds inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Inspection and maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Daily checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
As required Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
50 h Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
500 h Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1000 h Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
2000 h Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
3000 h Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
5000 h Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
6000 h Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
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Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Check engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Change the engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Change the engine oil lters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Drain the fuel lter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Change the fuel lter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Prime the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Check the air lter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Change the air lter element - check the vacuum switch . . . . . . . . . . . . . . . . . . . . . . . . 135
Change the air lter safety element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Check the engine mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Clean the radiator and check for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Check the injection nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Check valve clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Check the intake and exhaust systems for leaks and tightness . . . . . . . . . . . . . . . . . . . 141
Check the cooling system for leaks and tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Flush the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Change engine coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Check the vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Check drive belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Check the fan drive idler pulley assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Fan hub, belt driven . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Check the turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Change the transmission oil and clean the lter screen . . . . . . . . . . . . . . . . . . . . . . . .
Change transmission oil lters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check transmission mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
151
151
152
153
Chassis, bodywork and ttings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Clean the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Check seat belt for condition and correct operation* . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Tighten wheel nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Check the tyres for damage and foreign objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Check the cab mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Truck welds inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Chassis frame . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check steer axle hub oil level . . . . . . . . . . . . . . . .
Clean and lubricate steer axle, check the mounting
Check and lubricate the drive shaft . . . . . . . . . . . .
Check the drive axle mounting . . . . . . . . . . . . . . .
Check the drive axle centre differential oil level . . .
Check the drive axle hub differential oil level . . . . .
VI
. . . . . . . . . . . . . . . . . . . . . . . . . . . 160
. . . . . . . . . . . . . . . . . . . . . . . . . . . 160
. . . . . . . . . . . . . . . . . . . . . . . . . . . 161
. . . . . . . . . . . . . . . . . . . . . . . . . . . 161
. . . . . . . . . . . . . . . . . . . . . . . . . . . 162
. . . . . . . . . . . . . . . . . . . . . . . . . . . 163
. . . . . . . . . . . . . . . . . . . . . . . . . . . 164
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Change the drive axle hub differential oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Check and adjust hub bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Check the steering lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Check the parking brake condition and mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Check the brake disc wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Electrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Check battery condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Check electric cables, connectors and connections for condition and tightness . . . . . . . 167
Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Check the hydraulic system, pumps, valves and lines . . . . . . . . . . . . . . . . . . . . . . . . . 168
Change the working hydraulic system oil suction lters . . . . . . . . . . . . . . . . . . . . . . . . 169
Change the brake hydraulic system oil suction lter . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Change the brake hydraulic system oil pressure lter . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Change the brake hydraulic system oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Change the hydraulic oil - working system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Load lift system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Check and lubricate boom cylinder, boom pivot and sliding bearings . . . . . . . . . . . . . . 176
Lubricate slewing ring bearing and gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Slew gearbox and brake oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Check and lubricate the twistlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Check and lubricate feet at the bottom of each leg . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Change the twistlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Special equipment, accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Check the central lubrication* lubricating points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Fill central lubrication* canister with grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Troubleshooting guide Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Troubleshooting guide hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
User manual feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
User manual improvement record. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Annex
6
Technical Data
Datasheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
VII
Table of contents
g
Circuit Diagrams
Electrical Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Electrical Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Hydraulic Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
VIII
1
Introduction
1 Introduction
Your Linde truck
Your Linde truck
Linde lift trucks offer the best in economy,
safety and driving convenience. Therefore it
is mainly in the hands of the operator to preserve the qualities of the trucks for a long and
protable service life and to make full use of
their benets on the job. For attachments, the
proprietary operating instructions supplied
with them are applicable. Follow all hints for
operating the lift truck and carry out the maintenance and care prescribed in the inspection
and maintenance schedule regularly, on time
and with the specied lubricants. This manual
tells you all you need to know about starting, running, servicing and maintaining your
lift truck. The terms front, rear, left and
right refer to the position in which the item
concerned is installed in the truck, looking forward in the travel direction.
Approved applications Linde lift trucks are
designed for transporting and lifting the loads
stated in the load capacity diagram. In particular, we refer to the attached VDMA booklet
"Safety rules for industrial trucks" and accident prevention rules of your trade association
and the special measures required for driving
on public roads in accordance with the trafc
regulations. The safety rules for the use of
industrial trucks must be followed under all
circumstances by the responsible persons,
especially by the operator and service personnel. The user, and not Linde, is responsible
for any danger arising from applications not
authorised by the manufacturer. If you desire
to use the truck for applications not mentioned
in the manual and convert or supplement it for
this purpose, please rst contact your authorised dealer. No changes, especially conversions or modications, may be made on your
truck without the prior permission of the manufacturer. Only qualied persons authorised
by Linde are allowed to service the trucks. To
keep your warranty valid, keep a record of all
maintenance services.
Technical note These operating instructions
or excerpts thereof may only be copied, translated or transmitted to third parties after prior
written approval by the manufacturer. Linde

pursues a policy of continuous progress in the
design and construction of its products. As a
result, the illustrations and technical details
referring to design, ttings and engineering
of lift trucks are subject to change if progress
warrants it. Therefore, the manufacturer will
not accept any claims based on the specications, illustrations and descriptions contained
in this operating manual. Please submit all
enquiries concerning your truck and all orders
for spare parts to your authorized distributor,
making sure to state your correct shipping
address. For repairs, use only genuine Linde
spare parts to ensure that your Linde truck will
maintain 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, hydraulic pump and transmission, also state the
serial number of the assembly. When taking
over the lift truck, transfer the details from the
assembly type plates into this operating manual.
Truck takeover Every truck undergoes careful
inspection before leaving the factory in order
to make sure that it will be in satisfactory
condition and fully equipped as ordered
when delivered to the customer. Authorised
distributors are under obligation to re-inspect
the truck before delivery and to hand it over in
good order. In order to avoid later complaints
and inconvenience to customers, you are
requested to ascertain that the truck is in
satisfactory condition and fully equipped
at the time of delivery and to acknowledge
orderly handing/taking over of the truck in the
manufacturers certicate of conformity.
The following technical documents are supplied with each truck:
Introduction 1
Your Linde truck
1 Operating instructions
1 EC certicate of conformity (The manufacturer certies that the industrial truck
conforms to EC guidelines for machines)
1 Safety rules for the use of industrial trucks
(VDMA)
We wish you satisfactory operation.
Linde Material Handling
1 Introduction
Technical Description
General
Type 357 reachstackers are designed to lift
and transport containers between 20 ft and
40 ft in lenght and at weights up to 45 tonnes.
Maximum travel speed is 25 k.p.h. loaded,
28 k.p.h. unloaded, and maximum climbing
gradient is 30.9%. The handler has automatic
self-levelling and sway damping, 95/185
rotation and +/- 800 mm sideshift.
Engine
The trucks are tted with a Cummins 11 litre
liquid cooled, 6 cylinder turbocharged direct
injection diesel engine which develops a rated
output of 250 kW maximum engine torque
is attained at 1100 rpm. The engine draws
fuel from two tanks tted in the chassis left
hand compartment and fuel consumption is
between 15-28 l/h (according to VDI cycle).
Engine lubricating oil is ltered by a twin
element oil lter and a rotary bypass lter.
The oil cooler is of the plate type and is located
under a cast-iron cover on the right-hand side
of the engine block. A combined cooler for
engine air, water and transmission oil is tted
in the engine compartment.
Cooling air is drawn through the radiator by the
engine cooling fan and is discharged through
the engine compartment and under the drive
axle.
Transmission
An automatic, electronically controlled fourspeed powershift transmission is driven by
the engine. Manual pre-selection of gears can
also be made. The driving direction is selected
with a control lever mounted on the steering
column.
Transmission Disconnect (De-clutch)

De-clutch is the standard transmission setting,
controlled by the APC unit and is activated by
depressing the brake pedal. The transmission
oil is ltered through a twin element lter tted
4
to the left hand side of the chassis in the engine

compartment.
Driving cabin, controls, switches and

instruments
The driving cab frame forms the load guard; it
conforms to International safety standards.
The cab is tted to a rolling platform and locked
at the rear of the chassis. (CH versions are
provided with an automated hydraulically
powered moving cabin as standard). To gain
access for maintenance services, it can be
unlocked and moved.
Steps and a walkway on the left hand side of
the truck are provided for normal access. The
right hand door can be used in an emergency.
On CH models an emergency exit is situated
at the rear of the cabin.
The cab and doors have large glazed areas
to allow the driver maximum visibility during
operations. Screen wipers and washers are
tted to the front, top and rear screens with
demist functions as part of the heater system
to maintain visibility.
The boom positioning and container handler
functions are controlled by a central control
lever mounted on the drivers control centre.
Operational travel speed of the truck is restricted to 5 km/hr when: - the load lifted exceeds 70% of the truck
capacity at the given mast position.
- the boom is extended to 930 cms above
normal travel position height.
System faults are indicated on the truck status
display screen tted in the cab to the right
of the operator. Working light switches are
mounted in a panel tted on the left of the
steering column at the front windscreen lower
corner.
Also indicated on the truck status display
screen when driving is the actual gear selected, engine revs (selectable) and the fuel
level in litres. When the twistlocks are locked
Introduction 1
into a container actual load weight, maximum
load weight, boom angle and boom length
are displayed. The truck status display unit
also logs all lifting and driving activities, and
all error codes and fault codes along with the
operators actions when error and fault codes
are displayed.
The gearchange control unit and combined
electrical control switch are tted on either side
of the steering column. The switches for the
top and rear windscreen wipers and washers
are tted on the drivers control centre.
The windscreen washer reservoir is tted to
the right rear of the cab, with access to the ller
cap from the outside of the cab.
The ventilation switch and temperature
regulator is tted to the rear right of the cab.
The right rear skin panels of the cab can be
removed to allow access to the windscreen
washer reservoir.
The heater / fresh air unit is tted behind
the rear access door. This can be pivoted
outwards to allow access for maintenance.
The fuel ller cap is located within a compartment in the left side of the chassis behind a
lockable door.
Drive Axle
The drive (load) axle is driven by the transmission through a propeller shaft. The axle
is a double reduction type with spiral bevel
primary and hub planetary reduction gears.
The half shafts are fully oating, with the hubs
running on adjustable taper roller bearings.
Steer Axle
The steer (rear) axle is mounted on bushes,
which allow sufcient wheel movement
for stability over uneven ground. Steering
movement is provided by a double acting
hydraulic cylinder, acting on xed length
steering links. The steering stub axles pivot
on adjustable roller bearings and the steering
links are tted with spherical bearings.
Steering
The steering is a hydrostatic power system,
which operates the rear wheels with the
steering wheel via the steering cylinder. The
steering system can also be operated when
the engine is stopped, but a greater effort is
required to turn the steering wheel.
Braking System
The truck braking system is hydraulically operated. It is designed as a Fail Safe system
which will not release unless hydraulic pressure in the system is correct. Audible warning
of low pressure in the brake hydraulic system
is given by a buzzer tted in the drivers cab
and a visual warning on the truck status display unit.
The service brake is controlled by connected
foot pedals, one tted on either side of the
steering column.
The parking brake by an electrical push button
tted on the drivers control centre and is
automatically applied after the truck has been
stationary for 4 seconds.
An engine mounted oil pump draws oil from a
tank in the right hand chassis compartment.
The oil passes through a pressure lter and
is circulated through the brake chambers in
the drive axle to provide brake cooling and
lubrication, with a high pressure bleed to the
brake system pressure accumulator.
The service brakes are of the oil immersed
disc type. The disc type parking brake is tted
to the drive axle differential.
The service brake is controlled by valves tted
directly under the service brake pedals which
are mechanically connected to each other
using a rigid bar. The pedal control valve is
connected directly to the main brake system
control valve tted on the top of the brake
system oil lter block on the chassis.
Transmission disconnect is activated when
either of the brake pedals are depressed and
throttle selected.
1 Introduction
Working and Steering Hydraulics
The working hydraulic and steering hydraulic
systems are supplied by a single pump and
two pumps mounted in tandem which are
tted to the transmission.
The pumps draw oil through positive suction
lters from a tank built into the right hand chassis compartment and deliver at regulated pressure to the ow selection valves and steering
priority valve. With the truck stationary and no
working or steering function selected, pressure in the pump control system is maintained
between 435 and 725 p.s.i., with all other ows
returned to the hydraulic oil tank.
The ow selection, steering priority and
hydraulic control valves for the mast and
handler are mounted under the centre engine
compartment cover on the right hand side of
the chassis. They are operated by the central
control lever, and switches mounted on the
drivers control centre and the steering hand
pump.
A bleed from each control valve operates
the engine speed-up control cylinder on
the fuel injection pump. In operation the
steering system demand is given priority with
the working hydraulic functions selected as
demand requires.
When there is no steering demand all steering
pump delivery is diverted if required, to the
working system. Pressure relief valves
are tted in all hydraulic circuits to prevent
overloading.
Telescopic Boom
The telescopic boom comprises two square
section tubes. It is raised and lowered by
two single-acting hydraulic lift cylinders tted
between the chassis and the boom, and it is
extended and retracted by a double acting
hydraulic cylinder tted inside the boom.
Movement of the inner boom within the outer
is guided by heavy-duty main and side thrust
bearing pads. The boom assembly pivots on
two large bearings tted to the outer section,
with the head of the inner section having
6
bearings for the handler turntable and levelling

cylinders.
The hydraulic service lines to the lift and
extension cylinders have lock valves tted
to prevent sudden lowering of the boom upon
loss of hydraulic pressure .
The extension cylinder is attached to the inner
and outer boom sections.
Container Handler
The container handler has a hydraulic rotator and a spreader beam assembly. The
hydraulic rotator is attached to the boom by
bearings tted at the turntable top plate. Two
hydraulic brake drive units are tted on the
turntable top plate and both units are meshed
to a slewing gear tted on the turntable bottom
plate.
The spreader beam has a centre section
manufactured from two square tubes in which
the beam extensions slide. Two hydraulic
cylinders for extending the beam extensions
to the container length are attached to each
beam extension and to the centre beam.
The electrical control boxes for the beam
functions are tted on the top of the beam,
together with the hydraulic hoses. A beam
locking hydraulic cylinder (optional on TL
models standard on CH models), is tted on
each end of the centre section, each cylinder
has a sliding bolt which engages in a slot at the
24 and 30 extension positions.
The twistlock mechanisms are tted in each
end of the cross beams. They engage in the
corner castings of the container and are locked
or unlocked with a cross shaft. When the
container is raised, it is suspended on these
four twistlocks.
The positions of the twistlocks are indicated
by a three colour light display tted under the
boom head and duplicated in a repeater unit
mounted on the top left-hand side of the front
cab windscreen rail.
Additionally mechanical ags are tted to the
rear twistlocks to show the positions. Interlock
Introduction 1
Intended use
switches cut out the boom lift function if all four
twistlocks are not locked properly.
If hazardous operating conditions are detected, the yellow indicators illuminate progressively as the condition becomes less safe.
Electrical System
If unsafe operating conditions occur, the red

indicators illuminate and the safety system
prevents further unsafe operation. Any further
movement of the boom or handler is allowed
only if it gives a safe load state.
The truck has a 24 V DC electrical system

supplied by the alternator. Two 12 V 143
Ah heavy-duty batteries connected in series
are tted in the leftside chassis compartment
beside the air lter. A battery isolator facility is
included with safety in mind, as well as acting
as an anti-theft device.
The battery isolator is located between the two
lockable compartments on the left side of the
chassis.
The electrical fuse box for main truck systems,
is located at the rear right of the cab.
The truck is tted with basic road lighting, including sidemarker and tail lights, headlights,
stop lights and turn indicator lights, and reverse warning buzzer. The working lights, 8
chassis, 4 boom, are tted to illuminate the
area around the truck.
Safety Systems and Shut Down Devices

The truck safety system uses sensors tted on
the boom, chassis and lift cylinders to detect
overload. The system gives a visual indication
of the safety state to the driver using a series
of green, yellow and red colour lights.
When operating conditions are safe, the green
indicators illuminate.
When the red indicators illuminate an audible buzzer sounds within the cabin. A second
buzzer is tted and will emit an audible warning
when the load exceeds 75% of the truck capacity. The frequency of this buzzer increases
until 100% of the load is reached.
These indications are also displayed on the
truck status display screen in the cab. A load
safety status bar is displayed whenever a
load is locked onto the spreader which gives a
visual indication of the safety of the load.
Automatic lubrication system*

The truck is tted with an electrically operated
automatic lubrication system which supplies
grease to key points around the truck indicated
below.
Measured quantities of new grease are
supplied at regular pre-programmed timed
intervals to ensure efcient operation of wear
pads, bearings etc..
Indicator lights are tted inside the drivers cab
which inform the operator of the status of the
lubrication system.
* option
Intended use
Linde trucks are designed for transporting and
stacking the loads stated in the load capacity
diagram. In particular;
the special measures required for driving on

public roads in accordance with the C.U.R.,
other local regulations.
we refer to the VDMA Guidelines for the

normal and proper use of industrial trucks
(or BITA for UK market),
the safety rules of your trade association,
The rules for the intended and approved

use of industrial trucks must be followed
under all circumstances by the responsible
persons, especially by the operator and
service personnel.
1 Introduction
Improper use
The user, and not Linde, is responsible for
any danger arising from applications not
authorised by the manufacturer.
No changes, particularly no modications and

additions, may be made to the truck without
the approval of the manufacturer.
If you desire to use the truck for applications

not mentioned in this manual, please rst
contact your authorised dealer.
Improper use
The operating company or driver, and not the
manufacturer, is liable if the truck is used in a
manner that is not permitted.
WARNING
One of the major causes of accidents involving lift
trucks is the operator ignoring, or being unaware of
basic safe operating practices.
In order to ensure the safety of the operator and
others, a few basic safe operating practices outlined
below must be followed.
Never operate the truck in a potentially explosive atmosphere.

Never carry passengers (unless a buddy seat
is tted).
Do not overload the truck beyond its rated
capacity 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 greasy
surfaces.
Do not travel on uneven or obstructed ground.
Do not park the truck in front of re extinguishers, emergency exits or gangways where it
can cause an obstruction.
Never alight from a moving truck.
Prior to, and whilst travelling, ALWAYS look in

the direction of travel.
Be aware of pedestrians, and avoid situations
where they could become trapped between
the truck and a xed object.
When approaching blind corners, always
sound the horn.
Only use the truck and any attachments for
authorised applications.
When transporting a load, follow the directions
in the user manual.
On a ramp or incline: Ensure the truck
has adequate ground clearance to clear the
camber Raise the load sufciently to clear
the camber
Travel uphill with the load leading
Travel downhill with the load trailing
When raising the load lift device, ensure there
is adequate clearance.
When working near overhead electric cables,
observe the safe distance established by the
responsible authorities.
Make sure the surface on which you are travelling is capable of supporting the combined
weight of the truck and load.
Never leave the truck unattended with a raised

load.
Before leaving the operators driving position,

always turn the ignition off and ensure the park
brake is applied.
Operating Procedures
Summary
Always adapt your driving style to the conditions of the roadway, particularly hazardous
work areas and the load being transported.
A safe, competent operator is one who takes

pride in the way they operate their truck,
respects the goods they handle, and follows
Introduction 1
Truck takeover
the correct operating procedures. NEVER
TAKE CHANCES.
Symbols used
The precautions Danger, Warning, Caution,
Note und Environment Note in this manual
are provided to indicate special hazards
or unusual information requiring special
identication:
DANGER
indicates hazards that may result in personal injury
or death and/or substantial damage to the product.
WARNING
indicates hazards that may result in personal injury
and/or substantial damage to the product.
CAUTION
indicates hazards that may result in damage to or
destruction of the product.
NOTE
Identies technical information requiring

special attention because the connection may
not even be obvious to skilled personnel.
ENVIRONMENT NOTE
The information contained herein must be

observed, otherwise environmental damage
may occur.
For your safety other symbols are also used.
Please note the different symbols.
Commissioning
Check the engine oil level
Check the lifting device and attachments
Check coolant level in expansion reservoir
Regenerate the soot lter (option)
Refuel the truck
The truck can be operated at full speed immediately. Avoid sustained high loads on
the working hydraulic system and transmission system in the rst 50 hours of operation.
Re-tighten wheel nuts daily prior to starting
operation until they are seated rmly, i.e. until
no further tightening is possible.
Check the condition of the battery

Check the tyre ination pressure
Tighten the wheel nuts
Working hydraulic system: Check the oil
level
Check the braking system
Tighten opposite wheel nuts to a torque of

680 Nm.
Check the steering system
Truck takeover
Every container handler undergoes careful
inspection before leaving the factory in order
to make sure that it will be in satisfactory
condition and fully equipped as ordered
when delivered to the customer. Authorised

distributors are under obligation to reinspect
the truck before delivery and to hand it over in
good order.
9
1 Introduction
Truck takeover
In order to avoid later complaints and inconvenience to customers, you are requested to
ascertain that the truck is in satisfactory condition and fully equipped at the time of delivery
and to acknowledge orderly handing/taking
over of the truck in the manufacturers certicate of conformity.
Linde pursues a policy of continuous improvement in the design and manufacture of its
products. The illustrations and technical details referring to design, ttings and engineering of lift trucks are subject to change or modication as a result of technological progress
by Linde.
Linde is therefore unable to consider any
claims based on the specications, illustrations and descriptions contained in this Operating Instructions manual.
Please submit all enquiries concerning Linde
container handling truck orders for spare parts
to your local Linde representative, making
sure to give the correct delivery address.
For repairs use only original Linde spare parts.
Only in this way can it be guaranteed that your
Linde truck maintains its original technical
standard.
These operating instructions or excerpts
thereof may only be copied, translated or
transmitted to third parties after prior written
approval by the manufacturer.
When ordering spare parts, please specify the
part number and state the following truck data:
10
Truck model:
Serial number/year of manufacture:
Hand over date:
Additionally, specify the serial number of the
engine, mast, hydrostatic hydraulic pump,
drive pump and drive motors when ordering
parts 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 type

plates on the truck. We recommend that you
transfer this information to this manual for
ease of future reference.
The following technical documents are supplied with each fork truck:
1 Operating Instructions
1 EC certicate of conformity (The manufacturer certies that the industrial truck
conforms to EC guidelines for machines)
Safety rules for the use of industrial trucks
(VDMA)
We wish you satisfactory operation.
Linde Material Handling
Introduction 1
EC declaration of conformity
The manufacturer declares that the truck
complies with the requirements of the EC
directives valid at the time of marketing. This is
conrmed by the EC declaration of conformity
and by the CE labelling on the nameplate. See
also the following explanation.
An independent structural change or addition
to the truck can compromise safety, thus
invalidating the EC declaration of conformity.
The EC declaration of conformity must be
carefully stored and made available to the
responsible authorities.
Declaration
Linde Industrial Park
Merthyr Tydl, 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
11
1 Introduction
12
2
Safety
2 Safety
Safety rules
Safety rules
Safety rules
WARNING
Exercise care when operating your machine in
wind velocities of 24 knots / 28 mph / 45 km h or
greater, handling characteristics may be affected,
specically, high lifting and lowering operations.
Further information should be sought from the
manufacturer, or local statutory authorities.
The responsible persons, particularly the truck

operator and servicing personnel, must be
instructed in the safety rules for the normal
and proper use of the trucks included with
these operating instructions.
The employer must ensure that the operator
has understood all safety information.
Please observe the guidelines and safety
rules therein for example:
information on the operation of container
handling trucks
rules for roadways and work areas
rights, duties and safety rules for the
operator
operation in special areas
!
WARNING
The operator (employer) or the responsible

person must ensure that all the guidelines
and safety rules applicable for your truck
are observed. When instructing a trained
operator, acquaint him with the:
special features of the truck
optional attachments
special operating and working area characteristics, by training and practice driving,
shifting and steering operations until they
are completely mastered.
Only then start to train for stacking operations.
The stability of the truck in the work is ensured
if employed properly. Should the truck tip
over during unauthorised application or due
to incorrect operation, always follow the
instructions depicted below.
In case of tip-over
Follow these
Instructions
Stay
buckled up
Safety precautions
The precautions WARNING, CAUTION, ATTENTION and NOTE in this manual are provided to indicate special dangers or unusual
information requiring special identication:
DANGER
Indicates hazards that may result in personal injury
or death and/or substantial damage to the product
14
information related to starting, driving and

braking
service and repair information
recurrent inspections, accident prevention
check
disposal of grease, oil and batteries
remaining risks
Don't jump
Hold on tight
Brace feet
lean away
WARNING
Indicates hazards that may result in personal injury
and/or substantial damage to the product
CAUTION
Indicates hazards that may result in damage to or
destruction of the product
Safety 2
Safety rules
CAUTION
CAUTION
This note is found on various
positions of the truck where special
attention is required. Read the
appropriate section of your operating
instructions.
Improper handling of coolant and coolant additives

puts your health and the environment at risk.
Always handle fuel, lubricants and coolant as
required and as specied by the manufacturer.
Accident prevention check

NOTE
Identies technical information requiring

special attention because the connection may
not even be obvious to skilled personnel.
Handling fuel, lubricants and coolant

Only store uids and lubricants in approved
containers at specied storage places, as they
could be inammable. Do not allow them to
come into contact with hot objects or naked
ame.
Only use clean containers when replenishing
uids and lubricants.
Follow the manufacturers safety and disposal
instructions when using uids, lubricants and
cleaning compounds. Avoid spilling uids and
lubricants.
Remove any spillage immediately with a suitable binding agent and dispose of as specied.
Also dispose of used or contaminated uids
and lubricants as specied.
Follow laws and regulations.
Clean the area surrounding the part in question before lubrication, lter renewal or repairs
in the hydraulic system. Discard parts in an
environmentally friendly way.
CAUTION
Medical aid is required if such an injury occurs.
Do not allow hydraulic oil under pressure, for
example at a leak, to penetrate the skin.
The accident prevention rules in some countries prescribe that the forklift truck must be
checked at least once a year for proper working condition by trained personnel. Please
contact your authorised dealer in this regard.
Operation of container handlers in the

plant area
WARNING
Many plant areas are so-called limited public trafc
areas. We advise you to check if your company
liability insurance covers any damages occurring
with your truck against third parties on limited
public trafc areas.
Running-in Instructions
The truck can be operated at full speed immediately. Avoid sustained high loads on
the working hydraulic system and transmission system in the rst 50 hours of operation.
Re-tighten wheel nuts daily prior to starting
operation until they are seated rmly, i.e. until
no further tightening is possible.
Tighten opposite wheel nuts to a torque of 350
Nm.
NOTE
Observe the tightening instructions on the tag
attached to the steering column.
Checks prior to rst operation*
Coolant level in reservoir

Engine oil level
Fuel level
Working hydraulic system oil level
Tightness of wheel nuts
Tyre pressure
15
2 Safety
Safety rules
Drive motors oil volume

Battery terminals
Boom and spreader
Function of braking system
Function of steering system
Regenerate the soot lter (option)
Daily checks*
Coolant level in reservoir

Engine oil level
Hydraulic system oil level
Tyre pressure
Windscreen washer uid level
Clean, check and adjust mirrors
*A description of the services can also be

located in the alphabetical index.
Do not operate with guards removed

CAUTION
Do not operate the truck with guards removed
Danger of injury.
NOTE
Guards and covers are tted to prevent injury,

and should only be removed for maintenance
purposes. They should be retted before
returning the truck to service.
Park Brake
CAUTION
Always check that the park brake (manual and
automatic), is applied before leaving the truck.
Automatic park brake - option.
Malfunctions
In the event of a malfunction park the truck in a
safe condition, lower the load and shut off the
engine.
If tted the truck override system may be used
to make the truck safe and in some cases a
limp home mode is available to allow the truck
to be moved to a safe location for investigation
into the malfunction.
CAUTION
Some safety features are disabled when the override function is activated. Exercise extreme caution.
Do not continue to operate the truck.
Handling Fuel, Lubricants and Coolant

16
Only store uids and lubricants in approved

containers at specied storage places, as they
could be inammable. Do not allow them to
Safety 2
Safety rules
come into contact with hot objects or naked
ame.
Only use clean containers when replenishing
uids and lubricants. Follow the manufacturers safety and disposal instructions when
using uids, lubricants and cleaning compounds.
CAUTION
Improper handling of coolant and coolant additives
puts your health and the environment at risk.
Accident prevention check
Avoid spilling uids and lubricants. Remove

any spillage immediately with a suitable
binding agent and dispose of as specied.
Also dispose of used or contaminated uids
and lubricants as specied.
The accident prevention rules in some countries prescribe that the forklift truck must be
checked at least once a year for proper working condition by trained personnel. Please
contact your authorised dealer in this regard.
Follow laws and regulations.
Operation of forklift trucks in the plant area
Clean the area surrounding the part in question before lubrication, lter renewal or repairs
in the hydraulic system.
Discard parts in an environmentally friendly
way.
CAUTION
CAUTION
Many plant areas are so-called limited public trafc
areas.
We advise you to check if your company liability
insurance covers any damages occurring with your
fork truck against third parties on limited public
trafc areas.
Do not allow hydraulic oil under pressure, for

example at a leak, to penetrate the skin.
Medical aid is required if such an injury occurs.
Residual risks
Despite careful working and compliance with
all applicable standards and regulations, the
possibility of other dangers when using the
truck cannot be entirely excluded.
The truck and its possible attachments comply
with current safety regulations. Nevertheless,
even when the truck is used for its proper
purpose and all instructions are followed,
some residual risk cannot be excluded.
Even beyond the narrow danger areas of the
truck itself, a residual risk cannot be excluded.
Persons in this area around the truck must
exercise a heightened degree of awareness,
so that they can react immediately in the event
of any malfunction, incident or breakdown.
DANGER
Persons in the vicinity of the truck must be instructed regarding these dangers that arise through use
of the truck.
These operating instructions also contain additional
safety regulations.
Residual dangers can include:

Escape of consumables due to leakages or
the rupture of lines, hoses or containers,
Risk of accident when driving over difcult
ground such as gradients, smooth or
irregular surfaces, or poor visibility,
Risk of falling, tripping, slipping etc. when
moving on the truck, especially in the
wet, with leaking consumables or on icy
surfaces,
Risk of re and explosion due to the battery
and electrical voltages,
17
2 Safety
Noise emission data
Human error,
Disregarding the safety regulations,
Risk caused by unrepaired damage,
Risk caused by insufcient maintenance or

testing,
Risk caused by using the wrong consumables.
Stability
Stability is guaranteed if your truck is used
properly and according to its intended purpose. Common reasons for a loss of truck
stability include:
cornering at excessive speeds,
moving with the load raised,
moving with a load that is protruding to the
side (e.g. sideshift),
turning and driving diagonally across

slopes,
driving on slopes with the load on the
downhill 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, specically, high lifting and lowering operations. Further information should be sought from the manufacturer, your authorised distributor, or local statutory authorities.
Avoid operating the truck in high winds.

The values are determined in conformance
with EN 13059 on trucks with standard equipment 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/s Uncertainty K = 0.1 m/s
Frequency characteristic for hand arm vibrations
NOTE
The frequency characteristic for the human

body cannot be used to determine the actual
frequency load during operation. This load depends on the working conditions (conditions of
roadway, type of operation, etc) and must therefore be determined at the site, if necessary.
The specication of hand and arm vibration is
required by law, even if the values, as in this
case, do not indicate any danger.
Noise emission data

Noise emission data
Determined in the test cycle according to EN
12053 from the weighted data in the operating
modes DRIVING, LIFTING, IDLE.
18
Noise level at the drivers station

357 LPAZ = 72 dB(A)
While lifting Lpa = 75 dB(A)
While Idling LPb = 61 dB(A)
Safety 2
Noise emission data
While driving LPc = 75dB(A)
Uncertainty KPA = 4 dB(A)
19
2 Safety
Noise emission data
20
3
Overview
3 Overview
1
2
3
4
5
6
7
8
9
10
11
12
22
Lift cylinder
Boom
Boom extension cylinder
Levelling cylinder
Rotator head
Indicator lights
Container handler
Transmission cover
Drive axle
Transmission
Variable displacement pumps
Engine
13
14
15
16
17
18
19
20
21
22
23
Exhaust system
Steer axle
Cooling system radiator
Bonnet
Heater / Climate control* system
Air intake system
Drivers cab
Fuse and relay box
Battery and air lter access door
Battery isolator
Fuel ller access door
Overview 3
General view of the handler
* option

1
2
15
3
4
14
13
12
11
10
6
8
1
2
3
4
5
6
7
8
Inner boom
Levelling cylinder
Rotator drive motor
Handler electrical box
Handler centre beam
Sideshift sliding bearings
Sideshift cylinder
Twistlocks
9
10
11
12
13
14
15
Extension sliding bearings

Twistlocks guides
Handler extension
Hydraulic system control valves
Rotator gearbox
Rotator brake
Handler mountin pin
23
3 Overview
6
1
7
F
N
R
9
10
11
16
15
12
13
14
d3571000
1
2
3
4
5
6
7
8
24
Left hand display unit (LHD)

Electronic gear shift control lever (EGS)
Turn indicator lamp
Steering wheel
Multiple function electrical control lever
Ignition key switch
Display screen
Central control lever (joystick)
9
10
11
12
13
14
15
16
Drivers control centre (DCC)

Parking brake switch
Hazard warning light switch
Emergency shutdown switch
Emergency override key
Heater control
Accelerator pedal
Service brake pedals
Overview 3

LHP
RHP
SC
F
N
R
d3571001
Left hand control panel (LHP)
1
Left hand panel
2
Headlamp main beam indicator light
Right hand control panel (RHP)
1
Right hand panel
Truck status display
Steering column (SC)

1
Electronic gear shift control lever (EGS)
2
Turn indicator lamp
3
Multiple function electrical control lever
25
3 Overview
DCC
LSSP
5 4 3
6
7
TI
CHI
1
2
1
CRB 1
3
4
5
d3571002
Drivers control centre (DCC)

1
2
Twistlock switch
3
Top screen wiper and washer switch
4
Rear screen wiper and washer switch
5
Parking brake button
6
Hazard warning indicator light switch
7
Emergency stop button
8
Override switch
Load safety system panel (LSSP)
1
Load state indicator
26
Twistlock indicators (TI)

1
Truck status display indicator lights
2
Boom indicator lights
3
Flag indicators on handler
Combi-Handler indicators (CHI)
1
Handler indicator lights
2
Boom indicator lights
Cab rear bulkhead (CRB 1)
1
Climate control unit
2
Fan speed switch
3&4
Temperature regulation switches
5
Climate control switch
Overview 3
NOTE
A warning buzzer will sound if brake system

hydraulic pressure is low. A warning buzzer
will also sound if maximum load/position is
approached (red illuminated LEDs).
27
3 Overview
28
4
Operation
4 Operation
Mirrors
CAUTION
Rear view mirrors should be cleaned and adjusted
to suit the operator before commencement of
operation, and it should be noted that they are
only provided for checking the vicinity of the truck
before moving off, and to monitor the rear trafc
area. Reversing is only allowed with a direct view in
the reverse direction of travel.

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

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

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

Lift lever (1)inside the cabin, or pull down
the 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 leaving

the truck unattended.
30
3
d3561007
Operation 4
Opening the transmission cover
Opening the engine cover

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

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

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

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

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

Pull transmission cover (1) down against
gas strut pressure.
clockwise.
31
4 Operation
Opening the working hydraulic system oil tank cover
Opening the cabin rear
compartment door
1
2
Release catches (1&2) on door (3).

3
Open the door under control until the strut

(4) engages.
Closing the cabin rear compartment door

Raise door (3) to unlock strut (4) and then
lower the door to the closed position.
Push door inward until the catches (1&2)
engage.
WARNING
d3561012
Danger of injury due to trapped ngers

Take care when closing door (2).
Opening the working hydraulic

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

tank cover
Check that all tank covers and llers are
closed.
Lower cover (1).
Fit deck key (2) into lock (3) and turn
clockwise to close the lock.
32
d3561013
Operation 4
Opening the battery and air lter compartment door
Opening the brake hydraulic

system oil tank cover

Raise cover (1).
2
Closing the brake hydraulic system oil

tank cover
Check that all tank covers and llers are
closed.
Lower cover (1).
d3561014

clockwise to close the lock.
Opening the battery and air

lter compartment door
Check that door (1) swing area is free from
obstruction.
Insert key (2) and turn it anticlockwise to

open the lock.
Pull door (1) open fully.
Closing the battery and air lter compartment door

Check that door (1) swing area is free from
obstruction.
Close the door and turn key (2) clockwise to
close the lock.
d3561015
33
4 Operation
Adjusting the drivers seat
Opening the fuse box cover
The fuse box (1) is situated inside the cabin,
to the rear of the drivers seat.
Check that fuse box door (2) lowering area

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

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

NOTE
Maximum driving comfort is obtained and

vibrations are reduced by setting the seat to
the correct weight of the driver.
Setting the drivers weight

Sit on the drivers seat.
Rotate the weight setting adjuster (1) until
the drivers weight shows in the window.
d3561033
34
Operation 4
Adjusting the seat position
For a horizontal adjustment of the seat lift
lever (5).
Slide the seat forward until the desired
position to the steering wheel and pedals
is achieved.
Re-engage the lever (5).
1
d3561034
Setting the seat height

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

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

Raise both levers (3&4) and push the
cushion down to the desired height.
Adjusting the seat cushion angle
d3561035
Lift both levers (3&4) individually and raise

or lower the cushion to the desired angle.
Adjusting the seat backrest angle

Push handle (2) forwards and set the
backrest to the desired angle.
Re-engage the handle.
NOTE
Long sitting puts excessive strain on the spinal

column. Prevent strain with regular, light
exercising.
35
4 Operation
Check battery condition
Isolating the battery
NOTE
In case of an electrical re isolate the battery to

ensure any recovery work can be carried out
safely.The battery Isolator does not shut down
the engine, but isolates the truck electrically
and should be used only for maintenance
purposes or in the case of emergency.
ISOLATOR
To isolate the battery rotate isolator handle

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

handle (1) fully clockwise.
d3571081

The battery is tted in the left hand chassis
compartment (1) with the air lter and fuel
system water separator.
Check the battery, for cracks in the casing
and leakage of electrolyte.
Remove corrosion on battery terminals and

check the connections are tight.
Smear the terminals with non acid grease.
d3561023
36
Operation 4
Tighten wheel nuts
Check tyre condition and

pressure
NOTE
Low tyre pressure reduces the tyre service life

and the stability of the truck.
Check tyres for damage or excessive wear.
Remove any foreign objects from the
treads.
Check tyres for specied pressure.

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

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

CAUTION
On new trucks, or if a wheel has been removed and
replaced, the wheel nuts must be checked before
use and daily for two weeks.
Check wheel nuts every 100 hours.
Torque all wheel nuts to: approx. 350 Nm.
d3561020
37
4 Operation
Check brake hydraulic system oil level
Check working hydraulic
system oil level
CAUTION
The hydraulic oil and tank may be at working
temperature.
Danger of scalding
Fully lower the boom.

Close the spreader to the 20 position.
Stop the engine and put the parking brake
on.
Check sight glass (3) located on the RHS of

the truck.
d3571004
If required, replenish with hydraulic oil to the

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

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

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

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

high mark on the dipstick.
38
Operation 4
Open tank cover (2).
Fill to upper level in sight glass (4).
Ret ller cap (2) and close tank cover (2).
WARNING
The oil level must not drop below the low marking or
the brake may malfunction.
Maintain correct oil level.

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

parking brake ON and stop the engine.
39
4 Operation
Filling fuel
Behind the cab, remove dipstick (2) and
wipe with a clean cloth.
Fully re-insert dipstick (2) and remove it
again.
1
The oil level should be between the High

and LOW marks on dipstick (2).
If necessary, unscrew ller cap (3) and ll
engine oil as far as the high mark.
Insert dipstick (2), ret the ller cap.

NOTE
2
Filling capacity between HIGH and LOW level

marks is approximately 5 lts.
d3571018
Total lling capacity ............ approx. 35 lts.
Checking the fuel level

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

40
Operation 4
Check the transmission oil level
The fuel tank ller cap (1) located in the front
access panel on the left side of the truck.
d3571073
Remove fuel cap (1), (if the fuel cap is

lockable, rotate ap (2) and use the key
provided in lock (3) to unlock).
Fill the tank with clean diesel fuel.
Fit the tank ller cap (1) (lock the fuel cap if
tted).
NOTE
Maximum fuel capacity - 800 L

3
d3571074
Check the transmission oil

level
CAUTION
The engine must be running when making the oil
level check. Ensure that the truck is parked on
rm level ground with the parking brake on and the
transmission in neutral.
41
4 Operation
CAUTION
The engine and transmission will be at working
temperature. Danger of burns and scalds.
lubricants.
Start the engine and run it until the transmission oil is at operating temperature.
Open the transmission cover.
Remove ller cap (1) on the left hand
chassis wall.
Remove dipstick (2) and wipe it with a clean

cloth.
Replace dipstick (2) and remove it again.
d3571075
Check that the oil level is between the HIGH

and LOW mark on the dipstick.
If necessary, replenish oil through ller cap

(3), up to the high mark on dipstick (2).
FUL
L
Ret the dipstick

Fit the transmission ller cap.
Close the transmission cover.
2
Total lling capacity ......... 60 lts.

marks is approximately approx. 10 lts.
3
AD
NOTE
d3571076
42
Operation 4
Check windscreen washer reservoir uid level
Check coolant level in header

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

high marks.
If required, replenish with coolant mixture.
Ret ller cap (1).

d3571018
NOTE
In hot climates check the coolant level twice

daily.
Check windscreen washer

reservoir uid level
NOTE
The windscreen washer reservoir is tted

under a exible cover in the cab right rear bulkhead. The reservoir should be replenished
using a good quality washer uid/water mixed
to the uid manufacturers specications.
Lift exible cover (1).
Open reservoir cap (2).

Fill the reservoir to the base of the ller neck
with washer uid/water mixture.
d3561176
Close reservoir cap (2).

Fit exible cover (1).
43
4 Operation
Checking the twistlocks and warning lights for proper operation
Checking the twistlocks and
warning lights for proper
operation
2, 3
NOTE
A container is required for this inspection. The

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

lower the twistlocks into the corner castings.
When the twistlocks are seated, yellow lights
(2), and red lights (3) will illuminate on the
boom twistlock indicators and on the truck
status display screen. Indicator ags (4) on
the handler are in the not locked position
d3571016
If the twistlocks are not correctly seated, lights

(2) will ash.
Lock the twistlocks.
Yellow lights (2) will remain illuminated. Red
lights (3) will extinguish, and green lights
(1) will illuminate on the boom twistlock
indicators and on the truck status display
screen. Indicator ags (4) must be in the
locked (orange) position.
If the twistlocks are not correctly locked lights
(1) or (3) will ash, the truck status display
screen will indicate which twistlock is not
correctly locked.
Lift the handler slightly.
Yellow indicator lights (2) extinguish.
Handler and indicator lights are working
properly.
CAUTION
Contact your authorised dealer if one of the functions and indicator lights does not operate as described above.
44
Operation 4
Normal start
Normal start
NOTE
The engine is equipped with a start-stop

system controlled by the engine oil pressure.
When the engine does not reach or hold
operating pressure when starting or during
operation, the engine is shut off. Please
CAUTION
If this start-stop system is activated, discontinue
the starting procedure to prevent damage to the
engine.
WARNING
Danger of carbon monoxide poisoning!
Do not let the engine run in unventilated enclosed
spaces.
CAUTION
Do not operate the starter with the engine running!
This will damage the engine and starter.
Starting the engine
I
II
III
NOTE
The directional lever to the left of the steering

column must be in the neutral position.
Sit on the drivers seat.
Insert ignition key (1).
Turn the key clockwise to position (I). The
electrical system is now energised, and an
audible buzzer sounds while hydraulic and
engine oil pressures are checked by the
ECM and found to be within specications.
The red indicator lights on the mast and in
the cabin are illuminated.
d3571020
On the truck display monitor, enter the driver

pin code by pressing buttons A, B, C & D
until the correct code is shown.
Press F2 to enter.
45
4 Operation
Normal start
NOTE
Driver pin code is optional.

The truck can then be started normally.
Ensure the truck is in neutral, and that the
parking brake is applied.
After the buzzer has stopped, turn the
key clockwise to position (III), the engine
warning lights illuminate.
As soon as the engine starts, release the
ignition key.
The engine warning lights extinguish.
NOTE
If the engine does not start after 20 seconds,

wait at least 2 minutes before repeating the
starting procedure. If the engine fails to start
after the third attempt, check the uidity of
the diesel fuel and the battery charge levels
against the recommended values.
Electronic control module system

The Cummins engine is tted with an advanced electronic monitoring and fuel injection system controlled by the ECM (electronic
control module). This unit will indicate faults or
potential problems on display screen.
NOTE
Do not start the engine if an engine fault is

displayed on the truck status display.
On start up all of the lights will illuminate, and
extinguish after a few seconds in the order
yellow, red, blue. When a fault is detected by
the ECM the engine will be shut down or power
will be reduced.
There is a fault analysis procedure available please contact your authorised Linde dealer
for further information.
CAUTION
Failure to observe the warning lights could lead to
serious engine damage.
46
Operation 4
Normal start
CAUTION
On start up, the truck must always be in neutral.
If forward or reverse gears are selected before
switching on the ignition, start up is isolated, and
the truck cannot be started.
Cold Start
Turn ignition key to position II and hold for
15 - 20 seconds.
On the truck display monitor, enter the driver

pin code by pressing buttons A, B, C & D
until the correct code is shown.
2
3
Press F2 to enter.
NOTE
Driver pin code is optional.

Turn key clockwise to position (III).
As soon as the engine starts, release the
accelerator pedal and return the key to
position (II).
d3571021
Release ignition key.

NOTE
Do not warm up the engine at idle speed.

Always allow time for the engine to warm up
before using maximum speed, especially
in cold climates. The engine will attain its
operating temperature after running briey
with a moderate load and at various revs.
Stopping the engine

NOTE
Do not stop the engine at full speed, allow to

idle for at least 3 minutes before shutting off.
Release accelerator pedal (4).
Bring the truck to a controlled stop.
Press parking brake button (3).
Shift the electronic gear shift control lever to
neutral and let the engine idle for 3 minutes
to achieve a temperature balance.
47
4 Operation
CAUTION
With engines tted with a turbocharger there is also
the danger of the shaft bearing running dry and
becoming damaged due to the high speed of the
turbocharger shaft (approx. 100,000 rpm at full
speed).
Turn ignition key anticlockwise to the zero

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

The drive monitors purpose is to efciently
control the trucks hydraulic system and
drive line by utilising both analog and digital
information from various sensors. This will
give the driver a complete overview of the
trucks status and activities during operation,
and give a complete history of the trucks
activities. It also provides truck information
such as:
48
Load table
Engine serial number
Machine serial number
Transmission serial number
Hydraulic pump serial number
Valve serial number
Spreader serial number
Boom serial number
Machine model
Commission date
Operation 4
Start-up menu
5
6
7
8
16
9
15
14
12
13
11
10
d3571023
1
2
3
4
5
6
7
8
9
10
Selected gear
Speedometer
Clock
Engine menu
Transmission menu
Hydraulics menu
Spreader menu
Measure and adjustment menus
Scroller knob
Return key
11
12
13
14
15
16
F5 key. In main screen (shown) this button

alternates automatic / manual wiper operation
F4 key. In main menu screen resets the trip
counter
F3 key. In main menu screen resets the trip
fuel counter
F2 key. In main menu screen turns engine
rpm monitor on / off
F1 key. In main menu screen toggles
between rst / second gear start
Fuel level indicator
The scroller knob

49
4 Operation
To step up/down in the menu, turn scroller
knob(8). The selected function is highlighted.
Press scroller knob (8) to activate the selected
function.
NOTE
Menu content may vary depending on which

screen is open.
Driver pin code (optional)

When the ignition is switched on this screen is
displayed.
Enter the driver pin code by pressing
buttons A, B, C & D until the correct code
is shown.
Press F2 to enter
The truck can then be started normally.
Main screen
When the truck has been started the main
screen is displayed.
The main screen displays:
Selected startup gear
Current engine RPM
Total distance travelled
Trip distance
Total fuel used
Trip fuel used
Idle hours
Active hours
Press (F1) to toggle between rst and
second 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
Operation 4
Press (B) to open the transmission menu
Press (C) to open the hydraulics menu
Engine menu
With the main screen displayed, press (A)
to go to the engine screen.
This screen displays:
gear selected
truck speed
fuel level
battery voltage
engine oil temperature
total fuel used
trip fuel used
engine oil pressure
engine boost pressure
manifold intake pressure
engine torque
This menu screen will be displayed for a preset

time and will then return to the main screen.
Press (A) again to view truck history statistics.
Press () to return to the main screen.
Press () once to exit and return to the main
menu.
51
4 Operation
Transmission menu
With the main screen displayed, press (B)
gear selected
truck speed
fuel level
driving speed
transmission oil temperature
accelerator and brake pedal positions
total distance travelled
trip distance
total economy
trip economy

Hydraulics menu
With the main screen displayed, press (C)
gear selected
truck speed
fuel level
joystick position (X & Y axis)
hydraulic oil temperature

52
Operation 4
Spreader menu
With the main screen displayed, press (D)
status of the load on the spreader
status of each leg
Press (D) again to display the spreader
information menu.
Adjust & measure menu

Press () in main screen.
Press (F1) to go to sub-menu Adjust.
Press (F2) to go to sub-menu Measure.
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 Adjust
Press (F1) to enter the adjust list.
Rotate scroller knob to select required
setting.
53
4 Operation
Press scroller knob.
Press (A) to adjust setting.
Press () once to return to the previous
menu, and again to return to the Adjust &
measure main screen.
Sub-menu Measure
Press () in main screen.
Press (F2) to go to sub-menu Measure.

Rotate scroller knob to select required
setting.

Press (A) to toggle between raw value and
scaled value.
Press () once to return to the previous
menu, and again to return to the Adjust &
measure main screen.
54
Operation 4
Sub-menu Preferences
Press (F3) in the Adjust & measure main
menu.
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 & measure
main menu.
Third menu Date/time

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

Select settings by pressing buttons (A - D).
Change settings by pressing the scroller
knob.
Save settings by pressing the scroller knob.
main menu.
55
4 Operation
Third menu Language
Select the required language by turning the
scroller knob.
Save settings by pressing the scroller knob.
main menu.
Sub menu Info

Press (F4) in the Adjust & measure main
menu.
Press (A) to view modules status.
56
Operation 4
Press (B) to view modem information and
status.
Press (C) to view truck logs

Rotate scroller knob to required log.
Press scroller knob to view log data.

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

Alarm, Warning and Critical.
Message
These are messages indicating faults which
may not require immediate action, and may be
rectied at the next scheduled service interval.
Warning
These are messages which should be acted
upon as soon as it is safe to do so.
Alarm
57
4 Operation
These are messages which must be acted
upon immediately.
Critical
These are messages which indicate a fault
which may cause serious mechanical damage
to the truck.
Examples of faults detected;
Water in fuel
Low Battery voltage
Low Battery charge
Engine coolant temperature
Air cleaner restriction
Hydraulic oil temperature
Brake oil temperature
Engine oil pressure
Coolant temperature
Low oil pressure in brake system
These faults are also identied with a fault
code. A full list of fault codes can be found in
the annex.
An example of a message which may not
require immediate attention is water in fuel
message.
When this message is shown, the operator
may decide to temporarily ignore the
message until the next scheduled service
interval.
An example of a warning which requires
immediate attention is engine oil temperature
warning.
58
Operation 4
When this message is shown, immediate
action is required to rectify the fault.
An example of an alarm message which
requires attention as soon as possible is
spreader lock/unlock which indicates a hardwire fault on the truck.
When this message is shown, action is

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

action is required to rectify the fault to
prevent serious mechanical damage to
the truck.
CAUTION
Failure to act accordingly when warnings are
displayed may result in serious damage.
Do not continue to operate the truck if critical faults
are indicated.
59
4 Operation
Start-up indications
Overload safety switch
Operating overload safety switch (1) will
enable the handler lowering function as long
as the switch is operated so that the handler
can be lowered along with the load.
NOTE
Overload safety switch (1) may only be used

by authorised persons who can estimate and
bear responsibility for the safety risk when
lowering the load. Some safety features are
disabled when the overload safety switch is
activated - exercise extreme caution.
When the Overload safety switch (1) is operated, the truck display unit will also warn the
driver that this activity will be logged.
F
N
R
1
d3571022
Override options are displayed.
Start-up indications
The load safety system has an automatic
self-test function, which operates whenever
the truck electrical system is energised. After
a successful self-test (duration approx. 10
sec), the green LEDs will illuminate.
WARNING
Contact your authorised dealer in case of defect.
Do not operate the truck if the load safety system
self-test is not correct, i.e. no illumination of green
LEDs and sounding of the buzzer.
60
Operation 4
Driving
Driving
WARNING
wind velocities of 24 knots / 28 mph or 45 km/h or
manufacturer, your authorised distributor, or local
statutory authorities
CAUTION
Travel on slopes over 15% is not allowed as a rule
due to the prescribed minimum brake applications
and truck stability characteristics. Before driving
on steeper slopes you should contact your dealer.
The climbing ability rates given in the data sheet
were derived from the tractive force of the truck and
they apply only for crossing obstacles and for small
differences in level.
Always accommodate your driving style to suit

the conditions of the roadway (rough surfaces
etc.) especially hazardous work areas and the
load.
CAUTION
Always look in the direction of travel and have an
adequate overview of the road ahead, including
to the sides when steering. When driving, ensure
that the road ahead is clear. If goods obstructing
vision are being transported, drive the truck with
the load trailing. If this is not possible, a second
person shall walk in front of the truck as a guide. The
truck should then only be driven at walking speed
with particular caution being exercised. If visibility
aids are required (e.g. mirrors, camera/monitor),
to ensure adequate sight, then training should
be given for driving with these aids. Reversing
with a mirror for example, shall be exercised with
particular care.
61
4 Operation
Gear shift control
Gear shift control
The gear control (APC 200) is an electronically
controlled system which detects truck speed
through the transmission and selects the
appropriate gear for a driving condition.
The system will default to second gear start
(as factory setting, rst gear start is available).
The anti-reverse facility prevents the transmission from engaging reverse direction drive
until the truck is stopped. The operating lever
is tted to the left of the steering column and
has a dual function control lever (1), (direction
and gear selector).
F
N
R
The control lever has three movements, two of

which select the drive direction (fore / aft), with
the third selecting gears (rotate).
d3561053
Selecting the travel direction

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

travel.
At the preset speed the transmission will automatically select 3rd gear. Also, at the preset
speed the transmission will automatically select 4th gear.
d3571037
62
Operation 4
Gear shift control
Slowing down and stopping
Operate brake pedal (3).
Controlled transmission drive dump will
take place during the depression of brake
pedal (4), when accelerator pedal (3) is
depressed.
Transmission drive is re-engaged upon
depression of accelerator pedal (3).
F
N
R
Manual 1st gear selection when stopped

To select forward 1st gear
Push electronic gear shift control lever (5)
forward.
1
d3571038
Rotate the gear selector knob clockwise.

Gear selection will be displayed on the
MDM display screen.
To select reverse 1st gear
Pull electronic gear shift control lever (5) to
the rear.
Rotate the gear selector knob clockwise.
Gear selection will be displayed on the
MDM display screen.
Preselection of 1st gear when travelling

NOTE
1st gear can be preselected for manoeuvring

and on the approach to steep gradients when
travelling.
CAUTION
Danger of incorrect transmission operation causing
severe damage.
Do not hold gear change lever (5) in the rotated
position after selecting the gear.
To preselect 1st gear

From 4th gear - Rotate gear selector lever
(5) clockwise three times.
From 3rd gear - Rotate gear selector lever
(5) clockwise twice.
63
4 Operation
Steering
From 2nd gear - Rotate gear lever (5)
clockwise once.
NOTE
After pre-selection of 1st gear the transmission

will remain in 1st gear until speed increases
above the preset speed or until the truck
is stopped and NEUTRAL is selected. On
reversion to automatic gear change, 1st
gear is available only by manual selection
or pre-selection.
Steering
Start the engine and drive the truck.
Turn the steering wheel to the left and right
through the full cycle.
Turning radius Wa:
6.4mtr wheelbase: 8.6 m
7 mtr wheelbase: 9.3 m
NOTE
Very little effort is required to turn the steering

wheel. This is especially benecial when operating in narrow aisles. To avoid unnecessary
tyre wear, turn the steering only when the truck
is moving.
WARNING
Contact your authorised dealer if steering requires
too much effort or if there is too much play in the
steering.
64
Operation 4
Operating transmission dump
Stopping the truck

Depress brake pedal (3) to slowly brake the
truck to a standstill.
Press parking brake button before releasing
brake pedal (3).
Move electronic gear shift control lever (4)
to neutral.
1
F
N
R
NOTE
The transmission will automatically disengage

gear when brake pedal (3) is depressed.
Lower the handler and ground any load.
d3571082
Allow the engine to idle for at least 3 minutes

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

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

varies steering resistance dependant upon
the operation of the machine.
65
4 Operation
Parking brake
Service brake
To operate the service brake:
Release accelerator pedal (2) and allow it to
return to its rest position.
Depress either brake pedal (3).
F
N
R
d3571039
Parking brake
The parking brake button (2) for applying the
parking brake is mounted in the drivers control
centre located to the right of the seat.
This is illuminated for low light recognition.
2
d3571037
To release the parking brake, depress

parking brake button (2). The parking brake
warning symbol in the truck display monitor
will extinguish.
To apply the parking brake manually,
depress parking brake button (2) again.
The parking brake warning symbol in the
truck display monitor will illuminate.
During operation, should the truck become
stationary for 4 seconds or more in neutral
(no gear is selected), the parking brake will
automatically switch on.
66
Operation 4
To release the parking brake depress
parking brake button (2). The parking brake
will extinguish.
During operation, should the truck become
stationary for 5 seconds or more while in
gear (forward or reverse gear selected), the
parking brake will automatically switch on.
To release the parking brake gently depress
accelerator pedal (3). The parking brake
will extinguish.
WARNING
If the braking system is becoming faulty or worn,
Do not drive your truck with faulty brakes.
Truck lighting and turn

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

left-hand panel (1).
3
4
5
To illuminate the side marker lights:

Push light switch (3) to the rst position.
SC
To illuminate the side marker lights and dip

beam headlights:
Push light switch (3) to the second position.
The side marker lights and dip beam headlights are on.
The indicator lamp in the light switch will
illuminate when the side marker and dip beam
headlights are illuminated.
F
N
R
d3571019
To illuminate the working lights* on the handler

and boom:
Depress light switch (4) fully.
To illuminate additional working lights* :
Depress light switch (5) fully.
* option
67
4 Operation
Turning on the main beam headlights
Push multiple function electrical lever (6)
away from the steering wheel to illuminate
the main beam headlights permanently.
Headlight main beam indicator light (2) will
be illuminated.
O I II
Pull multiple function electrical lever (6)

towards the steering wheel to ash the
headlights.
NOTE
The main beam headlight can only be turned

on permanently when switch (3) is turned on.
d3561060
Turning on the turn indicator lights

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

function electrical control lever (6) on the
right-hand side of the steering column
down. Turn indicator warning light (7) will
ash.
NOTE
To stop turn indicator lights ashing multiple

function electrical lever must be returned to its
central position manually.
68
d3561061
Operation 4
Operating the horn
Operating the hazard warning

lights
The hazard warning light switch (2) is located

in the drivers central control panel (1).
Push button (2) to operate the hazard
warning lights.
Push button (2) again to turn the hazard

warning lights off.
NOTE
The indicator light in RHP illuminates.

d3561069
Operating the horn

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

the end of multiple function electrical control
lever (1).
d3561062
69
4 Operation
Turning on the front windscreen wiper
The front windscreen wiper switch (3) is part of
multiple function electrical control lever (1).
For fast wiping: Turn switch (3) from the

zero position back two steps to position (4).
O I II
For slow wiping: Turn switch (3) from the

zero position one step back to position (5).
For intermittent wiping turn switch (3)

from the zero position one step forward
to position (2).
NOTE
d3561063
The wiper motor is tted with a thermal cut-out

which, during operation, will switch off the
wipers to prevent overheating of the motor,
when the windscreen is dry.
Turning on the front windscreen washer

The windscreen washer switch (2) is located
on the end of multiple function electrical
control lever (1) . It is the collar surrounding
the horn button.
Push switch (2).

O I II
NOTE
The washer stops automatically when the

switch is released.
d3561064
70
Operation 4
To operate rear screen wiper and washer
The rear screen wiper/washer switch (2) is
tted in the drivers central control panel (1).
To operate the wiper.
Push switch (2) to the rst position.
To operate the wiper and washer.

Push switch (2) all the way down and hold.
NOTE
The washer stops automatically when switch

is released. The wiper continues to operate
until the switch is returned to the starting
position.
d3561065
NOTE
The wiper motor is tted with a thermal cut-out

which, during operation, will switch off the
wipers to prevent overheating of the motor,
To operate top screen wiper and washer

The top screen wiper/washer switch (3) is
tted in the drivers central control panel (1).
To operate the wiper.
Push switch (3) to the rst position.
To operate the wiper and washer.
Push switch (3) all the way down and hold.
NOTE
The washer stops automatically when switch

is released. The wiper continues to operate
until the switch is returned to the starting
position.
71
4 Operation
Automatic wiper function
2
Press button (F5) to operate automatic

wipers.
When the automatic wiper function is activated, the front wipers will operate at all times
unless turned off manually.
In addition, when reverse gear is selected the
rear wipers will operate and will stop when
reverse is de-selected.
Also, whenever the boom angle is greater than
a pre-set height the top wipers will operate,
and will stop when the boom is lowered below
the pre-set height.
5
6
7
8
16
9
15
14
12
13
11
10
d3571023
NOTE
Switch positions may differ.

NOTE
The wiper motors are tted with a thermal

cut-out which, during operation, will switch off
the wipers to prevent overheating of the motor
To operate the cab pre-heater

system *
The cab pre-heater (1) is tted in the cab rear
right corner. The heater operates for 120
minutes (default setting).
2
P
7 6 5 4 3
(1) Cab pre-heater

(2) Temperature controller (rotate to increase / decrease cab temperature)
(3) Forward
(4) Backward
(5) Heating (depress to activate / deactivate
heating)
(6) Preselection
(7) Clock time
d3571084
NOTE
The cab pre-heater must not be used indoors.
72
Operation 4
NOTE
Always shut off the heater when refuelling the

truck.
* Option
To operate climate control *

NOTE
Do not operate the system with all vents

closed. Heating and cooling systems will
operate only while the engine is running and
the batteries are charging.
3
4
5
Switch the fan on and select required fan

speed by rotating switch (2).
NOTE
The indicator display (3) shows the current

cab temperature in normal operating mode.
Select temperature by depressing up/down
buttons (4), a single press increases/decreases the temperature by one degree.
d3561067
NOTE
Temperature is selectable between 5 and

30C.
When frost button (5) is selected (switch
illumination changes from yellow to green),
additional cooling is obtained.
NOTE
Where maximum heating effect is required,

the air conditioning should be disengaged.
Adjust vents to suit.
NOTE
Maximum heating/cooling effect will be achieved with lower vents open.
73
4 Operation
Fuses
Opening the fuse box cover
The fuse box (1) is situated inside the cabin,
to the rear of the drivers seat.
Check that fuse box door (2) lowering area

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

Check that door raising area is free from
obstruction.
Close door (2), insert key (or coin) into lock
and turn fully clockwise.
d3571015
Fuses
The truck and handler electrical circuits are
protected by fuses in fuse box (1) tted behind
the cab rear compartment door.
WARNING
1
2
If fuses fail continuously, stop the truck, ground the

load and stop the engine. Contact local authorised
dealer. Danger of re and severe damage to
equipment.
Do not continue to operate with faulty electrical
circuits.
To check the fuses, open the cab rear compartment door and take off fuse box covers
(2).
d3561068
01
Ignition switch
30 A
02
Iqan cab MDL unit
10A
03
Iqan cab front XS2-A0 unit
15A
04
Iqan cab fusebox XS2-A1 unit
15A
05
Spare
06
Iqan chassis left XT2 - 0 unit
20A
07
Iqan chassis right XT2 - 1unit
20A
08
External modem
3A
74
Operation 4
Fuses
09
Elme Iqan ES supply
30A
10
Elme spreader supply 1
10A
11
10A
12
10A
13
Elme ignition supply
10A
14
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 asher
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
75
4 Operation
Fuses
41
Side lights / dipped lights
15A
42
Switch illumination
1A
43
Side lights left
3A
44
Side lights right
3A
45
Dip light left
5A
46
Dip light right
5A
47
Head lights left
10A
48
Head lights right
10A
49
Indicators
5A
50
Reverse lights / buzzer
10A
51
Spreader lights
20A
52
Boom lights
20A
53
Side spot lights
10A
54
Cab roof lights
20A
55
LFM ignition
3A
56
Red dot air con unit 1
15A
57
Red dot air con unit 2
15A
58
Heated seat
5A
59
Heated seat
1A
60
Heated mirrors
5A
61
Spare
62
Spare
63
Spare
64
Spare
* optional
76
Operation 4
Boom and handler controls

The standard control for mast and handler is
the central control lever (1) (joystick).
DCC
1
NOTE
The symbol of the control lever movements

are shown on a label attached to the windscreen pane to the right of the driver. Observe
the symbols with direction arrows.

CAUTION
Use the reach stacker only for authorised applications. The operator must be trained in the handling
of containers, the boom and handler
d3571065
Do not operate this machine if you are not trained.
NOTE
The central control lever has been calibrated

to allow 5% movement in all directions before
function is activated.
The central control lever (1) is mounted on
the drivers control centre to the right of the
seat. Always shift the control lever gently and
slowly. The control lever returns to its initial
position automatically when released.
NOTE
When operating central control lever (1), the

engine speed will increase automatically to
the power required for operating the rotation,
sideshifting and telescoping the handler.
Operating accelerator pedal for higher speeds
does not have any effect on the speed of
these work cycles. Central control lever (1)
is provided for lifting and lowering, rotating
and slewing the handler.
77
4 Operation
To lift the boom
Pull central control lever (1) back.
DCC
1
To lower the boom

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

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

Push central control lever (1) to the left.
d3571067
78
Operation 4
Operating the sideshift
CAUTION
Do not operate the sideshift with a container in the

handler and the container grounded.
Danger of severe damage to the equipment.
3
If necessary, raise the load slightly.

2
NOTE
The handler beam centre line is indicated by a

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

CAUTION
A foul condition can occur between the truck,
load and handler, while rotating the handler. This
condition can occur with or without load. ALWAYS
observe the load and handler while rotating the
handler.
Do not slew the handler if fouling of the load can

occur. Danger of severe damage to the handler.
Rotating the handler clockwise

Press and hold the left side of button (4) on
central control lever (1).
Rotating the handler anticlockwise
Press and hold the right side of button (4) on
central control lever (1).
d3571069
NOTE
The front face of the handler is identied by

yellow and black high visibility markings on the
sideshift bearing mountings. The rear face of
the handler is identied by white uorescent
markings and the beam sideshift centring
marks.
79
4 Operation
Before lifting a load
The beam spreader opens and closes to 20 ft
and 40 ft for standard containers.
Setting the spreader to container width 40 ft
Press and hold button (5) on central control
lever (1).
Setting the spreader to container width 20 ft

Press and hold button (7) on central control
lever (1).
Twistlock autolock*
* option
5
9
8
6
7
To operate twistlock autolock, depress

button (6).
Vertical lift*
* option
To operate vertical lift, depress button (8)
and pull back central control lever (1).
d3571070
Power pump lock*

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

WARNING
wind velocities of 24 knots / 28 mph or 45 km / h or
000.000.00.00

manufacturer, your authorised distributor, or local
statutory authorities.
Before lifting a load, check the load capacity

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

status display unit.
80
Operation 4
In the main screen, press ().
Press F4 (info).
Rotate scroller knob until load table is
highlighted.
81
4 Operation
Picking up a container
Press scroller knob to view load table
information.
To return to the main screen, press () three
times.
WARNING
The values stated on the load capacity diagram and
the handler apply for the standard containers and
towed loads.
These values must not be exceeded as this will
reduce the stability of the truck and the strength of
the handler.
NOTE
Maximum capacity is governed by the height

of lift and the load centre distance.
Picking up a container TL model
WARNING
Do not attempt to lift a load or continue to lift if the
twistlocks do not seat and lock correctly.
WARNING
No person is allowed to stand underneath the
elevated load.
The twistlocks must be unlocked and red

indicator lamps (3)must be illuminated.
Approach the container to be lifted as
carefully and accurately as possible.
2, 3
Raise and extend the mast sufciently to

allow the handler to clear the load and
intervening stacks.
2, 3
d3571016
82
Operation 4
Stop the truck centred and as close as
possible to the container.
NOTE
After a period of approx 5 seconds * the

parking brake is applied, and the direction
control lever shifts to the neutral position
automatically. In this condition, lift speed is
regulated by throttle.
20'
40'
d3571053
Lower the handler over the container using

the sideshift, slew, outreach and inreach
and mast for nal positioning.
NOTE
The levelling system will automatically set

the handler with a 5 tilt up. As the handler
is lowered on the container, the levelling
cylinders reset allowing the twistlocks to enter
into the front container pockets rst.
d3571054
Lock the twistlocks.

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

Move the truck and rotate the load as
necessary until it is free of obstructions.
83
4 Operation
Raise or lower the load to travelling height.
Picking up a container CH model

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

indicator lamps (3)must be illuminated.
Approach the container to be lifted as
carefully and accurately as possible.
2, 3
Raise and extend the mast sufciently to

allow the handler to clear the load and
intervening stacks.
2, 3
d3571016
84
Operation 4
Stop the truck centred and as close as
possible to the container.
NOTE

If necessary move the cab so that the back
legs can be observed.
Position the legs in front of the load using
boom raise/lower and extend/retract controls.
20'
40'
d3571053
For sloping trailers, use slope pyle* to

compensate, (* option).
NOTE
The levelling system will automatically set

the handler with a 5 tilt up. As the handler
is lowered on the container, the levelling
cylinders reset allowing the twistlocks to enter
into the front container pockets rst.
2 4
1 3
NOTE
When the container handler legs are activated

the handler is set horizontal automatically.
d3571056
85
4 Operation
Lower the front legs. Indicators (2 & 4)
illuminate, and indicator (6) extinguishes.
CHI
NOTE
Indicator (5)will ash while legs are in motion.

Lower the back legs. Indicators (1 & 3)
illuminate.
2
1
4
3
NOTE
When all legs are lowered, indicator (5)

illuminates.
d3571078
Clamp the legs. The load status is indicated

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

of the ground or transport vehicle.
Release the parking brake.
Move the truck and rotate the load as
necessary until it is free of obstructions.
86
Operation 4
Travelling with loads
Raise or lower the load to travelling height.
Automatic parking brake operation

When stationary, with the footbrake applied
and in gear, following a period of 5 seconds*,
the handbrake will engage and neutral will be
selected automatically.
NOTE
During this time the working hydraulics speed

is regulated by the throttle pedal.
Upon gear selection (forward/reverse), engine
revs falling below 950 r.p.m, and activation of
the throttle pedal the handbrake will disengage
and selected travel direction will commence.
d3571055
(* variable 0.5 - 5 seconds)

WARNING
Do not stand underneath an elevated load.
d3571062
87
4 Operation
Travel with the container centred (no
sideshift).
d3571060
Transport the load as low as possible whilst

maintaining forward visibility.
NOTE
If the travel lift height is exceeded, truck speed

will be automatically reduced to 3 m.p.h. (5
kph). Lower the load to the travel height to
return to normal truck speed.
CAUTION
Always look in the direction of travel and have an
adequate overview of the road ahead, including
to the sides when steering. When driving, ensure
that the road ahead is clear. If goods obstructing
vision are being transported, drive the truck with
the load trailing. If this is not possible, a second
person shall walk in front of the truck as a guide. The
truck should then only be driven at walking speed
with particular caution being exercised. If visibility
aids are required (e.g. mirrors, camera/monitor),
to ensure adequate sight, then training should
be given for driving with these aids. Reversing
with a mirror for example, shall be exercised with
particular care.
88
d3571055
Operation 4
Depositing the load
Depositing the load

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

the load as carefully and as accurately as
possible.
Lift the handler to the correct height.
Carefully move into the stack.
NOTE

d3571063
89
4 Operation
Depositing the load
Lower the load onto the stack using the
sideshift and rotate for nal positioning.
TL model
Slowly lower the handler until the twistlocks
are loose in the load and the yellow indicator
lamps are illuminated in addition to the
green indicator lamps.
Unlock the twistlocks. The yellow and red
lamps will illuminate and no ags are visible.
NOTE
For sloping trailers use Slope pyle * to compensate (* option).

Lift the handler up out of the corner castings.
d3571064
The yellow lamps extinguish, the red lamps

continue to illuminate and no ags are
visible.
CH model
Slowly lower the handler until the legs are
no longer seated. Indicators (1,2,3, & 4) will
extinguish.
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 automatically

release the parking brake as soon as the
accelerator 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 load
elevated.
90
Operation 4
Trailer coupling
Parking the truck

Lower the boom and ground the load.
Apply the parking brake.
NOTE
The parking brake will be applied automatically if neutral is selected and after the truck
has been stationary for approx 5 seconds.
Stop the engine and remove the ignition key
from the key switch.
Lock the cabin door and remove the door
key.
NOTE
When parking the CH model, take care not

to damage the front and rear legs on the
container handler.
Trailer coupling
NOTE
The trailer coupling should be used only for

towing light trailers inside the plant working
area (refer to the technical data for nominal
towing capacity).
Lift tow pin (1).
Place the tow bar in coupling recess in the
lower retaining hole.
Push tow pin (1) down to engage the

drawbar.
d3561088
91
4 Operation
Wheel change
Wheel change
WARNING
Before removing a wheel on the steer or drive axle,
deate the tyre to under 2 bar pressure.
Danger of damage or injury through wheel rims.
To remove a wheel
Drive axle outer wheels:
Remove wheel nuts (6) and lugs (5).
Release the outer wedge band (4) from
wheel (3) by striking the rim using a hammer
and drift.
Remove wheel.
56
d3181051
Drive axle inner wheels:

Release the inner wedge band (2) from the
hub.
Remove wheel (1) from hub.
Steer axle wheels
Remove the wheel nuts and lugs.
Remove the wheel.
Wheel mounting
CAUTION
When a wheel has been removed and replaced, the
wheel nuts must be checked before use and daily
for two weeks.
Drive axle inner wheels:

Fit wheel (1) to the hub. Ensure that the
tyre ination valve extension is positioned
correctly in the hub cutaway.
Fit centre wedge band (2).
Drive axle outer wheels:
Fit wheel (3). Ensure the tyre ination valve
is correctly located in the hub cutaway.
Fit outer wedge band (4).
92
Operation 4
Towing
NOTE
Tighten opposite wheel nuts sequentially

spanner tight then torque to the correct torque
setting.
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 t directly to the hub.

Wheel nut torque = 680 Nm.
Inate tyres to 10 bar (145 psi)
Towing
If the truck must be towed, rst release the
hydraulic parking brake and remove the
propeller shaft.
NOTE
Disconnect the propshaft at the drive axle end

only.
WARNING
Care must be taken to ensure the propshaft is
suspended clear of the roadway.
CAUTION
The truck must only be towed with a rigid towbar and
by a vehicle with sufcient tractive braking power to
stop both vehicles.
NOTE
With the engine stopped, the truck can still be

steered, although with much increased effort
at the steering wheel.
Towing procedure
Lower and release the load.
93
4 Operation
Towing
Attach the towing vehicle to the towing pin
with a rigid tow bar (tractive and braking
power are sufcient).
Chock the drive axle wheels.
Releasing the parking brake

4
Remove cover (2) from brake calliper (4).
Turn bolt (3) anti-clockwise to release the

brake until the brake disc is clear.
Removing the propeller shaft

Remove bolts, nuts and spacers (5) on the
coupling joints.
5
2
Take off propeller shaft (1) and suspend it

with a chain, for example, to prevent it from
touching the ground during towing.
CAUTION
Because of a lack of hydraulic power during towing,
increased effort is required when steering.
d3561091
Tow the truck only with great caution and at a speed

of not over 3-5 kph.
After towing and repair

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

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

Detach the propeller shaft, position it and t
the axle.
Fit bolts, nuts and spacers (5) on the
coupling joints.
Tighten the bolts.
Torque approx ..... 135 Nm
94
Operation 4
Towing
CAUTION
Bolts may be used 2 times maximum.
Remove the chocks.

Check the function of the brakes after carrying
out repairs.
95
4 Operation
Towing
96
5
Maintenance
5 Maintenance
General remarks
General remarks
Taking the truck out of operation
If the truck is taken out of operation for over 2
months, it must be parked in a well ventilated,
frost-free, clean and dry room and the following measures must be carried out.
Measures before taking the truck out of

operation
Thoroughly clean the truck.
Rotate,Slew and sideshift the spreader.
Extend and retract the boom.
Raise, lower and tilt the boom several times
through the full cycle.
Check the hydraulic oil level and add oil if
needed.
Add diesel fuel.
Apply a thin lm of oil or grease on all
unpainted mechanical parts.
Lubricate the vehicle.
Check the condition of the battery. Coat
the battery terminals with non-acid grease
(follow the instructions of the battery manufacturer).
Spray all open electrical contacts with a
suitable contact spray.
NOTE
Block up the truck so that all wheels are clear of

the ground. This will prevent tyre deformation.
NOTE
Do not use plastic foil to cover the trucks as

this enhances the formation and collection of
condensation water.
Putting the truck back into operation

Thoroughly clean the truck.
Lubricate the truck.
Coat the battery terminals with non-acid
grease.
Check the condition of the battery.
Check the engine oil for condensation water
and change the oil if necessary.
Perform the same services as for commissioning.
Take the truck into service.
If the vehicle is to be taken out of operation for
over 6 months, contact your authorised dealer
for further measures.
General information
Your truck will remain operational only if the
maintenance and checks are carried out
regularly and according to the information
and instructions in the operating manual.
The maintenance may only be performed by
qualied authorised personnel. This work can
be carried out by your authorised distributor
under a service contract.
We recommend reserving a special service
area for the truck with a container or support
onto which the handler can be lowered to gain
easy and safe access to the service points.
98
If you wish to do the work yourself, we recommend that the rst three customer service
checks be carried out by your distributors
mechanic in the presence of the responsible
mechanic in your workshop, so that your staff
can receive the appropriate instruction.
For all servicing, the truck must be placed on
a level surface and the wheels secured. Stop
the engine and remove the ignition key.
When working on the truck with the mast elevated, secure it against inadvertent lowering.
Maintenance 5
General remarks
For work on the front end of the truck, secure
the mast against tilting back. No changes,
particularly no modications and additions,
may be made to the truck without the approval
of the manufacturer.
NOTE
Missing or damaged type and/or adhesive

labels must be replaced. See the Parts
Catalogue for location and order numbers.
Perform a functional check and trial run after
every servicing.
NOTE
When operating the truck under extreme

conditions (i.e. extreme heat or cold, intensive
dust concentration, etc.), the intervals given in
the maintenance schedule should be reduced
accordingly.
CAUTION
lubricants.
Work on the boom and the front part

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

chock the wheels.
Support the handler (on a container).
Turn the ignition key to the zero position and
remove it.
Lock all cab doors and remove the key.
99
5 Maintenance
General remarks
Hoisting the truck
3
DANGER
When loading the truck by crane, make sure no
persons are within the working range of the crane!
Do not step under the elevated load!
CAUTION
The weight of the unladen truck is between 70 & 84
tonnes.
Only use a crane and slinging gear with sufcient
lifting capacity.
CAUTION
2
1
d3571071
Safety lock (4) must close after attaching the slings

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

shown.
Attach two hooks to rear sling points (2) in
front 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 qualied
staff of your authorised dealer.
Table of weights
C 4230 TL / 5
70400 kg
C 4531 TL / 5
71400 kg
C 4234 TL / 5
73200 kg
C 4535 TL / 5
76300 kg
C 4540 TL / 5
77000 kg
C 4540 TL / 5 (2nd
rail)
77700 kg
100
Maintenance 5
General remarks
C 4226 CH / 5
73950 kg
C 4127 CH / 5
74900 kg
C 4527 CH / 5
74900 kg
C 4030 CH / 5
76700 kg
C 4531 CH / 5
81250 kg
C 4535 CH / 5
81970 kg
C 4535 CH / 5 (2nd
rail
83470 kg
101
5 Maintenance
General remarks
Inspection and maintenance data
Assembly
Aids/oils and lubrication
Filling capacities/rated
values
Engine
Engine oil
approx. 35 lts
Fuel tank
Diesel
approx. 800 lts
Cooling system
Water and antifreeze

mixture
approx. 45 lts
Working hydraulic system

oil tank
Hydraulic oil
approx. 800lts
Braking system oil tank
Hydraulic oil
Oil additive (mixed at ratio
6%)
approx. 100 lts

approx. 6lts
Brake relay hydraulic

system
Hydraulic oil
as required
No.
Drive axle differential
Gear oil
approx. 75 lts
Drive axle hub
Gear oil
each side approx. 7 lts
Steer axle hub
Gear oil
each side approx. 4 lts
10
Transmission
Transmission oil
approx. 60lts
11
Battery
Maintenance free
12
Tyres
Air
13
Wheel mounting nuts
14
Grease points on boom,

handler and chassis
Lubricating grease
15
Temperature sensor
Oil
16
Valve clearances
17
Fuel injection nozzle
102
10 bar
350 Nm
Diesel
as required
Engine oil temperature to
130C
Inlet 0.2 mm
Exhaust 0.5 mm
Operating pressure 246 bar
Pressure setting 264 bar
Maintenance 5
General remarks
Fuel and oil recommendations

Engine oils
e.g. Mobil Glygoyle 22
API classication: CCMC D5, API-CE specication oils may be used but must be renewed
at 250 hour service intervals. API classication: CH-4 or ACEA E5 may be used for up to
500 hour service intervals.
Hydraulic oil for working hydraulics
Oil grades
Engine oils of API classication CD or less are
not recommended due to the extended drain
cycle given for this engine application.
During engine operation, part of the oil serving
as a lubricant for the piston is combusted
(consumed). The products of combustion
and the high temperatures combined lead
to wear, particularly of the chemical oil
additives. For this reason the oil must be
changed at certain intervals.
Since this oil wear depends on the operating
conditions and the quality of the oil (oil performance) and fuel used, oil change intervals of
different lengths result.
Oil additives of any kind must not be used with
any of the recommended engine oils. Use of
additives will invalidate the warranty.
The longest possible oil change interval for
lubricating oil in the engine is one year. This
means that the oil must be renewed at least
once every year, regardless of the oil change
intervals.
Gear oil
MIL-L2105B, API GL5, SAE 90 or multi
grade oils for normal external temperatures,
recommended - 75w 90.
Sae 140 or mulitgrade oils for external temperatures over 30 C
ISO VG 46 (factory lling)

Hydraulic oil analysis
The working hydraulic system has a capacity
of approx. 800 ltrs. To reduce the high level
of expenditure required if the oil is renewed at
the 3000 hour service, the operator may use a
reputable oil analysis company to determine
the state of the hydraulic oil. This analysis
should be made between 2750 and 3000
hours run.
The results of the analysis should be recorded
to support any warrant claim which may arise
from defects in the working hydraulic system
subsequent to the analysis. Where oil analysis
is not available, the recommended 3000 hour
oil renewal is mandatory.
Hydraulic oil (brake system, brake cylinder)
ISO VG 46 (factory lling)
Hydraulic oil additives (brake system)
Use only pre-mixed Lubrizol solution.
Electrical contact grease
For use on all electrical connections.
Lubricating grease
Linde heavy duty grease with additives EP and
MOS2. Designation acc. to DIN 51825-KPF
2K-20 (see the Parts Catalogue for the order
number). Any mixing with grease types other
than lithium-based greases is not allowed.
Battery grease
Non-acidic grease (terminal grease).
Transmission oil
Chain spray
Only Dexron III oil is approved for use.
Linde chain spray (see the Parts Catalogue for

the order number).
Handler slew gearbox and brake

SAE 90 Gear oil to with additives to specication J306a.
e.g. Esso compressor oil G150
Central lubrication
The grease must be an EP grade NLGI-0
grease with a lithium/calcium base. It must
103
5 Maintenance
General remarks
not contain any additives such as graphite or
PTFE.
If the sulphur content is 0.5 to 1%, the oil

change intervals must be halved.
A grease from Greenlube is recommended.

If difcult to obtain, please contact your
authorised dealer.
If the values are higher, contact the manufacturer of the lift truck or the supplier of the
lubricant.
Coolant
Only use coolants with a monoethylene glycol
base and containing a rust inhibitor.
Do not mix with antifreeze containing
ethanolamine.
Mixing ratio for lower temperatures:
Temperature
down to
Antifreeze
%
Mixture ratio
water:antifreeze
-12C
25
1:3
-18C
33
1:2
-22C
40
1:1.5
-37C
50
1:1
-60C
66
2:1
Diesel fuel
Use only Diesel fuel to DIN EN 590 with a
cetane number not lower than 45.
The sulphur content should not exceed 0.5 %.
NOTE
As the ambient temperature decreases, so

does the uidity of Diesel fuel due to the
precipitation of parafn. If summer grade
diesel fuel is used, malfunctions can result.
For this reason, winter grade diesel fuel that
functions reliably at temperatures down to
approximately -15C is available in the cold
season of the year.
The addition of any form of additive will invalidate the engine manufacturers warranty.
In winter, ll only winter diesel fuel to prevent
any clogging caused by parafn precipitation.
At very low temperatures you must reckon with
disturbing precipitations even if winter diesel
fuel is used.
NOTE
These are only recommendations. In case

of doubt we recommend you contact your
authorised dealer.
NOTE
The digital clock display must be reset whenever the battery isolator has been used for more than
four days.
Check the condition of structured components

CAUTION
Work on the truck on level ground. Lower the
carriage, stop the engine and put the parking brake
on when working.
CAUTION
This maintenance procedure requires to be carried
out at heights of more than 2 metres. Use suitable
access equipment. Danger of fall injuries.
Examine the structural components of the

truck to assure their integrity. Inspection
should cover all areas of the main structures
and their connections. Attention should be
given to welds and material adjoining welds,
104
Maintenance 5
General remarks
particularly at changes of section, bolted
interfaces 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, missing
retaining rings and abnormal wear.
Truck welds inspection

NOTE
It is very important that these inspections are

carried out as specied in daylight or with
adequate articial lighting, to allow close
examination of the welds. Please follow the
guidelines below:
CAUTION
These maintenance procedures may need to be
carried out at heights of more than 2 metres. Use
suitable access equipment.
Danger of fall injuries.
Wash the truck thoroughly and allow to dry.

Corrosion and/or deposits should be
removed to facilitate the inspection.
Carry out a detailed inspection of all welded
joints on the chassis, load lifting device and
attachment.
If there is any visible abnormality which
suggests that a crack is present, carry
out a more detailed inspection using non
destructive methods.
Please forward copies of any existing structural inspection reports (as advised in the
service operators manual) to LHTD.
Reports including any photographs should
be sent to Mr. Andrew Dickson, (email:
andrew.dickson@linde-htd.com) as soon as
they are available.
105
5 Maintenance
Inspection and maintenance schedule
Daily checks
Check the tyres for damage and foreign
objects
Check the uid level in the washer uid

reservoir
Check the working hydraulics oil level
Check the fuel level
Check the brake hydraulic system oil level
Check the handler for visible damage
Check the hydraulic oil level in the brake

system reservoir
Check the operation of the twistlocks and

indicator lights
Clean, check and adjust mirrors
Check the coolant level in the heater tank
Check the central warning system
Check the engine oil level
106
Maintenance 5
As required Service plan

At operating hours
As
required
Carried
out
9
Comment
Depending on application, environmental conditions and driving style, the following
procedures should be carried out at the intervals shown above.
General
Clean the truck (if necessary)
Check the seat belt
Check and adjust mirrors
Check washer bottle level
Read out error log and delete
Enter next maintenance interval
Engine
Drain the fuel lter
Prime the fuel system
Check the air lter - replace if necessary
Check the air lter safety element - replace if necessary
Check coolant level in the reservoir
Check and clean the climate control lter element (option)
Transmission
Check transmission oil level
Chassis, bodywork and ttings
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
107
5 Maintenance
Carried
out
At operating hours
As
required
Check the steering lock

Clean and lubricate the steer axle, check the mounting
Check steer axle hub oil level
Check and lubricate the drive shaft
Controls
Check the functionality of the control levers
Check the functionality of the braking system (park brake and service brake)
Check the functionality of the absent driver seat switch (if tted)
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
Maintenance 5
50 h Service plan
At operating hours
50h
Carried
out
9
General
Check the seat belt
Engine
Change engine oil
Change engine oil lter
Check the air lter
Check the air lter safety element
Drain the water separators in the fuel system
Change the fuel lter
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 lter
Clean and lubricate all pivots and joints
Check cab mountings
Check steer axle, check mounting
Check drive axle mounting
Change transmission oil lter canisters
109
5 Maintenance
Carried
out
At operating hours
50h
Steering and wheels

Check the wheel nuts for tightness
Check tyre pressure
Clean and lubricate steering axle
Check mounting of steering axle
Check mounting of steering cylinder and steering axle swivel pins
Controls
Check the battery condition
Check the electrical system
Hydraulics
Check hydraulic oil level
Check the hydraulic system, drive motors, pumps, valves and lines for leaks
Clean the radiator and check for leaks
Load lift device
Check and lubricate the boom cylinder, boom pivot and sliding bearings
Check the handler hydraulic system gearbox and electrical lines
Change handler slewing gearbox and brake oil
Lubricate slewing ring bearing and gear
Lubricate the twistlocks
Subsequent tasks
Check the central lubrication* lubricating points
110
Maintenance 5
500 h Service plan

At operating hours
500
1500
2500
3500
4500
5500
6500
7500
8500
9500
10500
11500
12500
13500
14500
15500
16500
17500
18500
19500
Carried
out
9
General
Check the seat belt
Enter the next maintenance interval
Engine
Change engine oil
Check engine mounting
Check vacuum switch
Check intake and exhaust system for leaks
Check turbocharger
Check condition and tension of drive belt
Check the mounting of the turbocharger intake pipe
Transmission
Check and adjust the steer stops
Chassis
Check mounting of the steer axle, mast and drivers cabin
Check condition of the overhead guard frame
111
5 Maintenance
At operating hours
500
1500
2500
3500
4500
5500
6500
7500
8500
9500
10500
11500
12500
13500
14500
15500
16500
17500
18500
19500
Carried
out
9

Steering and wheels
Check wheel nuts for correct torque
Check tyre pressure
Check the steering
Check mounting of the steer cylinder
Check and lubricate steer axle link arms and swivel pins
Check wheel hub bearing end oat
Check the security of the axle clamp and drive motors
Controls
Check the functionality of the absent driver seat switch
Check batteries
Check electric cables, cable connectors and connections for condition and tightness
Check the functionality of the electrical system
Hydraulics
Hydraulic system: Check the oil level.
Check the hydraulic tank breather lter
Check condition of auxiliary hoses and replace if necessary
Load lift device
112
Maintenance 5
At operating hours
500
1500
2500
3500
4500
5500
6500
7500
8500
9500
10500
11500
12500
13500
14500
15500
16500
17500
18500
19500
Carried
out
9
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
113
5 Maintenance
1000 h Service plan
At operating hours
1000
7000
11000
13000
19000
17000
Carried
out
9
General
Check the seat belt
Engine
Change engine oil
Check the engine mountings
Change the air lter element
Check the vacuum switch
Check the intake and exhaust system for leaks and tightness
Transmission
Check the transmission mountings
Change the transmission oil
Chassis
Check cab mountings
Check the condition of the overhead guard frame
114
Maintenance 5
At operating hours
1000
7000
11000
13000
17000
19000
Carried
out
9
Steering and wheels

Check tyre pressure
Check the steering
Controls
Check the batteries
Hydraulics
Hydraulic system: Check the oil level.
Clean the radiator and hydraulic oil cooler
Load lift device
115
5 Maintenance
At operating hours
1000
7000
19000
11000
13000
17000
Carried
out
9

Subsequent tasks
116
Maintenance 5
2000 h Service plan

At operating hours
2000h
4000h
16000
20000
8000
10000
14000
Carried
out
9
General
Check the seat belt
Engine
Change engine oil
Change fuel lter
Check engine mounting
Renew air lter element
Renew safety element
Change the fuel tank breather lter
Renew engine coolant and lter
Check air con drive belt (if tted)
Check cooling fan belt tensioner
Check viscous vibration damper
Check vacuum switch
Check intake and exhaust pipes for leaks
Transmission
Chassis
Check condition of the overhead guard frame
117
5 Maintenance
At operating hours
2000h
4000h
16000
20000
8000
10000
14000
Carried
out
9

Steering and wheels
Check tyre pressure
Check the steering
Check the condition of the steer axle
Clean and lubricate steer axle, check the drive axle mounting
Check the drive axle centre and hub differential oil level
Check and adjust hub bearings
Controls
Check the batteries
Hydraulics
Hydraulic system: check the oil level.
Renew the feed, pressure, suction and breather lter
118
Maintenance 5
At operating hours
2000h
4000h
16000
20000
8000
10000
14000
Carried
out
9
Load lift device

Inspect load lifting device for proper operation
Lubricate tilt cylinder bearings
Subsequent tasks
119
5 Maintenance
3000 h Service plan
Carried
out
At operating hours
3000
9000
15000
General
Check the seat belt
Engine
Change engine oil
Check safety element
Check vacuum switch
Check cooling fan belt tensioner
Check coolant concentration
Check vibration damper
Check starter motor, alternator and injection pump
Transmission
Chassis
Check cab mountings
120
Maintenance 5
Carried
out
At operating hours
3000
9000
15000
Change transmission oil lter canisters

Check condition of structural components
Steering and wheels
Check tyre pressure
Check the steering
Controls
Check the batteries
Hydraulics
Change the brake hydraulic system oil
Change the working hydraulic system oil
Clean the hydraulic tank pre-lter
Change hydraulic oil lter
121
5 Maintenance
Carried
out
At operating hours
3000
9000
15000
Renew the feed, pressure, suction and breather lter

Check hydraulic pump mounting bolts
Load lift device
Change the handler slewing gearbox and brake oil
Check the condition of the boom mountings
Subsequent tasks
General overall check
122
Maintenance 5
5000 h Service plan

Carried
out
At operating hours
5000
10000
15000
20000
General
Check the seat belt
Engine
Change engine oil
Change the air lter safety element
Check vacuum switch
Check coolant concentration
Check valve clearances
Transmission
Chassis
123
5 Maintenance
Carried
out
At operating hours
5000
10000
15000
20000
Steering and wheels

Check tyre pressure
Check the steering
Controls
Check the batteries
Hydraulics
Check the brake hydraulic system oil
Check the working hydraulic system oil
Load lift device
124
Maintenance 5
Carried
out
At operating hours
5000
10000
15000
20000
Change the twistlocks

Check the handler extension cylinder bearing pads
Subsequent tasks
125
5 Maintenance
6000 h Service plan
Carried
out
At operating hours
6000
12000
18000
General
Check the seat belt
Engine
Change engine oil
Check the fan drive idler pulley assembly and belt
Check the turbocharger
Check the vibration damper
Flush the cooling system
Change the coolant and coolant lter
Check starter motor, alternator and injection pump
Transmission
Chassis
126
Maintenance 5
Carried
out
At operating hours
6000
12000
18000
Check cab mountings

Change the fuel tank breather lter
Steering and wheels
Check tyre pressure
Check the steering
Controls
Check the batteries
Hydraulics
Change the working hydraulic system oil
127
5 Maintenance
Engine
Carried
out
At operating hours
6000
12000
18000

Load lift device
Change the handler slewing gearbox and brake oil
Check the handler extension cylinder bearing pads
Subsequent tasks
Engine
CAUTION
The bonnet opens forward leaving open access
to the engine compartment from both sides of the
truck.
CAUTION
Danger of scalding.
128
Maintenance 5
Engine
CAUTION
lubricants.
Park the truck on rm level ground, put the

parking brake ON and stop the engine.
Behind the cab, remove dipstick (2) and
wipe with a clean cloth.
Fully re-insert dipstick (2) and remove it
again.
1
The oil level should be between the High

and LOW marks on dipstick (2).
If necessary, unscrew ller cap (3) and ll
engine oil as far as the high mark.
Insert dipstick (2), ret the ller cap.

NOTE

marks is approximately 5 lts.
d3571018
Total lling capacity ............ approx. 35 lts.
Change the engine oil

CAUTION
lubricants.
CAUTION
anger of burns and scalding.
Engine and engine oil may be at operating temperature.
NOTE
Change the oil when the engine is at operating

temperature.
d3561122
Open the engine cover.

Put a catch tray with a capacity of at least 35
lts under drain plug (1).
Remove oil drain plug (1) and drain the
engine oil.
129
5 Maintenance
Engine
Clean drain plug (1) and install with a new
washer.
Torque drain plug (1) to 60 Nm (45 lb. ft.).
Remove oil ller cap (3) on the ller neck.
Fill engine oil.
Capacity ............... approx. 35 lts.
Fill engine oil.
Check the engine oil level. The oil level
should be between the high and low marks.
The oil level must not exceed the high mark.
Start the engine and check drain plug (1) for
leakage.
Stop the engine and wait at least 5 minutes
for the oil level to stabilise.
Check the oil level again and replenish
engine oil, if necessary.
Change the engine oil lters

CAUTION
lubricants.
CAUTION
Engine and engine oil may be at operating temperature. Danger of burns and scalding.
Open the bonnet.

Put a catch tray with a capacity of at least 10
lts under oil lters (2).
Loosen lters (2) using a lter wrench and
remove by hand.
2
d3561124
Clean lter housing (1).
130
Maintenance 5
Engine
Check lter seal rings (3) in new lters for
proper seating.
2
Fill new llers slowly with oil.
Lubricate seal rings (3) of new lters with

engine oil.
Install lters (2) by hand until seal rings
(3)mate with the lter head, then tighten
by quarter turns using a lter wrench with
tightening band.
Start the engine and check the seal faces
for leakage.
Stop the engine and wait for at least 5
minutes for the engine oil level to stabilise.
Check the engine oil level and replenish
engine oil if necessary.
2
2
d3561125
131
5 Maintenance
Engine
Drain the fuel lter
CAUTION
lubricants.
The fuel lter is located in the air lter/battery

compartment on the left-hand side of the
chassis.
Visual check for any water in the water
separator, draining it if required.
Place a catch tray of approximately 11 pints

capacity under sediment bowl (1).
Release drain screw (2) and drain the
sediment/water.
2
d3561097
132
Tighten drain screw (2) as soon as clean

fuel ows.
Maintenance 5
Engine

CAUTION
lubricants.
CAUTION
Engine and engine oil may be at operating temperature. Danger of burns and scalding.
Place a catch tray of at least 6 ltrs capacity

under lter element (2) to catch the fuel.
2
Using lter wrench, remove lter, and seal

ring (1).
Clean all components with parafn derivatives (washing petrol) and dry with compressed air.
d3561126
Fit a new seal ring (1) to the lter head.

Fill the new lter with fuel before tting.
Rotate lter by hand until the gasket contacts lter head surface, then to of a
turn further, maximum.
Prime the fuel system

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

pump (1).
Fill the pump with clean fuel.
Ret ller cap (1).
d3561098
133
5 Maintenance
Engine
Check the air lter
NOTE
This service is only required once after the rst

50 service hours. Further service intervals as
required.
WARNING
This work may only be performed by the qualied
staff of your authorised dealer.
CAUTION
Clean the air lter casing with a damp cloth.
Do not clean the lter element.
The use of wet cleaning agents will destroy the

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

door.
Unscrew nut (1) and remove the lter end
cover.
2
1
Empty the dust collected in the cover and

wipe it with a clean damp cloth.
Replace dust valve (3) to remove any
collected dust. If necessary, clean the dust
valve with a damp cloth.
Replace dust valve if split or torn.
Unscrew wing nut (4) and carefully remove
lter element (5).
Wipe the inside of lter casing (6) using a
damp cloth.
d3561100
Examine the lter.
134
Maintenance 5
Engine
Replace the lter element if it is damaged,
after 1000 service hours or at least every 12
months.
Before installing a new lter element, examine
it for damage with an inspection lamp held
inside the element.
Examine the seals for damage.
Renew the lter or seals if damaged.
Examine the safety element. Renew if
damaged.
Install lter element (5) into lter casing (6)

and secure it with wing nut (4).
Ret end cover (2), ensuring that dust valve
(3) is positioned through the deck plate, and
secure with the wing nut.
Close the air lter/battery compartment

door.
6
d3561101
Change the air lter element - check

the vacuum switch
2
1
At least every 12 months or after 5 cleanings.

CAUTION
Work on the truck on level ground.
Lower the mast and handler, stop the engine and
put the parking brake on when working.
CAUTION
Stop engine before servicing the air Intake system.
Do not start the engine with the lter element
removed. Wear a protective mask for all services
on the air Intake system.
d3561100
CAUTION
Clean the lter case with a damp cloth.
Do not wet clean the lter element.
Open the air lter/battery compartment

door.
135
5 Maintenance
Engine
Unscrew nut (1) and remove lter end cover
(2).
wipe clean with a damp cloth.
Remove dust valve (3) and clean with a
damp cloth.
Renew dust valve (3) if damaged.
Unscrew wing nut (4), remove element (5)
and discard it.
Wipe lter casing (6) with a damp cloth.
Examine the new lter element for damage
before installation.
Install lter element (5) into lter casing (6)

and secure with wing nut (4).
Ret end cover (2) and secure with nut (1).
Ensure that dust valve (3) is positioned
through the casing hole.
Ensure that dust valve (3) is pointing

downwards.
Remove the intake hose from the air lter
intake.
d3561102
Close the air lter Intake when the engine

is running. The Air lter restriction warning
indicator will be visible on the truck display
unit.
NOTE
If air lter restriction indicator is not shown on

the truck display unit, contact your authorised
dealer.
Ret the intake hose.
Close the air lter/battery compartment
door
136
Maintenance 5
Engine
WARNING
7
6
Stop the engine before servicing the air intake

system.
WARNING
Under no circumstances must the safety element
be cleaned, or an attempt made to start the truck
with the safety element removed.
CAUTION
5
4
Clean the lter casing with a damp cloth. Do not

clean the lter element.
1
3
The use of cleaning agents will destroy the

lter element. Follow the precautions for
handling uids and lubricants.
d3561156
Unscrew nut (1) and remove lter end cover

(2).
wipe clean with a damp cloth.
Remove dust valve (3) and clean with a
damp cloth.
Renew the dust valve if damaged.
Ret dust valve (3).
Unscrew wing nut (4) and remove main
air lter element (5). Inspect and renew if
damaged.
2
1
Unscrew nut (6) and remove safety element

(7).
Examine the new safety element for signs
of damage, before installation.
Fit safety element (5) into lter casing (8)
and secure with nut (6).
Ret main air lter (5) into lter casing (8)
and secure with wing nut (4).
Ret end cover (2) and secure with nut (1).
Ensure that dust valve (3) is positioned
through casing hole (9).
d3561100
137
5 Maintenance
Engine
CAUTION
Engine and transmission may be at operating
temperature. Danger of burns and scalding.
Check the engine mountings and spherelastic

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

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

radiator and oil cooler of any debris.
Clean the radiator and oil cooler ns with
compressed air or use a cold cleaner or
steam jet if necessary.
Start the engine and let it idle to allow water
to evaporate quickly.
Check the cooling system for leaks with the
engine at operating temperature.
Install the radiator grille.
138
Maintenance 5
Engine
Check the injection nozzles

Servicing of the Injection nozzles before the
normal interval is indicated if the engine is:
Misring
Knocking in one or more cylinders
Overheating
Losing power
Emitting smoky black exhaust

Using more fuel
NOTE
Technical skill and knowledge are required

for this adjustment. Please contact your
authorised dealer

CAUTION
CAUTION
Engine and radiator may be at operating temperature.
Danger of scalds and burns.
Isolate the battery.

Remove the rocker arm cover nuts and seal
rings.
d3561144
Remove the rocker arm covers and gaskets.

Rotate the accessory drive clockwise until
the A valve set mark on the accessory drive
pulley is aligned with the pointer on the gear
cover.
NOTE
The number 1 cylinder is at the front end of the

engine.
Check the clearances of the valves of
cylinder 1.
Valve clearance when warm or cold:
Inlet valve ......... 0.2 mm
Exhaust valve ......... 0.5 mm
Adjust the valve clearances, if required.
139
5 Maintenance
Engine
Turn the crankshaft in the normal direction
of rotation and check and adjust, if required,
the valve clearances in the following sequence:
Start
Pulley
position
Set
injector
Cylinder
valve
Advance
to
Advance
to
Advance
to
Advance
to
Advance
to
Advance
to
Firing
order
153624
Install the rocker arm cover.

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

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

damaged.
140
d3571085
Maintenance 5
Engine
Inspect hose clips for security, tighten if
necessary.
Check the overall condition of the exhaust
system, replace any pipes or the silencer If
badly corroded.
Check that the exhaust mounting ange
nuts are tight.
Check that the exhaust clamps are tight.
Check that the silencer mountings are
secure.
Torque ......... 56 Nm (41 lb. ft.)
Check that the tail pipe mounting bolts are
secure.
d3571086
Torque ......... 56 Nm (41 lb. ft.)
Check the cooling system for leaks

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

bottom hoses, replace if deteriorated.
d3561145
Check that hose clamps are secure.

WARNING
Do not run the engine with the thermostat removed
141
5 Maintenance
Engine
Flush the cooling system
CAUTION
Do not remove the pressure cap, while the engine
is hot. Wait until the coolant temperature is below
50C before removing the pressure cap. Danger of
scalds or burns.
d3561163
CAUTION
Coolant is toxic. Keep away from children and
animals. Dispose of waste coolant according to
local regulations.
Drain the cooling system, do not allow the

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

the system, if the drained water is still dirty,
repeat the process until drained water is
clean.
Fill the cooling system with pre-mixed
coolant/water mixture - see Fuel and oil
recommendations.
142
Maintenance 5
Engine
Change engine coolant
CAUTION
Follow the precautions for uids and lubricants.
CAUTION
Do not remove the radiator cap or drain plugs
when the radiator Is hot or with the engine running.
CAUTION

The radiator drain plug Is tted at the base of

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

Place a container of at least 45 lts capacity
under radiator drain plug (2).
Remove the engine undertray.
Place a container of at least 45 lts capacity
under engine drain plug (3).
Remove the drain plugs and allow the
coolant to drain.
Flush out the radiator through the ller cap
aperture.
Ret radiator drain plug (2).
Ret engine drain plug (3).
Fill the cooling system with a water-antifreeze mixture.

Ret the radiator cap (1).
Run the engine for 5 minutes.
Check the coolant level, replenishing
coolant if required.
d3561153
Check the cooling system for leaks.

Fit the undertray.
143
5 Maintenance
Engine
NOTE
Capacity of cooling system ......... 44 lts
144
Maintenance 5
Engine
Check the vibration damper

NOTE
Silicone uid inside the vibration damper will

become solid after extensive service, which
makes the vibration damper inoperative.
This could cause major engine or driveline
problems.
Check the vibration damper for evidence of
loss of uid, dents, and wobble.
Inspect the vibration damper thickness for
any deformation or raising of the damper
front cover plate.
If any deformations or variations are detected, please contact your authorised
dealer.
d3561157
Check drive belt tension

CAUTION
Danger of burns.
The engine and radiator may be at operating temperature.
Examine the drive belt for tension and excessive wear, cracks and traces of oil. Renew
damaged drive belts.
This belt drive system is equipped with an
automatic belt tensioner which CANNOT
be adjusted. Only visual inspection of belt
tensioner is required.
If the belt tensioner is hitting either of the
cast stops (limiters), check the mounting
brackets and belt length.
d3561110
145
5 Maintenance
Engine
Check the fan drive idler pulley
assembly
Remove fan drive belt (1).
d3561158
Inspect the idler pulley for:

Freedom of rotation,
Damaged or broken pulley groove.
d3561159
146
Maintenance 5
Engine
Measure the idler pulley end clearance.
Min ......... 0.025mm
Max ......... 0.250mm
If end clearances are not within these
measurements, contact your authorised
dealer.
d3561160
Fan hub, belt driven

Remove fan drive belt (1).
d3561158
147
5 Maintenance
Engine
Inspect the idler pulley for:
Freedom of rotation,
Damaged or broken pulley groove.
d3561161
Measure the idler pulley end clearance.

Min ......... 0.08mm
Max ......... 0.41mm
dealer.
d3561162
148
Maintenance 5
Engine
Check the turbocharger

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

Remove the intake and exhaust piping from
the turbocharger.
d3561166
149
5 Maintenance
Engine
Use a wire type feeler gauge to measure the
clearance between the compressor wheel
and housing.
Gently push the compressor wheel toward
the compressor housing and gauge.
Record this clearance
d3561167
With the feeler gauge in the same location,

gently push the compressor wheel away
from the compressor housing and measure
the clearance between the compressor
wheel and housing.
Record this clearance
Subtract the smaller clearance from the
larger clearance, this is the radial bearing
clearance.
Min ......... 0.15mm
Max ......... 0.64mm
dealer.
150
d3561168
Maintenance 5
Gearbox
Check the Axial clearance
Use a dial depth gauge.
Push the rotor assembly away from the
gauge.
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 measurements, contact your authorised dealer.
Re-t the intake and exhaust piping.
d3561169
Gearbox
Change the transmission oil and
clean the lter screen
CAUTION
CAUTION
Open the engine compartment front cover.

Remove the engine compartment front
under trays.
Place a catch tray of at least 60 lts capacity
under drain plug (1).
2
1
d3561141
Remove drain plug (1) and allow the oil to

drain. Remove and discard the plug seal
ring.
Remove plug (2) from the housing with the
lter screen attached.
Remove and discard the seal ring on drain
plug (1).
Wash the screen assembly in parafn
derivatives such as benzene and dry with
compressed air (max. 5 bar).
151
5 Maintenance
Gearbox
Fit drain plug (1) with a new seal ring and
tighten.
Install screen assembly and plug (2) with
new seal ring.
Torque to 13 - 20 Nm (10 - 15 lb. ft.)
Remove transmission ller cap (3) and ll
transmission oil.
Capacity ........ 60 lts
Start the engine and check for leaks at the
seal faces.
Check the transmission oil level, replenishing oil If required.

Fit the engine compartment front under
trays.
Close the engine compartment front cover.
d3561142
Change transmission oil lters

CAUTION
lubricants.
CAUTION
2
3
Filters and oil may be hot. Danger of burns and

scalding.

Place a catch tray of at least 11 pints
capacity under the lters (1).
Loosen lters using a lter wrench and
remove by hand
d3561121
Clean the lter head.

Fill the new lter with transmission oil.
Lubricate lter seals (2) with transmission
oil.
Install new lters and tighten by hand only.
Start the engine and check for leaks at the
seal faces
Check the transmission oil level and replenish oil if necessary.
152
Maintenance 5
Close the engine compartment front cover.
Check transmission mountings

CAUTION

brake on when working..
CAUTION
Check the condition of the rubber mounts.

Renew the rubber mounts, if damaged.
Torque ......... 175 Nm (129 lbf- ft.)
3
d3561140

Torque ......... 195 Nm (145 lbf- ft.)
Torque ......... 100 Nm (75 lbf- ft.)
Torque ......... 250 Nm (185 lbf- ft.)

Clean the truck
NOTE
The frequency of cleaning depends on the

use of the truck. If used with very aggressive
media like salt water, fertilizer, chemicals,
cement, etc., a thorough cleaning is required
after the completion of work.
153
5 Maintenance
CAUTION
Use hot steam or intensive degreasing solutions
with the utmost care. The grease in sealed forlife bearings may dissolve and leak out. Since
re-greasing is not possible, this will result in damage
to the bearing.
Follow the precautions for handling lubricants and
uids.
CAUTION
Wear protective clothing and eye protectors.
When cleaning with a pressure washer, do not
expose electrical components or air lter intake
lines to the direct jet, cover them rst.
Before lubrication, clean the grease nipples,

oil ller openings and surrounding areas.
Remove stubborn dirt with a cold cleaner when
cleaning with an air jet.
NOTE
If the truck is cleaned frequently, increase

lubrication intervals accordingly.
When cleaning with degreasing cleaning
solutions, allow sufcient time for the cleaner
to soak in and then ush with a strong water
jet.
After cleaning the engine, allow it to run warm
to dry it in order to prevent any malfunctions
due to the ingress of water.
154
Maintenance 5
Check seat belt for condition and

correct operation*
NOTE
For safety reasons the condition and proper

operation of the retention system should be
inspected regularly (monthly).
Under extreme operating conditions this
check is required daily before taking the truck
into operation.
Pull belt (1) out fully and inspect for fraying.

Check lock (2) for correct operation and the
retractor for proper return of the belt.
Check covers for damage.
d3591093
Check the automatic lock.

Park the truck on level ground.
Pull out the belt with a jerk. The automatic
lock should prevent the belt from unrolling
from retractor (3).
Slide the seat fully forward.
Tilt the backrest fully forward.
* option
CAUTION
Have a defective seat belt replaced immediately by
your authorised dealer.
Do not operate the truck with a faulty seat belt.
To prevent accidents, check that all adjustments are properly engaged before operating
the truck.
Do not operate the seat adjusting devices
while operating the truck.
Seat belts must be applied before operation of
the truck.
After an accident, the seat belt must be
renewed. In the case of seat belts attached
to the operator seat, the seat and mounting of
the seat must also be inspected by qualied
personnel.
Nuts and bolts should be checked regularly
for tightness. An unstable seat can indicate
155
5 Maintenance
loose bolts or other faults. If malfunctions in
the operation of the seat are detected (eg seat
cushioning), contact your authorised dealer
immediately to eliminate the cause.
If the seat belt is not checked, you put your
health in danger and there is a higher risk of
accidents.
Tighten wheel nuts

CAUTION
On new trucks, or if a wheel has been removed and
replaced, the wheel nuts must be checked before
use and daily for two weeks.
Check wheel nuts every 100 hours.
Torque all wheel nuts to: approx. 350 Nm.
d3561020
156
Maintenance 5
Check the tyres for damage and

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

Check the front cab mountings
1
NOTE
Access to front cab mounting bolts (1) is from

under the cab oor 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 from

below.
Check that the front cab mounting bolts (2)
are secure;
d3561128
Tighten to 56 Nm (41 lb. ft.) if required.
157
5 Maintenance
Check the rear cab mountings
NOTE
1
Access to rear cab mounting bolts (1 & 2)

Is from under the cab behind the cab rear
compartment door.
Check that cab mounting bolts (1) are
secure;
Tighten to 115 Nm (85 lb. ft.) If required.
Check that cab mounting bolts (2) are
secure;
Tighten to 56 Nm (41 lb. ft.) If required.

d3561129

NOTE
It is very important that these inspections are

carried out as specied in daylight or with
adequate articial lighting, to allow close
examination of the welds. Please follow the
guidelines below:
CAUTION
These maintenance procedures may need to be
carried out at heights of more than 2 metres. Use
suitable access equipment.
In line with the recommended maintenance

schedules for the regular inspection of the
boom and lifting equipment, please follow
these procedures for the full inspection of the
inner and outer boom.
Wash the truck thoroughly and allow to dry.
Corrosion and/or deposits should be
removed to facilitate the inspection.
Park the machine with the boom extended
fully and lowered to allow close examination
of the inner boom.
158
Maintenance 5
Examine both sides of the inner boom as
shown.
It is advisable to check regularly for signs of
metal fatigue. These areas are indicated.
In order to carry out the inspection most
efciently, ensure that the boom is cleaned
of dust water and grease before inspection.
Initially, removal of any paint will not be
necessary to identify whether cracks are
present.
Carry out a visual inspection of the areas of
the boom as indicated.
Carry out a visual inspection of the areas of

the chassis as indicated.
NOTE
Should evidence of cracks be detected

contact Linde Heavy Truck Division Limited
immediately. Details of cracks detected
and their position, also machine usage and
site conditions should be relayed to the
Linde Heavy Truck Division Limited Service
Manager - Tel: +44 1443 624345 Fax: +44
1443 624302
159
5 Maintenance
Chassis frame
Chassis frame
CAUTION
lubricants.
1
CAUTION
Work on the truck on level ground. Retract and
lower the boom, stop the engine and put the parking
Ensure that oil ller plug (1) is in the 3 o clock

position and drain plug (2) is in the 7 o clock
position.
Remove oil ller plug (1).
d3571011
Check oil is visible at the base of hub ller

hole (1).
If required, replenish oil to the base of the
ller hole (1).
Replace oil ller plug (1).
160
Maintenance 5
Chassis frame
Clean and lubricate steer axle, check

the mounting
CAUTION
2
CAUTION
Clean the steer axle.

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

Lubricate kingpin grease points (1&5), (4
positions).
Lubricate the drag link grease points (4), (4
positions).
Press the grease gun until clean lubricating
grease emerges at the bearings.

CAUTION
CAUTION
temperature.

Examine drive shaft coupling bolts (1) for
damage or signs of fretting.
d3561107
Check bolt torque loading.

Torque..............80 Nm (60 lb. ft)
Lubricate drive shaft grease points (2) (3
points)
161
5 Maintenance
Chassis frame
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 when
working.
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).
2
d3561118
162
Maintenance 5
Chassis frame
Check the drive axle centre differential oil level

CAUTION
working.
CAUTION
lubricants.
Remove ller plug (1).

Check that the oil is visible at the base of the
ller hole.
If required, replenish with oil to base of ller
hole.
d3561119
Capacity ................... max. approx 75 lts

Fit ller plug (1).
163
5 Maintenance
Chassis frame
Check the drive axle hub differential
oil level
CAUTION
OIL

working.
CAUTION
2

lubricants.
Position the truck so that the drive axle hub

level indicator mark (1) is horizontal.
d3561120
Check that the oil is visible at the base of the

hub ller hole.
If required, replenish with oil to the base of
the ller hole.
Capacity ................. max. approx. 7 lts
Fit ller plug (2).
Repeat for the other hub.
Change the drive axle hub differential oil
CAUTION
OIL
CAUTION
Position the truck so that the drive axle hub

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

Remove drain plug (3) and allow the oil to
drain completely.
Remove and discard the plug seal rings.
164
Maintenance 5
Controls
Fit drain plug (3) with a new seal ring.
Fill the differential with gear oil to the base
of the ller hole.
Fit ller plug (1) with a new seal ring.
Repeat for the other hub.
NOTE
Maximum oil capacity each side ......... 7 lts

Correctly adjusted hub bearings must not
allow any perceptible end oat, but allow the
wheel to rotate freely without binding.
NOTE
The bearing play can only be checked with the

wheel raised.
Using a jack of sufcient capacity, raise the
truck on the side on which the bearing play
is to be checked and secure the truck with
squared timbers.
In case of bearing play, contact your authorised dealer.
Controls
Check the steering lock
NOTE
Please contact your authorised dealer for this

check.
165
5 Maintenance
Electrics
Check the parking brake condition
and mounting
CAUTION
Examine brake disc (3) for wear and damage.

Check the thickness of lining material on
brake pads (2) . Renew pads if thickness is
less than 2 mm.
Examine calliper bolts (1) for wear, renew if

required. Check that the nuts and split pins
are secure.
d3561146
Check the brake disc wear

NOTE
Please contact your authorised dealer for

renewal of the brake discs.
Electrics
The battery is tted in the left hand chassis
compartment (1) with the air lter and fuel
system water separator.
Check the battery, for cracks in the casing
and leakage of electrolyte.
Remove corrosion on battery terminals and

check the connections are tight.
Smear the terminals with non acid grease.
d3561023
166
Maintenance 5
Electrics
Check electric cables, connectors and connections for condition and tightness
Examine cable connections for looseness
and corrosion.
Inspect the earth lead for loose connection.
Examine the electrical wiring for chafng
and loose connections.
NOTE
Corroded connections and cracked cables

lead to a drop in voltages, which may cause
starting difculties.
Remove corrosion and replace cracked
cables.
167
5 Maintenance
Hydraulics
Hydraulics
Check the hydraulic system, pumps, valves and lines
Check all connections between the oil
tank, pumps and control valves for leaks.
If necessary, tighten any loose joints.
Check the lift, tilt and steer cylinders for
leaks.
168
Renew any cracked hoses.

Check the hoses for damage and chafng,
renew if necessary.
Maintenance 5
Hydraulics
Change the working hydraulic

system oil suction lters
CAUTION
lubricants. Danger of burns.
The oil tank, lter and hydraulic oil may be at
operating temperature.
De-pressurise the tank by rotating the ller

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

Press retainer down, rotate through 90 and
lift out to allow removal and replacement of
lters (3).
2
1
d3571088
169
5 Maintenance
Hydraulics
Lift out lters (3).
Replace lters (3) and seals.
3
Check oil level and replenish, if required

Dispose of used lters according to local
authority guidelines.
d3571089
Change the brake hydraulic system

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

(3) in the brake oil tank, and an in-line pressure
lter (10). The in-line lter (10) is situated
on the left hand side of the chassis near the
transmission.
Chock the wheels of the truck and deplete
any stored pressure in the brake circuit.
170
Maintenance 5
Hydraulics
Unscrew lter case (12).
Remove and discard lter element (12) and
seal ring (11).
Fit new seal ring (11) to lter element (12).
Check that seal ring (11) is correctly seated
and lubricated with oil.
Prime new lter element (12) with new oil.
Engage new lter element (12) into the lter
head (10) and tighten.
10
11
12
d3571090
To replace suction strainer (3), remove and

retain union nuts (2).
1
2
Lift lter cover (1) and strainer (3) from tank

The strainer (3) can be cleaned using
compressed air unless damaged, in which
case it can be removed by unscrewing by
hand and replaced by repeating the above
procedure.
4
3
Start the engine and check the joints for

leakage, tighten nuts (2), if required.
NOTE
The hydraulic system is self priming when the

engine is running.
d3571091
Stop the engine and check the brake

hydraulic system oil level, replenishing
hydraulic oil if required.
171
5 Maintenance
Hydraulics
oil pressure lter
CAUTION
CAUTION
CAUTION
Oil lter and hydraulic oil may be at operating
The lter is tted on the left side of engine

compartment.
d3561137
Place a catch tray of at least 2 L capacity

under the lter assembly.
Unscrew lter case (1).
Remove and discard lter element (2) and
seal ring (5).
Check that seal ring (3) in new lter element
(2) is tted correctly and lubricate with
hydraulic oil.
Fit new seal ring (5) to lter case (4) and
lubricate with hydraulic oil.
Fit lter element (2) to lter head.
Engage lter case (4) into lter head and

tighten.
Start the engine and check the joint for leakage, tightening the lter case if necessary.
Stop the engine and check the brake system
hydraulic oil level, replenishing hydraulic oil
if necessary.
d3561138

oil
CAUTION
lubricants.
172
Maintenance 5
Hydraulics
CAUTION
Hydraulic oil and hydraulic oil tank may be at
CAUTION
NOTE
Note the addition of 6% Lubrizol to the hydraulic oil.

The drain plugs on the hydraulic oil tank for the
working hydraulic system and braking system
are located at the base of the tank immediately
in front of the right-hand steer wheel. The
drain plug for the hydraulic braking system is
located behind the drain plug for the working
hydraulics.
under the drain plug.
Remove the drain plug and allow the
hydraulic oil to drain completely.
Remove and discard the drain plug sealing
ring.
Install the drain plug with a new sealing ring.
d3571092
173
5 Maintenance
Hydraulics
Fill hydraulic oil into the tank checking the
sight glass (1), frequently to check the oil
level.
Capacity ......... 100 lts
Start the engine and carry out a functional
test of the breaking system hydraulics.
Stop the engine and check the oil level in
the hydraulic oil tank on sight glass (1). If
required, ll the oil tank with clean hydraulic
oil until the oil level is between the HIGH and
LOW marks.
d3571092
174
Maintenance 5
Hydraulics
Change the hydraulic oil - working

system
CAUTION
lubricants.
CAUTION
Hydraulic oil and hydraulic oil tank may be at
operating temperature. Danger of scalds and
burns.
CAUTION
NOTE
The operator can have the hydraulic oil

analysed after about 2750 service hours to
determine if the hydraulic oil must be changed
at 3000 service hours. (Refer to analysis of
hydraulic oil.)
The drain plugs on the hydraulic oil tank for the
working hydraulic system and braking system
are located at the base of the tank immediately
in front of the right-hand steer wheel. The
drain plug for the working hydraulic system is
nearest to the front end of the truck.
under the drain plug.
Remove the drain plug and allow the
hydraulic oil to drain completely.
Remove and discard the seating ring on the
plug. Ret the drain plug with a new sealing
ring.
Remove the dipstick with breather valve (1)

and ll the tank with hydraulic oil.
Capacity ......... 800 lts
Start the engine and carry out a functional
test of the working hydraulics.
Stop the engine and check the oil level
in the hydraulic oil tank with the dipstick. If
d3561155
175
5 Maintenance
Load lift system
required, add hydraulic oil up to the between
the HIGH and LOW marks on the dipstick.
Load lift system

Check and lubricate boom cylinder, boom pivot and sliding bearings
A
1
3
5
A
6
2
2
4
d3571012
CAUTION
CAUTION
access equipment.
Check that all stop plates (4) on the inner

and outer boom are tted and tight (4
plates).
176
Maintenance 5
Load lift system
Check pin (5) for tightness.
Check pin (2) for tightness.
Lubricate all grease points with grease (14
grease points).
For lubrication use a grease gun until fresh
Lubricate slewing ring bearing and

gear
CAUTION

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

points).
Using a brush, apply grease to the ring gear
(2).
177
5 Maintenance
Load lift system
Slew gearbox and brake oil level
check
CAUTION
lubricants.
CAUTION
CAUTION
access equipment.
d3571007
Remove level/ller plug (1).

The hydraulic oil level must be at the lower
edge of ller hole (1).
If necessary, ll hydraulic oil to the base of
the hole.
Fit level/ller plug (1).
Check and lubricate the twistlocks

CAUTION
working.
WARNING
The twistlocks (2) are wearing parts. These must be
inspected regularly for damage, correct operation
and wear. Do not operate the truck if damage,
malfunctions or heavy wear are evident.
Check twistlocks (2) in area (4) by measuring between (A) and (B).
This measurement must not be smaller than
1 inch, (the wear limit).
d3561117
Renew the twistlocks if the wear limit is

exceeded.
178
Maintenance 5
Load lift system
Lubricate grease nipples (1 & 3) (3 on each
twistlock).
3
d3561116
Check and lubricate feet at the

bottom of each leg
CAUTION
lubricants.
CAUTION

Lubricate the nipple in the centre shaft (1).

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

179
5 Maintenance
Special equipment, accessories
Change the twistlocks
WARNING
The twistlocks are wearing parts and must be
replaced for safety reasons after maximum 5000
service hours.
Contact your authorised dealer for renewal of

the twistlocks.

Check the central lubrication*
lubricating points
NOTE
This check is required only once after the rst

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

grease
NOTE
The central lubrication canister is located

behind the battery/air lter cover on the
left-hand side of the truck.
Open the battery/air lter cover (2).
Remove dust cap (3) on the canister ller
nipple.
Clean the ller nipple and install the ller

tube of the grease gun.
Fill grease up to the maximum level indicator on the canister.
d3561105
Remove the ller tube and t dust cap (3).
180
Maintenance 5
NOTE
If lling is difcult, clean the lter in the canister.

Close the battery/air lter cover (2).
* Option
181
5 Maintenance
Troubleshooting
Troubleshooting
Troubleshooting guide Diesel engine
Trouble
Possible cause
Correction
Engine will not start
Fuel tank empty
Rell the tank
Fuel lter clogged
Renew the fuel lter, use

winter fuel
Drain, clean the fuel lter
Water in fuel system lter
Check for electric current with

test lamp. If there is no current,
check fuse and switch
Fuel line leakage
Check all pipe connections for
leaks and tighten ttings
Battery charging indicator light Tighten terminal clamps
not illuminated although lamp at battery, check cable
is ok
connections
Preheating system defective
Check the power supply.
Check the cables and connections at the preheat/starting
switch. If the fault cannot be
remedied, contact your authorised dealer.
These faults should always be
Fuel pump defective
checked correctly by skilled
Injection nozzles defective
staff. Please contact your
Injection pump defective
authorised dealer
Check battery, clean battery
Engine starting performance is Battery power is too low.
Battery terminal loose or
terminals, tighten clamps and
poor
oxidised, causing the starter to cover with non-acidic grease
turn only slowly
Fuel supply insufcient
Renew the fuel lter. Check
the fuel line connections for
leaks, and tighten ttings
Restriction or air in fuel system
due to parran deposits in
winter
Particularly in winter:
Use engine oil appropriate for
Filled engine oil viscosity too
the ambient temperature
high
Let engine continue to run until
Engine running and buzzer
Oil pressure in hydraulic
minimum pressure is reached
sounding
braking system below
operating pressure
Fuel shut off solenoid fails to
open
182
Maintenance 5
Troubleshooting
Engine running unevenly with
poor performance
Excessive exhaust smoke
Idle running trouble
Engine overheating, red

warning light in instrument
panel illuminated. Stop the
engine immediately.
Engine oil pressure too low.

Stop the engine immediately.
Fuel supply insufcient.
Renew the fuel lter. Check

the fuel line connections for
leaks and tighten ttings.
Restriction or air in fuel system Use winter fuel in the cold
due to parafn deposits in
season.
winter.
Injection pump overow valve Contact your authorised
not functioning correctly
dealer.
Adjust valve clearances.
Valve clearances not as
Contact your authorised
specied.
dealer.
Injection nozzles defective.
Drain oil to the high mark on
Engine oil level too high.
the dipstick.
Adjust valve clearances.
Poor compression due to
burned-in or broken piston
dealer.
rings or incorrect valve
clearances.
Fuel system not in order
Clean and inspect fuel lter
renew if necessary. Clean the
fuel pump. Check fuel return
lines and injection lines for
leaks.
Engine speed setting incorrect May only be adjusted by skilled
staff. Contact your authorised
dealer.
Coolant level low.
Check cooling system for
leaks, seal if necessary. Add
coolant.
Fan V-belt either slack or
Tighten or renew the V-belt.
broken.
Radiator ns restricted due to Clean the radiator.
dirt or foreign objects.
Injection system setting
incorrect.
dealer.
Leaks in the lubricating
system.
dealer.
Add lubricating oil.
Oil level too low.
Battery charging indicator light Alternator RPM too low.

illuminated during operation
Alternator not charging the
battery because alternator or
relay defective.
Check V-belt tension.

dealer.
183
5 Maintenance
Troubleshooting
Troubleshooting guide hydraulic system
Trouble
Possible cause
Correction
Abnormal noise
Suction lter restricted.
Renew the suction lter.
Suction hoses leaking, oil

foaming.
Hydraulic pump or motor failure,
seals defective, causing air
intake.
Incorrect oil viscosity, low oil
level in tank or in hydraulic
pump.
Pump suction defective, noise.
Tighten lines. Check oil level, top

up if necessary.
Have hydraulic unit inspected by
your authorised dealer.
No or too low pressure in

system
Oil pressure uctuating
No oil ow or low oil ow
Hydraulic oil temperature

too high
184
Pump failure, leakages,

pressure valves do not close,
valve seat damage.
Pipe broken or leaky.
Change oil, be sure to use the

correct viscosity, replenish oil.
Change oil, replenish oil.
Contact your authorised dealer.
Replace or tighten line.
Oil of low viscosity, causing high

leakage losses.
Oil temperature warning lamp
illuminated.
Cause as under abnormal
noise.
Pressure relief valves or boost
pressure valves sticking.
Lift and tilt cylinders have tight
spots.
Boom does not extend
completely or retracts slightly
after being extended.
Suction lter restricted (if
accompanied by noise).
Pump faulty, leakage, pressure
relief valves do not close, valve
seat damaged.
Pipe broken or leaky
Replace or tighten line.
Valves restricted.
Hydraulic system overheating.
Check oil level, use specied oil,

clean oil cooler, if needed.
Pump failure, valves leaky.

Oil level too low or oil cooler
defective.
Change oil, be sure to use oil of

correct viscosity.
Check oil level, clean oil cooler.
See under abnormal noise.
Replenish hydraulic oil.
Clean or replace suction lter.

Check oil level, if necessary top

up oil. Clean cooler and check for
leaks. If defective, contact your
authorised dealer.
Maintenance
User manual feedback

User manual improvement record.
As part of Linde Heavy Truck Divisions
commitment to continuous improvement
please complete the form below to let us
know if there are any discrepancies within
this technical publication.
NOTE
Please be aware that amendments will be

assessed for validity, collated and updates will
be made according to scheduled updates.
Page
Existing content
number
Proposed content
amendment
185
186
Maintenance
Index
g
NUMBERS AND SYMBOLS

1000 h Service plan
2000 h Service plan
3000 h Service plan
500 h Service plan .
5000 h Service plan
6000 h Service plan
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.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
114
117
120
111
123
126
A
Accident prevention check . . . . . . . . . . . 15
Adjusting the drivers seat . . . . . . . . . . . . 34
B
Before lifting a load . . . . . . . . . . . . . . . . . 80
Boom and handler controls . . . . . . . . . . . 77
C
Cab door opening and closing . . . . . . . . . 30
Cabin door - closing . . . . . . . . . . . . . . . . 30
Change engine coolant . . . . . . . . . . . . 143
Change the air lter element - check
the vacuum switch . . . . . . . . . . . 135
Change the air lter safety element . . . . 137
Change the brake hydraulic system oil . 172
pressure lter . . . . . . . . . . . . . . . 172
suction lter . . . . . . . . . . . . . . . . 170
Change the drive axle hub differential
oil . . . . . . . . . . . . . . . . . . . . . . . 164
Change the engine oil . . . . . . . . . . . . . . 129
Change the engine oil lters . . . . . . . . . 130
Change the fuel lter . . . . . . . . . . . . . . 133
Change the hydraulic oil - working
system . . . . . . . . . . . . . . . . . . . . 175
Change the transmission oil and clean
the lter screen . . . . . . . . . . . . . . 151
Change the twistlocks . . . . . . . . . . . . . 180
Change the working hydraulic system
oil suction lters . . . . . . . . . . . . . 169
Change transmission oil lters . . . . . . . 152
Check and adjust hub bearings . . . . . . . 165
Check and lubricate boom cylinder,

boom pivot and sliding bearings . 176
Check and lubricate feet at the bottom
of each leg . . . . . . . . . . . . . . . . . 179
Check and lubricate the drive shaft . . . . 161
Check and lubricate the twistlocks . . . . 178
Check battery condition . . . . . . . . . 36, 166
Check brake hydraulic system oil level . . 38
Check coolant level in header tank . . . . . 43
Check drive belt tension . . . . . . . . . . . . 145
Check electric cables, connectors and
connections for condition and
tightness . . . . . . . . . . . . . . . . . . 167
Check engine oil level . . . . . . . . . . . 39, 128
Check seat belt for condition and
correct operation* . . . . . . . . . . . . 155
Check steer axle hub oil level . . . . . . . . 160
Check the air lter . . . . . . . . . . . . . . . . 134
Check the brake disc wear . . . . . . . . . . 166
Check the cab mountings . . . . . . . . . . . 157
Check the central lubrication*
lubricating points . . . . . . . . . . . . 180
Check the condition of structured
components . . . . . . . . . . . . . . . . 104
Check the cooling system for leaks and
tightness . . . . . . . . . . . . . . . . . . 141
Check the drive axle centre differential
oil level . . . . . . . . . . . . . . . . . . . 163
Check the drive axle hub differential oil
level . . . . . . . . . . . . . . . . . . . . . . 164
Check the drive axle mounting . . . . . . . 162
Check the engine mountings . . . . . . . . 138
Check the fan drive idler pulley
assembly . . . . . . . . . . . . . . . . . . 146
Check the front cab mountings . . . . . . . 157
Check the hydraulic system, pumps,
valves and lines . . . . . . . . . . . . . 168
Check the injection nozzles . . . . . . . . . 139
Check the intake and exhaust systems
for leaks and tightness . . . . . . . . 141
Check the parking brake condition and
mounting . . . . . . . . . . . . . . . . . . 166
Check the rear cab mountings . . . . . . . 158
Check the steering lock . . . . . . . . . . . . 165
187
Index
g
Check the transmission oil level . . . . . . . 41
Check the turbocharger . . . . . . . . . . . . 149
Check the tyres for damage and foreign
objects . . . . . . . . . . . . . . . . . . . . 157
Check the vibration damper . . . . . . . . . 145
Check transmission mountings . . . . . . . 153
Check tyre condition and pressure . . . . . 37
Check valve clearances . . . . . . . . . . . . 139
Check windscreen washer reservoir
uid level . . . . . . . . . . . . . . . . . . . 43
Check working hydraulic system oil level . 38
Checking the fuel level . . . . . . . . . . . . . . 40
Checking the twistlocks and warning
lights for proper operation . . . . . . . 44
Checks prior to rst operation* . . . . . . . . 15
Clean and lubricate steer axle, check
the mounting . . . . . . . . . . . . . . . 161
Clean the radiator and check for leaks . . 138
Clean the truck . . . . . . . . . . . . . . . . . . . 153
Closing the battery and air lter
compartment door . . . . . . . . . . . . 33
Closing the brake hydraulic system oil
tank cover . . . . . . . . . . . . . . . . . . 33
Closing the cabin rear compartment
door . . . . . . . . . . . . . . . . . . . . . . . 32
Closing the engine cover . . . . . . . . . . . . 31
Closing the fuse box cover . . . . . . . . 34, 74
Closing the transmission cover . . . . . . . . 31
Closing the working hydraulic system
oil tank cover . . . . . . . . . . . . . . . . 32
Cold Start . . . . . . . . . . . . . . . . . . . . . . . 47
Improper use . . . . . . . . . . . . . . . . . . . . . . 8
Inspection and maintenance data . . . . . 102
Isolating the battery . . . . . . . . . . . . . . . . 36
Daily checks . . . . . . . . . . . . . . . . .
Daily checks* . . . . . . . . . . . . . . . . .
Danger notices
Graduation . . . . . . . . . . . . . . . .
Declaration of conformity . . . . . . . .
Depositing the load . . . . . . . . . . . .
Drain the fuel lter . . . . . . . . . . . . .
Driving . . . . . . . . . . . . . . . . . . . . . .
188
. . . 106
. . . . 16
..... 9
. . . . 11
. . . . 89
. . . 132
. . . . 61
EC declaration of conformity . . . . . . . . . . 11
Electrical Circuit . . . . . . . . . . . . . . . . . . 201
Electronic control module System . . . . . . 46
F
Fan hub, belt driven . . . . . . . . . . . . . . . 147
Fill central lubrication* canister with
grease . . . . . . . . . . . . . . . . . . . . 180
Filling fuel . . . . . . . . . . . . . . . . . . . . . . . 40
First 50 h . . . . . . . . . . . . . . . . . . . . . . . 109
Flush the cooling system . . . . . . . . . . . 142
Frequency characteristic for human
body vibrations . . . . . . . . . . . . . . . 18
Fuel and oil recommendations . . . . . . . 103
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . 74
G
Gear shift control . . . . . . . .
General information . . . . . .
General view of the truck . .
.........
.........
.........
.........
.
.
.
.
62
98
23
22
H
Handling Fuel, Lubricants and
Coolant . . . . . . . . . . . . . . . . . 15 16
Hoisting the truck . . . . . . . . . . . . . . . . . 100
Hydraulic Circuit . . . . . . . . . . . . . . . . . . 221
L
Lubricate slewing ring bearing and
gear . . . . . . . . . . . . . . . . . . . . . . 177
M
Malfunctions during operation . . . . . . . . . 57
Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Index
g
Normal start . . . . . . . . . . . . . . . . . . . . . . 45
Safety Precautions . . . . . . . . . . . . . . . . . 14
Securing the open cabin door . . . . . . . . . 30
Service brake . . . . . . . . . . . . . . . . . . . . . 66
Service plan . . . . . . . . . . . . . . . . . . . . . 107
Slew gearbox and brake oil level check . 178
Stability . . . . . . . . . . . . . . . . . . . . . . . . . 18
Start-up indications . . . . . . . . . . . . . . . . 60
Starting the engine . . . . . . . . . . . . . . . . . 45
Steering . . . . . . . . . . . . . . . . . . . . . . . . . 64
Stopping the engine . . . . . . . . . . . . . . . . 47
Stopping the truck . . . . . . . . . . . . . . . . . 65
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . 9
O
Opening the battery and air lter
compartment door . . . . . . . . . . . . 33
Opening the brake hydraulic system oil
tank cover . . . . . . . . . . . . . . . . . . 33
Opening the cabin door from the inside . . 30
Opening the cabin rear compartment
door . . . . . . . . . . . . . . . . . . . . . . . 32
Opening the engine cover . . . . . . . . . . . . 31
Opening the fuse box cover . . . . . . . 34, 74
Opening the transmission cover . . . . . . . 31
Opening the working hydraulic system
oil tank cover . . . . . . . . . . . . . . . . 32
Operating the hazard warning lights . . . . 69
Operating the horn . . . . . . . . . . . . . . . . . 69
Operating the spreader . . . . . . . . . . . . . 80
Operating transmission dump . . . . . . . . . 65
Operation of container handlers in the
plant area . . . . . . . . . . . . . . . . . . 15
Overload safety switch . . . . . . . . . . . . . . 60
P
Parking brake . . . . . . . . . . . . . . . . . . . . 66
Parking the truck . . . . . . . . . . . . . . . . . . 91
Picking up a container . . . . . . . . . . . . . . 82
Picking up a container CH model . . . . . . 84
Picking up a container TL model . . . . . . . 82
Prime the fuel system . . . . . . . . . . . . . . 133
R
Residual risks . . . . . . . . . . . . . . . . . . . . 17
Running-in Instructions . . . . . . . . . . . . . 15
T
Taking the truck out of operation . . . . . . . 98
Technical Data . . . . . . . . . . . . . . . . . . . 197
Tighten wheel nuts . . . . . . . . . . . . . 37, 156
To operate the cab pre-heater system * . . 72
Towing . . . . . . . . . . . . . . . . . . . . . . . . . 93
Trailer coupling . . . . . . . . . . . . . . . . . . . 91
Travelling with loads . . . . . . . . . . . . . . . . 87
Troubleshooting guide Diesel engine . . 182
Troubleshooting guide hydraulic
system . . . . . . . . . . . . . . . . . . . . 184
Truck lighting and turn indicators . . . . . . . 67
Truck status display . . . . . . . . . . . . . . . . 48
Truck welds inspection . . . . . . . . . 105, 158
Turning on the front windscreen wiper . . . 70
Tyre Specications - Drive and Steer
Axle . . . . . . . . . . . . . . . . . . . . . . . 37
W
Wheel change . . . . . . . . . . . . . . . . . . . . 92
Work on the boom and the front part of
the truck . . . . . . . . . . . . . . . . . . . . 99
189
Linde Material Handling GmbH

3578011501 EN 2010/01/27
Reachstacker
Original instructions
Annex
C4230 - C4540 TL /5,

C4026 - C4535 CH /5
3578011501 EN 2010/01/27
6
Technical Data
196
Technical Data
Technical Data 6
Datasheet
Datasheet
Technical Data
LINDE
Reachstacker
Data sheet for material handling equipment
357 05
DFG
Designation acc. To VDI 3586
VDI 2198
Registration note to VDI 3586
October 2008
1.1
Manufacturer
1.2
Model designation
1.3
Power unit: battery, diesel, LP gas, mains power
Linde
Linde
Linde
Linde
Linde
Linde
Linde
Linde
Linde
Linde
Linde
Linde
Linde
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)
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
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
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
y (mm)
6400
6400
6400
6400
7000
7000
6400
6400
6400
6400
6400
7000
1.6
1.8
Axle centre to fork face
1.9
Wheelbase
(L1 - 1 / 2 high)
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
(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
(L2)
kg
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
3.1
Tyres, front/rear. SE = (superelastic), P = (pneumatic)
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
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/ ()
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
4.4
Lift
4.5
Height , telescopic boom extended
4.7
h1 (mm)
(L1,L2,L3)
Height of overhead guard (cabin)
18900
5115
5115
5215
5215
5555
5115
5115
5115
5115
5215
5215
5555
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
18900
18900
19000
19000
19100
18900
18900
18900
18900
19000
19000
19100
h6 (mm)
3900
3900
3900
4000
4000
4400
3900
3900
3900
3900
4000
4000
4400
h7 (mm)
2840
2840
2840
2940
2940
3340
2840
2840
2840
2840
2940
2940
3340
h10 (mm)
600
600
600
700
700
700
600
600
600
600
700
700
700
1885
1885
1885
1985
1985
1985
1885
1885
1885
1885
1985
1985
1505
4.8
Height, operators seat/stand-on platform
4.12
Towing coupling height

Cabin travel movement
h12 (mm)
Twistlock height lowered
h13 (mm)
Twistlock height lowered (with over-ride activated)
h13 (mm)
4.15
5115
h3 (mm) 15900 / 14100 / 11350

h4 (mm)
3392
4.19
Overll length with attachment
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)
l1 (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
m1 (mm)
11618
345
11618
345
11618
345
11618
345
12220
345
12220
345
11618
345
11618
345
11618
345
11618
345
11618
345
12220
345
12220
4.31
Ground clearance, minimum
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
345
13050
13050
13050
14510
14510
4.34
Stacking aisle 40' container
Ast (mm)
13050
13050
13050
13050
14510
14510
13050
13050
4.35
Turning radius
Wa (mm)
8605
8605
8605
8605
9275
9275
8605
8605
8605
8605
8605
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
5.3
Lowering speed, with/without load
5.5
Tractive force, with/without load
5.6
Maximum tractive force, with/without load
5.7
Climbing ability, with/without load
5.8
Maximum climbing ability, with/without load
5.9
Service brake
Battery voltage, rated capacity
7.1
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
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
346
346
346
346
382
382
346
346
346
346
382
383
392
392
392
392
425
425
392
392
392
392
425
425
425
28
28
28
28
31.5
31.5
28
28
28
28
31.5
31.5
31.5
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
1 kph
1 kph
Acceleration time, with/without load
5.10
6.4
9275
s
V/Ah
Engine manufacturer/type
382
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
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)
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
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
/ cm
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
280
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
Torque converter 4 / 4
160
160
160
160
160
160
160
160
160
160
160
160
160
8.1
Type of drive control
8.2
Working pressure for attachments
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
(mm)
50
50
50
50
50
50
50
50
50
50
50
50
50
C4540 TL / 4
C4535 CH / 4
4.1
Telescopic boom lift angle, Raised/lowered
4.2
Height telescopic boom lowered
4.4
Climbing ability, with/without load
4.5
Height , telescopic boom extended
bar
C4230 TL / 4
C4531 TL / 4
C4234 TL / 4
C4535 TL / 4
C4540 TL / 4
C4026 CH / 4
C4127 CH / 4
C4527 CH / 4
C4030 CH / 4
C4531 CH / 4
C4535 CH / 4
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
5115
5115
5115
5215
5215
5555
5115
5115
5115
5115
5215
5215
5555
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
16560
16560
16560
16660
16660
16760
16560
16560
16560
16560
16660
16660
16760
2nd Rail
(L1,L2,L3)
2nd Rail
56 / 0
197
6 Technical Data
Datasheet
Dimensional illustration
Ast
TL
L1
a
2
Wa
a
2
L2
L1
L3
L2
L1
L3
L2
L1
L3
L2
L1
b13
h4
b11
b1
b3
b2
h3/L1
b10
h3/L2
h3/L3
20
9 6"
1495
40
1790
3840
6280
AST Travelling aisle
20'
10225
10225 / 13980
40'
13050
13050 / 14 510
h4
Ast
40
20
Rotation
30
45
30
45
Model capacity
42000 kg
42000 kg
45000 kg
45000 kg
Distance (a)
4200 mm
4100 mm
4200 mm
4100 mm
Capacity (a)
25000 kg
25000 kg
28000 kg
28000 kg
Distance (b)
5300 mm
5300 mm
Capacity (b)
20000 kg
20000 kg
CH
h3/L1
L1
h3/L3
b11
b1
b3
b10
a
2
L2
L1
L3
L2
L1
L3
L2
L1
h3/L2
b2
9 6"
h13
b13
1790
Wa
3840
6280
?/?
a
2
500
h1
h6
h7
h13
h10
m2
y
96
96
m1
l2
l1
L3
L1
d3571003
198
7
Circuit Diagrams
200
Circuit Diagrams
Circuit Diagrams 7
Electrical Circuit Diagram

Electrical Circuit
Page 1
X4
210
412
411
19
6
114
:1
:1
X9
S4
SP
M9
Y37
:115/129/137
507
OEM1
GND
506
464
15-1/15-2
30-1A/30-1B
29
25
497
409
25
497
29
A1
BAT
A3
B3
29
30
39
S2
IGN
DANA CLARK
TE27 TRANS
B4
S3
37
40
XSP
129
353
38
IGN
Cummins engine QSM Tier3

Management System
150
:2
18 28
BAT2
137
G1
M1
GND
+
-
EX
8 17
BAT1
115
B+
G2
I+
463
250
122
B+
OEM2
A B
+24V
:1
SP
SP
S3
409
:4
900-K
:87
:30
45
496
:3
125
:2
497a
06-2
XS2-A1 Pin 6 Pg3: (196)
:5
129a
130
:4
X1
110
124
28
X10B Pin 5 Pg1: (64)
409
13
:8
:7
X1
4
14
:2
:7
497b
11
12
:85
:4
129b
K15
:86
30-1A/30-1B
09-2
250
:87
:8
X10A
496a
X2A
:3
X10A
K8
:85
K16
10
:13
:87
129d
:1
0-07
:86
5A
:5
X10B
496c
11-21A
XT2-A0 Pin 7 Pg4: (249)
K1
5A
:16
:7
:1
129c
16
:6
24v (IQAN +) E/S :28
F33
:15
:6
S1-A
IQAN XS2-A1 Pin 9

Pg3: (180)
F20
K16 Pin 4Pg1: (30)
10A
:14
496b
II
:7
F19
10A
:17
129e
II15/54
:4
:3
:2
F18
20A
:14
24v (IQAN +) E/S :45
900-AC
50A
S2
S5
F21
210
S1
28-B
28-A
30A
:5
3A
900-AG
30
:86
11-2
:2
S1
1A
F9
:30
16-A
FM1
:30
:7
R32
916
:8
11-21
30-11
:15
X4
11-21B
X97
45-B
45-A
30A
F1
:85
:13
IQAN XS2-A1 Pin 11Pg3: (163)
5A
:2
F34
:30
496
B19
:29
:26
:25
30-15
:1
F17
15-1/15-2
X10B
24v (IGN +) Isolator :15
110
:8
30
120A
30-1A/30-1B
C1
916
FM2
Aircon clutch X105 pin 6 Pg10: (764)
24v (BAT +) :60

24v (BAT +) Isolator :30
Chassis Ground 0v
1
10
12
14
16
18
20
Non harness wiring Linde engine harness Chasis harness
22
24
26
28
30
32
34
36
38
40
42
44
46
48
50
52
54
56
58
60
62
64
66
68
70
72
74
76
78
80
Cab harness
201
900
81
202
83
85
87
89
90
Non harness wiring

92
94
Cab harness
96
98
100
:37
102
:2
104
:3
:4
106
:5
108
:6
110
112
114
116
118
120
122
124
126
128
130
132
134
136
138
140
142
144
146
:7
X SP900
148
150
IQAN-XS2-(A0) CAB FRONT

Address resistor
152
154
-L
T)
-E
R
:16 :30 :17
24-1
:9
:8
IN
(V
PR
30-1
29-1C
42-1C
42-1D
42-1A
29-1B
X94
+24v Ign & E/Stop (28)
-H
ER
:39
17-1
:7
5
PB )
6)
39-1
:4
(A
:25
:6
EA
:38
16-1
:5
(S
:13
25-1
38-1
13-1
:10
(C N-H
A )
N
-L
A )
N
(C -H
A )
N
-L (A
)
D
ER D)
JS
)
PB
1)
12-1
:6
(D F) (
I N JS
(D -H PB
IN )(JS 2)
-I) P
(J B 3
(D
S
)
I
PB
(D N-J
IN ) (J 4)
S
-K P
)(J B
IN
(D
:12
)(JS
-G
IN
ER C)
JS
)
:5
IN
(D
EA
:11
IN
D
:4
(V
:10
(S
:10
(V
EA
JS-6
(C
N2
11-1
:3
(S
ER B)
JS
)
IN
:2
:42
(V
10-1
900-FM
EA
ER A)
JS
)
:29
IN
:2
:1
EA
42-1
29-1A
100-AJ
(S
:31
:18
:4
EF
:1
(V
:01 :07
29-1
S58
(S
:5
0
EF
:10
:09
II
I 0 II
(-V
:03
5V
S57
31-1
:09
(+
:32
18-1
32-1
:2
:01 :07
:19
N
:03
(C
-N
W
IN
LG
19-1
I 0 II
(F
R (
N D
T I
LG N
S -M
U )
P)
(F
R
N (D
T I
LG N
S -L
D )
W
N
)
:6
P)
-O
:33
U
:10
(D
S56
IN
:01 :07
LG
(D
R
:09
EA
EA
33-1
:03
(R
(R
:20
P)
-P
:3
X93
IN
LH
0
LA
:14
:34
20-1
I 0 II
(D
:1
03-0A
:36
(L
IN
34-1
15A
XS2-A1 Pin 41 Pg:3 (234)
:23
LA -Q
M )
P)
:3
(D
ED
:2
-R
IN
RH
-L
(D
21-1
:2
XS2-A1 Pin 27 Pg:3 (232)
:9
S
(D
LO IN
C -S
K )
ED
)
:21
ER
ER
:35
(L
X88
PA UT
R -C
( D E) )
(S O U
PA T
R (D E) D)
(S OU
PA T
R -E
(D E) )
(S OU
PA T
R -F
(D E) )
(S OU
PA T
R -G
( D E) )
(S O U
PA T
R (D E) H)
(S OU
PA T
R -I
( D E) )
(S O U
PA T
( D RE) J )
(S O U
PA T
R -K
(D E) )
(S OU
PA T
R -L
E) )
EA
EA
F3
02-0A
:22
:8
PR
PR
28-B
42-1B
03-0
:15
(S
(S
(S
35-1A
28-1A
28-1
:7
MDL Pin 41 Pg:6 (470)
-BAT OUTPUTS
S34
PA UT
R -A
( D E) )
(S O U
PA T
R -B
E) )
(
:28
(D
35-1
28-1
S33
(S
SWNIT T)
C
H
)
(D
(D
+BAT
INPUTS
MDL Pin 27 Pg:6 (470)
02-0
900-C
7 Circuit Diagrams
Page 2
SP42-1
XSP29-1A
JS-10
:1
:2
ILF2
3A
PB5
PB3
H9 H10
II
PB6
:26 :40 :27 :41
156
PB4
II
PB2
:1
14-1
158
PB1
B31
:3
:24
:14
01-1
R21
CAN-bus
XS2-0
Cab floor ground 0v
160
Container Handler adaptor harness
161
163
165
167
169
170
Non harness wiring

172
X SP900
174
176
178

180
182
184
186
188
190
192
194
196
K10
198
200
:1
202
X105-A
K16
204
CBFB
:1
X108
X SP900
206
BUZZER
:14
:13
208
210
:1
B7
B8
:2
:2
212
214
:1
216
218
:9
220
222
224
:07
226
:04
:10
S20 Pg: (236)
S30 Pg:11 (842) S31 Pg:11 (864)
X SP901-E
228
230
:10
:11
Cab floor ground 0v
232
S19
OVERIDE
:25
BUZZER
234
:33
Address resistor
03-2
II
:26 :40 :27 :41
236
28-2C
XS2-A1 PIN 03
28-2B
100-AJ
:1
X94
900-F
S1
0
19-2
:01 :07
:09
-L
100-A
:03
900-FL
33-2
28-2K
X94
:24
25-2
100-AH
28-2J
28-2F
28-2E
28-2H
28-2I
28-2G
-H
24-2
I
(A
(C
ab NR F)
ev
de
)
r o (D
ve IN
rid -P
e )
p
(O
/ri (D b )
de I
ke Ny O
sw )
)
ea
pr
(S
(D
:13
/P
(C DI
ab N
Fw-E)
d
)
:10
(C N-H
A )
N
(C -L)
A
N
(C -H
A )
N
-L (A
)
ER
IP
II
/P
IQAN-XS2-(A1) CAB (FUSEBOX)

W
ER
I 0 II
(C
IP
:01 :07
/M
900-FK
:09
0-41
:03
:12
13-2
100-AB
:03
(TO
O UT
P A I)
U
TO
/M
dw D)
n
)
:10
IN
II
ks
S18
0-27
:02
ac
100-AA
:09
(D
12-2
:34
(D
:01 :07
(D
(J
I 0 II
( R OU
EA T
R -L
A )
U
TO
ac Nks C
up)
)
(D
(J
900-FE
:20
34-2
100-AF
:03
ES UT
ET -H
P/ )
B
LA
PA N2 R)
)
20-2
I
(D
r)
(U
S13
03-0A
:37
-Q
2
:31
(D
:10
(R
rm TbuG)
zz
e
II
la
IN
I 0 II
02-0A
:05
PA
900-FD
:01 :07
(A O
N3
(D
:17
31-2
(U
17-2
I
(D
r)
ze
owDI
er Nsl K
op )
e
)
(P (D
ow IN
er -L
sl )
op
e
)
(P
:10
:09
04-2
(D
T-
II
(W OU
ar T
ni -F
ng )
bu
z
PMJ)
)
100-AG
:03
07-2
:06
:35
S12
03-2
I 0 II
02-2
:23
(D
900-FI
:01 :07
(E
:21
35-2
:09
XT2-A0 Pin 27 Pg: (312)
:86
:85
S11
XT2-A0 Pin 41 Pg: (314)
:86
:85
O
FF
21-2
:10
(D
900-FJ
II
(IG OU
N T
SW -K
IT )
C
H
(D
35 IN
'S to S)
p
in
)
35 (D
' S IN
to p T)
ou
t)
:16
(3
O
'/
(3
O
'/
28-2D
28-2A
:03
XS2-A0 Pin 41 Pg: (152)
:86
:85
:03
37-2
I 0 II
XS2-A0 Pin 27 Pg: (152)
:86
:85
05-2A
:22
(U U
PA T
/ p -D
ro )
g
lig
ht
)
:01 :07
:09
900-EH
K9
16-2
(D
IN
:30
ns -I)
io
n
30-2
I
te
:5
Ex
ct
-J
S8
(D
ra
IN
et
:03
05-2
:9
:39
S10
901-E
K8
(D
0'
I 0 II
0'
(4
(2
100-AE
:4
06-2
:8
(D
900-FH
:3
(H O U
or T
n -C
re )
la
y
)
39-2
:38
ra U T
ke coB)
ol
er
IN
PA -H
3 )
)
:2
(U
SP900
38-2
100-A
:1
900-FC
K4
(D
PA G)
3
)
IN
(U
(D
23-2
:36
(B O
:10
(D
ts
:31
900-K
:2
X110
22-2
:02
900-FB
ev U T
er -A
se )
lig
h
(D
10-2
:49a :58
900-AE
X108
(R
sw)
)
-A
:32
F42
900-AD
:15
0
09-2
-BAT
08-2
OUTPUTS
I
IN
ak
(D
br
:18
:01
ar
S7
900-AC
900-AA
INPUTS
(P
:15
32-2
Pg1: (28)
(D
:11
18-2
28-B
:3
(U OU
PA T
O -E
/P )
)
:28
11-2
28-2
15A
36-2
900-D
+BAT
F4
900
900
(IgDIN
n sw B
( ) )
(S DI
ea Nts M
w )
( 1)
(S DI
ea N
t s -N
w )
2
)
Circuit Diagrams 7
Page 3
+24v
:9
S20
S21
:10
900-FM
:19
:14
:1
14-2
01-2
R24
CAN-bus
XS2-1
:12
X10C
Cab floor ground 0v
238
240
Cab harness
203
241
204
243
245
247
K15
249
250
X
K1 Pg: (14)
252
Non harness wiring Cylinder harness

254
256
:86
:85
Y3
258
:1
:2
260
262
264
266
Linde engine harness Chasis harness

268
:1
:2
Y1
270
Cab harness
272
:1
Y2
274
E3
276
278
280
282
284
286
288
290
Pg8: (636)
:2
292
:18
E4
294
296
:31
298
:32
:1
:2
300
302
-B
:19
:20
304
:33
Y13
306
308
(C
A
(C N-H
A )
N
(C -L)
A
N
(C -H
A )
N
-L (A
)
:1
:2
Y10
310
-L
:22
Address resistor
:34
X2A
Chassis Ground 0v
312
314
316
:10
0-23
(A
-C
S54
-H
IQAN-XT2-(A0)
D
CHASSIS LEFT
P)
:5
IN
0-22
R7
-B
P)
0-28D
0-28E
120
Pg:4 (247)
120
126F
126D
0-13A
:5
IN
1
:12
(V
C
0-12
:3
(
A V
EF
:2
(J
(J
5V
(+
R6
-)
M U
ov T
in -B
g )
R c
(M E ab
pr
ov Top
in B
C g ca+) sup
O
pl
U b pr
y)
TB op s
)
up
C
R
pl
ET
y)
0-37
:37
O
(
p)
-H
:1
0-42C
0-42B
:5
0-30
:17
:1
126a
0-16
:6
:38
N4
em
:25
IN
:1
lt
0-13B
:2
oi
:24
(V
:2
ke
:6
ra
:3
(B
bar
0-38
bar
(F (V
ue IN
l l -I
ev )
el
)
R11
:1
(S
:2
T
ea -A
de )
rp
E
ro
pr T
p
ea -A
su
C der +) ppl
O
y)
pr
U
T- op s
A
) uppl
C
y)
R
ET
-A
-)
R10
pr
:3
:8
R5
XT2-A1 Pin 27 Pg:5 (390)
:1
(S
3A
0-25
:4
(V
ILF3
B IN
O TT E
O )
M
2)
(L
IF
T
:13
0-24
0-13H
0-13D
0-28G
XT2-A1 Pin 41 Pg:5 (390)
:5
(V
B IN
O TT D
O )
M
1)
bar
(L
IF
T
0-13
bar
0-36
bar
(-V
0-28F
0-13C
:2
EF
:36
:35
(L VI
IF N
T -G
TO )
P
2)
R8
FW
:3
(B OU
ra T
ke ligE)
ht
s)
(D
)
A
TD
G
U
VI
0-35
:1
R4
0-41
0-27
:4
O
EV
:39
(L VI
IF N
T -F
TO )
P
1)
0-28C
0-13G
:2
:7
0-20
(D
:3
TC
0-39
R9
:3
0-19
:3
VI
PR VI
ES NSU J)
R
E)
:1
R12
X51
0-18
IL
(P
:21
id
no
le
:3
:1
Pg:4(294)
Pg:4(274)
XS2-A1 Pin 16 Pg: (232)
:1
0-17
(D
S14
(M
ke
so
TB
ra
0-28B
28-B
+24V
XS2-A1 Pin 30 Pg: (234)
SP
db
Pg:4 (306)
:2
(M
0-21
:1
0-06
:7
an
ra (VI
ke N
oi -A
lf )
ilt
er
(B
:9
0-05
OUTPUTS
(D
ay
el
:1
42
:29
tr
:16
(H
20A
0-04
:15
ar
st
TF
INPUTS
:42
+BAT
in
:28
X 0-42A1
ng
SP
0-03
-BAT
(D
0-28
F6
(E
0-42
0-28
X11
0-07
Pg:4 (306)
0-28A
:4
24
171
130
126a
0-15
X10C
0-29
7 Circuit Diagrams
Page 4
0-421a

Pg:5 (382)
Pg:5 (382)
S55
PLT
SP
X-SPARE
:23
:14
:27 :41 :16 :30
318
0-14
:1 R20
0-01
CAN-bus
XT2-0
Chassis Ground 0v
320
Jacks harness
321
323
325
327
Non harness wiring

329
330
332
Chasis harness
334
Y5
336
338
Cab harness
340

Y6
342
:2
344
346
:1
:2
348
Y7
Y8
350
352
354
Chassis Ground 0v
356
:1
:2
358
360
362
364
:02
:1
:2
366
Y4
Y9
368
370
372
:05
X-SPARE
:1
:2
374
376
:04
:08
:1
:2
378
380
382
384
Y38
386
A
(C N-H
A )
N
(C -L)
A
N
(C -H
A )
N
-L (A
)
D
IQAN-XT2-(A1T)
D
-L
:3
:25
:06
:1
Y39
:2
388
390
1-35
126C
126F
I
I
:4
Address resistor
392
x cm
S53
394
1-13D
1-13E
1-13C
1-13B
0-42D
0-42A
1-12E
1-12D
1-12C
1-12B
1-12A
-H
1-25
:6
S52
(A
CHASSIS RIGHT
R
-E
IN
1
(V
IN
K 2 F
D )
W
C
(V
C
(J
(J
:23
T
K -E
S
(C
O
A
(D
P)
1-23
(J
TC
S
N5
:24
1)
:4
-C
LE
:2
R13
1-24
:3
2)
:22
I
A N
-D
:1
(V
M
(B
LE
IN
:5
1-22
1-21
S17
(V
:21
LE IN
N -B
G )
TH
2)
(V
:36
(B
(B
LE IN
N -A
G )
TH
1)
(V
:2
:4
(D
LV
E
:6
(J
VA
(B
470
1-13J
:1
0-30
:34
(D
TR
:3
(P OU
IL T
O T D
W )
D
O
)
(P
(P W
U M
M -A
P )
C
O
N
ET ET
pr -B
op -)
va
lv
1-36
5 sec
:3
XT2-A0 Pin 30 Pg: (316)
0-16
:33
e)
ve
:12
(R R
O VI
IL N
TE -G
M )
P
)
1-12
1-13
1-28B
632
1-13G
1-28C
28-B
+24V
XT2-A0 Pin 16 Pg: (314)
:19
(C
(H
YD
:13
(C
)
)
EF
EF
(-V
5V
(+
:37
(R OU
ET T
pr -B
op )
va
l
ve
e)
lv
R23
:2
1-06
1-04
:20
:1
1-05
+)
va
1-37
:1
1-02
(E OU
XT T
pr -B
op )
va
l
(C
LE H)
VE
L
IN
IL
:2
1-34
ro
e)
(V
:3
1-33
-)
lv
va
XT ET
p -B
(E
ET
o -A
pr
TA
:10
R17
126B
:1
120
126A
:1
:32
1-19
:31
ft
YD
:38
(C
e)
LS
lv
bar
1-38
bar
(C
(H
S16
(li
:2
S15
va
TA
:2
1-20
:18
op
IN
R18
644
:2
SU -I)
R
E)
(V
ES
1-28D
1-13H
:1
pr
PR
:39
ft
(P
:3
(li
1-39
:2
(C
ve
E)
SU
:1
1-32
:17
INPUTS
owET
er -A
pr +
op )
va
l
X10C
(L
:42
+BAT
-J
IN
(V
:28
ES
PR
X11
1-31
:29
(C
(L
1-42
:17
e)
TS
(L OU
ow
erT-A
pr )
op
va
lv
TP
1-28
:5
1-18
-BAT
(C
1-28
F7
1-17
1-28A
20A
126B
1-15
:15
1-29
Circuit Diagrams 7
Page 5
Pg:4 (320)
Pg:4 (320)
R14
:5
X-SPARE
:35
:14
396
1-14
:27 :41 :26 :40
1-01
:1
398
R19
CAN-bus
XT2-A1
:07
Chassis Ground 0v
400
Jacks harness
205
7 Circuit Diagrams
Page 6
+ 24v
+ 24v
C
D
28-B
28-8
16-0
:16
30-0
:30
31-0
_O
F5
F4
F3
:2
:3
:5
02-0
:02
:03
:04
:05
:08
XS2-A0 PIN 40
04-0
J1939 ENG / TRANS (X90)
05-0
J1939 ENG / TRANS (X90)
06-0
:06
:07
XS2-A0 PIN 26
03-0
LFM CONT (X97)
07-0
LFM CONT (X97)
08-0
J1939 SPREADER / UPA
09-0
J1939 SPREADER / UPA
:09
J1
F2
F1
B14
:1
:31
IQ
J1
E)
PA
X102
(D
(S
(D
O
(D
(S
:10
01-0F
33-0
(B
(S
:11
(
(S
(R RS
ER
S2 23 (R
B
VI
93
93
PE
U
C (
32 2-D S2
E V
S
9
9
N
B IN
- D A 32
(C (C (C (C (C (C (C (C
R
TA -R
A A A AN
A -F
A AN A
A
A
K )
N N N
N
TA O EA
E
-D -D N-C N-C -B -B -A -A
PS
U
D
I
N
)
L) H L) H) L) H)
T
Y
CAN-bus L) H)
)
)
)
)
(V
IN
-E
PS )
PO )
T)
-D
IN
(V
(B
2)
-L
IT
IN
SW
VR
(+
(D
(H
(-V EF
R )
EF
)
(
(E V
XE IN
L -C
PO
T)
TE
-K
LE
IN
SE
32-0
21-0
20-0
01-0
14-0
19-0
IQAN-MDL
:4
RS232
RPM
N1
:33
:32
:40
:8
:3
:26
3A
bar
:3
:21
:19
:20
:1
(S
(D
(S
:12
28-0E
01-0E
:3
:B
:14
(W
IP
ER
(M
:35
:34
(D
(FINW
(D D)M)
EV IN
ER -N
SE )
)
(D
35-0
34-0
38-0
:38
:24
:39
(M
(D
(S
:41
:H
F8
:2
:3
24-0
25-0
:25
:2
:8
:7
:4
:23 :36 :37 :18
(R
(D
(S
:27
R2
:1
bar
:2
:C
:A
:B
VI DIN
N G O
C )
A
O (D B 1
VI IN )
N G P
C )
A
B
2)
:3
:2
R3
:1
R1
:2
(S25 Pg:11 (830)

R
39-0
:1
(S25 Pg:11 (830)
22
14
18-0
22-0
31B J
28-0D
01-0D
:5
R1-A
SPARE OUTPUTS
(D
27-0
14-0C
01-0C
14-0A
01-0B
01-0A
SP01-0A
R26
:A
3A
S22
53B 53
(D
IN
(D -A
I )
(D N-B
(DIN- )
C
(DIN- )
IN D)
-E
)
23-0
28-0
INPUTS
:22
42-0
+RTC
R1
:C
21
P U P U P U PA U
P
P
P
T- AREUT- AREUT- AREUT- ARE T- ARE T- ARE T- RE TH ) G ) F ) E ) D ) C ) B ) A)
)
)
)
)
)
)
)
ILF1
24v (IQAN +) E/S :28
0v
:13
:4
+5v
(S
(D
13-0
SP14-0
:6
+BAT
13
1
2
3
4
:28
X100
:3
X104
S6
F
N
R
KD
:42
:1
15
36-0
28-0A
XSP28-0
:9
R1-A
15
10A
:13
28-0BA
28-0B
:5
S22
37-0
916-A
F2
R31
28-0C
28-B
:1
0v
14-0B
+5v
(E (V
XE IN
L -B
PO
T)
1)
24v (IQAN +) E/S :28

24v (BAT +) :60
-BAT
:15
900-EI
900-B
X-MDL
X SP900-E
900-E
900
X SP900
Fusebox ground 0v
401
403
405
407
409
410
412
414
416
418
420
422
424
426
428
430
432
434
436
438
440
442
444
446
448
450
452
454
456
458
460
462
464
466
468
470
472
474
476
478
480
Cab harness
206
Circuit Diagrams 7
Page 7
N1 MDL
N2
(Cab)
XS2-(A0)
N3
(cab front)
XT2-(A0)
N4
N5
(Chassis LHS)
XS2
XS2
C3
XS2-(A1)
(Cab fuse box)
XA2
XT2-(A1T)
(Chassis RHS)
XA2
(R11) RS232 IQAN prigram / diagnostic interface plug
ADDRESS
)
-L
-H
A
(C
R19
:14
(C
)
-L
-H
(C
(C
:27 :41
IQAN-BUS
0-16
0-30
0-16
ADDRESS
)
-L
-H
A
(C
(C
)
-L
-H
(C
(C
:06
0-41
0-41
0-27
:03
0-27
XT2-1
R20
:14
IQAN-BUS
IQAN-BUS
R25
J1939 ENGINE / TRANS BUS
J1939 ENGINE / TRANS BUS

05-0B
:B
04-0B
:A
:B
CAN-L
:A
CAN-H
:C SCREEN 1
:C
05-0A
:B
04-0A
:A
X112
SCREEN 1
:13
:B
05-0A
:A
04-0A
(P10) DANA Transmission harness CAN interface plug
X97
DANA PRE-WIRED TRANSMISSION HARNES
485
487
489
B3
R11
J2
(Connector J2)
AC
B
J1939 BUS SCREEN

GRND POINT ENGINE ECU
Engine ECM unit
:37 SCREEN 1
J2
J1939 Spreader
(R11) RS232 Dana transmission controller prigram / diagnostic

interface plug
P2
P1
N8 LINDE
483
X11
:01
:02
X89
481
ADDRESS
)
-L
-H
A
(C
(C
0-41
)
-L
-H
:01
0-27
:41
:02
02-0A
:27
:26 :40 :16 :30
X112
04-0
X19
P10
05-0
SCREEN 1
:A
04-0B
:B
04-0
05-0B
05-0
:11
:12
:40
R24
:14
:01
SCREEN
X90
CAN OPEN LHC BUS

06-0
07-0
:14
:C
0-27
0-41
X10-C
IQAN-BUS
IQAN-BUS
SCREEN
(C
:26
:01
XT2-0
:01
XS2-1
R21
03-0A
:41
:14
(C
ADDRESS
)
-L
-H
02-0A
(C
03-0
(C
:27
02-0
(C
(C
-L
-H
-H
-A
N
A
02-0
:40
03-0A
-H
-L
-B
-A
N
A
(C
04-0
03-0
05-0
:02
06-0
(C
)
-L
-H
-B
N
A
(C
-C
-L
-C
N
A
:03
SP08-0
CAN 2.0B J1939 BUS

08-0B
09-0B
:B
(C
:04
07-0
(C
:06 :05
SP09-0
:A
(C
-H
-L
-D
-D
(C
:07
08-0
(C
09-0
:1
:2
X100
J1939 Printer
:08
X
X
08-0A
XS2-0
:26
XXX
:09
09-0A
X-MDL
C1
C1
C1
:01
0-30
C1
C1
490
:47 05-0A
:46
LFM
492
B4
04-0A
Transmission controller
(DANA SPICER TE-17)
494
496
498
500
Non harness wiring Linde engine harness Chasis harness
502
504
506
508
510
512
514
516
518
520
522
524
526
528
530
532
534
536
538
540
542
544
546
548
550
552
554
556
558
560
Cab harness
207
7 Circuit Diagrams
Page 8
24v (Bat +) Isolator (30)
24v (Bat +) Isolator (30)

15-3/15-4
30-1A/30-1B
:14
:19
Pg8: (592)
400
15-32
:09
IQAN XS2-A1 Pin 8

Pg2: (90)
0 I II
:02
II
15/1
II
5
56
08-2
S23
K3
:87
II
:85
:87
S25
56A
347
900-EC
563
565
567
569
570
572
Non harness wiring Chasis harness
208
574
576
578
Cab harness
580
582
584
588
590
592
594
596
598
06-B
06-A
346A
346
919
346R
346R
317R
346L
346L
347
347-A
:2
X
:2
X35L
E2
E1
E15
E14
B11
600
602
604
606
608
610
612
614
616
Chassis Ground 0v
618
620
622
624
626
628
630
632
344
343
357
333/339
:85
334/339
586
X4
X35L
:86
:9
:16
:11
334/339
H6
E21
E13
E12
K3
900-A
E11
E10
Chassis Grnd 0v
561
:3
X35L
E20
:28
:4 X10B
X4
317R
309
:3
X35L
900
900-FA
I 0 II
:3
E4
E3
:12
:14
900-ED
E19
:10
333/339
E18
:26
X10B
:13
X4
5A
5A
:32
X10A
345R
345L
308
321
325
E17
:9
:9
X
900-AB
320
:2
:8
X4
324
:1
:30
:27
F46
F45
10A
10A
317L
:7
X10B
:25
:31
F48
F47
1A
:22
345R
:6
:31
:29
F42
3A
345L
327
:12
317A
317
:24
327
320
:23
:49A
:11
326
F43
F44
3A
49A
:10
:12
:11
:8
49A
X35R
E16
IQAN XT2-AO Pin 6

Pg4: (278)
K5
t
S25
S25-B
:49
Pg8: (616)
:4
II
X4
345
400
:10
317L
327-B
327-C
X10A
:06
:03
:49
56B
49
320-C
:1
S25-B
:49A
327-A
320-B
:R
H7
320-A
49A1
:L
:31
:86
900-AA
S24
K4
:30
I 0 II
:30
355
:01
30-17A
:30
15-21
:15
15-21A
30-16
15-31
10A
15A
:21
:18
:2
100-BC
:13
24v switch illumination
F50
F23
15A
5A
5A
:7
:9
F41
F22
F49
1 0
:6
24v Ign + (:15)
30-17
:1
15-1/15-2
30-1/30-1A
15-3/15-4
24v Ign + (:15)
634
636
638
640
Light harness
Circuit Diagrams 7
Page 9
:5
20A
10A
:16
100-BD
:10
:1
:1
E23A:1
:2
:1
E23
E22
900
900
900
E23:2
SP900
Chassis Ground 0v
647
649
Non harness wiring
650
652
654
Chasis harness
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
E23A:2
710
SP900
:1
:1
900
SP900
901-ED
901-EE
E9
E8
SP900
645
:02
X4A
643
:09
12-A
12
E6
E7
641
:06
E23:1
:3
:2
:05
:01
:10
:11
:10
X4
15-36
15-35
15-36A
X10B
:7
:5
:02
:01
:6
:5
X109
:09
S32
:10
X10A
:1
:06
145
193
900-E
189
59
:02
:01
:10
X88
:05
S28
:9
:8
:1
900-EE
148
924A
:02
:01
X4
:09
S27
S26
X10A
:06
:05
900-EB
925
15-35A
:09
15-34
15-34A
:06
:05
900-EA
194
15-33
15-33A
12
100-B
:18
:17
100-BA
:15
:6
F54
F53
20A
20A
:20
100-BB
5A
:4
F52
F51
15-3/15-4
:3
15-3/15-4
:8
F40
15-3/15-4
24v Ign + (:15)

15-3/15-4
15-1/15-2
24v Ign + (:15)

712
714
716
718
720
Cab harness
209
7 Circuit Diagrams
Page 10
24v Bat + (:30)
30-1A/30-1B
30-1A/30-1B
15-1/15-2
24v Bat + (:30)
:12
:8
F24
F35
F28
5A
24v Ign + (:15)
:3
30A
15A
:15
30-27
30-18
15-13
:24
:20
250
256
257
253
:8
:6
:7
:5
22-2
IQAN XS2-A1 Pin 22

Pg3: (186)
:4
:3
:2
255
:1
251/252
X105
254
24v Ign + (:15)
Pg1: (36)Aircon clutch
K9
:30
:86
:85
251
252
900-AD
:87
:1
:2
:3
:4
:6
:5
:7
X43
:1
E5
329
329-A
E5
251
252
B16
263
262
261
E5
:2
901-C
M2
S46
SP901-E
SP901
264
901-E
901-B
901-EB
Chassis Ground 0v
Chassis Ground 0v
721
723
725
727
Non harness wiring
210
729
730
732
Cab harness
734
736
738
740
742
744
746
748
750
752
754
756
758
760
762
764
766
768
770
772
774
776
778
780
782
784
786
788
790
792
794
796
798
800
Heater / blower harness
Circuit Diagrams 7
Page 11
24v Bat + (:30)
24v Ign + (:15)
24v Ign + (:15)
:5
30-1A/30-1B
15-1/15-2
30-1A/30-1B
24v Bat + (:30)
:10
F37
:11
F26
15A
F27
10A
10A
:22
15-15
:17
:23
(IQAN XS2-A1)Pin 4 Pg 3 (226)
(IQAN XS2-A1)Pin 7 Pg 3 (222)
04-2
07-2
15-15B
X SP15-15
:6
S25-A
:6
226-B
1004
30-23
:87
:87a
:86
K7
:85
85
84
:30
(IQAN MDL Pin 34 Pg 6 (442)
M5
:2
:3
:2
X14
:1
M4
M7
:3
:2
:4
M6
M3
M8
M5
M7
+24v Wash/wipe o/p
0v
K6
:30
X14
K2
24v wash
o/p
+24v Wash/wipe o/p
30-22
:87a
:85
X14
:5
:06 :09
1002
1002-A
:87
:86
48
:2
:3
58-B
15
56
:5
31B
1001
S31
VII
:02 :07 :03
15-15A
:6
S
57-B
86
15-15C
56
229
240-B
226-A
:4
:2
:3
900-FG
57-A
SP57
34-0
SP58
(IQAN MDL Pin 35 Pg 6 (444)
R30
D2
D3
SP34-0A
58-A
SP226
D1
50
:06 :09
SP240
240-A
:02 :07 :03
226
58
S30
VII
1004-A
:8
1003
:7
900-FF
:4
+24v
86
:1
35-0
:3
S25-B
53C
240
229
31B
57
53
0v
:2
53B
24v wash
o/p
I
+24v
Pg.2 (234)
:08
:11
+24v wipe o/p
0
+24v
+24v
100-AC
04-2A
J
0
1
2
:05
:08
:11
+24v wipe o/p
Pg.2 (234)
100-AD
07-2A
:05
47
15
S25
31
K2
900-AF
:1
SP901
SP901
SP901
:4
SP901
:1
901-F
:3
30-23A
X14
:1
901-D
900
:4
:3
901-A
X SP900
901-A
901
900
SP901
:3
901-A
X14
:1
30-22A
X14
M4
XSP900
X SP901
Cab floor ground 0v
Cab floor Ground 0v
801
803
805
807
809
810
812
814
816
818
820
822
824
826
828
830
832
834
836
838
840
842
844
846
848
850
852
854
856
858
860
862
864
866
868
870
872
874
876
878
880
Cab harness
211
7 Circuit Diagrams
Page 12
24v Ign + E/stop (:45)
:08
916-B
:06
Pg:2 (124)
:19
100-AK
5A
:30
X94 Pin 1
15-17
:22
24v (BAT +) :60
F39
5A
:19
24v (IGN +) Isolator :15
:7
F31
5A
3A
15-1/15-2
30-2C
15-3/15-4
15-3/15-4
:29
:10
30-31
30-30
30-29
15-411
:21
:26
24v (BAT +) Isolator :30
F58
F55
3A
5A
:23 :28
45-6
15-14
10A
1A
:23
F25
F29
15-310
5A
30A
:16
F30
F59
:7
15-37
F15
F36
:9
:25
30-21
:11 :27
30-2A
:11
30-2B
:4
15-3/15-4
45-B
15-1/15-2
24v Ign + (:15)
30-1A/30-1B
24v (IQAN +) E/S :45
24v Bat + (:30)
:2
:3
S29
P7 SP08-0 P7 SP09-0
(495)
(495)
:1
:07
:05
:4
:3
:2
:1
:2
X100
B22
B19
06-0
MDL Pin 6 Pg 6 (474)
900-G
900-H
SP900
SP900
X97
:4
900
900
B21
:14
901-J
CAN-H
:13
+VE
-VE
901-EC
SP901-E
901-E
RADIO
B27
12v
:3
B26
CAN-L
GND
12v
24v
B23
L inde
07-0
GND
B25
B20
X101
MDL Pin 7 Pg 6 (474)
24v
:1
X94 Pin 2
:7 :8
:2
:1
15-311
11-21
:5
11-21B
:6
Pg:1 (24)
09-0A
08-0A
Pg:1 (26)
Cab floor Ground 0v
Cab floor ground 0v
881
883
885
887
Non harness wiring
212
889
890
892
Cab harness
894
896
898
900
902
904
906
908
910
912
914
916
918
920
922
924
926
928
930
932
934
936
938
940
942
944
946
948
950
952
954
956
958
960
Options harness
Circuit Diagrams 7
Page 13
24v Bat + (:30)
:6
:31
:31
F32
F38
F60
5A
5A
24v Ign + (:15)
15-3/4
24v Ign + (:15)
30-2D
15-1/15-2
24v Bat + (:30)
5A
:32
:32
:01
:01
1010
30-28A
30-28
15-16
15-412
:18
:09
:09
S37
S35
:8
0
X10-C
:05
:03
:10
:1
X91
X106
:5
:4
:5
:6
X113
:7
X10-B
1012
1011
1010
1009
1008
15-16
:4
:2
X106
:6
:3
X10-C
X10-C
X10-C
:1
1005
:1
:10
1005
:05
:03
:1
:12
:1
:2
X95
X103
X95
X91
:1
:05
:03
B24
:09
HR
B28
FWD
B30
B29
S36
:01
:3
:1
:2
1006
X10-C
:2
1007
X91
X92
:3
:2
:4
H17
900-EF
E24
SP900
999
900-EF
900-EG
H16
998
:10
SP900
X
Chassis Ground 0v
Chassis Ground 0v
961
963
965
967
Non harness wiring
969
970
972
Cab harness
974
976
978
980
982
984
986
988
990
992
994
996
998
1000
1002
1004
1006
1008
1010
1012
1014
1016
1018
1020
1022
1024
1026
1028
1030
1032
1034
1036
1038
1040
Options harness
213
7 Circuit Diagrams
Page 14

24v Ign + (:15)
:32
45-5
:16
(CORE 15)
45-4
:15
(CORE 14)
45-3
:14
(CORE 13)
45-2
:13
A&B 16 Pin Harting Socket on ELME spreader
(CORE 16)
(CORE 15)
(CORE 14)
(CORE 12)
:10
(CORE 10)
:2
(CORE 1)
GY
(CORE 2)/G/Y
:1
(CORE 3)
:12
(CORE 11)
(CORE10)
(CORE 9)
(CORE 6)
(CORE 8)
(CORE 7)
(CORE 5)
(CORE 4)
G/Y
:4
:6
:7
:1
:2
:3
:4
:5
:6
:7
(CORE 11)
:1
21-1
(CORE 1)
:8
(CORE 7)
189
:7
59
34-1
12 x 1.5mm multicore cable
X89
09-0B
IQAN MDL Pin 9 Pg6: (472)
F 3 Pin Deutsch
2 CORE 0.5 mm twisted pair cable
21-1
1043
1045
1047
Non harness wiring
214
1049
1050
1052
1054
1056
1058
1060
1062
1064
1066
1068
1070
1072
1074
1076
1078
1080
1082
1084
:H2 Not locked

:H3 Seated
:1
:H1 locked
(CORE 13)
:13
(CORE 12)
:12
(CORE 11)
:11
B
:Legs frnt dwn
:Legs frnt up
:Clamped RH
:Clamped LH
:10
:Seated foot rear RH
:9
(CORE 9)
:Seated foot front RH
:8
:Seated foot rear LH
:7
:1
:Seated foot front LH
C
:Can high (j1939)
:2
1086
:Can low (j1939)
:3
:C
:Screen
C 6 pin Harting plug on ELME spreader
X111
1041
:0V
:3
:14
:B
:B
:Work light LH
(CORE 14)
:A
:5
:2
(CORE 7)
:A
:Work light RH
:0V
:4
(CORE 8)
08-0B
:GND CAN
:6
(CORE 10)
:0V
:0V
GY
(CORES (2/4/6/9/10/11)
:+24V IGN (3A)
:8
(CORE 14)
(CORE 8)
:11
:+24V E/stop (10A)
:0V
900-I
(CORE 1)
:+24V E/stop (10A)

:+24V E/stop (10A)
:9
D 8 Pin Cannon plug (CORE 2)
(CORE 2)
(CORE 8)
(CORE 7)
E 7 Pin Cannon plug
:+24V E/stop (10A)
:10
(CORE 8)
(CORE 3)
(CORE 9)
900-I
:10
(CORE 3)
:11
(CORE 4)
(CORE 10)
189
:13
:12
(CORE 5)
(CORE 12)
S26 Pin 2 Pg9: (662)
:9
45-2
15-8
(CORE 6)
(CORE 13)
(CORE 3)
(CORE 4)
:3
34-1
:4
(CORE 5)
(CORE 11)
(CORE 3)
(CORE 5)
(CORE 6)
:8
(CORE 4)
S26 Pin 1 Pg9: (656)
(CORE 6)
(CORE 7)
59
59
(CORE 9)
34-1
(CORE 5)
(CORE 10)
:3
:6
:5
(CORE 4)
16 x 1.5mm core Lapp cable
(CORE 6)
(CORE 5)
(CORE 1)
(CORE 8)
(CORE 13)
(CORE 7)
(CORE 7)
:4
:2
:7
189
G/Y
45-2
21-1
(CORE 8)
(CORE 3)
(CORE 14)
(CORE 7)
:8
900-I
(CORE 8)
(CORE 1)
(CORE 15)
(CORE 9)
(CORE 4)
45-3
(CORE 13)
(CORE 12)
(CORE 10)
:9
(CORE 3)
:6
:5
:14
(CORE 9)
(CORE 16)
(CORE 9)
45-4
:15
(CORE 10)
(CORE 2)
:7
45-4
45-3
(CORE 11)
(CORE 11)
(CORE 2)
:1
45-5
:11
(CORE 11)
H18-H25
H9-H11
(CORE 12)
(CORE 2)
15-8
:12
15-8
(CORE 15)
(CORE 14)
(CORE 13)
(CORE 1)
X88
15-8
(CORE 12)
:16
1088
1090
1092
1094
1096
1098
ELME Combi Can Bus Spreader
3A
(CORE 16)
45-5
(CORE 16)
(CORE 1)
15
45-B
45-4
45-3
:31
:22
:21
:20
X109
F13
10A
10A
10A
:19
45-2
F14
F12
F11
10A
:10
:9
:8
45-5
:7
F10
45-B
45-B
45-B
24v Ign + (:15)
1100
1102
1104
1106
1108
1110
1112
1114
1116
1118
1120
Cab harness
Circuit Diagrams 7
Page 15

24v Ign + (:15)
(CORE 15)
45-4
:15
(CORE 14)
45-3
:14
15-8
:12
:11
(CORE 11)
(CORE 12)

34-1
:3
59
:8
(CORE 3)
189
900-I
:9
34-1
(CORE 7)
:10
(CORE 4)
:3
(CORE 3)
:2
(CORE 8)
(CORE 1)
:11
21-1
(CORE 4)
(CORE 3)
(CORE 5)
:4
(CORE 4)
S26 Pin 2 Pg9: (662)
(CORE 6)
:5
59
(CORE 5)
(CORE 3)
(CORE 7)
:6
(CORE 6)
(CORE 5)
(CORE 13)
45-2
(CORE 12)
15-8
:12
:1
(CORE 1)
GY
(CORE 2)/G/Y
:1
(CORE 3)
:12
:4
:0V
:0V
:9
:0V
(CORE 8)
:8
(CORE 7)
189
:7
:GND CAN
:Work light RH
:6
:0V
:5
59
(CORE 5)
:Work light LH
:4
(CORE 4)
:0V
:3
34-1
(CORE 3)
:H2 Not locked
:2
(CORE 2)
:H3 Seated
:1
21-1
(CORE 1)
:6
:+24V IGN (3A)
:10
(CORE 6)
(CORE 2)
:+24V E/stop (10A)

:+24V E/stop (10A)
:11
900-I
(CORE 8)
:7
189
(CORE 13)
(CORE 1)
:8
(CORE 3)
900-I
(CORE 4)
:2
:14
:13
(CORE 9)
(CORE 1)
21-1
45-3
(CORE 9)
(CORE 14)
(CORE 7)
(CORE 14)
:+24V E/stop (10A)

:+24V E/stop (10A)
:H1 locked
GY
:0V
E 7 Pin Cannon plug
:7
(CORE 4)
45-2
:4
(CORE 15)
:15
(CORE 10)
:9
(CORE 2)
45-3
:5
:16
45-4
(CORE 10)
45-4
45-5
(CORE 15)
(CORE 11)
(CORE 11)
:10
(CORE 16)
:6
(CORE 12)
(CORE 2)
:7
(CORE 12)
(CORE 16)
(CORE 13)
(CORE 2)
45-5
:13
(CORE 8)
S26 Pin 1 Pg9: (656)
(CORE 15)
(CORE 14)
(CORE 1)
15-8
:1
45-2
(CORE 9)
A 16 Pin Harting Socket on ELME spreader
(CORE 16)

(CORE 13)
(CORE 10)
:16
ELME Can Bus Spreader
:32
45-5
(CORE 1)
:22
X88
45-4
45-3
45-2
3A
:21
:20
(CORE 16)
15-8
:19
X109
:31
F13
10A
10A
10A
15
45-B
F14
F12
F11
10A
:10
:9
:8
45-5
:7
F10
45-B
45-B
45-B
24v Ign + (:15)
(CORES (2/4/6/9/10/11)
X89
C 6 Pin Harting Socket on ELME spreader

08-0B
:A
09-0B
:B
F 3 Pin Deutsch
:A
:C
1123
1125
1127
1129
Non harness wiring
1130
1132
1134
1136
1138
1140
1142
1144
1146
1148
1150
1152
1154
1156
1158
1160
1162
1164
:C
1166
C
:Can high (j1939)
:2
C 6 pin Harting plug on ELME spreader
X111
1121
:1
:B
1168
1170
1172
1174
1176
1178
1180
1182
1184
1186
1188
:Can low (j1939)
:3
1190
:Screen
1192
1194
1196
1198
1200
Cab harness
215
7 Circuit Diagrams
Page 16
1201
216
1203
PAGE LEFT INTENTIONALLY BLANK
1205
1207
1209
1210
1212
1214
1216
1218
1220
1222
1224
1226
1228
1230
1232
1234
1236
1238
1240
1242
1244
1246
1248
1250
1252
1254
1256
1258
1260
1262
1264
1266
1268
1270
1272
1274
1276
1278
1280
Circuit Diagrams 7
Page 17
217
7 Circuit Diagrams
Page 18
B3
B4
B7
B8
B11
E14
E 18
BIH
E20
B21
B22
B23
B24
B25
B26
B27
B28
B29
B30
B31
E1
E2
E3
E4
E5
E6
E7
E8
E9
E10
E11
E12
E13
E14
E15
E16
E17
E13
E19
E20
E21
E22
E23
E24
G1
G2
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
E
E
b
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
G
G
DESCRIPTION
PAGE
ENGINE ECM
TRANSMISSION MODULE
WARNING BUZZER
ALARM BUZZER
REVERSE SOUNDER
EXTERNAL MODEM
HORNS
LFM CONTROLLER
24/12V POWER CONVERTER
24V/12V CIG LIGHTER/ POWER OUTLET
J1939 PRINTER/ UPA DEVICE
RADIO
CENTRAL GREASING UNIT
DIESEL CAB HEATER
COMPRESSOR SEAT
HEATED SEAT
B ATTERY BOX RUN HOUR METER
FORWARD SOUNDER
HEATED VIRRORS
CONTAINER HANDLER JOYSTICK
REVERSE LIGHT L
REVERSE LIGHT R
BRAKE LIGHT L
BRAKE LIGHT R
INTERIOR LIGHT
ROTATING BEACON CAB
ROTATING BEACON BOOM
SPREADER LIGHTS
BOOM LIGHTS
SIDE LIGHTS- FRONT L
SIDE LIGHTS REAR L
SIDELIGHTS FRONT R
SIDE LIGHTS REAR R
HEADLIGHTS DIPPED L
HEADLIGHTS DIPPED R
INDCATOR LIGHT FRONT R
INDICATOR LIGHT REAR R
INDICATOR LIGHT FRONT L
INDICATOR LIGHT REAR L
HEADLIGHTS MAIN BEAM L
HEADLIGH S MAIN BEAM R
SIDE SPOT LlGHTS
CAB ROOF LIGHTS
STEP LIGHTING
ALTERNATOR
BATTERY
1
1
3
3
8
6
10
12
12
12
12
13
12
12
12
13
13
13
2
8
4& 8
4& 8
10
9
9
9
9
8
8
8
8
8
8
8
8
8
8
8
8
9
9
13
1
1
H5
H8
H7
H9
H10
H11
H12
HIS
H14
H15
HI8
H17
H13
H19
H20
H21
H22
H23
H24
H25
Kl
K2
K3
K4
K5
K8
K7
K8
K9
K10
K15
K1S
K17
K13
K13
K20
M1
M2
M3
M4
M5
M8
M7
M8
M9
M30
M 11
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
M
M
M
M
M
M
M
M
M
M
M
DESCRIPTION
PAGE
AIR CON LP/HP FAIL

MAIN BEAM INDICATOR LAMP
INDICATOR/ HAZARD WARNING LAMP
SPREADER LOCKED GREEN LAMP
SPREADER UN-LOCKED RED LAMP
SPREADER SEATED AMBER LAMP
AIR CON POWER ON LAMP
AIR CON CLUTCH ON LAMP
AIR CON CONDENSER ON LAMP
AIR CON TRINARY ON LAMP
CENTRAL GREASING ON LAMP
CENTRAL GREASING EMPTY LAMP
COMBI SPREADER LEGS FRONT DOWN LAMP
COMBI SPREADER LEGS FRONT UP LAMP
COMBI SPREADER CLAMPED RH LAMP
COMBI SPREADER CLAMPED LH LAMP
COMBI SPREADER SEATED FOOT REAR RH LAMP
COMBI SPREADER SEATED FOOT FRONT RH LAMP
COMBI SPREADER SEATED FOOT REAR LH LAMP
COMBI SPREADER SEATED FOOT FRONT LH LAMP
IGNITION RELAY
TIMER RELAY
HEADLIGHTS RELAY
REVERSE LIGHTS
INDICATOR FLASHER
REAR WIPER
TOP WIPER
BRAKE COOLER
HORN RELAY
UPA RELAY 1
STARTER MOTOR RELAY
IGN AUTO SWITCH OFF RELAY
IGNITION RELAY AIR CON BOARD (ACB)
CLUTCH RELAY AIR CON BOARD (ACB)
CONDENSER RELAY AIR CON BOARD (ACB)
TRINARY RELAY AIR CON BOARD (ACB)
STARTER M OTOR
HEATER BLOWER MOTOR
FRONTWINDSCREEN WASH PUMP MOTOR
FRONT WIPER MOTOR
REAR WINDSCREEN WIPER MOTOR
REAR WINDSCREEN WASH PUMP MOTOR
TOP WIPER MOTCR
TOP ROOF WINDOW WASH PUMP MOTOR
BRAKE COOLER PUMP MOTOR
AIR CON CONDENSER MOTOR 1
AIR CON CONDENSER MOTOR 2
16
8
8
2.14.15
2.14,15
2.14.15
16
16
16
16
13
13
14
14
14
14
14
14
14
14
1
11
8
3,8
8
1,3
3,10
3
1,4
1,3
16
16
16
16
1
10,16.17
11
11
11
11
11
11
1
16
16
R1
R2
R3
R4
R5
R6
R7
R8
R9
R10
R11
R12
R13
R14
R17
R18
R19
R20
R21
R22
R23
R24
R25
R28
R30
R31
R32
SI
52
S3
S4
S5
SB
SI
S8
310
311
312
313
314
315
316
317
316
S19
320
321
322
DESCRIPTION
PAGE
R
R
R
R
R
R
R
R
R
THROTTLE PEDAL
HYD BRAKE PRESSURE TRANSDUCER
HYD SERVICE BRAKE PRESSURE TRANSDUCER
1200 RESISTOR
1200 RESISTOR
FUEL LEVEL SENDER
BRAKE TEMP SENDER
LIFT TOP 2 PRESSURE TRANSDUCER
LIFT TOP 1 PRESSURE TRANSDUCER
8
6
8
4
4
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
S
S
S
S
S
S
S
S
S
S
5
S
S
S
S
S
S
S
S
S
S
LIFT BOTTOM 1 PRESSURE TRANSDUCER

PILOT PRESSURE TRANSDUCER
BOOM LEGTH SENSOR
BOOM ANGLE SENSOR
470 OHM RESISTOR
120 OHM RESISTOR
XT2-(A1T) 768 OHM ADDRESS RESISTOR
XT2-(AO) 287 OHM ADDRESS RESISTOR
X52-(AO) 287 OHM ADDRESS RESISTOR
AIR CON TEMP PROBE
HYDOILTEMP
XS2-(A1) 590 OHM ADDRESS RESISTOR
ENGINE ECU TERMINATING RESISTOR 120 OHM
BRAKE PEDAL
IQAN INPUT PROTECTION RESISTOR
IGNITION SWITCH
ISOLATOR SWITCH
COOLANT LEVEL SWITCH
AIR INTAKE SWITCH
EMERGENCY STOP
MOVING CAB UMIT SWITCH
SEAT SWITCH
PARK BRAKE P/B SWITCH
20' RETRACT 40' EXTENSION ROCKER SWITCH
301/ 35 ' STOPS IN/OUT ROCKER SWITCH
POWER SLOPE ROCKER SWITCH
UPA ROCKER SWITCH 2
BREAK OIL FILTER DRTY SWITCH
HYD LS PRESSURE
HYD P PRESSURE
HYD OIL TEMPERATURE
JACKS UP/DOWN ROCKER SWITCH
CAB FWD/REV ROCKER SWITCH
SPREADER RESET P/B
OVERIDE KEY SWITCH
GEAR SEL.FWD/REV .P/B STALK SWITCH
S23
S24
S25
S26
S27
S28
S29
S30
S31
S32
S33
S34
S35
S36
S37
S46
S47
S52
S53
S54
S55
S56
S57
S58
Yl
Y2
Y3
Y4
Y5
Y8
Y7
Y8
Y9
Y10
Y13
Y37
Y38
Y39
5
5
5
5
5,7
4,7
7
6
5
7
7
8
11
8
1
1,3
1
1
1
1
8
3
3
3
3
3
3
4
5
5
5
3
3
3
3
6
DESCRIPTION
PAGE
HAZARD WARNING P/B SWITCH

SIDE LIGHTS / HEADLIGHTS ROCKER SWITCH
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
3
S
S
S
S
S
S
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
H/LIGHTS DIP.FRONT WIPER. IND.HORN STALK SWITCH

D
SPREADER UGHTS ROCKER SWITCH
BOOM
LIGHTS ROCKER SWITCH
UGH LIGHTS ROCKER SWITCH
SIDE
HEATED SEAT ROCKER SWITCH
REAR WASH WIPE SPEED SELECT SWITCH
TOP WASH WIPE SPEED SELECT SWITCH
CAB ROOF LIGHTS
RH DOOR SWITCH
LH DOOR SWITCH
STEP LIGHTNG SWITCH CAB
STEP LIGHTING SWITCH BATTERY BOXSWITCH
HEATED MIRROR SWITCH
BLOWER SPEED SELECT SWITCH
AMBIENT TEMP STAT
JACK 1 DOWN SENSOR
JACK 1 DOWN SENSOR
JACK 2 UP SENSOR
JACK 2 UP SENSOR
CH LEGS CLAMP/UNCLAMP SWITCH
CH LEGS REAR UP/DWN SWITCH
CH LEGS FRONT UP/DWN SWITCH
MOVING CAB FWD VALVE
MOVING CAB REV VALVE
HANDBRAKE SOLENOID
PUMP CONTROL VALVE
LOWER PROP VALVE
LIFT PROP VALVE
EXTEND PROP VALVE
RETRACT PROP VALVE
PILOT WD VALVE
MOVING CAB PROP SUPPLY VALVE
SPREADER PROF SUPPLY VALVE
AIR CON COMPRESSSOR CLUTCH
JACKS UP VALVE
JACKS DOWN VALVE
8
8
8,11
9
9
9
12
11
11
9
2
2
13
13
13
10 16.17
16
5
5
4
4
2
2
2
4
4
4
5
5
5
5
5
5
4
4
Inspection dim.
Auxillary dim.
Drawn
Date
13.10.08 P HARLING MK5 Re-issue
Name
13.10.08 G J REES
Checked 14.10.08 P HARLING
Date
Title:
Confidential document
Refer to protection notice ISO
16016
218
Drawing number
Auth'd
M.check
HEAVY TRUCK DIVISION
5
5
Checked
Alteration
357 MK5
T10985
Change No
ELECTRICAL SCHEMATIC
Scale:
S:
Page:
357 802 0261
18 of 19
A:
Repl.
Orig.
A3
Circuit Diagrams 7
Page 19
PAGE
K2
1
6
2
3
4
5
6
1
14 & 15
14 & 15
14 & 15
14 & 15
14 & 15
12
K4
K5
K6
K7
K8
K9
K10
16
25
F1 26
27
F5 28
29
11
12
F16
F11
F12
15
F15
F10
21
14
F14
F7
20
F4
19
F6
18
F2
17
F3
F8
FC1
1
13
22
23
24
10
F9 30
F1332
31
FC2
F2926
27
21
F3028
29
11
12
F28
20
18
F26
25
19
17
10
F27
16
F25
15
F23
14
F24
13
F22
F19
F20
F17
1
1
1
1
1
8
8
10
12
11
11
10
12
12
12
12
1
1
10.16,17,18
F18
K1
F21
22
23
24
F3130
31
F3232
27
F42
F43
F4526
12
24
F41
25
11
19
20
21
22
23
17
18
F57
16
F39
15
10
F40
14
F38
13
F37
F35
F36
F44
FC3
1
21
F4628
29
F4730
31
F4832
K16
25
DESCRIPTION
K1
K2
K3
K4
K5
K6
K7
K8
K9
K10
K15
K16
K17
K18
K19
K20
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
IGNITION RELAY
WIPER RELAY
HEADLIGHTS RELAY
REVERSE LIGHTS
INDICATOR FLASHER
REAR WIPER
TOP WIPER
BRAKE COOLER
HORN RELAY
UPA RELAY 1
STARTER MOTOR RELAY
IGN AUTO SWITCH OFF RELAY
IGNITION RELAY AIR CON BOARD (ACB)
CLUTCH RELAY AIR CON BOARD (ACB)
CONDENSER RELAY AIR CON BOARD (ACB)
TRINARY RELAY AIR CON BOARD (ACB)
F55
F56
16
17
18
19
20
F6126
27
F6228
29
11
12
F60
F54
15
F58
F53
14
F51
13
F52
F59
FC4
1
22
23
24
10
F6330
31
F6432
PAGE
1
11
8
3&8
8
11
11
1&3
3 & 10
3
1&4
1&3
16
16
16
16
ACB
Inspection dim.
Auxillary dim.
Date
Name
Drawn 13.10.08 G J REES
Checked14.10.08 P HARLING
13.10.08
Date
Title:
Auth'd
M.check
HEAVY TRUCK DIVISION

Confidential document
Refer to protection notice ISO
16016
K3
F33
TRUCK IQAN ES SUPPLY

IQAN CAB MDL UINT
IQAN CAB FRONT XS2-AO UNIT
IQAN CAB FUSEBOX XS2-A1 UNIT
SPARE
IQAN CHASSIS LEFT XT2-0 UNIT
IQAN CHASSIS RIGHT XT2-1 UNT
EXTERNAL MODEM
ELME IQAN ES SUPPLY
ELME SPREADER SUPPLY 1
ELME IGN SUPPLY
J1939 PRINTER /UPA
SPARE
IGNITION SWITCH
ENGINE ECM 1
ENGINE ECM 2
TRANSMISSION
BRAKE COOLER MOTOR
HAZARD WARNING LIGHTS
HEADLIGHTS FLASHER
INTERIOR LIGHT
LFM BAT+ SUPPLY
REAR WIPER
TOP WIPER
HORN SUPPLY
DIESEL CAB HEATER 1
DIESEL CAB HEATER 2
COMPRESSOR SEAT
STEP LIGHTING
TRANSMISSION
ALTERNATOR EXCITATION
HEATER BLOWER
24/1 2V CONVERTER
FRONT WIPER/HORN
CENTRAL GREASING
RADIO
ROTATING BEACON
SIDE LIGHTS / DIP LIGHTS
SWITCH ILLUMINATION
SIDE LIGHTS LEFT
SIDE LIGHTS RIGHT
DIP LIGHTS LEFT
DIP LIGHTS RIGHT
HEAD LIGHTS LEFT
HEAD UGHTS RIGHT
INDICATORS
REVERSE LIGHTS / SOUNDER
SPREADER LIGHTS
BOOM LIGHTS
SIDE SPOT LIGHTS
CAB ROOF LIGHTS
LFM IGN
RED DOT AIR CON UMT 1
RED DOT AIR CON UNT 2
HEATED SEAT
HEATED SEAT
HEATED MIRRORS
SPARE
SPARE
SPARE
SPARE
F34
30A
10A
15A
15A
/
20A
20A
3A
30A
10A
10A
10A
10A
10A
5A
/
5A
10A
10A
5A
20A
5A
15A
5A
5A
10A
10A
5A
10A
10A
5A
5A
5A
3A
30A
20A
15A
10A
5A
5A
15A
1A
3A
3A
5A
5A
10A
10A
5A
10A
20A
20A
10A
20A
3A
15A
15A
5A
1A
5A
/
/
/
/
F49
IGN
ES
ES
ES
ES
ES
ES
ES
IGN
ES
ES
ES
ES
ES
ES
ES
BAT+
BAT+
BAT+
BAT+
BAT+
BAT+
BAT+
BAT+
BAT+
BAT+
BAT+
BAT+
BAT+
BAT+
BAT+
BAT+
IGN
IGN
IGN
IGN
IGN
IGN
IGN
IGN
IGN
IGN
IGN
IGN
IGN
IGN
IGN
IGN
IGN
IGN
IGN
IGN
IGN
IGN
IGN
IGN
IGN
IGN
IGN
IGN
IGN
IGN
IGN
IGN
F50
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
P HARLING MK5 Re-issue
Checked
Alteration
T10985
Change No
357 MK5
ELECTRICAL SCHEMATIC
Drawing number
DESCRIPTION
F1
F2
F3
F4
F5
F6
F7
F8
F9
F10
F11
F12
F13
F14
F15
F16
F17
F18
F19
F20
F21
F22
F23
F24
F25
F26
F27
F28
F29
F30
F31
F32
F33
F34
F35
F36
F37
F38
F39
F40
F41
F42
F43
F44
F45
F46
F47
F48
F49
F50
F51
F52
F53
F54
F55
F56
F57
F58
F59
F60
F61
F62
F63
F64
Scale:
NONE
S:
Page:
357 802 0261
19 of 19
A:
Repl.
Orig.
A3
219
7 Circuit Diagrams
220
Circuit Diagrams 7
Hydraulic Circuit Diagram
Hydraulic Circuit Diagram

Hydraulic Circuit
Page 1
225/180*2918 LWB
200/180*2918 SWB
225/180*2918 LWB
200/180*2918 SWB
200/160*2*272
MB
380bar
EXTENTION CYLINDER
170/150*7583
1.4mm
STEERING
CYLINDER
LIFT CYLINDER
DN19
DN30
MX
MX
DN38
B1
A1
B
A
110Lit/min
70Lit/min
0.3mm
420bar
420bar
0.1bar
19.7bar+0.1
1mm
200bar
LS
R
1mm
19.8bar+0.1
1mm
260bar
DN25
3bar
B
0.1bar
B
3bar
200bar
JACKS CYL.RHS
L
0.3mm
1mm
260bar
100/60X380
JACKS CYL.LHS
CR
100/60X380
CL
pmax=210bar
L1
L2
p max
=32bar
xE
B1
A1
MB
SPREADER HYDR. SCHEMATIC

SHOULD BE SUPPLIED BY
SPREADER MANUFACTURER
lower
DN8
DN6
spreader
100lit/min
405bar+20
A1
B1
A2
B2
pressure
9lit/min
lift
DN6
380bar+20
380bar+20
EF
retr.
110lit/min
27lit/min
Z
110lit/min
70lit/min
DN6
max.
max.
max.
max.
ext.
HP
PS
LS=180bar
p=
440mA-1350mA=min.7.5bar-max.28.5bar
LS
HT
1bar
LS=180bar
DN6
LS=210 bar
1bar
LS
leak
spreader
DN8
310+10bar
5-1bar
3+-0.6bar
60+6bar
xLS
xP
DN25-30
LS1
P2
P1
X1
OPTION
hydraulic
moving cab
DN25-30
5bar
DN25-30
DN18
DN15
DN8
DN38
p=34bar
DN30
LS2
35bar pres.
FOR SPREADER
DUMP CYLINDER
2
1
n=2200rpm
24lit/min
19ccm
V=0.75 Lit
pNitr.
=15bar
0.5bar
p=160bar
DN25
300mA=8.5bar
p=35bar
10 m
WDO VALVE
3B6
SP
X1
T
DN50
105ccm
11ccm
DN8
Y
DN18 pmax= 1.5bar
LS1
pmax=1.5bar
DN25
7 m
LS2
p=24bar
turbo pressure of engine

1.1-2.7bar abs.
1.35bar
1.15+0.03bar abs.
0.95bar
DN50
to brake system
10 m
2.5bar
105ccm
Tank return spreader
abs.
abs.
10 m
10 m
2.5bar
1.5bar
19ccm
from brake tank
221
Linde Material Handling GmbH

3578011501 EN 2010/01/27

357 en 0110

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Reachstacker

C4230 - C4540 TL /5,

Linde - Your Partner

Operating Instructions 3578011501 EN 2010/01/27

Linde industrial trucks enjoy a worldwide

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

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

Gauges, switches and warning lights

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

Opening the working hydraulic system oil tank cover . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Opening the battery and air lter compartment door . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Checking the fuel level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Checking the twistlocks and warning lights for proper operation . . . . . . . . . . . . . . . . . . 44

Overload safety switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Stopping the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Truck lighting and turn indicators

Operating the hazard warning lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Operating Instructions 3578011501 EN 2010/01/27

Opening the fuse box cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Before lifting a load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Parking the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Operating Instructions 3578011501 EN 2010/01/27

Chassis, bodywork and ttings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Operating Instructions 3578011501 EN 2010/01/27

Operating Instructions 3578011501 EN 2010/01/27

Operating Instructions 3578011501 EN 2010/01/27

written approval by the manufacturer. Linde

Operating Instructions 3578011501 EN 2010/01/27

Operating Instructions 3578011501 EN 2010/01/27

Transmission Disconnect (De-clutch)

to the left hand side of the chassis in the engine

Driving cabin, controls, switches and

Operating Instructions 3578011501 EN 2010/01/27

bearings for the handler turntable and levelling

Operating Instructions 3578011501 EN 2010/01/27

If unsafe operating conditions occur, the red

The truck has a 24 V DC electrical system

Safety Systems and Shut Down Devices

Automatic lubrication system*

the special measures required for driving on

we refer to the VDMA Guidelines for the

The rules for the intended and approved

Operating Instructions 3578011501 EN 2010/01/27

No changes, particularly no modications and

If you desire to use the truck for applications

Never operate the truck in a potentially explosive atmosphere.

Prior to, and whilst travelling, ALWAYS look in

Never leave the truck unattended with a raised

Before leaving the operators driving position,

A safe, competent operator is one who takes

Identies technical information requiring

The information contained herein must be

Check the lifting device and attachments

Check coolant level in expansion reservoir

Regenerate the soot lter (option)

Refuel the truck

Check the condition of the battery

Tighten opposite wheel nuts to a torque of

Check the steering system

when delivered to the customer. Authorised

This information can be found on the type

Operating Instructions 3578011501 EN 2010/01/27

according to these operating instructions